TWIN DISC

INCORPORATED

Installation
and
Operator’s
Electronic
Manual Control

MGX Express Control

Model: EC050

Document Number: 1022510

 NOTICE

Twin Disc, Incorporated makes no warranty or guaranty of any

kind, expressed, implied or otherwise, with regard to the
information contained within this manual. Twin Disc, Incorporated
has developed this manual through research and testing of the
information contained therein. Twin Disc, Incorporated assumes
no responsibility for any errors that may appear in this manual
and shall not be liable under any circumstances for incidental,
consequential or punitive damages in connection with, or arising
out of, the use of this manual. The information contained within
this manual is subject to change without notice.
 Document Number
1022510

May, 2007

MGX Express Control

Installation and
Operator’s Manual
 LIMITED TWIN DISC GENERAL WARRANTY,
LIMITATIONS OF REMEDIES AND LIMITATION OF OTHER WARRANTIES
A. Twin Disc, Incorporated warrants all assembled products and parts (except component products or parts on which written
warranties are issued by the respective manufacturers thereof and 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 products
and parts other than Rockford power take-offs, such warranty shall extend for a period of twenty-four (24) months from the
date of original shipment by Twin Disc, Incorporated to the original customer, but not to exceed twelve (12) months of
service or two thousand (2,000) hours of service, whichever occurs first. For Rockford power take-offs products and parts,
such warranty shall extend for a period of fifteen (15) months from the date of original shipment by Twin Disc, Incorporated
to the original customer, but not to exceed twelve (12) months of service or one thousand five hundred (1,500) hours 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 and fitness for a particular
purpose and no other warranties are implied or intended to be given by Twin Disc, Incorporated.
The original customer does not rely upon any tests or inspections by Twin Disc, Incorporated or on Twin Disc,
Incorporated's application engineering.

B. In consideration of the Limited Twin Disc General Warranty (hereafter called warranty) and price Twin Disc,
Incorporated charges (which reflects Twin Disc, Incorporated's limited liability), 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, Incorporated be either the repair or
replacement of any Twin Disc, Incorporated part or product found by Twin Disc, Incorporated to be defective (or
equivalent credit). Under no circumstances, including a failure of the exclusive remedy, shall Twin Disc,
Incorporated be liable for economic loss, consequential, punitive or incidental damages. The above warranty and
remedy are subject to the following terms and conditions:
1. Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to
Twin Disc, Incorporated within sixty (60) days after completion of the in warranty repair.
2. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted from
abuse, neglect, improper maintenance or accident.
3. The warranty is void if any modifications are made to any product or part without the prior written consent of Twin
Disc, Incorporated.
4. The warranty is void unless the product or part is properly transported, stored and cared for from the date of shipment
to the date placed in service.
5. The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the
product or part with installations properly engineered and in accordance with the practices , methods and instructions
approved or provided by Twin Disc, Incorporated.
6. The warranty is void unless all required replacement parts or products are of Twin Disc origin or are Twin Disc
authorized replacement parts, and otherwise identical with components of the original equipment. Replacement parts
or products not of Twin Disc origin are not warranted by Twin Disc, Incorporated.
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 or 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.

*Note The Above constitutes the basic Twin Disc, Incorporated General Limited Warranty and may be supplemented by additional published
warranty terms dependent upon the product involved. Supplementary warranty terms are available upon request.

April 20, 2007 TDWP0001 rev 2007

Twin Disc, Incorporated Table of Contents

Table of Contents
Introduction ...........................................................9
General Information ............................................................................ 9
Safety and General Precautions ..................................................... 10
Replacement Parts ............................................................................ 11
Source of Service Information......................................................... 12
Warranty .............................................................................................. 12

Installation ............................................................13
General................................................................................................ 13
Connector Kits ................................................................................... 13
Install the Control on GP Valve Body.............................................. 14
Install Speed Pickups ........................................................................ 14
Wiring of Battery, Manual Override Switch, and Start Relay ....... 16
Wiring of Speed Pickups .................................................................. 17
Wiring of Solenoid Inputs ................................................................. 17
Wiring of “Not In Neutral” Indicator (NIN) ....................................... 17
Install Customer Supplied Troll Switch .......................................... 18
Ignition Wiring .................................................................................... 18
Install Customer Supplied Express Switch ................................... 19
Operation with Troll and Express Switches .................................. 20
Installation of Customer Supplied Slip Speed Signal Device...... 20
Installation of Customer Supplied Slip Speed Voltage Input Potentiometer 20
Installation of Customer Supplied Slip Speed Voltage Signal ..................... 21
Installation of Customer Supplied Slip Speed Current Signal ...................... 21
Measurement of Gear Ratio ............................................................. 22

Operation ..............................................................23
General................................................................................................ 23
Modes of Operation .......................................................................... 24
Cruise Mode.................................................................................................. 24
Troll Mode ..................................................................................................... 25
Express Mode ............................................................................................... 26

