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MIMS Machinery Movers mimsriggers.com

SERVICE MANUAL

UPPER LEyEF{

!` i...``."I<AGE REj|JRN

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SERVICE MANUAL

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SUPPLEMENTAL TOWMOTORQUE ADJUSTMENTS

CREEPER PEDAL ADJUSTMENT: (EARLY MOD-ELS WITH ROUDun CREEPER PEDAL) (See Page1.)

Creeper pedal travel should be set so that thepedal contacts the stop bolt (1/32 inch additionaltravel after the valveplunger is all the way into thevalve body). Adjust creeper pedal by lengtheningor shortening the adjustable yoke at the valve.

CREEPER PEDAL ADJUSTMENT: (RATE MODELSWITII STANDARD CLUTCH CREEPER PEDAL)

To adjust this t]xpe of creeper pedal linkage pro-ceed as follows: Disconnect the upper lever fromthe creeper lever support, mounted on the trans-mission, by removing the cotter pin and slippingthe upper lever off the creeper lever support.IJOOSenthe lOCkingPlng inthe end Of the Cross Shaft.The springloaded lowercontrol lever will then ro-tate the cam plate until both creeper control leverpins contact the left edge of the holes in the camplate. Tighten the locking plug approximately 10foot pounds of torque maldng sure the cross shaftdoes not rotate in the cam plate.

Move the creeper plunger to its fully extendedposition and place the creeper pedal against thepedal stop.

Withthe creeperplunger extended and the creeperpedal against the stop) reinstall the upper lever onthe creeper lever support. The hole in the upperlever should be aligned with the pin in the lowerlever. To make this alignmentl loosen ball jointjam nuts, then turn ball joint and upper leverl asan assembly} in or out as necessary to align pinand hole. After adjustmentis set, tightenball jointjam nuts and install washers and cotter pins asnecessary.

NOTE

On Models 540, 600, 670 and 680-P,followthe same adjustment procedure except whenaligning the hole in the upper lever and thepin in the lower lever'disconnect the adjust-able yokeat the brake pedal. Turn yoke andlever as an assemblyin or out as necessaryto align pin and hole.

After the initial linkage adjustments have beenmade, it may be necessary to make further adjust-ments to the linkage after the truckhas been drivenfor the first time.

1. If the clutch does not completely disengagewith the creeper pedal positioned between one ortwo inches from the floor board) the ball joint oradjustableyoke maybe adjustedto have the creeperplunger positioned somewhat into the valve bodywith the pedal fully released. The plunger shouldnot be positic)ned into the valve body sufficiently asto cause an increase in the shift eycle time or theclutches to slip. The position of the plunger thatwould cause achange in the shift cycle time varieswith each valve body due to the internal'cored oilpassages in the valve body.

2. If the pedal position for creeping the truck isnot the same in forward and reverse gearl the camplate may be rotated slightly on the cross Shaft tOcompensate for the difference in travel ofthe clutchlinkage. If the pedal position is lower in forwardgear than in reverse, rotate the cam plate on thecross shaft in a clockwise direction (viewed fromthe left side of truck). Ifthe pedalpositionis higherin forward gear than in reverse gear, rotate thecam pla.te on the cross shaft in a countercloctw7iSedirection. This adjustment may be required witheach rebuild of the transmission that affects theamount of travel of the clutch linkage.

I It is necessarythat the movement of the creeperplunger closely follow the movement of the creeper.pedal due to the nature of this control mechanism.A binding or sticking condition in the linkage thatresults in an abrupt movementof the plunger in thevalve bodyl causes the truck to lurch and givesdifficulty in controlling the truck speed duringcreeping. Tlle linkage Should be lubricated withSAP 30 engine oil at eachpivotjointduring assemblyand none of the linkage should bepainted. The link-age return spring preloads the linkage to take upthe initial clearances at each pivot point, and anyincrease in clearance due to wear.

CREEPER PEDAL AND LINKAGE

(LATE MODELS)

The following information contained in thesesupplement pa.gee refers to the adjustments of thiswhew style" creeper pedal linkage. Variations inoperation between "early modelw linkage and Mlatemodelw linkage is given under the title uHow toCreep in Tight Spots".


SERVICE MANUAL

This new style linkage is quite sensitive in itscreeper pedal actions, therefore, accurate adjust-ments are required for best efficiency and operationof the truck during "creepingw.

Identification between "early" and nlate" modellinkage can bc distinguished as follows: Earlymodels have a round button-type creeper pedalwhile the late models use apedal similar to a stand-ard transmission clutch pedal.

HOW TO 'ICREEP" IN TIGHT SPOTS"

(LATE MODELS)

Procedures for creepihg in tight spots areessen-tially the same as those used in the "earlymodels"except that extremely easier creeper pedal actionis obtained through the newly designed linkage. Ineffect, the creeper pedal linkage is given a hydraulicand mechanical assist by the shift cylinder, crossshaft and cam plate. The amount of creeper pedaleffort varies only with the force exerted by the

creeperpedal returnspring. This enables the oper-ator to "ride" the creeper pedal for less effortwhen inching. It is not necessary to "pump" thecreeper pedal for inclling) it iS Only necessary tOmove it slightlyup and down. After a few trips theoperator can readily determine the amount of pedaltravel necessary for inching.

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SERVICE MANUAL

TOWJVIOTOROuI

SERVICE MANUAL

The Service Manual is divided into sections as listed in the Table of Cc)ntents.

It contains service and repair instructions for Towmotorque Transmissions a.s used

on Towmotor Models 540, 600) 670 and 680-P.

The service and repair infc)rmation contained in tlliS manual covers the trams-

missions being currently produced and sold by the Towmotor Corporation.

When ordering replacement parts be sure to use genuine Towmotor Specified

Replacement Parts. Use of substitute parts results in lower operating efficiency

of the lift truck.

SERVICE DEPARTMENT

TOWMOTOR CORPORATION

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SERVICE MANUAL

TABLE OF CONTENTSPage

IIOW TODRIVEWITHTOWMOTORQUE,....................... 1

DESCFIIPTION ............... ....I..''.'..... .'.........

ShiftingCycleTime''..................-................

CreeperPedalOperation..................................

BrakingwithTowmoTorque................................

TOWMOTORQUE OILSYSTEM................-.......I......

Description'.I.........................-.-......'..'..

OilChecking)DrainingandFilling ...........................

OilPressureCheck . . . ....

ClutchCooling Check...... I

TOWMOTORQUE ADJ USTMENTS

CreeperPedal Adjustment... IControl Lever Adjustment... I

Clutch Adjustment and Operation Check........

TOWMOTORQUE TROUBLE SHOOTING.........................

PrimaryChecks...............'''.I....................

TroubleConditionsandCheckPoints .'..I....................

REPAm INSTRUCTIONS ....... ..I......................... i;;6TowmoToI.queReplacement................................ 10

Disassembly..,.........,............................. 10

Assembly.......................................,..., 16

OilPump.................

Duplex Clutch and Shifting LinkageShiftOperating Cylinder.......

ContI.OIVa-lve .............

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HOW TO DRIVE WITH TOWMOTOROuE

CFiEEPERPEDAL

I. Position shift lever in neutI.al and Start engine.Positioning shift lever in neutral operates a safetyswitch which closes a circuit to the sta.rting motorand permits operator to start engine.

2. Shift control lever and push ga,s pedal. Pushshift lever forward to go forward. Pull leverback-ward for reverse. Push gas pedal and move shiftlever at the same time.

HOW TO "CREEP"

SHIFTLEVER

3. Drive Towmotor. Once Towmotor is in mo-tion, the driver need only step on the gas pedal forspeed control - a-nd move control lever if he wantsto change direction.

4. To stop. Release gaspedalandsteponbrakesto stop Towmotor. It is not necessarytomove con-tI.Ol lever into neutral or step on creeperpedal.

lN UTICHT SPOTSw(EARLY MODELS)

To drive Towmotor at a creeping speed and stilloperate engines at high speed for fast liftingJ tiltingOr accessory OPeI.atiOn...

First... Push creeper pedal to floor. Thisactionstops power from engine to wheels.

Second... Lift foot to let pedal come back abouthalfway. This action will causepartialdrive motionfrom engine to wheels.

Third... Move pedal up and down from floor tohalfway position and at the same time press downon gas pedal. The repeatedaction of pushing creeperpedal down quickly and releasing it slowlywill causeshort periods of partial drive motion and Towmotorwill move at a smooth, controlled creeping speed.High engine speed will allow fast lifting} tilting orother hydraulic actions.

HOW TO SPEED uP 'lSHunLE TYPE" OPERATION

For fast "shuttle type, ' opeI.atiOn, Change traveldirection without stopping Towmotor completely(low engine speed recommended).

First... When Towmotor is twoor threefeetfromload, pull shift leverbacloward. This leaves driver,shands free to operate lift controls.

