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Contents
1. bottom of the transmission case Its function is to change engagement of either forward or reverse clutch plates by oil pressure admitted to either side of the piston The cylinder is double acting and actuates the clutch through linkage connected to an operating yoke SHIFT OPERATING CYLINDER REPAIR If the operating cylinder is found to be faulty be cause of broken neutral springs or leakage past the piston seal or end plug seal itis possible to repair the cylinder while the transmission is installed in the vehicle or with the transmission removedfrom the vehicle SHIFT OPERATING CYLINDER REPLACEMENT with transmission installed in vehicle See Figure 9 To disassemble remove end plug retainer ring 7 Screw a 3 8 16NC bolt in the tapped hole of the end plug and use as a puller Remove the piston nut 3 Remove screws and washers 14 then pull the cylinder body free of the transmission case leaving the piston rod at tached intact Reassemble in the reverse manner using a new gasket between cylinder and case After installation of shift cylinder check for clutch neutral setting Refer to Adjustments section and figure 4 SHIFT OPERATING CYLINDER REPLACEMENT with transmission removed from vehicle To replace shift operating cylinder it is neces sary to disassemble the transmission only as far as follows Disconnect lines at cylinder remove con verter converter case with oil pump and clutch flywheel an2. TOWMOTORQUE OIL SYSTEM DESCRIPTION The heart of the oil system is the oil pump which is located between the torque converter and the con verter case The sleeve extension at the center of the converter is provided with lugs which engage the oil pump drive gear The pump is driven con tinuously while the engine is operating Oil is pumped from the surip through a strainer then to the oil pump The oil pump output is directed to the various units affected by the oil 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 Oilis directed to the convert er through provisions in the pump support and the stator anchor From the converter it passes through a pressure regulator valve converter output shaft and pump support then back to the sump Clutch System Oil is directed through a restric tion to the forward and reverse clutch Atthe clutch the oil flows out between the clutch hubs and onto the driven discs This means that the clutchthat is not driving can be cooled during its disengaged period so that it is cool and wet with oil when the next engagement is necessary Oil from the clutch returns as spray directly to the sump Control System The control system receives its oil from aconnection inthe pump output line Basic
3. to drain the oil Oil will drain through opening in the flywheel housing To drain oil from transmission case remove the magnetic drain plug Clean drain plug to remove metal chips or foreign material When draining is completed replace bottom plug and transmission case plug Fill the transmission through the breather cap opening using a funnel Capacity is 12 quarts Operate engine for 10 or 15 minutes then remove oil level plug and recheck oil level The factory recommends the use of Automatic MIMS sWavicee wo AVEC RW Ea P Di THE ONE MAN GANG miangaggers com Transmission Type A oil to assure best opera tion Engine oi SAE 10 maybe used temporarily but not for any period of service longer than a few days OIL PRESSURE CHECK Normal operating pressures for the Towmo Torque oil systems are as follows Engine Speed rpm Oil Pressure psi Procedure 1 Pressures should be checked after a warm up period so that the inspection will reflect actual operating conditions 2 Insert test gage 160 psi in pump outlet fitting 3 Check pressures with engine operating trans mission shift lever in neutral and creeper pedal depressed If normal pressures are not obtained refer to Trouble Shooting Condition VI and VII CLUTCH COOLING CHECK Check cooling supply to the clutches by discon necting the oil line from the control valve housing and inserting a fitting with a 1 16
4. 16 29 and 14 8 ASSEMBLE AND INSTALL CLUTCH ASSEMBLY a See Figure 6 Assemble clutch assembly as described in clutch repair section Install complete assembly 7 8 and 6 Make certain that all clutch levers 1 are inserted in shifter ring groove 21 and that reverse clutch plate splines are fully engaged on reverse clutch shaft b See Figure 6 Install forward clutch plate MIMS Maekmke g TRONS FOR A iImMANgGers com 17 and make sure that splines of clutch plate are fully engaged on forward clutch shaft 9 ASSEMBLE AND INSTALL CONVERTER CASE WITH CLUTCH FLYWHEEL AND OUTPUT SHAFT ASSEMBLED a See Figure 5 Install bearing 2 inconverter case 1 and secure with retainer ring 19 b See Figure 6 Assemble output shaft 27 to clutch flywheel 12 and secure with screws and lock wire 24 and 32 c See Figure 6 Install clutch flywheel and output shaft 12 and 27 in converter case bearing and secure with retainer ring 20 Install bearing 10 in flanged end of output shaft d See Figure 5 Place new seal ring 25 in position on transmission case and install convert er case assembly Secure with nuts screws and washers 8 24 and 32 10 ASSEMBLE AND INSTALL OIL PUMP ASSEMBLY a Assemble oil pump as described in repair section b See Figure 5 Place new gasket 5 do not use sealing compound in position and install oil pump 9 through 18 Secure pump with screws 21
5. AND HIGH POWER REQUIREMENTS WITH NORMAL ENGINE SPEED 1200 to 1400 rpm Check for binding in transmission causedby a faulty bearing or interference at other points check bushing between clutch output sleeve and output shaft If the universal joint is dis connected it would help isolate the cause of the trouble If lack of acceleration and power is in reverse only check the flywheel for free spin with the transmission cover removed If it does not spin freely the clutch output shaft bearing could be faulty Drag in drive axle Check for drag in drive axle including hand brake and foot brakes This condition is likely to appear in new trucks due to tightness of new parts In this case the condition should disappear after a few hours of operation LACK OF ACCELERATION AND POWER UNDER FULL THROTTLE AND HIGH POWER REQUIREMENTS WITH HIGH ENGINE SPEED above 1500 rpm Excessive clutch slippage Refer to Condition XV EXCESSIVE CLUTCH SLIPPAGE IN EITHER OR BOTH DIRECTIONS Refer to Condition VL Air leak in pump suction line Refer to Con dition V for indication of leakage Low oil pressure 3 vn on for p a Pump oil inlet screen plugged Refer to Con dition IX Item 4 Faulty shift cylinder or linkage Refer to Con dition IX Item 6 and Condition XI Item 4 Scored shifter and carrier Refer to Condition XI Item 5 Loss of pump prime Refer to Condition IX Item I Clutches worn R
6. ASSEMBLY a See Figure 5 Cut lock wire 33 and remove screws 21 then separate oil pump assembly 9 through 18 and gasket 5 from inside converter case To disassemble oil pump refer to Oil Pump repair section 5 REMOVE AND DISASSEMBLE CONVERTER CASE WITH CLUTCH FLYWHEEL AND OUT PUT SHAFT ASSEMBLED a See Figure 6 Cut lock wire 31 and remove screws 23 fastening clutch assembly 1 through 8 to clutch flywheel 12 b See Figure 5 Remove nuts screws and washers 8 24 and 32 then separate converter case with clutch flywheel and output shaft assem bled from transmission case Remove large seal ring 25 c See Figure 6 Remove bearing 10 from flanged end of output shaft 27 d See Figure 5 Remove retainer ring 20 then press clutch flywheel and output shaft assembly out of converter case bearing 2 e See Figure 6 Cut lock wire 32 and remove screws 24 securing output shaft 27 to clutch flywheel 12 f See Figure 5 Remove retainer ring 19 and press bearing 2 out of converter case 1 6 REMOVE AND DISASSEMBLE CLUTCH ASSEMBLY a See Figure 6 Remove forward clutch plate 17 from face of clutch pressure plate 7 b See Figure 6 Lift out clutch assembly 7 8 and 6 To disassemble clutch for repair purposes refer to Clutch Repair section 7 REMOVE SHIFT OPERATING LINK YOKE AND SHAFT a See Figure 6 Remove cotter pins washers and link pins 14 29 and