MGX Express Control Module Operator’s Manual #1022510 7

Table of Contents Twin Disc, Incorporated

Troubleshooting ..................................................27
General ................................................................................................ 27
Normal Operation .............................................................................. 27
Operational Problems ....................................................................... 27
Symptom: Cruise mode does not work ......................................... 29
Symptom: Unable to transition from Cruise mode to Troll mode
or Express mode .......................................................................... 31
Symptom: Troll mode does not work ............................................. 33
Symptom: Trolling or Express has incorrect speed range ........ 35
Symptom: Trolling or Express mode entered, but propeller
speed does not respond to slip speed command (No LED fault
codes) ............................................................................................. 35
Symptom: Propeller speed not maintained while in Troll or Ex-
press mode .................................................................................... 36
Symptom: Express mode does not work ...................................... 37
Symptom: Unable to transition from Troll to Express mode ..... 39
Symptom: Harsh shifting experience in Express mode .............. 39
Symptom: All preceding troubleshooting has been performed
and one or more of the following problems still exist. ............ 40

Engineering Drawings ........................................41

List of Engineering Drawings .......................................................... 41
1022320 (sheet 1 of 2) MGX Express Module Installation ......... 43
1022320 (sheet 2 of 2) MGX Express Module Installation .......... 44

8 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Introduction

Introduction

General Information

This publication provides information for the Twin Disc MGX Express Module
for control of general purpose valves on Twin Disc marine transmissions.
Specific engineering details and performance characteristics can be obtained
from the Product Service Department of Twin Disc Incorporated, Racine,
Wisconsin, USA.

Operation and maintenance personnel responsible for this equipment should

be familiar with this publication and have it at their disposal. A thorough
understanding and application of the material in this manual will result in
consistent performance from the unit and help reduce downtime.

MGX Express Control Module Operator’s Manual #1022510 9

Introduction Twin Disc, Incorporated

Safety and General Precautions

General

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

Important Safety Notice

Proper installation, maintenance, and operation procedures must be followed

due to the possible danger to person(s) or property from accidents that may
result from the use of machinery. Twin Disc, Inc. will not be responsible for
personal injury resulting from careless maintenance/working practices.

Inspect as necessary to assure safe operations under prevailing conditions.

Proper guards and other safety devices that may be specified in safety codes
should be provided. These devices are neither provided by, nor are they the
responsibility of Twin Disc, Inc.

10 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Introduction

Replacement Parts

All replacement parts or products 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 authorized Twin Disc distributor or service
dealer. Contact Twin Disc for the distributor or service dealer near you.

Twin Disc, having stipulated the part 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.

MGX Express Control Module Operator’s Manual #1022510 11

Introduction Twin Disc, Incorporated

Source of Service Information

For the latest service information on Twin Disc products, contact any Twin Disc
distributor or service dealer. This can be done on the Twin Disc corporate web
site found at [http://www.twindisc.com]. Provide your transmission model
number, transmission serial number, and EC050 control part number to obtain
information on your unit. If necessary, contact the Product Service Department
of Twin Disc, International S.A., Nivelles, Belgium, or Twin Disc, Incorporated,
Racine, Wisconsin, 53405-3698, USA by e-mail at [email protected].

Warranty

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

12 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Installation

Installation

General

This control is designed to be mounted on top of the Twin Disc GP Valve

assemblies.

All customer wiring attaches to the EC050 control by connectors that are
supplied with the EC050 control. All connections must be made according to
the wiring schematic that is identified in this manual. Failure to follow the
installation procedures identified here can result in damage to the EC050 control
or other hardware.

Connector Kits

All necessary connectors and mounting hardware are included with the control.
Additional connectors can be purchased separately from Twin Disc.

MGX Express Control Module Operator’s Manual #1022510 13

Installation Twin Disc, Incorporated

Install the Control on GP Valve Body

Mount the EC050 control to the top section of the GP control valve. Install four
M6-1.0 capscrews with lockwashers, and torque them to 9.5 Nm (7 lb.-ft.).

Figure 1. Place the EC050 Control onto Valve and tighten screws

Install Speed Pickups

Engine speed and propeller speed sensors are available for all Twin Disc MGX
model marine transmissions. Twin Disc supplied speed sensors must be
installed in the transmission if they are not already there.

Threaded Mounting Hole

1. Remove the plugs (if applicable) from the threaded speed pickup holes
in the transmission housing.

2. Rotate the transmission shafts until a gear tooth is centered in the speed
pickup hole.

3. Apply MA908 (Loctite 242) to the threads of the speed sensor and screw
it in until the tip contacts the tip of the gear tooth.

4. Back the input speed sensor off ONE complete turn, and tighten the jam
nut to 9 Nm (80 in-lb).

5. Back the output speed sensor off TWO complete turns, and tighten the
jam nut to 9 Nm (80 in-lb).

14 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Installation

Non-Threaded Mounting Hole

Note: Transmissions without threaded output speed pickup

holes must have a speed wheel mounted on the output
flange of the transmission, or have an output flange that
has machined external teeth.

1. If a speed sensor bracket is not present, obtain a bracket and associated

mounting hardware and attach the bracket to the transmission.

2. Thread a jam nut onto the sensor followed by one flat washer.

3. Rotate the transmission shafts until a gear tooth is centered in the speed
pickup hole.

4. Thread the jam nut far enough toward the top of the sensor such that
when the sensor is inserted through the slot in the bracket, the face of
the sensor contacts the speed wheel. With the sensor protruding through
the bracket, install a second flat washer onto the sensor and thread the
bottom jam nut onto the sensor.

5. Hold the tip of the sensor in contact with the outer diameter of the speed
wheel tooth.

6. While holding the sensor in contact with the speed wheel tooth, screw
the top or outer jam nut toward the bracket until it is snug without backing
the sensor away from the tooth.