Second... Let Towmotor coastupto load, operat-ing lift control lever.S aS neCeSSar.y and StePPingOnfoot brakes if necessary.

Third... Press gas pedalwhen loadingor unload-ing is completed.

DO NOT USE TOWMOTOROuE AS A BRAKE

lhthen Towmotor is moving (high engine speed) and stopping?step onbrakepedalto slow downor stop. Doshift leveI` iS moved for Change Of direction before not use Towmotorque as a constant braking power.


SERVICE MANUAL

TOWMOTOR TOWMOTOROUE DRIVE

SUPPLY LINES TOOPERATING CYLINDER

FOR DIRECTIONSELECTION

Fie. 1. To-oTorque TretlsmlSSiOn - A.Bembled View

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SERVICE MANUAL

AIR COOLING

FAN SHROUD

TORQUE

CONVERTER

COOLING AIR

OUTLET

FOFtWARD IDLER

GEAR

OUTPUT GEAR

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DESCRIPTION

Flo. 2. To-oTc,rc(ue C:uta-E\y

TowmoTorque is designed to provide hydI.a.uliC-ally controlled power... to eliminate gear shiftingand clutching delays... and to provide effortlessdriver control.

The TowmoTorque drive is a heavy duty> arrandoil cooled hydraulic torque converter type trans-mission. The principle operating parts are a hy-draulic torque converter, a duplex directional clutchfor forward and reverse travel, and a constant-mesh, drop-down t]pe gear train tha.t requires noshifting. DI.iVing torque iS transmitted Smoothlyand efficiently from the engine through the converterto the drive wheels for either forward or. reversemovement. Control of forward or reverse directionis accomplished by a flip c)I the control lever whichis positioned at the steering wheel.

The hydraulic torque converter is a combing.lionfluid coupling and torque converter of the single-stnge, thI.ee-element type. The three elements arethe impel|er, the turbine| and the statoI.. The im-peller is driven by the engine flywheel, the turbinedrives the clutch, and the statorpl.ovides the abilityto multiply torque.

FORWAF]D

DIRECTIONAL-CLUTCH

REVERSEOIRECTIONAL-CLUTCH

REVERSE DRIVINGGEAR

FORWARD DRIVINCGEAR

CREEP CONTROLVALVE FILuNGER

DIRECTIONAL CONTROLVALVE PLUNGER

OUTPUT SHAFTCONNECTION

The duplex directional clutch consists of aclutchf1]rvheel driven by the converter, a double-facedpressure plate, and forward and reverse clutchplates. These parts) plus operating links}pins}etc.are enclosed in a. clutch cover. Clutch plates areconed to assure rapid disengagement.

The gear train is a drop-down type consisting ofSPLIT t]Pe gears Which are in COnStant mesh. Gearshafts are supported by heavy-duty ball and/orroller bearings.

The converter, clutch, and gear train are housedin two individual caces bolted together. The conveI.t-or case houses the hydraulic torque converter andthe transmission case houses theduplexclutch andthe gear train.

SHIFTING CYCLE TIAAE

The shifting cycle, to either forward or reverse,should be accomplished ln 3/4 to 1-1/3 seconds afterthe control lever is movedintothe desiredposition.For acomplete reversalof directionI shifting shouldrequire 2 seconds after the control lever is moved.


SERVICE MANUAL

The shifting lever is designed for finger tiPCOn-trol. Movement of the lever should I.equirenO moreeffort than a flipping of the fingers.

CREEPER PEDAL OPERATIONwhen the creeper IJedal iS in the fully released

position or partially depressed up to the half-wayposition (with truck in motion)) drivemotionshouldcontinue.

When the creeper pedal is fully depressed Withthe truck in motion, power to the dI.iVe Wheels willcease imTrlediatelyJ regardless of c.ontrol level.

position or engine speed. Do not confuse "OVer-rol1" or coast witll drive motion.

when the creeper pedal is released from afully-depressed position to an approximate half-wayposi-tion (with control lever in forward or I.eVerSe),gradual clutch engagement should occur.

BRAKING WITH TOWJVLOTOROUEvIlen Towmotor is in motion (high engine I.Pm)

and control lever is shifted for opposite directionbefore stopping truck, stop or slow dc)wn truckwithfoot brakes. Do not use TowmoTorque torque con-verter as a constant braking power.

TOWMOTOROUE OIL SYSTEM

DESCRIPTIONThe heart of the oil system iStheOil Pump Which

is located between the torque converter andthe con-verter case. The sleeve extension at the Center ofthe converter is provided with lugs which engagethe oil pump drive gear. The pump is driven COn-tinuously while the engine is operating. Oil ispumped from the sump) through a strainer, then tothe oil pump. The oil pump outputisdirected tO thevarious units affected by the c)il system.

The oil flow in the system iS directed in the fol-lowing manner: (1) pump to radiator heat exchanger,(2) radiator heat exchanger to converter, (3) radia-tor heat exchanger to clutch, and (4) pump to con-trol system. See figure 3.

converter system. Oil is directedto the convert-er through provisions in the pump support and thestator anchor. Fromthe COnVerter,itPasSeS througha pI.eSSure regulator Valve, COnVerter Output Shaft,and pump support) then back to the sump.

clutch System. Oil is directedthrough a restric-tion to the forward and reverse clutch. At the clutch,the oil flows out between the clutch hubs and ontothe driven discs. This means that the ClutChthat iSnot driving can be cooled during its disengagedperiod so that it is cool and wet with oil when thenext engagement is necessary. Oil from the clutchreturns as spray directly to the sump.

Control System. The c,ontrol system receives itsoil from aconnection in the puTrIPOutPut line. Basic-ally| oil from the pump passes from the pumpthrough the control valve, accumulator valve, intothe shift cylinder, back through the accumulatorva.lve to the control valve then it is dischargedinto the sump.

The control valve is provided with two plungerswhich act as valves to control direction selection

and creeper action. The direction plunger iS oper-ated by the control lever mounted on the steeringcolumn. The creeper plunger is operated by thecreeper pedal.

shifting of the control lever moves the directionalplunger to introduce oil into the double-acting shiftcylinder, which in turn produces engagement of theclutch in the desiI.ed direction. Flow of oil to thedirectional plunger and eventually to the shift cyl-inder. iS COntrOlled by the CreePerPlunger POSitiOn.

uThen the creeper pedal is fully released, thecreeper plunger is positioned to allow free flow ofoil to the directional plunger. When directionalplunger is in a forward or reverse position) oilflows to either side of shift cylinder which in tumengages the clutch in the desired direction.

when the creeper pedal is fully depI.eSSed, Oilflows to the directional plunger and to the shiftcylinder and is blocked, thus preventing shift cyl-inder opera.tic)n to engage clutch.

when the creeper pedal is released half-wayJOilflow to the directional plunger is permitted, but itmust travel through a restricted opening. With thedirectional plunger in a forward c)r reverse posi-tion, oil flow to the shift cylinder is controlled bythis restricted opening in such a manner that itslows down speed of clutch engagement. If the pedalis held in the half-way position, the clutchwill soonbecome engaged but not as ra.pidly aswhenpedal isfully released.

A pressuI.e regulator Valve iS mounted in the boreof the creeper plunger. This valve limits maximumpressures in the system by controllingoil return tothe sump when the pump is delivering more oil thanthe system requires.

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Fie. 3. To-oTorque Oil Sy.8tem

OIL CHECKINO, DRAININOAND FILLING

The transmission should use little or no oil, how-ever, periodic checking of the level is necessarytoassure Proper OPeratiOn. Oil should be changedafter each 1500 hours of operation.

Oil level should be checked immediately afterstopping the engine. To check oil level remove oillevel plug in front cover. Oil should be level withthe bottom of the plug opening. If more than twoor three quarts are added at anyonetime, examinetransmission for external leaks. lThen filling isnecessaryJ OPerate engine and reCheCk Oil levelafter refilling.

To drain oil from converter., remove Case Coverto expose the converter. Remove plug from con-verter and crank engine l800 to dra.in the oil. oilwill drain through opening in the flywheel housing.

To drain oil from transmission case} reTnOVe themagnetic drain plug. Clean drain plug to removemetal chips or foreign material.

lThen draining is completed, replace bottomplugand transmission case plug.

Fill the transmission through the breather capopening using a funnel. Capacity is l2 quarts.Operate engine for |O or 15 minutes then removeoil level plug and recheck oil level.

The factory I.eCOmmendS the use of Automatic


SERVICE MANUAL

Transmission Type "A" oil to a.ssure best opera-tion. Engine oil SAE 10 maybeusedtemporarilybutnot for any periodofservicelongerthana few days.

OIL PRESSURE CHECK

Normal operating pressures for the Towmo-Torque oil systems are aS follows:

Engine Speed oil pressure (pst)(rpm)

500 25-351200 55-752400 70-90

Procedure

up period so that the inspection will reflect actualoperating conditions.

