....-,

LITHO. IN U. S. A.

'\ ....,.,..~

SERVICE AND REPAIR MANUAL.,.,

FOR

TORQUE CONVERI'ER

and

RESERVOIR ASSEMBLY

AS USED IN

Model HA - HAH - HF - HR - HU - HHIf'I

II PAYLOADER" Unit

FORM SD-20

MANUFACTURED BY

THE FRANK G. HOUGH CO •..".LIBERTYVILLE! ILLINOIS

_.

{»RJCE $1.00 Oct. 1955Reissued Dec. 1957

''_

TABLE OF CONTENTSPage No.

I. Intr oduction. . . 3

II. Description .. 3

A. Design ..B. Installation ••C. Operation .•.D. Oil Flow ..E. Operating Technique

33445

III. Service and Maintenance 6

A. Periodic Service of Torque Converter andReservoir Assembly ....

B. Location of Service Points66

1. Drain Plug . . . . . •2. Oil Cooler Breather Petcock •3. Oil Cooler Drain Plug ....4. Pump Inlet Tube Assembly5. Filter ....6. Filler Plug.7. Level Plug ..

.'

6666666

C. Draining the Torque Converter and Reservoir AssemblyD. Filling the Torque Converter and Reservoir Assembly ..E. Torque Converter and Reservoir Assembly Oil Filter.F. Oil Capacities .G. Pre -delivery Service .H. 30. 60 and 90-day Warranty Checks

777888

IV. Trouble Shooting •••....•........ 9

99999

9

91015151718

A. Oil Leaking from the Engine Flywheel Housing.B. Oil Leaking from the Clutch Housing .....•C. Lack of Torque Multiplication •..•.•.....D. Ove r heatdng ••.•.•.•.••.•.•.•••...E. Noisy - No Torque Output or Erratic Output.

v. Service and Ovez-haul ....

A. Over-haul Suggestions ..B. Disassembly of the Reservoir Housing AssemblyC. Disassembly of the Torque Converter .D. Tips on Inspection and Repair .E. Assembly of the Torque Converter ' .F. Assembly of the Reservoir Housing Assembly

1

Figure No.

4.5.6.7.B.9.10.11.12.13.14.15.16.17.is.

ILLUSTRATIONS

Page No.

1. Typical Converter Installation ..2. Right Hand Side of Converter and

Reservoir .

3

43. Left Hand Side of Converter and

Reservoir . 4451011121213131416lBlB191920

Output Shaft and Pump Group .Oil Flow Diagram .Clutch Installation ...•....Torque Converter and Reservoir Group ..Pump Group ....•............Orifice, Cover Plate and Relief ValvePump Inlet Tube Assembly .New Style Strap Installation ...•.•.Cross Sectional View of Torque ConverterTorque Converter .Converter Bolt Circle .Dial Indicator Check Points .Indicating Clutch Flywheel Housing .Indicating Flywheel.Clutch As sem bly ........••.•

2

I. INTRODUCTION

In the past few years, the nametorque converter has begun to play anincreasingly important part in the in­dustrial and con s t r u c t ion equipmentfields. To day, "PAYLOADER" unitsequipped with torque converters are doingmore work faster with less effort on thepart of the operator.

THE FRANKG. HOUGHCO. is nowproducing a hydraulic power take-off'unit which includes a torque convertermanufactured by Borg &: Beck, a divisionof the Borg- Warner Corporation. ThisP.T.O. is currently used on the follow­ing "PAYLOADER" units:

HA - SIN 26900 thru SIN 27349SIN 2A-27401 and up

HAH - SIN 51929 thru SIN 52100SIN 4A-1003 and up

HF - SIN 85061 and upHR - SiN 43800 and upHU - SIN 14A-1001 thru SIN 14A-1363

SIN 15A-1001 thru SIN 15A-1l19HH - SIN 18A-l00l thru SIN 18A-1448

SIN 19A-1001 thru SIN 19A-1l33

Basically, the P. T. O. assembly isthe same for all of these models. Wefeel, therefore, that one service manualwill cover all units.