7. Advance the top jam nut an additional TWO turns while holding the
sensor.

8. Hold the sensor in place in the bracket, and in line with the gear tooth,
and snug the bottom jam nut and washer against the bottom of the
bracket.

9. Tighten the top or outer jam nut to 9 Nm (80 in-lb).

MGX Express Control Module Operator’s Manual #1022510 15

Installation Twin Disc, Incorporated

Wiring of Battery, Manual Override Switch, and Start Relay

The control is designed to operate from standard 12 VDC or 24 VDC marine

engine power systems.

Dedicated 16 AWG wires must be used to supply power from the engine power
distribution system to the control power connector. These wires are to be a
maximum of 15 meters in length. A 5 amp fuse or circuit breaker must be
located near the power distribution system in the positive supply line. This fuse
must not exceed the time/current characteristics of an ATO type fuse. These
wires must be terminated with the connector that is provided. Note that terminal
1 is the positive connection.

Ring terminals have been provided in the positive supply wire on the EC050
control, and on the wire to terminal 1 of the battery connector. These wires
must be connected to one of the Manual Override Switches on the GP Valve
Assembly.

Note: These are the only wires that should be connected

to this switch.

Note: The manual override switch is rated at 20 amps max.

Note: See the “Manual Override Switch” wiring schematic

below.

The customer supplied Start Relay coil must be wired into terminals 1 and 12
of the J1 connector as shown in this manual. The contacts must be wired to the
vessel’s start circuit through one of the Manual Override Switches on the GP
Valve Assembly.

Note: These are the only wires that should be connected

to this switch.

Figure 2. “Manual Override Switch” wiring

16 MGX Express Control Module Operator’s Manual #1022510
Twin Disc, Incorporated Installation

Wiring of Speed Pickups

The connector ends on the Twin Disc speed pickup cables will mate with the
connectors on the control . The cables should be of sufficient length without
modification.

Wiring of Solenoid Inputs

The Solenoid A input must be connected to connector J1 with the positive side
to terminal 3, and the return to terminal 10. The Solenoid B input must be
connected to connector J1 with the positive side to terminal 2, and the return to
terminal 11.

The optically isolated inputs require a voltage potential difference of 10 VDC

minimum, and a 28 VDC maximum. The supply source must be capable of
delivering at least 10 mA.

Wiring of “Not In Neutral” Indicator (NIN)

The “not in neutral” relay contacts provide neutral status information to a

transmission control. The relay contacts are closed when the control is
commanding neutral, and open when the control is commanding gear. The
maximum current is 100 mA into a resistive load only. NIN must be wired to
terminals 4 and 9 as shown below.

Figure 3. “Not in Neutral” wiring

Note: These are the only wires that should be connected

to this relay.

MGX Express Control Module Operator’s Manual #1022510 17

Installation Twin Disc, Incorporated

Install Customer Supplied Troll Switch

A customer supplied Troll switch must be wired into terminal 8 of connector J1.
Terminal 5 is the power return line for the Troll switch signal. The Troll switch
input is not polarity dependent. The Troll switch and return line must be connected
in one of the four ways shown below.

Figure 4. Troll Wiring

Note: The Troll switch may be wired to the Mode 1 input or

to the Mode 1 return as shown.

Ignition Wiring

Terminal 6 of J1 must be connected to the battery positive (+) through the ignition
switch. Terminal 7 must remain open. Install the cavity plug seals that are
provided in any open locations in connector P1 before connecting it to J1.

18 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Installation

Install Customer Supplied Express Switch

A customer supplied Express switch must be wired into terminal 5 of connector

J2. Terminal 8 is the power return line for the Express switch signal. The Express
switch input is not polarity dependent. The Express switch and return line must
be connected in one of the four ways shown below.

Figure 5. Express Wiring

Note: The Express switch may be wired to the Mode 2 input

or to the Mode 2 return as shown.

MGX Express Control Module Operator’s Manual #1022510 19

Installation Twin Disc, Incorporated

Operation with Troll and Express Switches

The various combinations of the Troll and Express Switches result in operation
modes as shown in the figure below.

SWITCH STATE
MODE
EXPRESS TROLL
CRUISE OPEN OPEN
TROLL OPEN CLOSED
EXPRESS CLOSED OPEN
ERROR CLOSED CLOSED

Figure 6. Troll and Express switch combinations

Installation of Customer Supplied Slip Speed Signal Device

There are three different arrangements for controlling the slip speed with this
control. Determine the arrangement that is being used for this installation, and
proceed as identified below.

Installation of Customer Supplied Slip Speed Voltage Input Potentiometer

A customer supplied slip speed voltage input potentiometer (500 to 2000 ohms)
must be connected across terminal 1 and 12 of connector J2. The wiper from
this potentiometer must be connected to terminal 10 of connector J2.

Figure 7. Slip Speed Potentiometer

20 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Installation

Installation of Customer Supplied Slip Speed Voltage Signal

A customer supplied slip speed voltage signal must be connected to terminal

10, and the signal reference must be connected to terminal 12 of connector J2.

Figure 8. Slip Speed Voltage

Installation of Customer Supplied Slip Speed Current Signal

A customer supplied slip speed current input signal (4 to 20 mA) must be

connected to connector J2 with the positive side to terminal 4, and the return to
terminal 9.

Figure 9. Slip Speed Current

Note: J2 Pin 9 is common with battery negative.