2. Insert test gage (160 pst) in pump outlet fitting.

3. Check pressuI.eS With engine OPeratingJ trans-mission shift lever in neutI.a1, and creeper pedaldepressed. If normal pressures are not obta-ined,refer to Trouble Shootlng] Condition VI and VII.

CLUTCH COOLING CHECl(check cooling supply to the clutches by discon-

necting the oil line from the control valve housingand inserting a. fitting with a 1/16" diameter re-striction hole so that the discharge oilcanbe mea-sured. start the engine, operate at 1200 rpm andmeasure time required to pump 1 or 2 quarts ofoil through the restricted hole in the fitting. Onequart should take 15 seconds and two quartsshOuldtake 30 seconds. While the cap is off, blow through

1. Pressures should be checked after a.Warm- the Shaft tO assure that the Passage iS Clean.

TOWJVLOTOROu I ADJuSTJVIENTS(EARLY MODELS)

CREEPER PEDAL ADJUSTMENT.

creeper pedal travel should be set sO that thepedal contacts the stop bolt (1/32" additionaltravelafter the valve plunger is all the wayinto the valvebody). Adjust creeperpedal by lengtheningOr Short-ening the adjustable yoke at the valve.

CONTROL LEVER ADJUSTMENT.

control lever travel in both directions should beequal distance from the shift lever stop which islocated on the steering column. Adjust lever tI.averby lengthening or shortening the control lever rod(rod from the foot of the lever to thevalve).

CLUTCH ADJUSTMENTANDOPERATIONCHECK-

No adjustments are required Or Provided forclutch wear. The stroke of the shift cylinderiS de-

Fie. 4. Clutcl` Neutral Setting AdjuEltnlentDimensions

signed tcl completelywear out both clutchplates. Ad-justment shims located under the shift cylindermounting flange are factory adjustmentsfor neutralsetting. In the event of shift cylinder replacement,dimensions for neutral setting mustbe measured sothat correct neutral setting can be obtained throughshift cylinder adjusting skims. To checkthis dimen-sion, remove transmission top cover) then measurethe distance between the face of the clutch flywheeland the edge of one of the pressure plate drivinglugs. Dimension should be as shown in figure 4.

A simple check of correct clutch operation iS aSfollows: Set hand brake or move the truck aga.instsomething immovable with a little weight on theforks. Race the engine with shift lever in neutraland shift into a direction. Proper action shouldsharply decrease engine speed to approximately1200 to 14OO rpm and hold it there. Also it shouldtake no longer than three seconds fI.Om Start tOcompletion of engagement.

If clutches are slippingJ a Sharp decrease inengine speed will not be apparent but only a. slightmomentary slow down will occur for an instant)then engine will retuI.n tO its approximate Originalspeed.

To check clutch engagement with the creeperpedal in the half-way position, vehicle held station-ary as described above, and engine running a.bout1000 rpm , shift into adirection. The clutches shouldengage normally in the manner described above, buta longer period of time is necessary toaccomplishcomplete engagen`ent.

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TOWJVIOTOROUE TROUBLE SHOOTING

This trouble shooting guide is divided into twosections: (1) Primary checks and (2) specific. troubleconditions with their possible causes and remedies.

If trouble is encountered, perform checks with thetransm-ission warmed up. This can be convenientlyaccomplished by an exploratory roadtest in an effortto definitely establish the abnormal operating con-dition. After the Ira,nsmission is warrrled up} per-form operations contained under Primary Checks,then proceed with other inspections indicated for.specific trouble conditions.

Normal operating characteristics of the Towmo-Torque are described under instructions for Oper-ating Townlotor with TowmoTorque Drive. It is sug-gested that the service man become familiar withthese characteristics before attempting to analyzea troubled situation.

PRIMARY CHECKS

I. CHECK OIL LEVEL.

1. Check immediately alter operating engine tomake sure that all TowmoTorque cavities re-quiring oil are full. Refer to TowmoTorqueOil System for additional information.

II. CHECK CREEPER PEDAL AND SHIFT LEVERLINEAGE.

1. Check all linkage for good condition and cor-rect adjustment.

2. Shift lever travel in both dir.ections shouldbeequal distance from the shift lever stop whichis located on the steering column. Adjustlever travel by lengthening or shortening theshift lever rod (rod frorr\ the foot of the level.to the valve).

3. Creeper pedal shouldbe setforoperatorcom-fort and travel should be set so thatthe pedalcontacts the stop bolt (1/32" additionaltravelafter the valve plunger is all the way into thevalve body). Adjust cI.eePerPedalby lengthen-ing or shortening the ardjustable yoke at thevalve.

Ill. CHECK TRANSMISSION OIL PRESSURE.

1. Pressure should be checked alter a war.m-uPperiod so thatthe inspection will reflect actualoperating conditions. Method for checking isdescribed under instructions for Towmo-Torque C)il System. Normal pressures shouldbe as follows:

Engine Speed Oil Pressure (pst)(rpm)

500 Z5-351200 55-752400 70 -90

IV. CHECK OIL COOLING SYSTEM.

I. Check cooling supplyto clutchesby measuriIlgoil flow. For procedure, refer to instructionsunder TowmoTorque Oil System.

TROUBLE CONDITIONS ANDCHECK POINTS

v. TRANSMISSIC)N C)IL FOAMS OR OIL IS DIS-CHARGEI) FROM BREATHER.

1. Transmission over filled_

2. Transmission oil contaminated with water.

3. Incorrect oil in transmission.

4. Air leak in pump suction line.

VI. LOW C)IL PRESSURE.

1. Low transmission oil level.

2. Plugged pump inlet screen in sump. Refer toCondition IX, Item 4.

3- Pump faulty- Refer to Condition IX, Item 1.

4. System relief valve stuck open or leakingbe-cause of dirt.

5. Converter pressure regulator valve Stuckopen. Check by applying air pressure intonipple (at bottom of transmission) whichfeedsoil to the transmission. Valve should crackat approximately 25 psi or slightly more upto 35 psi.

6. Worn hushing (supporting converter outputshaft in collector ring). Valve operation checkperformed in Item 5 aboveJWOuldnOtdifferen-tiate between valve or hushing troubles} buteithel. trouble would necessitate disassemblyfor further inspection and correction.

7. Pinched or clogged supply line.

8. Air leak into pump supply passage or line.Refer to Condition V for indication of leakage.

9. Pump drive lugs shearedoff converter sleeve.Check by plugging pump outlet and turningconverter by hand, either with engineor afterdisconnecting converter drive straps from theflywheel. If the converter can be turned, thelugs are probably sheared. This condition


SERVICE MANUAL

would probably be ac.companied by excessivenoise.

|0. Worn O-ring seal in contI.OI Cylinder.

ll. If other checks fail to conclusively locate thedifficultyJ the Pump may be faulty. The pumpshould deliver approximately 3-1/2 gallons

ioeoroFTl::lt:e:tpelrOaOtOurer.pm engine speed and

VII. IIIGH OIL PRESSURE.

1. Jammed system I`elief Valve.

2. Pinched oil line.

3. Plugged oil line or passage.

VIII. ENGINE WILL NOT START OR STARTINGMOTOR NOT WORInNG.

1. A safety switch is mounted in theCOntrOI Valve.This switch will OPerate Only when the shiftlever is in neutral. If lever is not in neutralthe engine will not start.

2. Perform usua.1 checks for standard Causesof engine failing to start or starting motorfailing to operate.

3. If starting motor will not turn engine Over,make sure the usual standard checks aremade. If trouble is not found, check for Pumpseizure by disconnecting torque converterfrom flywheel, then see if starting mctorwillturn engine. Remote possibilities would beplugged hydra.ulic line and extreme pressureresulting in engine stall.

K. TorrmrfOTC)R WILL NOT MC)VE WITmhmEELSFREE TO TURN.

1. If this condition exists after truck has beenstanding over night and truck continues to re-fuse to move after operating engine fc)r oneminute, check oil pressure. If the pressurereading is low| it indicates loss of pump primedue to excessive clearances. Inspect pumpand upon verification of the trouble, replacepump. Also, check the clutches to assurethat prolonged use of a truck operating underthis condition (reduced pressure) has notdamaged the clutc.hes due to slippage.

2. I-ow oil pressure. Check Items listed underCondition VI.

3. Faulty Control linkage. Visually inspect allcontrol linkage to make sureitis ingood con-dition and correct ad]ustTnent.

4. Pump oil inlet screen plugged. This pumpinlet screen is located at bottom of trans-mission. If plugged conditicln does exist] itshould have been indicated by agradual slow-ing down of the shift cycle time.

X.

5. Clutches Worn. A completely worn Set Ofclutches is also a possible cause of truck notmoving. If this condition exists, it WOuldPrO-bably occur in one direction only andwouldbepreceeded by excessive slippage.

6. TI.uCk refuses tO mOVein One direction and/Ortends to creep. If truck operates in thiSman-nor when the shift lever is in neutral or withcreeper pedal depressed but was operatingcorrectly previously} checkfor abuckledshiftcylinder to snifter yoke push pull rod.