The purpose of the hydraulic torqueconverter is to multiply, within itself,the torque generated by the engine, andtransmit this increased torque throughthe transmis sion and into the final drive.Further, it reduces shock normally im­posed upon the gear train by suddensurges of power required to overcomeincreased work loads.

II. DESCRIPTION

A. Design

The torque converter is a simple,three-element type, normally consistingof a converter impeller (pump A), a con­verter runner (turbine B), and a reactionrunner (stator C). These parts, with thenecessary bearings and seals, arecoupled to an oil reservoir housing bymeans of the converter runner shaft (D)as shown in Fig. No.1.

Fig. No.1Typical Converter Installation

This torque converter ass em b I Yhas its own hydraulic system. The cast­ing between the clutch housing and the en­gine flywheel housing includes a hydraulicres e r v 0 i r, strainer. pump and reliefvalve. A filter and cooler (with the ex­ception ofHACandHAHS/N 51929throughSIN 52100), are al so a part of this system,though not contained within the housing.

B. Installation

Fig. No.2 shows a view of the sideof the unit which is on the right side ofthe "PAYLOADER". Just below the cen­ter of this side of the housing is a fittingwhichis an outlet from the pressure sideof the pump. The pump is contained with­in the housing. The line from this fittingcarries high pressure (40 - 50 P.S.I.)oil to the relief valve fitting which canbe seen extending above the housing onthe far side.

The other fitting shown on this sideis the outlet fitting for oil leaving theconverter and on its way to the filterand cooler. The electrical "sending"devices are for the oil temperature gaugeand for the high temperature warninghorn.

3

When the oil temperature exceeds2650 - 2850, safe working temperature,the "PAYLOADER" horn will blow untilthe temperature returns to the safeoperating range.

Fig. No.2R.H. Side of Converter & Reservoir

In this picture you can also see theclutch cover assembly which is bolted tothe clutch flywheel in the conventionalmanner.

In Fig. No.3 you see the inlet to thepressure relief valve at the top and theinlet to the orifice plate cover in thecenter of the left side housing cover.

Fig. No.3L.H. Side of Converter & Reservoir

Just below the orifice inlet is a1/8" pipe plug. This plug indicates theproper oil level in the reservoir for Model U'HAH"PAYLOADER" only.

Reading from left to right in Fig. No.4 are the output shaft, "0" ring for pump,collector block and pump assembly.

~i ;::::.

Fig. No.4Output Shaft and Pump Group u

C. Operation

In operation, the converter impelleris driven directly from the engine crank­shaft, and draws oil into itself and forcesthis oil, by centrifugal action, against theturbine and stator. Under load, the ac­tion of the oil against the turbine andstator multiplies the engine torque andcauses the turbine to transmit power tothe gear train. At a constant enginetorque input, the torque multiplication ofthe converter varies with the load im­posed upon the tractor. As the tractorload diminishes, the torque multiplica­tionis inverselyproportional to the speedratio until the f r e e whe e 1 poi ntisreached.

D. Oil Flow

Fig. No. 5 shows the oil flowthroughout the entire torque converter hy­draulic system. NOTE: The filter is used \Jon all models. Model HAC and HAHSiN51929 through SIN 52100 do not use thecooler.

4

CONVERTER

PRESS.RELIEFVALVE(45pd)

COOLER

INTERNAL LINES

Ti - .. - -l---------,ItI

ORIFICE

I ~EXTERNAL LINES

RESERVOIR

Fig. No.5Oil Flow Diagram

Oil is fed to the converter wheneverthe engine is running by the eccentric geartype pump which is within the housingdriven by the converter impeller. Theoil is pulled through a strainer in thereservoir before it enters the pump.

A part of the oil on the outlet sideof the pump is diverted by the collectorblock to an external copper tube whichleaves the housing at the lower fitting onthe right side and re-enters at the pres­sure relief valve on the top of the leftside of the housing. Oil pas ses throughthis line only when the relief valve pres­sure is exceeded and the valve is open.This pressure is about 40 - 50 P.S.I.It is not critical; it simply maintainsad e qua t e supercha rging of the torqueconverter. The relief valve is not adjust­able. The other portion of the pump out­put oil is directed to the torque con­verter through the hollow input shaft.