MGX Express Control Module Operator’s Manual #1022510 21

Installation Twin Disc, Incorporated

Measurement of Gear Ratio

A factory default gear ratio is programmed into the EC050 control. The actual
transmission ratio must be learned by the control after it is installed in the vessel.
After the installation is completed, the transmission must be shifted into gear in
Cruise mode, while the engine is at idle, and maintained for at least 15 seconds
to allow the proper gear ratio to be learned by the control. This gear ratio is
stored in the control’s memory.

Note: Failure to calibrate the gear ratio may result in poor

Troll or Express performance.

22 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Operation

Operation

General

The EC050 Control is used to command the transmission to neutral, forward,

and reverse while in the Cruise, Troll, and Express modes of operation. The
control continuously monitors various input signals, and controls the transmission
electrical valves accordingly. The control contains three LED’s to advise the
operator of control status.

The control continuously monitors several inputs, and updates transmission

control signals to optimize vessel operation.

While in Cruise mode, both the power LED and the energized solenoid LED
will display green.

While in Troll mode, the power LED will display green, and the energized
solenoid LED will display red.

While in Express mode, the power LED will display green, and the energized
solenoid LED will display yellow.

The three LED’s are also used to provide fault message information during
operation. See the Troubleshooting section of this manual for more information
on the significance of these LED’s.

MGX Express Control Module Operator’s Manual #1022510 23

Operation Twin Disc, Incorporated

Modes of Operation

Entrance into Cruise, Troll, or Express mode is based on the status of the Troll
and Express switch inputs, transmission engine speed, transmission propeller
shaft speed, transmission gear ratio, slip speed signal, and solenoid inputs.

For all modes of operation, the profile of curent versus time, for mode entry, is
predefined and may vary based on EC050 part number. The initial level of this
profile is factory set and may be field adjustable, by qualified technicians with
proper equipment, depending on the part number. Contact Twin Disc for more
information if adjustment is necessary.

Cruise Mode

To engage a clutch, an electrical signal will be supplied to the transmission

valve using a predefined profile of current versus time. This results in a pressure
rate of rise profile for optimum feel while avoiding transmission damage due to
excessive energy levels. The transmission clutch will be fully engaged when
operating in this mode.

Cruise mode will be entered from neutral whenever both the Troll and Express
switches are open, and a shift is commanded by the operator. This mode will
also be entered from Troll mode if an engine over-speed, over-acceleration, or
loss of engine speed signal has been detected.

Note: There are no inhibits restricting entry into Cruise

mode. Operators should only enter Cruise mode at
safe engine speed as defined in the transmission’s
Operator’s manual.

24 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Operation

Troll Mode

Troll mode allows a propeller shaft speed slower than Cruise mode by controlling
the slip of the forward or reverse clutch. The propeller speed will be controlled
by the slip speed signal. This signal can be provided from a potentiometer,
voltage signal, or current signal, depending on the installation. The control
learns the type of signal that is provided upon power up.

The EC050 control supports two types of Troll mode. Closed loop Troll is the
default Troll type. In the event of a propeller speed sensor failure, open loop
Troll is the effective Troll type. Closed loop Troll holds the commanded propeller
speed by measuring the speed and making adjustments to the valve coil current
to compensate for variations in propeller loading and transmission oil
temperature. If the propeller speed signal is missing or too low to be measured
by the control, open loop Troll will maintain a set pressure level, and propeller
speed could vary. The control will automatically return to closed loop Troll if the
propeller speed signal returns at a satisfactory level.

Troll mode operation is allowed over an engine speed range which is safe for
the particular transmission and is part number dependent.

Note: Measurement of gear ratio must be performed prior

to initial Troll mode operation.

MGX Express Control Module Operator’s Manual #1022510 25

Operation Twin Disc, Incorporated

Express Mode

The Express mode of operation allows the operator to combine low transmission
propeller speed, as in Troll operation, with high transmission propeller speed,
as in Cruise operation, without changing modes. The Express mode is entered
by closing the Express mode command switch. During the first half of the slip
speed command range, the transmission is in a controlled slip condition, as in
Troll. At higher slip speed command, the transmission becomes fully engaged
and vessel speed is controlled by engine throttle. The slip speed signal to
control propeller speed and throttle can be provided from a potentiometer,
voltage signal, or current signal, depending on the installation. The control
learns the type of signal that is provided upon power up.

Express mode operation with low transmission propeller speed is allowed over
an engine speed range which is safe for the particular transmission and is part
number dependent.

Note: Measurement of gear ratio must be performed prior

to initial Express mode operation.

Successful operation of Express mode requires precise engine control.

Transmission damage may result if engine throttle is not coordinated
with clutch engagement. Contact Twin Disc for coordination details.

The EC050 control supports two types of Express mode. Closed loop Express
is the default Express type. In the event of a propeller speed sensor failure,
open loop Express is the effective Express type. Closed loop Express at low
requested propeller speeds holds the commanded propeller speed by
measuring the speed and making adjustments to the valve coil current to
compensate for variations in propeller loading and transmission oil temperature.
If the propeller speed is too low to be measured by the control, open loop
Express will maintain a set pressure level, and propeller speed could vary. The
control will automatically return to closed loop Express if the propeller speed
signal returns to a satisfactory level.

26 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Troubleshooting

Troubleshooting

General

LED’s are provided on the control to aid in identifying problems that may prevent
normal operation.

Normal Operation

The chart below identifies LED status during normal conditions.