Also, if truck refuses to mOVeinOnedireC-tion, check the shift cylinder for abrokenneu-tral return spring which could have jammedand caused limited cylinder travel. With thetransmission cover removed, the shift mech-anism can be operated manually and visuallyinspected for other type interference whichmight be causing the trouble.

TOWMOTOR WILL NOT MOVE WITH\VIIEELSFREE TO TURN WHEN C)FF FLOOR.

I. This trouble is usuallycausedbyinterferenCein the transmission or line of drive. Refer toItems under Condition XIII.

xI. Torm¢OTOR CREEPS FORWARD OR BACK-WARDS WITH SHIFT I,EVER IN NEUTRALAND/OR CREEPER Pal)AL DEPRESSED.

I. cylinder neutral return springs broken. Brok-en spring nearest the piston rodendwillcausecreepage in forward. It will cause creepage inthis direction only when the shift lever is inneutral) a.ndwill cause slow release from thisdirection or occasionally hang up when thecreeper pedal is depressed. When the otherspring is broken, the truck will act normalwhen the lever is in neutral but the brokenspring will affect creeper pedal response inreverse. With either or both springs broken,the clutchwill hang up and not releaseproperlywhen the creeper pedal is depressed.

2. Loss of pump prime. Refer to Condition IX,Item 1.

3. Faulty needle bearing in the clutch flywheel atthe clutch output sleeve. This would causecreepage in reverse and would probably bevery noisy in the opposite direction. It canbechecked by removing the transmission coverand manually spinning the clutch flywheel.Flywheel should tut.n Very freely and Withoutnoise.

4. Scored and/or sticking shift cylinder or bentpiston rod in the cylinder. Check for thistrouble through the transmission accessopening.

5. Scored shifter carrier and shifter whichwould

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result in sluggishness. Inspect visuallythrough opening in transmission.

6. Faulty control linkage. Inspect all controllinkage to make sure it is in good conditionand correct adjustment.

XII_ LACK OF ACCEIJERATION ANI) I)OWERUNDER FULL THROTTLE AND HIGH POWERREQUIREMENTSWITH LOW ENGINE SPEED(approx. 1000 rpm or less

1. Oil pressure too high. Refer to ConditionVII.

2. Engine power low. Check timing and otherstandard conditions that may cause the engineto lose power.

3. Transmission oil pump or pump drive sleevehushing binding. This conditionwould probablybe accormpanied by excessive noise.

4. Stator one-way clutch slippage.Replace torquec.onverter. Do not replace converter unlessall other possible troubles ha.ve definitely beeneliminated.

XIII. LACK OF ACCELERATION ANI) POWERUNDER FULL TIIROTTLE AND HIGHPOWERREQUIREMENTS WITH NORMAL ENGINESPEEI) (12OO to 1400 rpm)

1. Check for binding in transmissioncauSedbyafaulty bearing or interference at otherpoints.check hushing between clutch output sleeveand output shalt. If the universal joint is dig-connected) it would help isolate the cause ofthe trouble.

2. If lack of acceleration andpower is in reverseonlyJ Check the flywheel for free SPin Withthetransmission cover removed. If it does notspin freely} the clutch output shalt bearingcould be faulty.

3. Drag in drive axle. Check for drag in driveaxle including hand brake and foc)I brakes.This condition is likely to appea.rim newtruCkSdue to tightness of new parts. In this case,the condition should disappear after a fewhours of operation.

XIV. LACK OF ACCELERATION Ann POWERUNDER FULL T[IROTTLE ANDHIGHPOWERREQUIREMENTS WITH HIGH ENGINE SPEED(above 1500 rpm)

1. Excessive clutch slippage. Refer. to ConditionXV.

XV. EXCESSIVE CLUTCH SLIPPAGE IN EITHEROR BOTII I)IRECTIONS.

1. Low oil pressure. Refer to Condition VI.

2. Air leak in pump suction line. Refer to Con-dition V for indication of leakage.

3. Pump oil inlet screen plugged. Refer to Con-dition IX) Item 4.

4- Faulty shift cylinder or linkage. Referto Con-dition IX, Item 6 and Condition XI, Item 4.

5. Scored shifter and carrier. Referto ConditionXI, Item 5.

6. IJOSS Of Pump Prime. Refer to Condition IX,Item I.

7. Clutches worn. Refer to ConditionTX,Items.

8. If slippage occurs when starting a stationar++truck and not while Operating the truck, thetrouble could be in the control linkage. Thiscondition would also be act.ompanied by sic)wshifting, unless the trouble is in the forwardaccumulator valve for the "small series"trucks- Tighten adjusting screw all the wayto see if the trouble stops. If sol simply re-adjust to maintain 1-1/2 to 3secondsengage-ment.

XVI, CLUTCHES I)a NOT DISENGAGE CLEANLYAND QUICKLYWIIENSIIIFTED TC) NEUTRALOR WIIEN CREEPER PEI)AL ISDEPRESSED.

1. Loss of pump prime. Refer to Condition IX,Item 1.

2. ClleCk Shift Cyllnder, linkage, and clutch out-put sleeve bearing as indicated under Con-dition XI.

3. CTheck clutch driven discs forpropercone andgIooving.

XVII. SLUGGISHNESS IN ENGAGEMENT TIME INSHIFTING CYCLE.

1. Make sure that control linkage isingoodcon-dition and correct adjustment.

2. Low oil pressure. Refer to Condition VI.

3. Air leak in Pump SuCtlOn line. Refer to Con-dition V for indication of leakage.

4. Pump oil inlet screen plugged. Refer to Con-dition IX, Item 4.

5. Farllty shift cylinder or linkage. Referto Con-dition IX, Item 6, and Condition XI, Item 4.

6. Scored shifter or carrier. Refer to ConditionXI, Item 5.

7. Loss of pumpprime. Refer to Condition IX,Item 1.

8. Clutches worn. Refer to ConditionK, Item 5.

XVIII. OVERHEATING AS EVDENCED BY ANOFFENSIVE ODOR FROM THE OILTHIS PLUS RADIATOR OVERHEATING.

1. Check for clutch slippage. Referto ConditionIV.


SERVICE MANUAL

2. If overheating ls ln radiator OnlyJ CheCk fanbelt and other standard usual causes for cool-ing system overheating.

3. Binding inlineofdrive. Checkforinterferencein line of drive as indicated in Items underCondition XIII.

4. If only oil overheating is present, check allcooler lines for plugging. Check cooler for aplugged condition. Check cooler bypass valvefor leaking (valve should cI.aCk at 30 psi).Check water side of cooler for cleanliness.Check all Items under Condition VIfor causesof low pressure.

5. Check tI.uCk OPerating COnditiOnS for factorswhich may cause overheating.

NOTE

Automatic TI.anSmiSSiOn Oil Type A does nothave an original bad odor butwhenithas beenoverheated it assumes a veI`y Offensive Odor.This odor can easily be used aS evidence Oroverheated oil. It would be good practice tomake a complete oil change alter an overheat-ing situation has been col.reCted,first becauseof damage to the oil anc] second for evidencethat the problem has been solved.

REPAIR INSTRUCTIONS

TOWJV\OTOROuE REPLACEW\ENTRemove Transmission and Engine from Truck.

1. Remove engine hood, left and right Side Plates,front plate, counterweight top plate and counter-weight.

2. Drain cooling system, then remove radiator.and hoses.

3. Remove floor plates} then disc.OnneCt Creeperpedal linkage and shift lever and linkage.

4. Disengage hydI.auliC Pump from engine timinggear cover by removing nuts and washers.

5. Disconnect exhaust system, fuel lines} elec-trical system connector and accelerator pedal andlinkage.

6. Disconnect engine mountings. Using asuitablehoist and cable sling) raise engine and transmissionup and out of vehicle, disengaging universal jointas engine is removed.

Remove Transmission from Engine.

CAU TION

The following proceduI.e must be fOl-lowed to eliminate damage by allowingtotal weight of tra,nsmission to hang onconverter.

Remove converter case cover. This will exposesix sol.ews that fasten converter to engine flywheel.Remove these screws before separating trans-mission from engine. Converter can be removedfI.Om transmission after TowmoTorque is separatedfrom engine.

Install Transmission on Engine.

Prior to installing transmission on engineJ mountconverter, carefully aligning driving lugs with oil

pump drive gear. \Then mounted properly} con-verter should touch the converter case. With con-verter in this position, assemble transrmission toengine and bolt case to engine. Slide convertertoward engine flywheel and align bolt holes. In-stall screws securing converter to engine flywheeland lock wire in pairs. Installconverter case cover.

Install Transmission and Engine in Truck.

1. Using a suitable hoist and cable slingJ lowerengine in place and engage the universal joint atthe same time. Connect engine mountings.

2. Install the exhaust system,fuellines)electri-cal system connector and accelerator pedal andlinkage.

3. install hydraulic pump on timing gear coverand secure with nuts and washers.