7. ally oil from the pump passes from the pump through the control valve accumulator valve into the shift cylinder back through the accumulator valve to the control valve then it is discharged into the sump The control valve is provided with two plungers which act as valves to control direction selection and creeper action The direction plunger is oper ated by the control lever mounted on the steering column The creeper plunger is operated by the creeper pedal Shifting of the control lever moves the directional plunger to introduce oil into the double acting shift cylinder which in turn produces engagement of the clutch in the desired direction Flow of oil to the directional plunger and eventually to the shift cyl inder is controlled by the creeper plunger position When the creeper pedal is fully released the creeper plunger is positioned to allow free flow of oil to the directional plunger When directional plunger is in a forward or reverse position oil flows to either side of shift cylinder which in turn engages the clutch in the desired direction When the creeper pedal is fully depressed oil flows to the directional plunger and to the shift cylinder and is blocked thus preventing shift cyl inder operation to engage clutch When the creeper pedal is released half way oil flow to the directional plunger is permitted but it must travel through a restricted opening With the directional plunger in a forward or rever
8. and lock wire 33 11 INSTALL TRANSMISSION TOP COVER AND TORQUE CONVERTER CASE COVER a See Figure 7 Place anew gasket 15 in posi tion and install top cover 12 Secure with screws and washers 33 35 amp 43 b See Figure 5 Place seals 26 and 27 in posi tion on cover 4 and install on converter case Secure with screws 22 and 23 washers 28 29 30 and 31 and nuts 6 and 7 12 ASSEMBLE AND INSTALL CONTROL VALVE FITTINGS AND HYDRAULIC LINES a See Figure 10 Assemble control valve as described in repair section Install control valve using a new gasket 27 against transmission case and secure with screws and washers 28 29 and 31 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 PUMP DESCRIPTION The transmission oil pump is mounted on the front side of the torque converter case directly in front of the torque converter Its function is to supply the necessary oil pressure to the torque converter hydraulic control system and lubrica tion and oil cooling to the clutch forward and re verse plates The oil pump is driven by the torque converter through two driving lugs OIL PUMP REPLACEMENT To remove oil pump it is necessary to remove the transmission from the vehicle See Towmo Torque Replacement With transmission out of ve
9. diameter re striction hole so that the discharge oilcan be mea sured Start the engine operate at 1200 rpm and measure time required to pump 1 or 2 quarts of oil through the restricted hole in the fitting One quart should take 15 seconds and two quarts should take 30 seconds While the cap is off blow through the shaft to assure that the passage is clean TOWMOTORQUE ADJUSTMENTS EARLY MODELS CREEPER PEDAL ADJUSTMENT Creeper pedal travel should be set so that the pedal contacts the stop bolt 1 32 additional travel after the valve plunger is all the way into the valve body Adjust creeper pedal by lengthening or short ening the adjustable yoke at the valve CONTROL LEVER ADJUSTMENT Control lever travel in both directions should be equal distance from the shift lever stop which is located on the steering column Adjust lever travel by lengthening or shortening the control lever rod rod from the foot of the lever to the valve CLUTCH ADJUSTMENT AND OPERATION CHECK No adjustments are required or provided for clutch wear The stroke of the shift cylinder is de PRESSURE PLATE DRIVING LUG 375 390 CLUTCH FLYWHEEL CLUTCH COVER Clutch Neutral Setting Adjustment Dimensions Fig 4 signed to completely wear out both clutch plates Ad justment shims located under the shift cylinder mounting flange are factory adjustments for neutral setting In the event of shift cylinder replacement dimens
10. if he wants to change direction 4 To stop Release gas pedal and step on brakes to stop Towmotor It is not necessary to move con trol lever into neutral or step on creeper pedal HOW TO CREEP IN TIGHT SPOTS EARLY To drive Towmotor at a creeping speed and still operate engines at high speed for fast lifting tilting or accessory operation First Push creeper pedal to floor This action stops power from engine to wheels Second Lift foot to let pedal come back about halfway This action will cause partial drive motion from engine to wheels MODELS Third Move pedal up and down fror floor to halfway position and at the same time press down on gas pedal The repeated action of pushing creeper pedal down quickly and releasing it slowly will cause short periods of partial drive motion and Towmotor will move at a smooth controlled creeping speed High engine speed will allow fast lifting tilting or other hydraulic actions HOW TO SPEED UP SHUTTLE TYPE OPERATION how to speed up shuttle type operation For fast shuttle type operation change travel direction without stopping Towmotor completely low engine speed recommended First When Towmotor is twoor three feet from load pull shift lever backward This leaves driver s hands free to operate lift controls Second Let Towmotor coast up to load operat ing lift control levers as necessary and stepping on fo
11. output shaft front cover 14 GASKET output shaft front cover 33 SCREW cap transmission case top cover 15 GASKET transmission case top cover 34 SCREW and WASHER idler gear shaft 16 GEAR forward cover 17 GEAR forward idler 35 SCREW and WASHER transmission case 18 GEAR output shaft cover 19 GEAR reverse 36 SHAFT reverse clutch 20 KEY reverse gear 37 BUSHING shaft 21 KEY woodruff idler gear 38 SHAFT forward clutch 22 NUT hex case to converter housing 39 SHAFT idler gear 23 PLUG output gear 40 SPACER idler gear 24 PLUG magnetic drain 41 WASHER lock case to converter housing 25 PLUG oil level 42 WASHER lock output shaft cover screw 26 RING retainer reverse gear and reverse 43 WASHER lock transmission case top gear shaft bearing cover screw ar Fig 7 Case Covers Gears and Shafts i nn 13 T 2476 eee 14 SG GSH 4g HA 77 ag 13 GG HA Y HA HA HA ig Z GG HA HA Description BRACKET ASSEMBLY relief valve mounting SLIP hose relief valve to radiator ELBOW 90 in right side of converter case ELBOW 45 in shift operating cylinder ELBOW 459 in strainer assembly ELBOW 90 in transmission case front cover HOSE ASSEMBLY converter case tee ta tee in relief valve HOSE ASSEMBLY flexible converter case tee to clutch HOSE ASSEMBLY lower tee at relief valve to lower radiator connection HOSE ASSEMBLY operating cylinder to control valve HOSE ASSEMBLY r
12. the clutch operating levers This clutch cover assembly is available from your Towmotor Factory Representative on an exchange basis Disassemble Clutch See Figure 6 The Clutch Cover assembly is made up of matched parts When disassembly is contemplated note the match mark ings one on the extension lug of the pressure plate and one matching mark on the cover adjacent to it On reassembly make sure these two marks are in the same relation The pressure plate cover levers and links are not individually re placable If any of these are damaged replace the complete clutch cover assembly with a new or re built assembly Levers and links must be kept in same relation to this position and levers must not be turned over Remove cotter pins 3 and lever clevis pins 4 fastening operating levers to clutch cover 6 slide out clutch pressure plate 7 and remove pivot pins 5 links 2 and levers 1 Lift out clutch plate 8 Disassemble Carrier Bearing and Shifter Ring See Figure 6 Remove retainer ring 19 andpress carrier 11 out of shifter ring 21 Remove re tainer ring 20 and press bearing 9 outof shifter ring 21 Clean and Inspect Clutch and Shifter Carrier Wash all parts in a clean solvent and dry with com pressed air Inspect clutch plates for worn linings and loose hub rivets Inspect operating levers links and pins for excessive wear one at a time and replace in original position Inspect faces of pressure p