Oil leaves the con v e r t er housingthrough the upper outlet on the right sideand is carried to the filter, the cooler andback to the reservoir through the orificeplate. On the HAand HAH,no cooler isrequired. Oil on the return side of theconverter is under a little less pressure,

usually varies from 25 to 30 P.S.I. Theorifice plate provides a flow restrictionwhichinsures a backpressure on the con­verter, filter and cooler.

E. Operating Technique

The operation of loading the bucketwith machines fitted with torque con­verters differ s in the technique used withordinary machines of this type.

The torque converter increases thenormal thrust onthe drive wheels, there­by crowding the bucket in the bank or faceofthe cut with a greater force than can beovercome by the hydraulic power gen­erated to raise the bucket out of the cut.This is especially true when the bucketis held near ground level while loadinghard or heavy material.

To overcome this crowding or"wedging" action imparted to the bucket,by the multiplied thrust of the drivewheels, the operator should decreasepressure on the foot pedal. Less pres­sure on the accelerator will diminishtorque output resulting in less drive thrust.

Keep the clutch engaged throughoutthe loading operation. Habitual inter­mittent declutching to govern the rate ofadvancement into the stock pile defeatsthe purpose of the torque converter, andcauses unnecessary wear on the clutch.Control the speed of the tractor into thestock pile by manipulation of the ac­celerator pedal, and in conjunction, op­erate the valve lever to fill the bucketcompletely in a single steady pass intothe stock pile. This will avoid spinningthe drive wheels or needing a series ofsuccessive short thrusts to obtain a fullpayload.

The technique used to load the buck­et on 1955 Model HA, HU, HH "PAY_LOADERII units varies con sid era b1Yfrom the technique used on earliermodels.

5

Basically, the bucket on the 1955units is loaded through a breakout actioncontrolled by the bucket lever in theoperator's compartment. This specialaction eliminates the need to raise theboom in order to fill the bucket as re­quired on earlier models. In the case ofthe 1955 models, the boom is used mainlyto raise the loaded bucket to dumping po­sition.

4. Inlet Tube Assembly- Use d on Mod e 1sHA, HAH, HF, HR,HU and HH and lo­cated on the inside ofthe converter hous­ing and above the bot­tom cover plate.

A. Periodic Service of the TorqueConverter and Reservoir Assembly

5. Filter - This serv­iceable item is lo­cated under the op­e rat 0 r' sse a t onModels HA and HAHand is mounted to themain frame on theright side of the en­gine in Models HF,HR, HUand HH.

III. SERVICEANDMAINTENANCE

Type "A" transmission fluid is recom­mended for use in the torque convertersystem and should be changed every 2, 000hours of operation. The converter filterelement should be changed every 500hours.

1. Drain Plug - On theModel HA,this serv­ice point is located atthe lower left corneron the front side ofthe converter hous­ing. The drain plugon ModelsHAH, HF,HR, HU and HH isloca ted at the lowerright corner on theb a ck sid e of thehousing.

6. Filler Plug - to fillthe con v e r t e r onModelHA,remove thebreather cap locatedat the left side and ontop of the housing.The fille r plug forModels HAH,HF, HR,HUand HHis locatedin the upper left corn­er on the back of theconverter housing.

uB. Location of Service Points

2. Oil Cooler BreatherPetcock - located atthe top corner and onthe left side of thecooler. NOTE: Thecooler is used onlyon Models HAH SIN4A-IOOlandUp, HF,HR, HU and HH.

7. Level Plug - The oillevel in the HA con­verter is measuredwith a dip stick in­stead of a level plug.The dip stick is anintegral part of thebreather cap locatedat the left side and ontop of the housing.NOTE: When the oilin the converter iscold it should reach1/4" above the bot­tom of the dip stick.With the engine shutoff and the oil tem­perature at 1200 F,the oil should reachnear the high markon the dip stick.