4. Connect shift lever and linkage, and creeperpedal and linkage. install floor plates.

5. Install radiator and hoses and fill systemwith proper coola,nt_

6. Install counterweight, counterweight top plate,front plate,left and right sideplates andengine hood.

DISASSEJVIBLY

DISASSEMBLE TRANSMISSION. Disassemble theTowmoTorque transmission as outlined in the fol-lowing numbered procedures.

1. REMOVE TORQUE CONVERTER.

a. See Figure 5. With transrmission and engrneassembly out of truck, remove torque converter (3)when separating transmission from engine) seeTowmotorqlle replacement.

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SERVICE MANUAL

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A

Ref.No. Descripticln

i CASE, torque converter2 BEARING, ball| converter case3 CONVERTER ASSEMBLY, torque4 C,OVER' torque converter case5 GASKET, converter oil p\1mP6 NUT,hexltCOVertOCaSe7 NUT,hex.|covertocase8 NUT, hex.} trams-ission case to cc)TIVerter Case9 HOUSING ASSEMBLY, pu-p

lO SEAL ASSEMBLY, oilll RING ASSEhABLY' collectorl2 BUSHING

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l3 RING, seal| largel4 RING, seal, smalll5 SCRE|h/, cap' collector ring to housingl6 SCREW, c.apt collector ring to housillgl7 WASHER' lock. collector ring screwl8 WASHER. lock, collector ring screwl9 RING, retainer| converter case bearing20 RING, retainer. output shaft and valve2| SCREW' cap| converter pu-p to converter case22 SCREW' cap| ccrver tocase23 SCREW. cap, cover tocasez4 SCREW, cap, torque converter case to transmit.Sic)n CaLSe25 SEAL, converter c:age to transmission Case26 SEAL, converter cc)ver| lowerZ7 SEAL, coI`Verter COVer| upper28 WASHER, flat, cover tc) case29 |ll/ASHER, flat' cover to case3O \l/ASHER, lock, c.over to case3l WASHER, lock, cover to c-a-se32 WASHER, lock' transmission case to torque cclnverter Case33 WIRE, locking, converter pump to converter case34 SCREW' cap| converter to flywheel35 SCREW, cap' trams-ission to flywheel housing36 WASHER' lock, transmission to flywheel housing screw37 WIRE, 1ocking' tclrque converter to flywheel

Fig. 5. Converter' Converter Case and Oil Pump

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SERVICE MANUAL

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Re£INo. Description

I LEVER, clutc:h operating2 LINK. lever topressure plate3 PIN, cotter, anchor pin4 PIN, lever anchor5 PIN, linkpivot6 PLATE, clutch cover7 PIJATE, clutch pressure8 PLATE ASSEMBLY, reverse clutch9 BEARING, ball| shi£ter carl.ier

lO BEARING, needle, forward clutc.h shaftll CARRIER, shifterlZ FLYWHEEL, clutchl3 LINK ASSEMBLY, shift opeI.atingl4 PIN, cotter' linkto operating yoke and op-

Crating cylinderl5 PIN, grooveJ Snifter ring|6 PIN, link to yoke and operating cylinder|7 PLATE ASSEMBLY. forward clutch18 PLUG, operating yoke shaft

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l9 RING, retainer' carrier to shifter ring20 RING, retainer, carrier bearing2l RING, shilter22 SCREW, c.ap| shifter sleeve totransmission

CL±Se

23 SCREW, cap| clutch assemblyto clutchflywheel

24 SCREW, cap| converter cutput shaft to clutchZ5 SCREW, set, operaLting yoke Shaft26 SHAFT, operating yokeZ7 SIIAFT and VALVE ASSEMBLY' cc)nverter

ou+putZ8 SLEEVE' shifteI.29 WASHER. flat, link to yoke and operating

cylinder3O WASHER' lock, shi£ter sleeve screw3l WIRE, locking. clutch cover screw32 WIRE, |clcking' converter output shaft to

clutch flywheel Screw33 YOKE, snifter operating

Fig. 6. Clutch Assembly. Cat-rler and Linkage

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SERVICE MANUAL

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Description

1

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I C,ASH, transmissioTl2 BEARING' bal|' forward clutch shaft3 BEARING, ball, idler gear shaft (front)4 BEARING, ball, output shaft (rear)5 BEARING' ball, reverse clutch shaft6 BEARING, ball, idler gear shaft (rear)7 BEARING, ball, output shaft (front)8 BREATHER' transmission case9 COVER and SEAL ASSEMBLY. output

shaft (front)lo SEAL, oil, output shaftll COVER, idler gear shaftl2 COVER, traLnSrniSSiOn Case topl3 GASKET, idler goal. Shaft Coverl4 GASKET, output shaft lrorlt coverl5 GASKET, trams-ission case top coverl6 GEAR, forwaLrdl7 GEAR, forward idlerl8 GEAR, output shaftl9 GEAR, reverse20 KEY' reverse gear2l KEY' woodruff, idler gearz2 NUT, hex'| case to converter housingZ3 PLUG, output gee-I24 PLUG, magnetic. drainz5 PLUG, oillevel26 RING, retainer, reverse gear. and reverse

gear shaft bearing

1

z7 RING, retainer| clutch forward ShaLftbearing

z8 RING, retaLiner| idler gear shaftz9 RING, retainer, output Shaft, front and rear

bearing (s-all)3O RING, retainer' output shaft, trout bearing

(large)3l SCREW andWASHER, ca-p. casetO

converter housing3Z SCREW, cap, output shaft front Cover33 SCREW' car)I transmission C-aSe top Cover34 SCREW and WASHER, idler gear shaft

Cover35 SCREW and WASHER, tran5-iSSiOn Case

COVET36 SIIAFT, reverse clutch37 RUSHING, shaft38 SIIAFT, forward clutch39 SIIAFT' idler gear40 SPACED, idler gear4l WASIIER, 1clck, case to converter housing42 WASHER, lock, output shaft cover screw43 WASIIER, lock, trams-isSiOn Case top

cover Screw

I-'£"1 Fig_ 7_ Case' Covers, Gears and ShEIttEl

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SERVICE MANUAL

I BRACKET ASSEMBLY, relief valvemounting

a C:LIP, hose| re|ief valve to radiator3 ELBOW, 900, in right side ol converter

Case4 ELBOW, 45O, in shift operating cylinder5 ELBOW, 45O, in strainer asse-bly6 ELBOW, 9OO' intransmission case front

Cover7 HOSEASSEMBLY, converter case tee to

tee in relief valve8 HOSE ASSEMBLY, flexibleI COnVerter

case tee to clutch9 HOSEASSEMBLY, lower tee at relief

valve to lower radiator connectionlO HOSE ASSEMBLY, operating cylinder to

control valvell HOSEASSEMBLY, reliefvalve tee to

3-way tee in cc,nverter housingl2 HOsEASSEMBLY, right side on converter

housing to strainer assembly

13 HOSE ASSEMBLY, shifter control valveto 3-waLy tee in COnVerter housing

l4 HOSEASSEMBLY, upper tee at reliefvalve to upper radiator connection

l5 SCREW, cap, reliefvalve' mountiTlgbracket to case

l6 STRAINER ASSEMBLYl7 TEE, 90C}, inreliefvalve|8 TEE, 3-way in converter housingl9 TEE, 1atera|| in I.elief valve2O TEE, conveI.tor CaseZI VALVEASSEMI3LY, I.elief22 CAP, adjust-ent23 PLUNGER24 RING, seal25 SEAT, plunger26 SPRING, plunger27 WASHER, plunger SPI.ing28 WASHER, lock, relief valve lrlOunting

bracket

FIB. 8. HydrBu11c1-1nes and Flttinga

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SERVICE MANUAL

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2. REMOVE AND I)ISASSEnmLE HYDRAULICLINES, FITTINGS AI\un CONTROL VALVE

a. See Figure 8. Disconnect hydraulic linesandfittings.

b. See Figure 10. Remove screws and washers(28, 29 and 31), then separate controlvalveassem-bly and ga.sket (27) from transmission case. Todisassemble a,ontrol valve for repair purposes,refer to Control Valve repair section.

3. REMOVE TOR UE CONVERTER CASE CC)VERAND TRANSMISSION TOP COVER.

a. see Figure 5. Remove screws (22 and 23),washers (28, 29, 30 and 31) and nuts (6and7),then remove cover (4) and cover seals (26 and 27).

b. See FiguI.e 7. Remove screws andwasherS(33, 35 and 43) and separate top cover (l2) andgasket (15) from transmission case (1).

REMOVE AND DISASSEMBLE OIL PUMPASSEMBLY.

a. see Figure 5. Cut lock wire (33) and removescrews (21), then separate oil pump a.ssembly (9through 18) and gasket (5) from inside convertercase. To disassemble oil pump) refer to Oil Pumprepair section.