13. 16 from inside transmis sion case Lift out link 13 b See Figure 6 Remove set screw 25 then using a brass drift and hammer drive against either plug 18 until the opposite plug 18 pops out and the yoke shaft 26 is exposed Drive onthe exposed yoke shaft in the opposite direction until the other plug 18 pops out Continue driving amp ntil yoke shaft is removed Remove operating yoke 33 8 REMOVE AND DISASSEMBLE CARRIER AND BEARING AND SHIFTER SLEEVE a See Figure 6 Slide carrier and bearing as sembly 9 11 15 19 20 and 21 assembled from shifter sleeve 28 b See Figure 6 To disassemble carrier and bearing remove retainer ring 19 and press car rier 11 out of shifter ring 21 Remove retainer ring 20 and press bearing 9 out of shifter ring c See Figure 6 Remove screws and washers 22 and 30 and separate shifter sleeve 28 from transmission case 9 REMOVE AND DISASSEMBLE SHIFT OPERAT ING CYLINDER a See Figure 9 14 and separate Remove screws and washers shift operating cylinder 1 from transmission case To disassemble shift operating cylinder refer to Operating Cylinder repair section Keep shims 16 intact for use in reassembly 10 REMOVE AND DISASSEMBLE FORWARD CLUTCH SHAFT AND GEAR a See Figure 7 Remove retainer ring 27 then press forward clutch shaft 38 out of bearing 2 Remove gear 16 b See Figure7 Remove bearing 2 from trans mis
14. IVE ODOR FROM THE OIL OR THIS PLUS RADIATOR OVERHEATING Check for clutch slippage Refer to Condition KV i aam 9 MIMS Mama CLE MANGiggers com 2 If overheating is in radiator only check fan belt and other standard usual causes for cool ing system overheating 3 Binding in line of drive Check for interference in line of drive as indicated in Items under Condition XIII 4 If only oil overheating is present check all cooler lines for plugging Check cooler for a plugged condition Check cooler bypass valve for leaking valve should crack at 30 psi Check water side of cooler for cleanliness Check all Items under Condition VIfor causes of low pressure 5 Check truck operating conditions for factors which may cause overheating NOTE Automatic Transmission Oil Type A does not have an original bad odor but when it has been overheated it assumes a very offensive odor This odor can easily be used as evidence of overheated oil It would be good practice to make a complete oil change after an overheat ing situation has been corrected first because of damage to the oil and second for evidence that the problem has been solved REPAIR INSTRUCTIONS TOWMOTORQUE REPLACEMENT Remove 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 flo
15. MIMS Machinerv Move mimsriaae om TOWMOTORQUE SERVICE MANUAL TOWMOTOR THE ONE MAN GANG FORK LIFT TRUCKS and TRACTORS MODELS 540 600 670 AND 680P ALSO APPLICABLE TO MODELS 3925 4225 4625 501P 5025 502P 600P AND 601P Price 1 00 16100 EUCLID AVE CLEVELAND 12 OHIO PACEMAKER SERIES PEDAL STOP CREEPER CONTROL LEVER PINS ADJUSTABLE YOKE UPPER LEVER CROSS SHAFT LOCKING gt Wa LINKAGE 4 LOCK RETURN SPRING ae ji CREEPER PLUNGER STREAMLINER SERIES CREEPER CONTROL LEVER PEDAL PINS STOP BALL JOINTS UPPER LEVER a ANZ RETURN SPRING A EIN CREEPER PLUNGER MIMS MSERMSE Q THE GWASTOR ONE MAN GANG IMANSers com SUPPLEMENTAL TOWMOTORQUE ADJUSTMENTS CREEPER PEDAL ADJUSTMENT EARLY MOD ELS WITH ROUND CREEPER PEDAL See Page 1 Creeper pedal travel should be set so that the pedal contacts the stop bolt 1 32 inch additional travel after the valve plunger is all the way into the valve body Adjust creeper pedal by lengthening or shortening the adjustable yoke at the valve CREEPER PEDAL ADJUSTMENT LATE MODELS WITH STANDARD CLUTCH CREEPER PEDAL To adjust this type of creeper pedal linkage pro ceed as follows Disconnect the upper lever from the creeper lever support mounted on the trans mission by removing the cotter pin and slipping the upper lever off the creeper lever support Loosen the locking plug i
16. OTORQUE ADJUSTMENTS SE Creeper Pedal Adjustment Control Lever Adjustment Clutch Adjustment and Operation Check TOWMOTORQUE TROUBLE SHOOTING Primary Checks re ae eth te Trouble Conditions and Check Points REPAIR INSTRUCTIONS Ka Shaws TowmoTorque Replacement Sete Disassembly gt 3 3 Assembly ae Ia ANI Sat WA Oil Pump ee at falas eGo ENTER Duplex Clutch and Shifting Linkage Kaa Shift Operating Cylinder KAA ne ie Control Valve shia ene ae ee Oe ae a k Dur Zu u ur m er E E r 2 ee we oe eee one a T da AN AMR RAARA a FP bf kW WH mM V oe he o aa i 02 10 0600 MIMS M amp HRMISE TOWN GTOR THE ONE MAN GANG NANE com HOW TO DRIVE WITH TOWMOTORGUE CREEPER PEDAL 1 Position shift lever in neutral and start engine Positioning shift lever in neutral operates a safety switch which closes a circuit to the starting motor and permits operator to start engine 2 Shift control lever and push gas pedal Push shift lever forward to go forward Pull lever back ward for reverse Push gas pedal and move shift lever at the same time FORWARD d REVERSE SHIFT LEVER 3 Drive Towmotor Once Towmotor is in mo tion the driver need only step on the gas pedal for speed control and move control lever
17. ard clutch shaft 27 SHAFT and VALVE ASSEMBLY converter ll CARRIER shifter output 12 FLYWHEEL clutch 28 SLEEVE shifter 13 LINK ASSEMBLY shift operating 29 WASHER flat link to yoke and operating 14 PIN cotter link to operating yoke and op cylinder erating cylinder 30 WASHER lock shifter sleeve screw 15 PIN groove shifter ring 31 WIRE locking clutch cover screw 16 PIN link to yoke and operating cylinder 32 WIRE locking converter output shaft to 17 PLATE ASSEMBLY forward clutch clutch flywheel screw 18 PLUG operating yoke shaft 33 YOKE shifter operating T 2305 Fig 6 Clutch Assembly Carrier and Linkage yy ne nn nn 12 MIMS Maatinety i 10 EA LIBimanuyers com Ref No Description 1 CASE transmission 2 BEARING ball forward clutch shaft 3 BEARING ball idler gear shaft front 4 BEARING ball output shaft rear 5 BEARING ball reverse clutch shaft 27 RING retainer clutch forward shaft 6 BEARING ball idler gear shaft rear bearing BEARING ball output shaft front 28 RING retainer idler gear shaft 8 BREATHER transmission case 29 RING retainer output shaft front and rear 9 COVER and SEAL ASSEMBLY output bearing small shaft front 30 RING retainer output shaft front bearing 10 SEAL oil output shaft large ll COVER idler gear shaft 31 SCREW and WASHER cap case to 12 COVER transmission case top converter housing 13 GASKET idler gear shaft cover 32 SCREW cap
18. ative The control valve requires no service other than clean ing if the valve should become inoperative due to dirt or other foreign matter in the oil system To prevent this situation from occurring the oil in the system must be kept clean and free of all dirt or sediment Disassemble Control Valve See Figure 10 To disassemble 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 valve plungers so that they can be returned to their ori ginal position if used in reassembly Remove plunger The forward and reverse plunger 13 is equipped with detent balls and a spring When disassembling care should be taken when removing the plunger 13 from the housing 5 as the detent balls 14 and spring 15 will pop out Remove snap ring 19 and washer 25 The creeper valve plunger 7 is equipped with a relief valve To disassemble unscrew and remove plunger eye 8 and seal ring 9 Remove spring 11 and valve 12 The control valve is equipped with an accumulator valve To disassemble unscrew and remove cap 3 gasket 4 spring 24 and plunger 16 Remove clutch shaft oil seal 21 Clean and Inspect Valve Wash all parts in aclean solvent Blow out all passages in valve housing with dry compressed air Inspect relief valve and seat for grooves and scra