Solenoid A or B
Power LED Mode of Operation
LED
green green Cruise

green red Troll

green yellow Express

green both off Neutral

Figure 10. LED Function During Normal Operation

Operational Problems

The chart on the following page provides an abbreviated guide to troubleshooting

some problem conditions. A more thorough troubleshooting procedure
including symptoms and corrective action follows the abbreviated guide.

Note: Always check the transmission manual for possible

non-control related problems if the suggested
corrections listed in the troubleshooting guide do
not solve the problem.

MGX Express Control Module Operator’s Manual #1022510 27

Troubleshooting Twin Disc, Incorporated

Power LED Function Definition Corrective Action

Power supply voltage and
Green None
direction signals normal
Power supply voltage less than Correct cause of low
Red
9.0 Volts voltage
Alternately
One or both direction inputs Correct cause of
flashing Green
active at power up direction input(s) active
and Yellow

Figure 11. Power LED Function

Solenoid A LED Solenoid B LED

Function Definition Corrective action
Color Color
Transmission commanded to
Off Off None
Neutral
Green Off Valve A commanded to Cruise None
Red Off Valve A commanded to Troll None
Off Green Valve B commanded to Cruise None
Off Red Valve B commanded to Troll None
Yellow Off Valve A commanded to Express None
Off Yellow Valve B commanded to Express None
Check the coil and
Flashing Red Off Valve A coil open or shorted
associated wiring
Check the coil and
Off Flashing Red Valve B coil open or shorted
associated wiring
Red Red Program Data Error Replace module
Simultaneously Flashing Red Both direction inputs active Select neutral
Both the voltage and the current
Simultaneously Flashing Yellow set point inputs are active or the Correct wiring or signal
set point input is out of range
Transmission input speed sensor Check the sensor and
Alternately Flashing Red
signal missing associated wiring
Transmission input speed is
Alternately Flashing Yellow Reduce engine speed
greater than the inhibit speed

Figure 12. Solenoid A LED and Solenoid B LED Function

28 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Troubleshooting

Troubleshooting Procedures

Symptom: Cruise mode does not work

Possible remedies:

Check for Fault Codes

♦ If Power LED (center) Red, low battery voltage detected. Correct low battery
voltage.

♦ If Power LED (center) alternately flashes Green to Yellow, a start-up fault has been
detected (forward or reverse direction selected when control is initially powered OR
low battery voltage detected while in gear and battery voltage returns to normal).
Remove power from both Solenoid A and B inputs (select neutral; fault clears
automatically). Check and correct low battery voltage if problem persists with
repeated transitions from neutral to gear.

♦ If Power LED (center) Green and Solenoid LED’s A or B constant Red, an internal
program data error has been detected. Re-power control. If the fault does not clear,
replace the control.

♦ If Solenoid LED’s A or B flash Red, a coil open / short is detected. Inspect coil
contacts, wiring harness, and connector contacts. Ensure all connector contacts are
clean (no paint, dirt, corrosion, etc). Measure coil resistance (~ 7-10 ohms).

♦ If Solenoid LED’s A and B simultaneously flash Red, both forward and reverse
directions are simultaneously selected and neutral to gear transition is inhibited.
Check Solenoid A and B input and return wiring.

♦ If Solenoid LED’s A and B simultaneously flash Yellow to Red, the simultaneous

selection of Troll and Express modes have been detected. Check Troll and Express
switch wiring.

♦ All other LED flashing will not affect Cruise mode operation.

MGX Express Control Module Operator’s Manual #1022510 29

Troubleshooting Twin Disc, Incorporated

Check for Power (center) LED not illuminated

No Power to Control
o Check fuse integrity. Replace blown fuse.
o Check Control Power and Control Ground wiring. Inspect wiring harness and
connector contacts. Ensure connector contacts are fully seated and clean
(no paint, dirt, corrosion, etc).
o Check the transmission manual override switch (control is not powered if in
override)
o Ignition switch input not active (> 8.0 Volts)

Ignition Switch Open

o Check Ignition switch wiring. Ensure Ignition return (J1 Pin 7) is not
connected. Inspect wiring harness, and connector contact. Ensure
connector contact is fully seated and clean (no paint, dirt, corrosion, etc).

Check Solenoid LED’s A & B (Green = Cruise)

♦ If Solenoid LED’s A or B Red or Yellow while in gear, Troll mode operation has been
requested. Check Troll switch wiring (switch open for Cruise mode).

Check transmission manual for possible non-control related

problems

30 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Troubleshooting

Symptom: Unable to transition from Cruise mode to Troll mode or

Express mode

Possible remedies:

Check for Fault Codes

♦ If Solenoid LED’s A and B alternately flash Red, the engine speed signal has not
been detected. Inspect engine speed sensor wiring harness and connector
contacts. Ensure all connector contacts are fully seated and clean (no paint, dirt,
corrosion, etc). Check engine speed sensor air gap (0.5 to 1.0 turn). With the
engine running, examine the signal from the sensor (1.0 V pk-pk minimum signal
amplitude; greater than zero frequency). Measure the resistance of the sensor
(approximately 913 ohms).

♦ If Solenoid LED’s A and B alternately flash Green while not in neutral, the propeller
speed signal has not been detected. Inspect propeller sensor wiring harness, and
contacts. Ensure all connector contacts are fully seated and clean (no paint, dirt,
corrosion, etc). Check the speed sensor air gap (1.0 to 3.0 turns). Measure the
resistance of the sensor (contacts C – B approximately 4600 ohms; A – B and A – C
neither open nor short). The transmission output sensor is a powered sensor and
will not operate if disconnected from the control. With the sensor connected to the
powered control, the voltage across contacts C - B will vary between two distinct
levels of 0.7 and 3.0 V as a tooth passes the pickup (square wave output; ± 0.1 V).
With the sensor connected to the powered control, the voltage across contacts A - B
will be 4.8 V (± 0.1 V).