5. REMOVE AND DISASSEMBLE COI\IVERTERCASE WITH CLUTCH FLYWHEEL APD OUT=PUT SHAFT ASSEMBLED.

a. See Figure 6. Cut lock wire (31) and removescrews (23) fastening clutch assembly (1 through 8)to clutch flywheel (|2).

b. see Figure 5. Remove nuts, SCreWS andwa.sheI.S (8, 24 and 32), then sepaI.ate ConvertercaseJ With Clutch flywheel and Output Shaft assem-bled, from tI.anSmiSSiOn Case. Remove large sealring (25).

c. see Figure 6. Remove bearing (10) fromflanged end of output shaft 027).

d. see Figure 5. Ren`overetainerring(20),thenpress clutch flywheel and output shalt asselrlblyout of converter case bearing (2).

e. See Figure 6. Cut lock wire (32) and removescrews (24) securing output shaft (27) to clutchflywheel (12).

i. see Figure 5. Remove retainer I.ing (19) andpress bearing (2) out of converter case (1).

6. REMOVE AND I)ISASSEMBLE CLUTCHASSEMBLY.

a. See Figure 6. Remove forward clutch plate(17) from face of clutch pressuI.e Plate (7).

b. see Figure 6. Lift out clutch asserrlbly (7, 8

and 6). To disassemble clutch for repairpurposesJrefer to Clutch Repair section.

7. REMOVE SHIFT OPERATING LINK YOKEAND SHAFT.

a. See Figure 6. Remove cotter pins) washersand link pins (14, 29 and 16) fI.OminSide transmis-sion case, Lift out link (13).

b. See Figure 6. Remove set screw (25),thenusing a brass drift and hammer, drive against eitllerplug (18) until the opposite plug (18) pops out andthe yoke shalt (26) is exposed. Drive onthe exposedyoke shaft, in the opposite direction, untilthe otherplug (18) pops out. Continue driving/&ntil yoke`Shaftis removed. Remove operating yoke. (33).

8- REMOVE ANI) DISASSEMBLE CARRIER ANT)BEARING, AND SHIFTER SLEEVE.

a. See Figure 6. Slide carrier andbearing aS-sembly} (9, ll, 15, 19, 20 and 21) assembled, fromsnifter sleeve (28).

b. See Figure 6. To disassemble carrier andbearing) remove retainer ring (19) and press car-rier (l1) out of snifter ring (21). Remove retainerring (20) and press bearing (9) out of shifteI. ring.

c. See Figure 6. Remove screws andwasherS(22 and 30) and separate shifter sleeve (28) fromtransmission case.

9. REMOVE AND DISASSEMBLE SHIFT OPERAT-ING CYLINDER.

a. see Figure 9. Remove screws andWaSherS(14) and separate shift operating cylinder (1)from transmission case. To disassemble shiftoperating cylinder, refer to Operating Cylinderrepair section. Keep shims (l6) intact for use inreassembly.

10. REMOVE AND DISASSEnne1'E FORWARDCLUTCH SHAFT AND GEAR.

a. see Figure 7. Removeretainerring(27),thenpress forward clutch shaft (38) out of bearing (2).Remove gear (|6).

b. see Figure7. Removebearing(2) fromtrans-mission case.

ll. REMOVE AND I)ISASSEMBLE REVERSECLUTCH SHAFT ANT) GEA

a. see Figure 7. Remove fI.Ont retainer ring(26) and press reverse clutch shaft (36) with bear-ing (5) assembled out of transmission Case. Liftout gear (19).

b. see Figure 7. To disassemble reverSeClutchshaft and bearing} remove key (20), then pressbearing (5) off shaft. Remove rear retainer ring(26) from shaft.

l5


SERVICE MANUAL

12. REMOVE AND DISASSEMBLE IDLER GEARSHAFT COVER SHAFT AND GEAR.

a-. see Figure 7. Remove screws andWasherS(34) and separate cover (ll) andgasket (13) fromtransmission case.

b. see Figure 7. Remove retainer rings (28).press shaft (39), with bearing (3) assembled, outof transmission case. Remove gear (17) andspacer(40). Press shaft (39) out of bearing (3). Removekey (21) from shalt.

c. Remove bearing (6) from tra.nsmission case.

13. FIEMOVE AND DISASSEMBLE OUTPUTSHAFT COVER AND GEAR ASSEMBLY.

a. See Figure 7. Remove screws (32)andwash-ers (42) fastening cover (9) to transmission case.

b. See Figure 7. Remove retainer ring (29t, atplug end of gear, and press complete coverJ gearand shalt assembly (4, 7,9, 10, 18, 29 and30) outof transmission case. Remove gasket (14).

c. See Figure 7. To disassemble cover andgear assembly) remove oil seal (10) and retainerring (29). Press gear assembly out of cover (9).Remove retainer ring (30) and press bearing (4)out of cover. press gear (18) out of bearing (4).Do not remove plug (23) from gear (18) unlessreplacement is necessary.

ASSEMBLYASSEMBLE TRANSMISSION. Assemble the Tow-moTorque transmission as outlined in the follow-ing numbered procedures.

1. ASSEMBLE AND INSTALL OUTPUT SHAFTGEAR AND COVER ASSEMBLY.

a. See Figure 7. If plug (23) was removed fromgear (18), install new plug. Press bearing (4) ongear (18) and secure with retainer ring (29). Pressbearing (7) in cover (9) and secure with retainerring (30). Install gear, with bearing assembled, incover (9) and secure with retainer ring (29).

b. see Figure 7. Positioll a newgasket(14) inplace on cover,then install cover assembly in trans-mission case. Secure cover with screws (32) andwashers (42). install new oil seal (10) in cover.

2. ASSEMBLE ANDINSTALLIDLERGEARSHAFTAND COVER.

a. See Figure 7. Install key (21) in idlershaft(39). Position gear (17) in transmission case) thenpress shaft and key into gear. Install spacer (40)and bearings (3 and 6). Secure bearings with re-tainer rings (28).

b. Install gasket (13), cover (|1), then securewith screws and washers (34).

3. ASSEMBLE AND INSTALL REVERSE CLUTCHSHAFT AND GEAR.

a. see F'igure 7. If hushing (37) was removedfrom shalt (36) install new busking. InstallreaI.re-tainer ring (26) in groove nearmiddleofshaft, theninstall bearing (5). Install key (20) in shalt. Placegear (19) in position and press shaft into gear. Se-cure gear to shaft with front retainer ring (26).

4. ASSEMBLE AND INSTALL FORWARD CLUTCHSHAFT AND GEAR.

a. See Figure 7. Install bearing(2) intransmis-sion case. Place gear(16) inpositionandslide shaft(38) through hollow shaft (36) and engage splinesin gear. Press shalt (38) intobearing(2) and securewith I.etainer ring (27).

5. ASSEMBLE Ann INSTALL SHIFT OPERATINGCYLINDE R.

a. See Figure9. Assembleshiftcylinderasdes-cribed in repair section. Place same number ofshims (16), removed in disassembly) onshiftoper-ating cylinder and install against transmissioncase. Secure with screws and washers (14).

NOTEIf new case or shift operating cylinderis used, adjust clearance as describedin adjustment section.

6. ASSEMBLE AND INSTALL SHIFTER SLEEVE,AND CARRIER AND BEARING.

a. see Figure 6. Install snifter sleeve (28) andsecure with screws and washers (22 and 30).

b. See Figure 6. Install bearing (9) in shifterring (21) and secure with retainer ring (20). Installcarrier (ll) in shifter ring bearing and securewith retainer ring (19). Slide complete assemblyon snifter sleeve (28).

7. ASSEMBLE AND INSTALL SHIFT OPERATINGYOKE SHAFT AND OPERATING LINK.

a. see Figure 6. Place shift operating yoke(33)in position and install operating yoke shaft (26).Secure shaft with set screw (25). Install plugs(18).Install links (13) and connect to operating cylinderand operating yoke with pins, washers and cotterpins (16, 29 and 14).

8. ASSEMBLE AND INSTALL CLUTCIIASS EMBLY.

a. See Figure 6. Assemble clutch asselrlbly aSdescribed in clutch repair section. Install completeassembly (7, 8 and 6). Make certain that all clutchlevers (1) are inserted in snifter ring groove (21)and that reverse clutch plate splines are fullyengaged on reverse clutch shalt.

b. See Figure 6. Install forwaLrd Clutch Plate

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SERVICE MANUAL

1 i:#y=##eo:=oervth=td=lljtncehs sof#tch plate are

9. ASSEMB1.E AND INSTAI.L CONVERTER CASEWITII CLUI'CH FLYWIIEEL At\ro OUTPUT

|

1

SHAFT ASSEMBLED.

a. see Figure 5. Install bearing (2) inconvertercase (1) and secure with retainer ring (19).

b. see Figure 6. Assemble output shaft (27) toclutcll flywheel (12) and secure with screws and lockwire (24 and 32).

a. see F'igure 6. Install clutch flywheel andoutput shaft (12 and 27) in converter case bearingand secure with retainer ring (20). Install bearing(10) in flanged end of output shalt.

d. see Figure 5. Place new seal ring (25) inposition on tra,nsmission case and instau convert-er. case assembly. Secure with nuts, screws andwashers (8, 24 and 32).