19. avel after the valve plunger is all the way into the valve body Adjust creeper pedal by lengthen ing or shortening the adjustable yoke at the valve IIL CHECK TRANSMISSION OIL PRESSURE 1 Pressure should be checked after a warm up period se that the inspection will reflect actual operating conditions Method for checking is described under instructions for Towmo Torque Oil System Normal pressures should be as follows Engine Speed on Oil Pressure psi IV CHECK OIL COOLING SYSTEM 1 Check cooling supply to clutches by measuring oil flow For procedure refer to instructions under Towmo Torque Oil System TROUBLE CONDITIONS AND CHECK POINTS V TRANSMISSION OIL FOAMS OR OIL IS DIS CHARGED 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 OIL PRESSURE 1 Low transmission oil level 2 Plugged pump inlet screen in sump Refer to Condition IX Item 4 Pump faulty Refer to Condition IX Item 1 System relief valve stuck open or leaking be cause of dirt 5 Converter pressure regulator valve stuck open Check by applying air pressure into nipple at bottom of transmission which feeds oil to the transmission Valve should crack at approximately 25 psi or slightly more up to 35 psi 6 Worn bushing supporting converter output shaft in collector ring Valve operation check p
20. cessive grooving inspect bearing also Use new O rings oil seal and gasket when re assembling pump Assemble Oil Pump See Figure 5 Install gears in pump body and make sure the side of the internal gear with driving lugs is toward the outside Lubri cate the gears with Automatic Transmission Fluid 17 MIMS Machine iE mimsuisgers com Position large and small O rings 13 and 14 in collector ring and assemble collector ring 11 to pump housing Secure assemblies together with socket head screws 15 and 16 Check freeness of gear rotation after assembling DUPLEX CLUTCH AND SHIFTING LINKAGE DESCRIPTION The duplex clutch is a double pressure plate type with two driving plates and is oil cooled by a spray system Clutch plates are coned to assure quick release from the pressure plates Control of direc tion is handled through a shifter ring engaging the clutch operating levers Shifter ring is moved back and forth by a yoke supported on a shaft Shift op erating cylinder piston rod is connected tothe yoke through linkage CLUTCH AND SHIFTER CARRIER REPLACEMENT To remove clutch assembly it is suggested that the transmission be removed from the vehicle see TowmoTorque Replacement With transmission removed and oil drained from the unit slide torque converter off converter output shaft and oil pump collector ring Remove transmission top cover Cut wire and remove screws fastening clutch as sembly to c
21. d output shaft assembled and complete clutch assembly Disconnect shift cylinder linkage at operating yoke Remove screws and washers and withdraw shift cylinder and shims When installing shift cylinder use anew seal ring between cylinder and case Connect link assembly Install clutch assembly converter case with oil pump and clutch flywheel and output shaft assem bled Connect lines to cylinder and install converter After installation of shift cylinder check for clutch neutral setting Refer to Adjustments section and figure 4 Disassemble Shift Operating Cylinder with trans mission removed from truck See Figure9 To disassemble cylinder for clean ing inspection or repair purposes remove large retainer ring 6 at bottom of cylinder Screw a 3 8 16NC bolt in tapped hole of the end plug as sembly 5 and use as a puller To disassemble end plug assy use a vise or arbor press and com 19 T 2479 20 MIMS eonig MOVE mimsuisgers com Description BODY shifter control valve BRACKET bellcrank support CAP accumulator valve GASKET accumulator valve cap HOUSING forward and reverse plunger PLUG pipe BODY plunger EYE plunger RING seal plunger eye RING snap SPRING compression VALVE plunger PLUNGER ASSEMBLY forward and reverse BALL forward and reverse plunger SPRING compression PLUNGER accumulator valve RETAINER forward and reverse plunger RING seal plu
22. dard checks are made If trouble is not found check for pump seizure by disconnecting torque converter from flywheel then see if starting motor will turn engine Remote possibilities would be plugged hydraulic line and extreme pressure resulting in engine stall IX TOWMOTOR WILL NOT MOVE WITH WHEELS FREE TO TURN 1 ff this condition exists after truck has been standing over night and truck continues to re fuse to move after operating engine for one minute check oil pressure If the pressure reading is low itindicates loss of pump prime due to excessive clearances Inspect pump and upon verification of the trouble replace pump Also check the clutches to assure that prolonged use of a truck operating under this condition reduced pressure has not damaged the clutches due to slippage Low oil pressure Check Items listed under Condition VL Faulty Control linkage Visually inspect all control linkage to make sureitisingood con dition and correct adjustment Pump oil inlet screen plugged This pump inlet screen is located at bottom of trans mission If plugged condition does exist it should have been indicated by agradual slow ing down of the shift cycle time 5 1 Clutches Worn A completely worn set of clutches is also a possible cause of truck not moving If this condition exists it would pro bably occur in one direction only and would be preceeded by excessive slippage Truck refuses to move ir one dir
23. der cross shaft and cam plate The amount of creeper pedal effort varies only with the force exerted by the creeper pedal returnspring This enables the oper ator to ride the creeper pedal for less effort when inching It is not necessary to pump the creeper pedal for inching it is only necessary to move it slightly up and down After a few trips the operator can readily determine the amount of pedal travel necessary for inching MIMS Machine ai martyiyers com TOWMOTORQUE SERVICE MANUAL The Service Manual is divided into sections as listed in the Table of Contents It contains service and repair instructions for Towmotorque Transmissions as used on Towmotor Models 540 600 670 and 680 P The service and repair information contained in this manual covers the trans 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 TABLE OF CONTENTS HOW TO DRIVE WITH TOWMOTORQUE DESCRIPTION Shifting Cycle Time Creeper Pedal Operation Braking with TowmoTorque kaa TOWMOTORGUE OIL SYSTEM Description re Oil Checking Draining and Filling Oil Pressure Check he Clutch Cooling Check TOWM
24. e gear to shaft with front retainer ring 26 4 ASSEMBLE AND INSTALL FORWARD CLUTCH SHAFT AND GEAR a See Figure 7 Install bearing 2 intransmis sion case Place gear 16 in position and slide shaft 38 through hollow shaft 36 and engage splines in gear Press shaft 38 into bearing 2 and secure with retainer ring 27 5 ASSEMBLE AND INSTALL SHIFT OPERATING CYLINDER SO a See Figure9 Assemble shift cylinder as des cribed in repair section Place same number of shims 16 removed in disassembly on shift oper ating cylinder and install against transmission case Secure with screws and washers 14 NOTE If new case or shift operating cylinder is used adjust clearance as described in adjustment section 6 ASSEMBLE AND INSTALL SHIFTER SLEEVE AND CARRIER AND BEARING a See Figure 6 Install shifter sleeve 28 and secure with screws and washers 22 and 30 b See Figure 6 Install bearing 9 in shifter ring 21 and secure with retainer ring 20 Install carrier 11 in shifter ring bearing and secure with retainer ring 19 Slide complete assembly on shifter sleeve 28 7 ASSEMBLE AND INSTALL SHIFT OPERATING YOKE 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 cylinder and operating yoke with pins washers and cotter pins
25. e gear train that requires no shifting Driving torque is transmitted smoothly and efficiently from the engine through the converter to the drive wheels for either forward or reverse movement Control of forward or reverse direction is accomplished by a flip of the control lever which is positioned at the steering wheel The hydraulic torque converter is a combination fluid coupling and torque converter of the single stage three element type The three elements are the impeller the turbine and the stator The im peller is driven by the engine flywheel the turbine drives the clutch and the stator provides the ability to multiply torqye FORWARD DIRECTIONAL CLUTCH REVERSE DIRECTIONAL CLUTCH REVERSE DRIVING GEAR FORWARD DRIVING GEAR CREEP CONTROL VALVE PLUNGER DIRECTIONAL CONTROL VALVE PLUNGER OUTPUT SHAFT CONNECTION ToswmoTorque Cutaway The duplex directional clutch consists of aclutch flywheel driven by the converter a double faced pressure plate and forward and reverse clutch plates These parts plus operating links pins etc are enclosed in a clutch cover Clutch plates are coned to assure rapid disengagement The gear train is a drop down type consisting of Spur type gears which are in constant mesh Gear shafts are supported by heavy duty ball and or roller bearings The converter clutch and gear train are housed in two individual cases bolted together The convert er case houses the hydraul