♦ If Solenoid LED’s A and B simultaneously flash Yellow, a slip speed command fault
has been detected (voltage and current active together OR signal out of range).
Inspect slip speed wiring and connector contacts. Ensure all connector contacts are
fully seated and clean (no paint, dirt, corrosion, etc). Ensure only one slip speed
command type is active when the control is powered. Ensure the signal being used
is within the specified range (see installation drawing for signal limits).

♦ If Solenoid LED’s A and B alternately flash Yellow, an engine speed has been
detected greater than the allowed speed (inhibit speed reached and coil current not
at maximum). Correct high engine speed signal. Fault automatically clears when
the engine speed signal falls below the re-enable frequency. Inhibit frequency and
re-enable frequency are P/N specific.
♦ If Solenoid LED’s A and B simultaneously flash Yellow to Red, the simultaneous
selection of Troll and Express modes have been detected. Check Troll and Express
switch wiring.

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Troubleshooting Twin Disc, Incorporated

Check Gear Frequency Ratio Calibration

♦ Enter Cruise mode with zero faults for a minimum of 15 seconds (control learns
frequency ratio when transmission fully engaged).

Check Troll and Express Switches

♦ Check Troll and Express switch wiring. Only the Troll switch shall be closed/active
when Troll mode has been requested. Only the Express switch shall be closed/
active when Express mode has been requested.

Check the slip speed command level

♦ Check the slip speed command signal. Ensure the slip speed command is within
3% of the minimum level.

Check transmission manual for possible non-control related

problems

32 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Troubleshooting

Symptom: Troll mode does not work

Possible remedies:

Check for Fault Codes

♦ If Power LED (center) Red, low battery voltage detected. Correct low battery
voltage.

♦ If Power LED (center) alternately flashes Green to Yellow, a start-up fault has been
detected (forward or reverse direction selected when control is initially powered OR
low battery voltage detected while in gear and battery voltage returns to normal).
Remove power from both Solenoid A and B inputs (select neutral; fault clears
automatically). Check and correct low battery voltage if problem persists with
repeated transitions from neutral to gear.

♦ If Power LED (center) Green and Solenoid LED’s A or B constant Red, an internal
program data error has been detected. Re-power control. If the fault does not clear,
replace the control.

♦ If Solenoid LED’s A or B flash Red, a coil open / short detected. Inspect coil
contacts, connector contacts, and wiring. Ensure all connector contacts are clean
(no paint, dirt, corrosion, etc). Measure coil resistance (~ 7-10 ohms).

♦ If Solenoid LED’s A and B simultaneously flash Red, both forward and reverse
directions simultaneously selected (neutral to gear transition inhibited). Check
Solenoid A and B inputs and return wiring.

♦ If Solenoid LED’s A and B alternately flash Red, the engine speed signal has not
been detected. Inspect engine speed sensor wiring harness and connector
contacts. Ensure all connector contacts are fully seated and clean (no paint, dirt,
corrosion, etc). Check engine speed sensor air gap (0.5 to 1.0 turn). With the
engine running, examine the signal from the sensor (1.0 V pk-pk minimum signal
amplitude; greater than zero frequency). Measure the resistance of the sensor
(approximately 913 ohms).

♦ If Solenoid LED’s A and B alternately flash Green while not in neutral, the propeller
speed signal has not been detected. Inspect propeller sensor wiring harness and
connector contacts. Ensure all connector contacts are fully seated and clean (no
paint, dirt, corrosion, etc). Check the speed sensor air gap (1.0 to 3.0 turns).
Measure the resistance of the sensor (contacts C – B approximately 4600 ohms; A
– B and A – C neither open nor short). The transmission output sensor is a powered
sensor and will not operate if disconnected from the control. With the sensor
connected to the powered control, the voltage across contacts C - B will vary
between two distinct levels of 0.7 and 3.0 V as a tooth passes the pickup (square
wave output; ± 0.1 V). With the sensor connected to the powered control, the
voltage across contacts A - B will be 4.8 V (± 0.1 V).

MGX Express Control Module Operator’s Manual #1022510 33

Troubleshooting Twin Disc, Incorporated

♦ If Solenoid LED’s A and B simultaneously flash Yellow, a slip speed command fault
has been detected (voltage and current active together OR signal out of range).
Inspect slip speed wiring harness and connector contacts. Ensure all connector
contacts are fully seated and clean (no paint, dirt, corrosion, etc). Ensure only one
slip speed command type is active when the control is powered. Ensure the signal
being used is within the specified range (see installation drawing for signal limits).

♦ If Solenoid LED’s A and B alternately flash Yellow, an engine speed has been
detected greater than the allowed speed (inhibit speed reached and coil current not
at maximum). Correct high engine speed signal. Fault automatically clears when
the engine speed signal falls below the re-enable frequency. Inhibit frequency and
re-enable frequency are P/N specific.
♦ If Solenoid LED’s A and B simultaneously flash Yellow to Red, the simultaneous
selection of Troll and Express modes has been detected. Check Troll and Express
Switch wiring.