10. ASSEnneLE AND INSTALL OIL PUMPASSEMBLY.

a. Assemble oil pump as described in repairsection.

b- See Figure 5. Place newgasket(5)(donotusesealing compound) in position and install oil pump(9 through 18). Secure pump with screws (21t, andlock wire (33).

ll. INSTALL TRANSMISSION TOP COVER ANI)TORQUE CONVERTER CASE COVER.

a. see Figure 7. Place anewgaSket(15)imposi-tion and install top cover (12). Secure with screwsand washers (33, 35 a 43).

b. see Figure 5. Place sea.ls (26and27) inposi-tion on cover (4) and install on converter case.secure with screws (22 and 23), washers (28] 29130 and 3l), and nuts (6 and 7).

12. ASSEMBLE AND INSTALL CONTRC)L VALVEFITTINGS AND HYDRAULIC LINES.

a. See Figure lO. Assemble control valve aSdescribed in repair section. Install control valveusing a new gasket (27) against transmission caseand secure with screwsandwashers(28,29and 3|).

b. See Figure 8. Install hydraulic lines and fit-tings.

13. INSTALL TORQUE CONVERTER.

a. see Figure 5. Install torque converter (3)when assembling transmission to engine, see Tow-moTorque replacement.

OIL PUAAP

DE SCRII) TION

The transmission Oil Pump iS mounted On thefront side of the torque converter case directly infront of the torque converter. Its function is tOsupply the necessary oil pressure to the torqueconverter} hydraulic control system , and lubrica-tion and oil cooling to the clutch forward and re-verse plates. The oil pump is driven by the tor.queconverter through two driving lugs.

OIL PUMP REPLACEMENT

To remove oil pumP} it iS necessary tO removethe transmission from the vehicle (See Towmo-Torque Replacement). With transmission Out ofvehicle and oil drained from the unit, slide torqueconverter off converter output shaft and oil pumpcollector ring. Remove lock wire, Screws andwashers and oil pump from converter case.

when installing oil pumpJ use a new gasket (dOnot use sealing cc)mpound) between oil pump andconverter case. slide torque converter over splinesof converter output shaft and oil pump collectorring and make sure drive lugs of torque converteraI.e engaged fully With notches Cut in the Oil pumpinternal gear. Install transmission and fill tO Pro-per oil level. Refer to "Oil CheckingJ DrainingandFilling" for proper procedures.

OIL. PUMP REPAIR

If the oil pump is found tO befaultyJ it iS rec-ommended that an exchange pumpbeprocuredfromyour Towmotor Representative.Disassemble Oil Pumfour 5/16 inch diameter

See Figure 5. Removesocket head screws (15)

and one 1/4 inch diameter socket head screw (let.Tap along parting line and separate Oil collectorring (ll) from pump housing (9). Remove |ar,geand small "Ou rings (13 and 14). Lift outpumPgears. RelnOve Oil Seal (10) from pump housing.

clean and Inspect Oil Pump. Was all parts in aclean solvent and dry with compre ssed air. Inspectgears and body for evidence of wear or damage.If excessive wear or clearances iS evident installa new pump body and gears. Note: Gear.S and bodyare matched and must be replaced as a unit. In-spect face of collector ring for scratches, scoringor excessive grooving, inspect bearing also.

use new "o» rings} oil seal andgasketwhen re-assembling pump.

Assemble Oil Pum See Figure 5. Install gearsin pump body and make surethesideof the internalgear with driving lugs is towardthe outside. Lubri-cate the gears with Automatic Transmission Fluid.

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SERVICE MANUAL

I,osition large and Small "O" rings (13 and 14) incollector ring and assemble Collector ring (|1) topump housing. secure assemblies together withsocket head screws (15 and 16). Check freeness ofgear rotation after assembling.

DUPLEX CLUTCH AND SHIFTINGLINl(AO|

DESCRIPTION

The duplex clutch is a double pressure plo.te typewith two driving plates and is oil cooledby a spraysystem. Clutch plates are coned to assuI.e quickrelease from the pressure plates. Control of direc-tion is handled through a shifter ring engaging theclutch operating levers. Snifter ring is movedbackand forth by a yoke supported on a shalt. Shift op-erating cylinder piston rod is connected tothe yokethrough linkage.

CLUTCH ANI) SIIIFTER CARRIERREPLACEMENT

To remove clutch assembly it ls suggested thatthe transmission be removed from the vehicle}seeTowmoTorque Replacement. With tI.anSmiSSiOnremoved and oil drained from the unit, slide torqueconverter off conveI.ten Output Shaft and Oil Pumpcollector ring. Remove tI.anSmiSSiOn top Cover.Cut wire and remove screws fastening clutch as-sembly to clutch flywheel. Remove bolts nuts andwashers securing converter case to transmissioncase. Lift off converter case with oil pump andclutch flywheel assembled. Remove forward clutchplate. Lift out clutch assembly. Slide off clutchcarrier assembly.

lhThen installing clutch assembly be sure that allclutch operating levers are in the groove of theclutch shifter I.ing and that Clutch Plates are in-stalled properly) clutch plate hubs must face theinside of the transmission or the unit cannot beassembled properly.

With clutch assembly installed, place fc)rwardclutch plate on clutch pressure plate and slidesplines of hub over splines of forward clutch shaft.Insert new "O" ring between cases and installconverter case, with oil pump and clutch flywheelassembled, against transmission case and securewith bolts) nuts and washers. Using a drift, alignholes in clutch cover with holes in clutch flywheel.Install screws and lock wire in pairs. Install topcover. Slide torque converter in place and installtransmission, see TowmoTorque Replac'ement.

CLUTCH AND SHIFTER CARRIER REPAIR

If clutch assembly is found to be faultyl becauseof excessive clutch plate slippage or because it,scompletely worn out, repair parts are available toa certain extent, that isl if replacement of pressure

plate, operating levers) links, or cover is nec-essary} a complete clutch cover assembled withthese items must be replaced because of alignTrlenton the clutch operating levers. This clutch coverassembly is available from your Towmotor FactoryRepresentative on an exchange basis.

Disassemble Clutch. See Figure 6. The ClutchCover assembly is made up of matchedparts. Whendisassembly is contemplated note the match mal.k-ings} one on the extension lug of the pressureplate] and one matching mark on thecoveradiacentto it. On reassembly make sure these two marksare in the same relation. The pressure plate,cover, levers and links are not individually re-placable. If any of these are damaged replace thecomplete clutch cover assembly with a new or re-built assembly. Levers and links must be kept insame relation to this position and levers must notbe turned over. Remove cotter pins (3) and leverclevis pins (4) fastening operating levers to clutchcover (6)I slide out clutch pressure plate (7) andremove pivot pins (5), links (2) and levers (1). Liftout clutch plate (8).

Disassemble Carrier] Bearing and Snifter Ring.See Figure 6. Remove retainer ring (19) andpresscarrier (ll) out of snifter ring (21). Remove re-tainer ring (20) and press bearing (9) outof shifterring (21).

Clean and Inspect Clutch and Snifter Carrier.Wash all parts in a cleansolventanddry with com-pressed air. Inspect clutch plates for wom liningsand loose hub rivets. Inspect operating levers>links and pins for excessive wear, one at atimeand replace in original position. Inspect faces ofpressure plate aJld Clutch cover. Inspect carrierbearing. Inspect bore of snifter carrier for exces-sive wear. Replace all faulty parts except, that ifCOVer, Pressure Plate, levers Or links need replac-ing, replace the complete clutch cover assembly.

Red.ssemble Clutch. See Figure 6. With indexmarkings in proper relation on pressure plateand cover, place clutch pla.te (8) on face of clutchcover (6). Slide pressure plate (7) with links (2)and pins (5) attached, in slots provided in clutchcover. Clutch construction eliminates need forcottel. pinning link pins. Align operating lever withholes in clutch cover and install clevis pins(4) andcc)tter pins (3).

Assemble Carrier, Bearing and Snifter Ring.See Figure 6. Press bearing (9) in snifter ring(2l) and secure with retainer ring (20). Presscarrier (Ill in shifter ring (21) and secure withretainer ring (19).