26. ecks and 2 specific trouble conditions with their possible causes and remedies If trouble is encountered perform checks with the transmission warmed up This can be conveniently accomplished by an exploratory road test in an effort to definitely establish the abnormal operating con dition After the transmission is warmed 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 Towmotor with TowmoTorque Drive Itis sug gested that the service man become familiar with these characteristics before attempting to analyze a troubled situation PRIMARY CHECKS I CHECK OIL LEVEL 1 Check immediately after operating engine to make sure that all TowmoTorque cavities re quiring oil are full Refer to TowmoTorque Oil System for additional information I CHECK CREEPER PEDAL AND SHIFT LEVER LINK AGE 1 Check all linkage for good condition and cor rect adjustment 2 Shift lever travel in both directions shouldbe equal distance from the shift lever stop which is located on the steering column Adjust lever travel by lengthening or shortening the shift lever rod rod from the foot of the lever to the valve 3 Creeper pedal should be set for operator com fort and travel should be set so thatthe pedal contacts the stop bolt 1 32 additional tr
27. ection and or tends to creep If truck operates in this man ner when the shift lever is in neutral or with creeper pedal depressed but was operating correctly previously check for a buckled shift cylinder to shifter yoke push puli rod Also if truck refuses to move in one direc tion check the shift cylinder for a broken neu tral return spring which could have jammed and caused limited cylinder travel With the transmission cover removed the shift mech anism can be operated manually and visually inspected for other type interference which might be causing the trouble X TOWMOTOR WILL NOT MOVE WITH WHEELS FREE TO TURN WHEN OFF FLOOR This trouble is usually caused by interference in the transmission or line of drive Refer to Items under Condition XIH XI TOWMOTOR CREEPS FORWARD OR BACK WARDS WITH SHIFT LEVER IN NEUTRAL AND OR CREEPER PEDAL DEPRESSED 1 Cylinder neutral return springs broken Brok en spring nearest the piston rod end will cause creepage in forward It will cause creepage in this direction only when the shift lever is in neutral and will cause slow release from this direction or occasionally hang up when the creeper pedal is depressed When the other spring is broken the truck will act normal when the lever is in neutral but the broken spring will affect creeper pedal response in reverse With either or both springs broken the clutch will hang up and not release properly when the creeper pedal is de
28. efer to Condition IX Item 5 If slippage occurs when starting a stationary truck and not while operating the truck the trouble could be in the control linkage This condition would also be accompanied by slow shifting unless the trouble is in the forward accumulator valve for the small series trucks Tighten adjusting screw all the way to see if the trouble stops If so simply re adjust to maintain 1 1 2 to 3 seconds engage ment XVI CLUTCHES DO NOT DISENGAGE CLEANLY 1 2 3 AND QUICKLY WHEN SHIFTED TO NEUTRAL OR WHEN CREEPER PEDALISDEPRESSED Loss of pump prime Refer to Condition IX Item 1 Check shift cylinder linkage and clutch out put sleeve bearing as indicated under Con dition XI Check clutch driven discs for proper cone and grooving XVII SLUGGISHNESS IN ENGAGEMENT TIME IN 1 aw 8 SHIFTING CYCLE Make sure that control linkage is in good con dition and correct adjustment Refer to Condition VI Air leak in pump suction line Refer to Con dition V for indication of leakage Low oil pressure Pump oil inlet screen plugged Refer to Con dition IX Item 4 Faulty shift cylinder or linkage Refer to Con dition IX Item 6 and Condition XI Item 4 Scored shifter or carrier Refer to Condition XI Item 5 Loss of pump prime Refer to Condition IX Item 1 Clutches worn Refer to Condition IX Item 5 XVII OVERHEATING AS EVIDENCED BY AN 1 OFFENS
29. elief valve tee to 3 way tee in converter housing HOSE ASSEMBLY right side on converter housing to strainer assembly gt MAINNBUICGers com HOSE ASSEMBLY shifter control valve to 3 way tee in converter housing HOSE ASSEMBLY upper tee at relief valve to upper radiator connection SCREW cap relief valve mounting bracket to case STRAINER ASSEMBLY TEE 90 in relief valve TEE 3 way in converter housing TEE lateral in relief valve TEE converter case VALVE ASSEMBLY relief CAP adjustment PLUNGER RING seal SEAT plunger SPRING plunger WASHER plunger spring WASHER lock relief valve mounting bracket Fig 8 Hydraulic Lines and Fittings MIMS Maekinesy fitererninanggers com 2 REMOVE AND DISASSEMBLE HYDRAULIC LINES FITTINGS AND CONTROL VALVE a See Figure 8 Disconnect hydraulic lines and fittings b See Figure 10 Remove screws and washers 28 29 and 31 then separate control valve assem bly and gasket 27 from transmission case To disassemble control valve for repair purposes refer to Control Valve repair section 3 REMOVE TORQUE CONVERTER CASE COVER AND TRANSMISSION TOP COVER a See Figure 5 Remove screws 22 and 23 washers 28 29 30 and 31 and nuts 6 and 7 then remove cover 4 and cover seals 26 and 27 b See Figure 7 Remove screws and washers 33 35 and 43 and separate top cover 12 and gasket 15 from transmission case 1 4 REMOVE AND DISASSEMBLE OIL PUMP
30. erformed in Item 5 above would not differen tiate between valve or bushing troubles but either trouble would necessitate disassembly for 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 sheared off converter sieeve Check by plugging pump outlet and turning converter by hand either with engine or after disconnecting converter drive straps from the flywheel If the converter can be turned the lugs are probably sheared This condition MIMS Rehia TOW MOTUS MmAMNEAggers com 10 11 v I would probably be accompanied by excessive noise Worn O ring seal in control cylinder If other checks fail to conclusively locate the difficulty the pump may be faulty The pump should deliver approximately 3 1 2 gallons per minute at 1000 rpm engine speed and 100 F oil temperature HIGH OIL PRESSURE Jammed system relief valve Pinched oil line Plugged oil line or passage ENGINE WILL NOT START OR STARTING MOTOR NOT WORKING A safety switch is mounted in the control valve This switch will operate only when the shift lever is in neutral If lever is not in neutral the engine will not start Perform usual checks for standard causes of engine failing to start or starting motor failing to operate If starting motor will not turn engine over make sure the usual stan
31. es from the floor board the ball joint or adjustable yoke may be adjusted to have the creeper plunger positioned somewhat into the valve body with the pedal fully released The plunger should not be positioned into the valve body sufficiently as to cause an increase in the shift cycle time or the clutches to slip The position of the plunger that would cause achange in the shift cycle time varies with each valve body due to the internal cored oil passages in the valve body 2 If the pedal position for creeping the truck is not the same in forward and reverse gear the cam plate may be rotated slightly on the cross shaft to compensate for the difference in travel ofthe clutch linkage If the pedal position is lower in forward gear than in reverse rotate the cam plate on the cross shaft in a clockwise direction viewed from the left side of truck Ifthe pedal positionis higher in forward gear than in reverse gear rotate the cam plate on the cross shaft in a counterclockwise direction This adjustment may be required with each rebuild of the transmission that affects the amount of travel of the clutch linkage It is necessary that the movement of the creeper plunger closely follow the movement of the creeper pedal due to the nature of this control mechanism A binding or sticking condition in the linkage that results in an abrupt movement of the plunger in the valve body causes the truck to lurch and gives difficulty in controlling the t