3. Oil Cooler Drain Plug- Located at the low­er corner ontheright side of thecooler.

6

Then start the engine and lock theparking brake. Shift the transmissiongears in the lowest speed range and en­gage the clutch. Open the throttle to fullopen position and maintain this operationuntil the torque converter oil tempera­ture reaches 1200 F. Bleed the air fromthe oil cooler while the engine is running.See Z, page 6. Then shut off engine andadd oil to the converter housing until itbegins to run out of the 1/811 oil levelhole (Model HAH) or is near the highmark on the dipstick (Model HA), or the1-1/211 pipe plug on Models HF, HR, HUand HH. The oil level plug and filler plugor breather cap may now be replaced.

A 1/811 pipe plug isused to check theconverter oil level onModel HAH.This plugis located below theorifice flange coveron the left side ofthe housing.

A 1-1/211 pipe plugon top left rear sideof the h 0 u sin g isused both as a fillerplug and oil level plugfor Model HF, HR,HU and HH IIPAY_LOADER" units.

C. Draining the TorqueConverter & Reservoir

Assembly

CAUTION:Donot drain oil from anypart of the torque converter system un­less the oil temperature is below 1500 F.

Open all breather petcocks and re­move filler plug before removing theoil cooler and converter drain plugs.Let all the oil drain from the housingand cooler, then start the engine, lettingit run momentarily about (I) one minute,to pump out the oil in the converter ele­ment. Then shut off engine. Next removethe inlet tube assembly from the under­side of the housing and clean out thesludge and dirt caught in the assemblyand bottom of reservoir. Replace theinlet tube assembly and bottom coverplate and the oil cooler and converterdrain plugs securely after cleaning. Besure the cover gasket is in place anddoes not leak. Change the converter fil­ter element when draining the converterhousing.

D. Filling the Torque Converter andReservoir Assembly

o Pour approximately 13 quarts of TypeIIAIItransmission fluid into the converterhousing at the filler plug.

NOTE: When refilling and checkingthe converter oil level always se surethat the oil temperature is 120 F. foraccurate checking.

E. Torque Converter & ReservoirAssembly Oil Filter

Change the torque converter filterelement every 500 hours of operation orat least once every four (4) months. Theengine must be shut off and the torqueconverter oil temperature must be below1500F. when changing the filter element.Add one (1) quart of Type "All transmis­sion fluid after the element is changed.

Change the filter element accordingto the instructions on the box from whichthe element was removed and replacethe filter cover tightly. Then start theengine letting it run at idle speed forabout 10 minutes to fully saturate thenew element with oil. Then shut off theengine, let it stand until the converteroil temperature is below 1500 F. forsafety. Check the oil level in the con­verter housing to be sure it is up to cor­rect height when the converter oil tem­perature is 1200F. This is necessary asoil will be retained in the filter contain­er, thereby reducing the oil level con­tained in the converter. Check the filtercover, hoses and connections for leaksbefore putting the machine to work.

7

F. Oil CapacitiesThe oil capacities of the hydraulic

torque converter systems are listed be­low. Always use a good grade of Type"A" transmission fluid.

CAPACITIES14-1/2 qts ,15 qts.17 qts.17 qts ,17 qts.17 qts.

G. Pre-Delivery Service

MODELSHAHAHHFHRHUHH

Too little emphasis on thoroughlychecking a "PAYLOADER" before it isdelivered to the customer can be dis­astrous. Therefore, we recommend thatthe following checks be made on the torqueconverter and reservoir housing assemblyas well as the checks outlined in theIIPAYLOADERII PRE-DELIVER YSERVICE CHECKLIST, Form No. SD-9.

1. Be certain that the oillevelin the reservoiris correct.

2. Check and adjust en­gine R.P.M.

3. Run the engine untilthe water tempera­ture is l500F-1800F,engage the emergencybrake, put the direc­tional lever in for­ward position, putthe range lever inhigh position and runengine at full R.P.M.for approximately 10minutes. Check foroil leaks in the res­erv oiran d a 11 0 illines.