Check for Power (center) LED not illuminated

No Power to Control
o Check fuse integrity. Replace blown fuse.
o Check Control Power and Control Ground wiring. Inspect wiring harness,
and contacts. Ensure contacts are fully seated and clean (no paint, etc).
o Check the transmission manual override switch (control not powered if in
override)
o Ignition switch input not active (> 8.0 volts)

Ignition Switch Open

o Check Ignition switch wiring. Ensure Ignition return (J1 Pin 7) is not
connected. Inspect wiring harness, and connector contact. Ensure
connector contact is fully seated and clean (no paint, dirt, corrosion, etc).

Check Solenoid LED’s A & B (Red = Troll)

♦ If Solenoid LED’s A or B are Green or Yellow while in gear, Cruise mode or Express
mode operation has been requested. Check Troll switch wiring (Troll switch closed/
active for Troll mode).

Check transmission manual for possible non-control related

problems

34 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Troubleshooting

Symptom: Trolling or Express has incorrect speed range

Possible remedies:

Check Gear Frequency Ratio Calibration

♦ Enter Cruise mode with zero faults for a minimum of 15 seconds (control learns
frequency ratio when transmission fully engaged).

Check transmission manual for possible non-control related

problems

Symptom: Trolling or Express mode entered, but propeller speed does

not respond to slip speed command (No LED fault codes)

Possible remedies:

Check Slip Speed Signal

♦ Inspect slip speed wiring connections. Measure slip speed signal (verify signal
levels; proper signal levels are indicated on installation drawing). Measure coil
current (verify current flowing through coil and responding to slip speed signal).
Troll mode or Express mode is not available when engine speed is missing.

Check transmission manual for possible non-control related

problems

MGX Express Control Module Operator’s Manual #1022510 35

Troubleshooting Twin Disc, Incorporated

Symptom: Propeller speed not maintained while in Troll or Express mode

Possible remedies:

Check Propeller Speed Sensor

♦ If Solenoid LED’s A and B alternately flash Green while not in neutral, the propeller
speed signal has not been detected and the control is operating in open loop Troll
mode or Express mode. Inspect propeller speed sensor wiring harness and
connector contacts. Ensure all connector contacts are fully seated and clean (no
paint, dirt, corrosion, etc). Check the speed sensor air gap (1.0 to 3.0 turns).
Measure the resistance of the sensor (contacts C – B approximately 4600 ohms; A
– B and A – C neither open nor short). The propeller speed sensor is a powered
sensor and will not operate if disconnected from the control. With the sensor
connected to the powered control, the voltage across contacts C - B will vary
between two distinct levels of 0.7 and 3.0 V as a tooth passes the pickup (square
wave output; ± 0.1 V). With the sensor connected to the powered control, the
voltage across contacts A - B will be 4.8 V (± 0.1 V).

Check transmission manual for possible non-control related

problems

36 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Troubleshooting

Symptom: Express mode does not work

Possible remedies:

Check for Fault Codes

♦ If Power LED (center) Red, low battery voltage detected. Correct low battery
voltage.

♦ If Power LED (center) alternately flashes Green to Yellow, a start-up fault has been
detected (forward or reverse direction selected when control is initially powered OR
low battery voltage detected while in gear and battery voltage returns to normal).
Remove power from both Solenoid A and B inputs (select neutral; fault clears
automatically). Check and correct low battery voltage if problem persists with
repeated transitions from neutral to gear.

♦ If Power LED (center) Green and Solenoid LED’s A or B constant Red, an internal
program data error has been detected. Re-power control. If the fault does not clear,
replace the control.

♦ If Solenoid LED’s A or B flash Red, coil open / short detected. Inspect coil
contacts, harness contacts, and wiring. Ensure all contacts are clean (no paint, etc).
Measure coil resistance (approximately 7-10 ohms).

♦ If Solenoid LED’s A and B simultaneously flash Red, both forward and reverse
directions simultaneously selected (neutral to gear transition inhibited). Check
Solenoid A and B inputs and return wiring.

♦ If Solenoid LED’s A and B simultaneously flash Yellow to Red, the simultaneous

selection of Troll and Express modes have been detected. Check Troll and Express
switch wiring.

♦ If Solenoid LED’s A and B alternately flash Red, the engine speed signal has not
been detected. Inspect engine speed sensor wiring harness, and contacts. Ensure
all contacts are fully seated and clean (no paint, etc). With the engine running,
examine the pickup signal to the control (1.0 V pk-pk minimum signal amplitude;
greater than zero frequency). If no signal or weak signal, check engine speed
sensor air gap (0.5 to 1.0 turn). Measure the resistance of the sensor
(approximately 913 ohms).

♦ If Solenoid LED’s A and B alternately flash Green while not in neutral, the propeller
speed signal has not been detected. Inspect propeller speed sensor wiring
harness, and contacts. Ensure all contacts are fully seated and clean (no paint, etc).
Check the speed sensor air gap (1.0 to 3.0 turns). Measure the resistance of the
sensor (contacts C – B approximately 4600 ohms; A – B and A – C neither open nor
short). The propeller speed sensor is a powered sensor and will not operate if
disconnected from the control. With the sensor connected to the powered control,
the voltage across contacts C-B will vary between two distinct levels of 0.7 and 3.0
V as a tooth passes the pickup (square wave output; ± 0.1 V). With the sensor
connected to the powered control, the voltage across contacts A-B will be 4.8 V (±
0.1 V).