32. gine in place and engage the universal joint at the same time Connect engine mountings 2 Install the exhaust system fuel lines electri cal system connector and accelerator pedal and linkage 3 Install hydraulic pump on timing gear cover and secure with nuts and washers 4 Connect shift lever and linkage and creeper pedal and linkage Install floor plates 5 Install radiator and hoses and fill system with proper coolant 6 Install counterweight counterweight top plate front plate left and right side plates and engine hood DISASSEMBLY DISASSEMBLE TRANSMISSION Disassemble the TowmoTorque transmission as outlined in the fol lowing numbered procedures 1 REMOVE TORQUE CONVERTER a See Figure 5 With transmission and engine assembly out of truck remove torque converter 3 when separating transmission from engine see Towmotorque replacement 10 VW MIMS Mastinvecg ro PELL INSTINGALS COM Description CASE torque converter BEARING ball converter case CONVERTER ASSEMBLY torque COVER torque converter case GASKET converter oil pump NUT hex cover to case NUT hex cover to case NUT hex transmission case to conyerter case HOUSING ASSEMBLY pump SEAL ASSEMBLY oil RING ASSEMBLY collector a aki Description RING seal large RING seal small SCREW cap collector ring to housing SCREW cap collector ring to housing WASHER lock collector ring screw WASHER loc
33. hicle and oi drained from the unit slide torque converter off converter output shaft and oil pump collector ring Remove lock wire screws and washers and oil pump from converter case When installing oil pump use a new gasket do not use sealing compound between oil pump and converter case Slide torque converter over splines of converter output shaft and oil pump collector ring and make sure drive lugs of torque converter are engaged fully with notches cut in the oil pump internal gear Install transmission and fill to pro per oil level Refer to Oil Checking Draining and Filling for proper procedures OIL PUMP REPAIR If the oil pump is found to be faulty it is rec ommended that an exchange pump be procuredfrom your Towmotor Representative Disassemble Oil Pump See Figure 5 Remove four 5 16 inch diameter socket head screws 15 and one 1 4 inch diameter socket head screw 16 Tap along parting line and separate oil collector ring 11 from pump housing 9 Remove large and small O rings 13 and 14 Lift out pump gears Remove oil seal 10 from pump housing Clean and Inspect Oil Pump Was all parts in a clean solvent and dry with compressed air Inspect gears and body for evidence of wear or damage If excessive wear or clearances is evident install a new pump body and gears Note Gears and body are matched and must be replaced as a unit In spect face of collector ring for scratches scoring or ex
34. ic torque converter and the transmission case houses the duplex clutch and the gear train SHIFTING CYCLE TIME The shifting cycle to either forward or reverse should be accomplished in 3 4 to 1 1 3 seconds after the control tever is moved into the desired position For acomplete reversal of direction shifting should require 2 seconds after the control lever is moved MIMS sMacinot TOMS WA MANSKIOgErTS cCOM The shifting lever is designed for finger tip con trol Movement of the lever should require no more effort than a flipping of the fingers CREEPER PEDAL OPERATION When the creeper pedal is in the fully released position or partially depressed up to the half way position with truck in motion drive motion should continue When the creeper pedal is fully depressed with the truck in motion power to the drive wheels will cease immediately regardless of control lever position or engine speed Do not confuse over roll or coast with drive motion When the creeper pedal is released from afully depressed position to an approximate half way posi tion with control lever in forward or reverse gradual clutch engagement should occur BRAKING WITH TOWMOTORQUE When Towmotor is in motion high engine rpm and control lever is shifted for opposite direction before stopping truck stop or slow down truck with foot brakes Do not use TowmoTorque torque con verter as a constant braking power
35. ions for neutral setting must be measured so that correct neutral setting can be obtained through shift cylinder adjusting shims To check this dimen sion remove transmission top cover then measure the distance between the face of the clutchflywheel and the edge of one of the pressure plate driving lugs Dimension should be as shown in figure 4 A simple check of correct clutch operation is as follows Set hand brake or move the truck against something immovable with a little weight on the forks Race the engine with shift lever in neutral and shift into a direction Proper action should sharply decrease engine speed to approximately 1200 to 1400 rpm and hold it there Also it should take no longer than three seconds from start to completion of engagement If clutches are slipping a sharp decrease in engine speed will not be apparent but only a slight momentary slow down will occur for an instant then engine will return to its approximate original speed To check clutch engagement with the creeper pedal in the half way position vehicle held station ary as described above and engine running about 1000 rpm shift into adirection The elutches should engage normally in the manner described above but a longer period of time is necessary toaccomplish complete engagement MIMS Mastrivery T TON AGTOR IIMANdeks com TOWMOTORQUE TROUBLE SHOOTING This trouble shooting guide is divided into two sections 1 Primary ch
36. k collector ring screw RING retainer converter case bearing RING retainer output shaft and valve SCREW cap converter pump to converter case SCREW cap cover to case SCREW cap cover to case SCREW cap torque converter case to transmission case SEAL converter case to transmission case SEAL converter cover lower SEAL converter cover upper WASHER flat cover to case WASHER flat cover to case WASHER lock cover to case WASHER lock cover to case WASHER lock transmission case to torque converter case WIRE locking converter pump to converter case SCREW cap converter to flywheel SCREW cap transmission to flywheel housing WASHER lock transmission to flywheel housing screw WIRE locking torque converter to flywheel T 230 Fig 5 Converter Converter Case and Oil Pump III Tr nn 11 MIMS Mangi niimeariggers com Ref No Description 19 RING retainer carrier to shifter ring 1 LEVER clutch operating 20 RING retainer carrier bearing 2 LINK lever to pressure plate 21 RING shifter 3 PIN cotter anchor pin 22 SCREW cap shifter sleeve to transmission 4 PIN lever anchor case 5 PIN link pivot 23 SCREW cap clutch assembly to clutch 6 PLATE clutch cover flywheel 7 PLATE clutch pressure 24 SCREW cap converter output shaft to clutch 8 PLATE ASSEMBLY reverse clutch 25 SCREW set operating yoke shaft 9 BEARING ball shifter carrier 26 SHAFT operating yoke 10 BEARING needle forw
37. late and clutch cover Inspect carrier bearing Inspect bore of shifter carrier for exces sive wear Replace all faulty parts except that if cover pressure plate levers or links need replac ing replace the complete clutch cover assembly Reassemble Clutch See Figure 6 With index markings in proper relation on pressure plate and cover place clutch plate 8 on face of clutch cover 6 Slide pressure plate 7 with links 2 and pins 5 attached in slots provided in clutch cover Clutch construction eliminates need for cotter pinning link pins Align operating lever with holes in clutch cover and install clevis pins 4 and cotter pins 3 Assemble Carrier Bearing and Shifter Ring See Figure 6 Press bearing 9 in shifter ring 21 and secure with retainer ring 20 Press carrier 11 in shifter ring 21 and secure with retainer ring 19 SHIFT OPERATING CYLINDER DESCRIPTION The shift operating cylinder is mounted on the MIMS Macrivery AZA SETOR imanggers com Description BODY GUIDE spring NUT piston shaft PISTON PLUG end RING retainer large RING retainer small ROD piston SEAL end plug SEAL piston SEAL piston SPRING upper SPRING lower SCREW and WASHER cylinder to transmission case SEAL cylinder to transmission case SPACER cylinder adjusting 1 32 thick SPACER cylinder adjusting 1 8 thick T 2907 1 Fig 9 Shift Operating Cylinder Assembly