4. If the horn does notsound when the con­verter oil tempera­ture reaches 2650F -2850 F, immediatelyred u c e the engineloadandallowthe en­gine to idle until theoil cools to at least1200 F. Then deter­mine why the warn­ing switch did notfunction properly.

H. 30, 60 and 90 DayWarranty Checks

It is generally accepted in the in­dustrial and con s t r u c t ion equipmentfields that actual field working conditionscannot be duplicated at the factory or inthe distributor's shop. Therefore, factorytests may not always find trouble thatcould be brought about by conditions inthe field later on.

Being well aware of the above, werecommend that 30, 60 and -90day war­ranty checks be made to try and find ifany of the problems listed under theTR0UBL E SHOOTINGsection below,exist. It is our firm belief that if de­fective material or poor workmanshipwas err 0n e 0 u sly introduced into themanufacture of the IIPAYLOADER", itwould cause trouble within 90 days afterthe unit was put into operation.

The warranty checks should in­clude all the steps 1is ted under Pre­Delivery Service as well as those listedbelow:

1. Determine if the cus­tomer is using thecorrect weight of oilin the converter andreservoir housingsystem.

2. Determine if the cus­tomer is changingthe oil filter and oilas recommended.

3. Determine if the cus­tomer has kept theclutch properly a<;l­justed.

4. Determine whether ornot the customer hasbeen abusing the ma­chine or operating inhigh gear when undersevere loading condi­tions and overheatingthe oil in the system.

The customer should be reminded thathe is solely responsible for the propermaintenance and operation of his unitthroughout its life.

8

IV. TROUBLE SHOOTING

.. The information in this section is

." pre sen ted as a guide to the operatorandmaintenance crew in locating troublein the torque converter and reservoirassembly.

A. Oil Leaking from theEngine Flywheel Housing

1. Cause: Rear engineoil seaJ leaking.Remedy: Install newseal.

2. Cause: P ump sea 1leaking.Remedy: Rep 1aceseal.

3. Cause: Broken orfrayed collector block"0" ring.Remedy: Replace "a'ring.

4. Cause: Dynaseal-washers leaking atpump.Remedy: Install newwashers.

NOTE: To make the above correc­tions, it will be necessary to remove thereservoir housing assembly from theengine.

B. Oil Leaking from the ClutchHousing

1. Cause: Output shaftseal leaking.Remedy: Replace theseal.

NOTE: To make the above correc­tions, it will be necessary to remove theP. T.O. housing, clutch flywheel and out­put shaft from the res e r v 0 i r housingassembly.

C. Lack of Torque Multiplication

1. Cause: Failure ofSprag clutch.Remedy: R epla c eSprag unit outer andinner race. Clean outentire system.

2. Cause: Clutch slip­ping.Remedy: Replace orreadjust clutch disc.

D. Overheating

1. Cause: Due to lackof oil circulation dueto:pump drive failureworn out pumpopen relief valveclogged inlet

screenclogged filterclogged orificeclogged coolerlow oil level

Remedy: Pressurec h e ck s at high andlow pre s sur e sidewill help to determinesource of trouble.

E. Noisy - No Torque Outputor Erratic Output

1. Cause:Broken strapsat engine flywheel.Remedy: Replace us­ing double strap persection on reas­sembly of converterelement to flywheel.

V. SERVICE& OVERHAUL

A. Overhaul Suggestions

We recommend that the disassemblyand assembly of the torque converter andreservoir assembly be handled by ourdistributors in their own repair shops.

No special tools are required to re­move the ass e m bly from the "PAY­LOADER". Disassembly, inspection, re­assembly and reinstallation can also bedone with common shop tools and equip­ment. In most cases, it will be necessaryto remove the engine unit from the"PAY­LOADER" in order to work on the con-

9

verter assembly. In the HA and HAH, itwill then be necessary to remove thetransmission from the assembly if workis to be done on the clutch or clutch fly­wheel or converter output shaft. Fig.No. 6 shows the clutch end of the con­verter assembly which is mounted on anHA "PAYLOADER" engine. The enginehas been removed from the tractor in thispicture and the converter assembly cannow be removed for disassembly, in­spection and reassembly.