SHIFT OPERATING CYLINDERDE SCRIP TION

The shift operating cylinder is mounted on the

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SERVICE MANUAL

as-l6 Ref.a -lOE=-m

No. Description

I BODY

2 GUIDE, spring

3 NUT, piston shaft

4 PISTON

5 PLUG,end

6 RING, retainertlarge

I 7 RING, retainer|

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1

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3

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small

8 ROD, piston

9 SEAL, endplug

lO SEAL, piston

ll SEAL, pistoTl

l2 SPRING,upper

13 SPRING, lower

l4 SCREW andWASHER,cylinder totransmissionCase

l5 SEAL, cylinderto tI.anSmiSSiOnCase

l6 SPACER' cylinderadJ uSting(I/32 thick)

l6 SPACED, cylinderadjusting(I/8 thick)

I-B901- 1

Fig. 9. Sh1|t Operatln4 C'ylirlder Assembly

bottom of the transmission case. Its function is tochange engagement of either forward or reverseclutch plates by oil pressure admitted to eitherside of the piston. The cylinder is double actingand actuates the clutch through linkage connectedto an operating yoke.

SHIFT OPERATING CYLINDER REPAIR

If the opeI.ating Cylinder. iS found tO be faulty be-cause of broken neutral springs or leakage pastthepiston seal or end plug seal,itispossible to repairthe cylinder while the transmissic)n is installed inthe vehicle or with the transmission removed fromthe vehicle.

SHIFT OPERATING CYLINDER REPLACEMENT(with transmission installed in vehicle

see FiguI.e 9. To disassemble, remove end Plugretainer ring (7). Screw a 3/8-16NC bolt in thetapped hole of the end plug and use as aPu|ler.Remove the piston nut (3). Remove screws andwashers (14), then pull the cylinder body free Ofthe transmission case, leaving the piston rod at-tached intact. Reassemble in the reverse mannerusing a new gasket between cylinder and case.

AfteI. inStaLllation of shift cylinder., Check forclutch neutral setting. Refer to "Adiustments"section and figure 4.

SHIFT OPERATING CYLINDER REPLACEMENT(with transmission removed from vehicle

To replace shift operating cylinder it iS neCeS-saI.y tO diSasSemble the transmission Only as far aSfollows: Disconnect lines at cylinder, remove COn-verter, converter case with oil pump and clutchflywheel and output shaft assembled, and completeclutch assembly. Disconnect shift Cylinder linkageat operating yoke. Remove screws and washersand withdraw shift cylinder and shims.

lThen installing shift cylinder, use anew seal ringbetween cylinder and case. Connect link asSembly-Install clutch assembly) converter Case With Oilpump and clutch flywheel and output shaft assem-bled. Connect lines tocy|inder and install converter.

After installation of shift cylinder, Check forclutch neutral setting. Refer to "Adjustments"section and figure 4.

Disassemble Shift Operating Cylinder. (with trans-mission removed fI.Om truck.)

see Figure 9. To disassemble cylinderfor clean-ingJ inspection Or repair PurPOSeSJ remove largeretainer ring (6) at bottom of cylinder. Screw a3/8-16NC bolt in tapped hole of the endPlug as-sembly (5) and use as a purler. To disassembleend plug assy) use a vise or arbor press and com-

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SERVICE MANUAL

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I BODY, shifter control valve2 BRACKET, bellcrank support3 CAP, accu-ulator valve4 GASKET, accumulator valve cap5 HOUSING, forward and reverse plunger6 PLUG'pipe7 BODY' plunger8 EYE, plunger9 RING, seal, plunger eye

lO RING, snaLPll SPRING, compressionl2 VALVE, plungerl3 PLUNGER ASSEhABLY, forward and reversel4 BALL, forward and reverse plungerl5 SPRING, compressionl6 PLUNGER, acclJ--ulatOr Valvel7 RETAINER, forward and reverse plungerl8 RING, seal, plunger|9 RING, snap' forward and reverse plunger20 RING, wiper, control valve plunger2l SEAL, oil, clutch shaft22 SCREW, bracket tc) control valve23 SCREW' mach., plunger retaiTler tC, COntrOI Valve24 SPRING, accu-u|ator valve25 WASHER, plaint forward and reverse plunger26 WASHER, lock, bellcrank support bracket27 GASKET, contI.OI Valve tO tra-nSmiSSiOn Case28 SC,REV, cap| control valve mounting29 SCREW, cap| control valve mounting30 SWITCH, limit3| WASIIER, lock, shifter valve

I-i-i=;

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3

Fig. 10. C.ontroI VEIIVe AaBembly

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SERVICE MANUAL

\ =er.e.a.Bseapprr'e=8=,'dVe==eS=.OwV,eyr=d-i.nee=.r*.g#ld,.t(h2a?release press or vise slowly and remove guide (2) )and spring (13). Remove end plug seal (9t fromend plug (5).

unscre-w piston rod nut (3) and remove piston (4)and "o" ring (ll) assembled Iron piston rod (8).Compress other spring guide and remove retainerring (7), spring guide (2) and spI'ing (12).

Clean and Ins ect Shift Cylinder. Washall parts in aclean solvent anddrywit compressedair. hspect cylinderbore for scratches andgrooveswhich would caLuSe Cutting Or SCratChing the Sealring and cause leakage. Use new seal rings whenreassembling cylinder.

AsseTnble Shift eratin Cylinder. (with trans-mission removed from truck.

see Figure 9. Insert small diameter spring (12)and spring guide (2) over boss in cylinder body.compress spring and install retainer ring (7).Install piston (4), with new seal ring (10) assem-bled in bore, and slide over piston rod end. Note,piston is equipped with recess for nut, install withrecess toward nut. secure piston with nut (3).

position large diaIY\eter spring (13) and SPI.ingguide (2) on end plug (5) and secure with retainerring (7). Install new seal ring (9) on endplug (5)

i and install plug assembly in botton` of cylinder.secure plug with large retainer rlng (6).

CONTROL VALVEDESCRIPTION

The control valve is mounted On the front Coverof the transmission case. Its function is to distributeoil under pressure to the shift operating cylinder.The control valve consists mainly of a housing inwhich two plungers are fittedto controloil directionthr.ough valve. One plunger is operatedby thetranS-mission shift lever and the other plunger is oper-ated bythe creeper pedal. The creeper pedalplungeris equipped with a relief valve to control maximumpressures in the system.

CC)NTROL VAT.VE REPLACEMENT

i

See Figure |0. To remove control valve, dis-connect oil lines aLnd COntrOl linkage. Removescrews (28 and 29) and washers (31) fastening valveto transmission case.

vThen installing control valve, use a gasket (27)between valve and case. Connect linkage. Checklinkage for fI.ee OPeratiOn and Correct adjustment,see Adjustment Section. Connect oil lines.

CONmOL VALVE REPAIRIf the control valve is found tO be faulty) it iS

recommended that a cc)mplete valve be procuredfrom your Towmotor Factory Representative. The

control valve requires no service other than clean-ing if the valve should become inoperative due todirt or other foreign matter in the oil system.To prevent this situation from occurring| the oilin the system must be kept clean and free of alldirt or sediment.

Disassemble Control Valve. See Figure 10. Todisassemble valve for cleaning or inspection pur-poses| remove screws (22 and 23) and washers(26) and remove retainer (17) and bracket (2).Remove wiper rings (20) and seal rings (18). Re-move plug (6) and limit switch (30). Mark valveplungers so that they can be returned to their or'i-ginal position if used in reassembly. Removeplunger.

The forward and reverse plunger (|3) is equippedwith detent balls and aspring. lThen disassembling}care should be taken when removing the plunger(l3) from the housing (5) as the decent balls (14)and spring (15) will pop out. Remove snap ring'(19t and washer (25).

The creeper valve plunger (7) is equipped with arelief valve. To disassemble, unscrew and removeplunger eye (8) and seal ring (9t. Remove spring(ll) and valve (12).

The control valve is equippedwith an accumulatorvalve. To disassemble, unscrew and remove Cap(3), gasket (4), spring (24) andplunger (16). Removeclutch shaft oil seal (21).

Clean and lns ect Valve. Wash all parts in acleansolvent. Blow out all pasEiageS in va.1ve housing withdry compressed a,ir. Inspect relief valve and seatfor grooves and scratches that may cause poorseating. Inspect plungers for grooves Or excessivewear._ check fit of plungers in housing. There shouldbe no perceptible side play. If plungers are looseor faulty in other respects, replace valve assembly.use new gaskets and seals when reassemblingcontrol valve.

Assemble Control Valve. See Figure 10. Insta.llnew plunger seal rings (18) and wiper rings (20)in housing. Install plunger (16) and spring (24) inbore of housing (1) and secure with new gasket(4) and cap (3).

install relief valve (12) and apring (Ill inbore ofcreeper valve plunger and secure with new Sealring (9) and eye (8). Insert plunger (7), with snapring (10) assembled, in valve housing.

Install washer (25) on plunger (13) and securewith snap ring (19). Install detent balls (14) andspring (|5) in plunger (13t and slide housing (5)over end of plunger until balls slip into recessedgroove. Install complete plunger in valve housing.

position retainer (17) and bracket (2) over plun-gers and secure with screws (22 and23) and washeI`(26). thstall limit switch (so) plug (6) and shaltseal. (21).

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iii - MIMS Riggers

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Transcript of iii - MIMS Riggers