38. lutch flywheel Remove bolts nuts and washers securing converter case to transmission case Lift off converter case with oil pump and clutch flywheel assembled Remove forward clutch plate Lift out clutch assembly Slide off clutch carrier assembly When installing clutch assembly be sure that all clutch operating levers are in the groove of the clutch shifter ring and that clutch plates are in stalled properly clutch plate hubs must face the inside of the transmission or the unit cannot be assembled properly With clutch assembly installed place forward clutch plate on clutch pressure plate and slide splines of hub over splines of forward clutch shaft Insert new O ring between cases and install converter case with oil pump and clutch flywheel assembled against transmission case and secure with bolts nuts and washers Using a drift align holes in clutch cover with holes in clutch flywheel Install screws and lock wire in pairs Install top cover Slide torque converter in place and install transmission see TowmoTorque Replacement CLUTCH AND SHIFTER CARRIER REPAIR If clutch assembly is found to be faulty because of excessive clutch plate slippage or because it s completely worn out repair parts are available to a certain extent that is if replacement of pressure 18 plate operating levers links or cover is nec essary a complete clutch cover assembled with these items must be replaced because of alignment on
39. nger RING snap forward and reverse plunger RING wiper control valve plunger SEAL oil clutch shaft SCREW bracket to control valve SCREW mach plunger retainer to control valve SPRING accumulator valve WASHER plain forward and reverse plunger WASHER lock bellcrank support bracket GASKET control valve to transmission case SCREW cap control valve mounting SCREW cap control valve mounting SWITCH limit WASHER lock shifter valve Fig 10 Control Valve Assembly MIMS Marke YA OY ADT LE imeaigaers com press spring guide remove retainer ring 7 then release press or vise slowly and remove guide 2 and spring 13 Remove end plug seal 9 from end plug 5 Unscrew piston rod nut 3 and remove piston 4 and O ring 11 assembled from piston rod 8 Compress other spring guide and remove retainer ring 7 spring guide 2 and spring 12 Clean_and Inspect Shift Operating Cylinder Wash all parts in aclean solvent and dry with compressed air Inspect cylinder bore for scratches and grooves which would cause cutting or scratching the seal ring and cause leakage Use new seal rings when reassembling cylinder Assemble Shift Operating 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 as
40. nthe end of the cross shaft The spring loaded lower control lever will then ro tate the cam plate until both creeper control lever pins contact the left edge of the holes in the cam plate Tighten the locking plug approximately 10 foot pounds of torque making sure the cross shaft does not rotate in the cam plate Move the creeper plunger to its fully extended position and place the creeper pedal against the pedal stop With the creeper plunger extended and the creeper pedal against the stop reinstall the upper lever on the creeper lever support The hole in the upper lever should be aligned with the pin in the lower lever To make this alignment loosen ball joint jam nuts then turn ball joint and upper lever as an assembly in or out as necessary to align pin and hole After adjustmentis set tighten ball joint jam nuts and install washers and cotter pins as necessary NOTE On Models 540 600 670 and 680 P follow the same adjustment procedure except when aligning the hole in the upper lever and the pin in the lower lever disconnect the adjust able yoke at the brake pedal Turn yoke and lever as an assembly in or out as necessary to align pin and hole After the initial linkage adjustments have been made it may be necessary to make further adjust ments to the linkage after the truck has been driven for the first time 1 If the clutch does not completely disengage with the creeper pedal positioned between one or two inch
41. or plates then disconnect creeper pedal linkage and shift lever and linkage 4 Disengage hydraulic pump from engine timing gear cover by removing nuts and washers 5 Disconnect exhaust system fuel lines elec trical system connector and accelerator pedal and linkage 6 Disconnect engine mountings Using a suitable hoist and cable sling raise engine and transmission up and out of vehicle disengaging universal joint as engine is removed Remove Transmission from Engine CAUTION The following procedure must be fol lowed to eliminate damage by allowing total weight of transmission to hang on converter Remove converter case cover This will expose six screws that fasten converter to engine flywheel Remove these screws before separating trans mission from engine Converter can be removed from transmission after Towmo Torque is separated from engine Install Transmission on Engine Prior to installing transmission on engine mount converter carefully aligning driving lugs with oil pump drive gear When mounted properly con verter should touch the converter case With con verter in this position assemble transmission to engine and bolt case to engine Slide converter toward engine flywheel and align bolt holes In stall screws securing converter to engine flywheel and lock wire inpairs Install converter case cover Install Transmission and Engine in Truck 1 Using a suitable hoist and cable sling lower en
42. ot brakes if necessary Third Press gas pedal when loading or unload ing is completed DO NOT USE TOWMOTORQUE AS A BRAKE When Towmotor is moving high engine speed and shift lever is moved for change of direction before stopping step on brake pedal to slow downor stop Do not use Towmotorque as a constant braking power MIMS sMachineg titties minsnagers com TOWMOTOR TOWMOTORQUE DRIVE BREATHER AND OIL FILLER CAP LIMIT SWITCH fe F SUPPLY LINE FOR CLUTCH COOLING CONTROL VALVE CREEP CONTROL VALVE PLUNGER DIRECTIONAL CONTROL VALVE PLUNGER SUPPLY LINE TO CONTROL zz VALVE PLUG Si OUTPUT SHAFT SHIFT E OPERATING 7 CYLINDER DRAIN PLUG SUPPLY LINES TO OPERATING CYLINDER FOR DIRECTION SELECTION f 1229 Fig 1 TowmoTorque Transmission Assembled View MIMS Mantivecy OWN CTOR MA Nge com DESCRIPTION AIR COOLING FAN SHROUD TORQUE CONVERTER COOLING AIR OUTLET FORWARD IDLER GEAR OUTPUT GEAR T 1233 Fig 2 TowmoTorque is designed to provide hydraulic ally controlled power to eliminate gear shifting and clutching delays and to provide effortless driver control The TowmoTorque drive is a heavy duty air and oil cooled hydraulic torque converter type trans mission The principle operating parts are a hy draulic torque converter a duplex directional clutch for forward and reverse travel and a constant mesh drop down typ
43. pressed 2 Loss of pump prime Refer to Condition IX Item 1 Faulty needle bearing in the clutch flywheel at the clutch output sleeve This would cause creepage in reverse and would probably be very noisy in the opposite direction It can be checked by removing the transmission cover and manually spinning the clutch flywheei Flywheel should turn very freely and without noise Scored and or sticking shift cylinder or bent piston rod in the cylinder Check for this trouble through the transmission access opening 5 Scored shifter carrier and shifter which would MIMS Matinee KUNENA bimsiggers com XIL XII XIV result in sluggishness Inspect visually through opening in transmission Faulty control linkage Inspect all control linkage to make sure it is in good condition and correct adjustment LACK OF ACCELERATION AND POWER UNDER FULL THROTTLE AND HIGH POWER REQUIREMENTS WITH LOW ENGINE SPEED approx 1000 rpm or less Oil pressure too high Refer to Condition VIL Engine power low Check timing and other standard conditions that may cause the engine to lose power Transmission oil pump or pump drive sleeve bushing binding This condition would probably be accompanied by excessive noise Stator one way clutch slippage Replace torque converter Do not replace converter unless all other possible troubles have definitely been eliminated LACK OF ACCELERATION AND POWER UNDER FULL THROTTLE