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Troubleshooting Twin Disc, Incorporated

♦ If Solenoid LED’s A and B simultaneously flash Yellow, a slip speed command fault
has been detected (voltage and current active together OR signal out of range).
Inspect slip speed wiring and harness. Ensure all contacts are fully seated and
clean (no paint, etc). Ensure only one slip speed command type is active when the
control is powered. Ensure the signal limits are within the specified range (see
installation drawing for signal limits).

♦ If Solenoid LED’s A and B alternately flash Yellow, an engine speed signal has been
detected greater than the allowed frequency (inhibit speed reached and coil current
not at maximum). Correct high engine speed signal (possible faulty engine control /
operation). Fault automatically clears when the engine speed falls below the re-
enable frequency. Inhibit frequency and re-enable frequency are P/N specific.

Check for Power (center) LED not illuminated

No Power to Control
o Check fuse integrity. Replace blown fuse.
o Check Control Power and Control Ground wiring. Inspect wiring harness,
and contacts. Ensure contacts are fully seated and clean (no paint, etc).
o Check the transmission manual override switch (control not powered if in
override)

Ignition Switch Open

o Check Ignition switch wiring. Ensure Ignition return (J1 Pin 7) is not
connected. Inspect wiring harness, and contact. Ensure contact is fully
seated and clean (no paint, etc).

Check Solenoid LED’s A and B (Yellow = Express)

♦ If Solenoid LED’s A or B Green or Red while in gear, Cruise or Troll mode operation
has been requested. Check Troll and Express switch wiring (ONLY Express switch
closed/active for Express mode).

Check transmission manual for possible non-control related

problems

38 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Troubleshooting

Symptom: Unable to transition from Troll mode to Express mode

Possible remedies:

Check the slip speed command level

♦ Check the slip speed command signal. Ensure the slip speed command is within
3% of the minimum level.

Check transmission manual for possible non-control related

problems

Symptom: Harsh shifting experience in Express mode

Possible remedies

Check for Fault Codes

♦ If Solenoid LED A and B simultaneously flash Yellow, a slip speed command fault
has been detected (voltage and current active together OR signal out of range).
Inspect slip speed wiring harness and connector contacts. Ensure all connector
contacts are fully seated and clean (no paint, dirt, corrosion, etc). Ensure only one
slip speed command type is active when the control is powered. Ensure the signal
being used is within the specified range (see installation drawing for signal limits).

♦ If Solenoid LED’s A and B alternately flash Yellow, an engine speed has been
detected greater than the allowed speed (inhibit speed reached and coil current is
not at maximum). Correct the high engine speed signal. The fault automatically
clears when the engine speed signal falls below the re-enable frequency. Inhibit
frequency and re-enable frequency are P/N specific.

Check the slip speed signal command

♦ Verify the slip speed command is at or above the proper level before the engine
throttle is increased above idle. Correct the engine throttle behavior.

Check the transmission manual for possible non-control related

problems.

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Troubleshooting Twin Disc, Incorporated

Additional Hardware Troubleshooting

(4 - 20 mA slip speed signal only)

Symptom: All preceding troubleshooting has been performed and one or

more of the following problems still exist.

♦ Troll or Express mode does not work

♦ Incorrect speed range
♦ LED’s A and B simultaneously flash yellow
♦ Incorrect slip speed current

Possible Remedies

Check 4 - 20 mA source signal

♦ Disconnect J2 from the module. Measure the current supplied to the module.
Consult the manufacturer for proper measurement setup.

Check the fuse internal to the control

♦ Remove the Deutsch 2 pin plug from the power connector. With a multi-meter set to
ohms, measure the resistance from the J2 Pin 9 contact to the black wire of the 2
pin power receptacle. If the resistance is not approximately zero ohms, the internal
fuse has been opened and the control must be replaced for the correct current loop
slip speed operation.

Measure the voltage of the circuit

♦ Remove the Deutsch 2 pin plug from the power connector. With a multi-meter set to
diode measurement, measure the voltage across the J2 Pin 9 and J2 Pin 4
contacts. With the multi-meter leads in one direction, the voltage will indicate an
overload. With the multi-meter leads in the other direction, the voltage across the
contacts will be 0.38 - 0.65 VDC. Re-insert the power connector, power the control,
and repeat the measurements. If the voltage across the contacts with the control
powered is not 0.10 - 0.20 VDC with the leads in both directions, the control must
be replaced for the correct current loop slip speed operation.

40 MGX Express Control Module Operator’s Manual #1022510

Twin Disc, Incorporated Engineering Drawings

Engineering Drawings

List of Engineering Drawings

The following pages include the engineering drawings that are specific to these
models. The engineering drawings included are listed below .

Note: Any part numbers listed in the following engineering

drawings are for reference only. Please refer to your bill
of material for part numbers specific to your model.

 1022320 (sheet 1 of 2) MGX Express Module Installation

 1022320 (sheet 2 of 2) MGX Express Module Installation

MGX Express Control Module Operator’s Manual #1022510 41

Engineering Drawings Twin Disc, Incorporated

42 MGX Express Control Module Operator’s Manual #1022510

TWIN DISC
WARNING
TWIN DISC TWIN DISC
WARNING WARNING
#1022510 05/07

TWIN DISC, INCORPORATED RACINE, WISCONSIN 53403, U.S.A. 262-638-4000/262-638-4482 (FAX) WWW.TWINDISC.COM