Fig. No.6Clutch Installation

B. Disassembly Procedurefor the

Reservoir Housing Assembly

As the assembly is removed fromthe flywheel housing the converter ele­ment itself will remain bolted to the fly­wheel. The assembly removed will thencontain all of the items shown in Fig. No.7 except item No.1, the converter ele­ment itself. All items in Fig. No.7 areserviceable as individual parts with theexception of the pump, Item No.2. If ithas been determined that the pump isthe source of trouble, it should be re­placed as a complete unit.

TORQUE CONVERTER & RESERVOIR ASSEMBLY GROUP VMODEL HA PAYLOADER ONLY

6789

1011121314* 15

116i 1718

Torque Converter Assembly -See Note . . . . . •...

Pump Assembly. . .. ..•. . ...Oil Seal (included in item 2) .Capscrew (Drilled Head) 5/16" N.C.

x 2-3/4" Long .Capscrew (Drilled Head) 5/16" N.C.

x 2- 5/8" Long. ......•. . ..Dynaseal Washer s . ... . ....Lockwire - #16 Half Hard Steel Wire"Oil Ring. . . . . . . . . .Collector Block. . .Seal Ring . . . . . . . .Retaining Ring. . . .Ball Bearing .. ..:Reservoir. . . . . . . . . . . .! Gasket - Cover (Upper). . . . •..Cover - Assembly (includes sleeve).Capscrew - 3/8" N.C. x 1-1/4"

Long - Cover ..Lockwasher - 3/8" Std. - Cover ...

119094 Flange - Cover ...........•..108013 Capscrew - 1/4" N.C. x 3/4" Long.

Lockwasher - 1/4" Std .

I

Plate - Orifice .Gasket - Flange .Plunger (Ball) .......•...•.•.Spring ......•.............Washer. . .Plug. . .Gasket - Cover (Lower). .. ..Cover - Lower. .. ..Capscrew - 3/8" N.C.

x 1" Long. .. . .Lockwasher - 3/8" Std. . . .Oil Seal . . . .Output Shaft ..Place Bolt. . .Flywheel. .Dowel.Pilot Bearing.Inlet Tube Assembly.Gasket - Inlet Tube.Capscrew - 1/4" N.C.

x 1-3/4" Long.Lockwasher - 1/4" Std ..

128530 Elbow - Reservoir125931 Tube .128531 Connector .128513 Tee .

II

PIug - Tee - 3/8"Sq. Hd, Pipe .

103488 Elbow (Into Cover) .•.....

115364 IpiPe - Oil Filler " ..110787 Breather & Filler Cap .

ItemNo.

19* 20*121222324252627

II

234

119157122690119163

Part INo. i Part Name

IAlways give the "Payloader" Serial Number with the Part Number

and Name of Items needed when ordering Repair Parts.

122362

5 1223592

122360

122467119088119153119176118866119821119899127625108117

119096119095116152119138114851116716119904119903108116

Qty.

24111111111

282930313233343536

119154119087119930123100122481123231119139

'1119159108018

6612211112211

6611611111

221111

3738394041

>:< Onorder for items 15, 21 & 22, supplythe following: 138532 Cover, 134152 Plun­ger and 138531 Spring. These new itemsalso ~bsolete items 17, 18, 19 and 20. \J

10

42

4344

\

l-r~~----~

Fig. 7TORQUE CONVERTER and RESERVOIR GROUP

11

Disassembly should proceed as fol­lows:

Place the housing (13) on a benchwith clutch side up. Use 3 wooden blocks4" thick to support the housing and pro­tect the shafts extending down.

Remove the clutch cover assemblyand disc. Remove the 6 flywheel placebolts. The flywheel (31) is doweled to theoutput shaft flange. It can be loos ened byrocking the wheel with alternate hamme rtapping at the edges of the wheel betweendowel pins. Use a soft hammer, rubberor leather, as the flywheel face is mildsteel. The pilot be a r in g should bepressed out from the engine side of theflywheel.