44. ruck speed during creeping The linkage should be lubricated with SAE 30 engine oil at each pivot joint during assembly and none of the linkage should be painted The link age return spring preloads the linkage to take up the initial clearances at each pivot point and any increase in clearance due to wear CREEPER PEDAL AND LINKAGE LATE MODELS The following information contained in these supplement pages refers to the adjustments of this new style creeper pedal linkage Variations in operation between early model linkage and late model linkage is given under the title How to Creep in Tight Spots MIMS Nleehioe ng DWMOGTOR THE ONE MAN GANG ARIUaGers com This new style linkage is quite sensitive in its creeper pedal actions therefore accurate adjust ments are required for best efficiency and operation of the truck during creeping Identification between early and late model linkage can be distinguished as follows Early models have a round button type creeper pedal while the late models use apedal similar toa stand ard transmission clutch pedal HOW TO CREEP IN TIGHT SPOTS LATE MODELS Procedures for creeping in tight spots are essen tially the same as those used in the early models except that extremely easier creeper pedal action is obtained through the newly designed linkage In effect the creeper pedal linkage is given a hydraulic and mechanical assist by the shift cylin
45. se posi tion oil flow to the shift cylinder is controlled by this restricted opening in such a manner that it slows down speed of clutch engagement If the pedal is held in the half way position the clutch will soon become engaged but not as rapidly as when pedal is fully released A pressure regulator valve is mounted in the bore of the creeper plunger This valve limits maximum pressures in the system by controlling oil return to the sump when the pump is delivering more oil than the system requires MIMS Madi nesa TO RADIATOR SHIFT OPERATING ee T 1919 Fig 3 OIL CHECKING DRAINING AND FILLING The transmission should use little or no oil how ever periodic checking of the level is necessary to assure proper operation Oil should be changed after each 1500 hours of operation Oil level should be checked immediately after stopping the engine To check oil level remove oil level plug in front cover Oil should be level with the bottom of the plug opening If more than two or three quarts are added at any onetime examine transmission for external leaks When filling is necessary operate engine and recheck oil level after refilling RELIEF VALVE SUPPLY LINE TO CONTROL VALVE TO CLUTCH To CONVERTER FROM S some p Et uD STRAINER TowmnoTorque Oil System To drain oil from converter remove case cover to expose the converter Remove plug from con verter and crank engine 180
46. sem bled in bore and slide over piston rod end Note piston is equipped with recess for nut install with recess toward nut Secure piston with nut 3 Position large diameter spring 13 and spring guide 2 on end plug 5 and secure with retainer ring 7 Install new seal ring 9 on end plug 5 and install plug assembly in bottom of cylinder Secure plug with large retainer ring 6 CONTROL VALVE DESCRIPTION The control valve is mounted on the front cover of the transmission case Its function is to distribute oil under pressure to the shift operating cylinder The control valve consists mainly of a housing in which two plungers are fitted to control oil direction through valve One plunger is operated by the trans mission shift lever and the other plunger is oper ated by the creeper pedal The creeper pedal plunger is equipped with a relief valve to control maximum pressures in the system CONTROL VALVE REPLACEMENT See Figure 10 To remove control valve dis connect oil lines and control linkage Remove screws 28 and 29 and washers 31 fastening valve to transmission case When installing control valve use a gasket 27 between valve and case Connect linkage Check linkage for free operation and correct adjustment see Adjustment Section Connect oil lines CONTROL VALVE REPAIR If the control valve is found to be faulty it is recommended that a complete valve be procured from your Towmotor Factory Represent
47. sion case 11 REMOVE AND DISASSEMBLE REVERSE CLUTCH SHAFT AND GEAR a See Figure 7 Remove front retainer ring 26 and press reverse clutch shaft 36 with bear ing 5 assembled out of transmission case Lift out gear 19 b See Figure 7 To disassemble reverse clutch shaft and bearing remove key 20 then press bearing 5 off shaft Remove rear retainer ring 26 from shaft MIMS Machine KU mimsviggers com 12 REMOVE AND DISASSEMBLE IDLER GEAR SHAFT COVER SHAFT AND GEAR a See Figure 7 Remove screws and washers 34 and separate cover 11 and gasket 13 from transmission case b See Figure 7 Remove retainer rings 28 Press shaft 39 with bearing 3 assembled out of transmission case Remove gear 17 andspacer 40 Press shaft 39 out of bearing 3 Remove key 21 from shaft c Remove bearing 6 from transmission case 13 REMOVE AND DISASSEMBLE OUTPUT SHAFT COVER AND GEAR ASSEMBLY a See Figure 7 Remove screws 32 and wash ers 42 fastening cover 9 to transmission case b See Figure 7 Remove retainer ring 29 at plug end of gear and press complete cover gear and shaft assembly 4 7 9 10 18 29 and 30 out of transmission case Remove gasket 14 c See Figure 7 To disassemble cover and gear assembly remove oil seal 10 and retainer ring 29 Press gear assembly out of cover 9 Remove retainer ring 30 and press bearing 4 out of cover Press gear 18 o
48. tches that may cause poor seating Inspect plungers for grooves or excessive wear Check fit of plungers in housing There should be no perceptible side play If plungers are loose or faulty in other respects replace valve assembly Use new gaskets and seals when reassembling control valve Assemble Control Valve See Figure 10 Install new plunger seal rings 18 and wiper rings 20 in housing Install plunger 16 and spring 24 in bore of housing 1 and secure with new gasket 4 and cap 3 Install relief valve 12 and spring 11 in bore of creeper valve plunger and secure with new seal ring 9 and eye 8 Insert plunger 7 with snap ring 10 assembled in valve housing Install washer 25 on plunger 13 and secure with snap ring 19 Install detent balls 14 and spring 15 in plunger 13 and slide housing 5 over end of plunger until balls slip into recessed groove Install complete plunger in valve housing Position retainer 17 and bracket 2 over plun gers and secure with screws 22 and 23 and washer 26 Install limit switch 30 plug 6 and shaft seal 21 i 0 21 MIMS Machinery Movers mimsriggers com
49. ut of bearing 4 Do not remove plug 23 from gear 18 unless replacement is necessary ASSEMBLY ASSEMBLE TRANSMISSION Assemble the Tow moTorque transmission as outlined in the follow ing numbered procedures 1 ASSEMBLE AND INSTALL OUTPUT SHAFT GEAR AND COVER ASSEMBLY a See Figure 7 If plug 23 was removed from gear 18 install new plug Press bearing 4 on gear 18 and secure with retainer ring 29 Press bearing 7 in cover 9 and secure with retainer ring 30 Install gear with bearing assembled in cover 9 and secure with retainer ring 29 b See Figure 7 Position a new gasket 14 in place on cover then install cover assembly in trans mission case Secure cover with screws 32 and washers 42 Install new oil seal 10 in cover 2 ASSEMBLE AND INSTALLIDLER GEARSHAFT AND COVER a See Figure 7 Install key 21 in idler shaft 39 Position gear 17 in transmission case then press 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 11 then secure with screws and washers 34 16 3 ASSEMBLE AND INSTALL REVERSE CLUTCH SHAFT AND GEAR a See Figure 7 If bushing 37 was removed from shaft 36 install new bushing Install rear re tainer ring 26 in groove near middle of shaft then install bearing 5 Install key 20 in shaft Place gear 19 in position and press shaft into gear Se cur
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