Turn the housing (13) over on the out­put side protecting the edges of the cast­ing from bench damage. In this positionthe 4wired screws (4 & 5) can be removedfrom the pump body (2). NOTE: Two ofthese screws are longer than the others,however they all use special "Dynasea1"washers (6). The pump (2) can now belifted out. Als0, the pump "0" ring (8)and collector block (9), Fig. No.7 can beremoved. Be careful not to damage theedges of the collector block; it must be agood fit in the housing. Fig. No. 8 showsthe pump assembly, "0" ring removedand the collector block in place.

Fig. No.8Pump Group

The output shaft (29) can be re­moved after the seal ring and the snapring have been removed. Press the out-put shaft through the bearing. The bear- Ving and seal can then be pressed or tappedout.

The cover, relief valve parts andorifice plate parts shownin Fig. No.9 cannowbe removed for inspection. The partsshown in Fig. No. 9 have been replacedby new and improved parts. If the coveron the unit is as sembled with a sleeve,spring and plunger or is assembled witha sleeve, spring and ball, it is stronglyrecommended that the parts checked (X)in the chart on page 20 be ordered and in­stalled according to "PAYLOADER"Modeland Serial Number. Installation of theparts listed in the chart eleminates the119094Flange, 108013Capscrews, 119096Orifice Plate and 119095 Gasket. (ReferFig. No.7) There is an orifice drilled inthe 135311 and 138532 covers.

IMPORTANT NOTE: If excessive conver-ter pressures are encountered on the VModel HA only, remove the 134152 plun-ger and the 138531 spring.

Fig. No.9Orifice, Cover Plate and Relief Valve

v

12

QTY, PART NO, DESCRIPTION HA HAH HF* HR* HU HHFig. 11

8 132850 Straps X X X X X X NewStyle Strap Installation8 4 129988 Spacers X X X X X X8 130823 Locknuts X X X X X X8 108092 Capscrews X8 108093 Capscrews X8 130824 Capscrews X X X X4 128571 Lockwire X X X X

13

The pump inlet tube assembly canbe found in the housing just above thebottom cover plate (26). It can be re­moved for inspection and cleaning. (SeeFig. No. 10)

Fig. No. 10Pump Inlet Tube Assembly

To remove the converter elementfrom the flywheel, first remove the lefthand motor mount. This uncovers a holeso that a wrench or screwdriver can beinserted to hold or turn the flywheel.Using a socket through the 1-1/2" pipeplug hole in the front side of the flywheelhousing, remove the eight (8) self-lockingnuts from the special caps crews holdingthe converter to the converter straps.Order and install the following parts' ifjust four straps are used to connect theconverter to the engine flywheel. Installnew straps as shown in Figure 11.

*NOTE: On Model HF "PAYLOADER"units with engine serial numbers prior to2876452-TC and on Model HRG "PAY­LOADER" units with engine serial num­bers prior to 2875683-TC, order 8-108091capscrews instead of 8-130824 capscrews.Also order 16-130823 locknuts instead of8. On Model HRD "PAYLOADER" unitswith engine serial n um be r s prior toA-2255722, order 8-108095 caps crewsinstead of 8-130824 capscrews. Alsoorder 16-130823 locknuts instead of 8.

One (1) 129988 spacer and two (2)132850 straps replace one (1) 119089strap. The spacer is placed against theengine flywheel between the straps andthe flywheel.

The 130823 locknuts replace thelocknuts formerly used to fasten thestraps to the converter. The new cap­screws replace the caps crews formerlyused to fasten the straps to the engineflywheel.

2•

_Q_ __.r

12 -----+------

I--~

Fig. No. 12Cross Sectional View of Torque Converter

14

C. Disassembly of theTorque Converter

It is very seldom that the converterhas to be repaired. Broken straps maycause external damage and dirty oil candamage the converter internally. Theparts shown in Fig. No. 12 are all serv­iceable as individual parts. In all cases,we recommend that our distributors re­pair the converter in their own shops.

1. Remove the two drain plugs(1) from the front cover as­sembly (4)and drain the oil.

2. Pmch-mark the blank holesin the cover assembly (4)and remove the ten nuts (2)and bolts (3) from the con­verter assembly. NOTE:The letter "0" stenciled onthe outside surface of theimpeller (7) must line upwith the letter 11011 stampedon the outside or front sideof the front cover as sembly(4)•

3. Using a leather or rubberhammer, tap the front coverassembly (4) away from theimpeller (7). Remove the110" ring (6), wa s he r (5)from the front cover assem­bly. Remove the turbine (8)and stator (9) with its com­ponentpartsfromtheimpel­ler (7). NOTE: The wordIIFRONTII appears on oneside of the stator (9). Thisside should face toward thefront cover ass em b 1Y (4)at the time of reassembly.

4. Remove both snap rings(10) from the stator (9}.Separate the thrust washers(Il) from the stator (9). Theouter ring (12) Sprag as­sembly (13) and inner race(14) may now be pressedfrom the stator (9).

NOTE: The word 'IFRONTIIappears on one side of theSprag as sembly· (13) andshould face toward the frontcover assembly (4) at thetime of reassembly.

5. To replace the impeller hub(17) or seal ring (18), re­move the capscrews (15) andnuts (16).

6. Refer to Section D"Tips onInspection and Repai r ".

D. Tips on Inspection and Repair

1. Cleaning - - Clean all partswith gasoline or commer­cial cleaning solvents.

2. Plan to replace all seals andgaskets when r-;;assembling.This includes the small castiron piston ring type seal onthe output shaft and the four(4) Dynaseal washers usedwith the pump body bolts inthe reservoir housing as­sembly.

3. The pump shouldnotbe serv­iced in the field. Replacewith new unit and send theused pump to the factory forrebuilding. (See Fig. No.9).

4. Ifaplunger instead of a ballis us ed in the cover plate,order and install those partslisted under Item No. 5 inSection B -- "Diaa ssernblyProcedure for the ReservoirHousing Assembl.y",

5. Check all machined sur­faces for cracks, scratchesand pits.

6. Be sure the intake pipe as­semblyand strainer areclean.

7. Inspect oil passages in thehousing.

8. Check hydraulic lines forchafing.

15

16

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.oZE-t

~Pot

N~OO~~~O~~NN~~~~~~~~~~~~~~~~~~~-N--~~~~~~~~~~~~~~OONNI~~~~~~~~~~~~~~-~~~~~~~-~~~~~-~~~~~~~-~\-~~~~~-~~--~-~-?--~N~~~~~OO~O-N~~~~~OO~~~_~~_~.-t

"'~Il¥

9. Check straps on engine fly­wheel. If r e qui red, in­stall new straps referredto in Item 7 under SectionB "Disassembly Pro­cedure for the ReservoirHousing As sembly;!' (Referto Fig. No. 11).

away from each side of thestator (9). Lock the wash­ers (11) in place with thesnap rings (10).

1. Coat a new seal ring (18)with a slight film of #2Permatex and insert theseal ring (18) in the recesson the inside of the impel­ler (7). Replace the im­peller hub (17) and securewith the capscrews (15) andlockwashers (16).

5. Block up the front coverassembly (4) so that thefront side does not touch thebench. The front side ofthe front cover as sembly (4)is that side which has thepro t r u din g shaft r ecess •which fits into the engineflywheel. Coat a new "O"ring (6) with type "A"automatic transmission oiland place it on the backside of the front cover as­sembly (4).

E. Assembly of the TorqueConverter (Refer toFig. No. 12 and 13)

2. Slowly rotate the Sprag as­sembly (13~ until it fits in­to the center of the outerring (12). Witha rotary mo­tion, insert the inner ring(14) into the center of theSprag assembly (13). NOTE:the splined end of the innerrace (14) should face to­ward the IIFRONT" side ofthe Sprag assembly (13).

6. Place the thrust washer (5)over the hub of the turbine(8). The side of the turbine(8) shown in Fig. 13 facestoward the front of the frontcover as semb1y (4). Placethe turbine (8) on the frontcover assembly (4).

3. Place the outer ring (12)with its component parts inthe center of the stator (9)so that the wide "I. D." flangeside of the Sprag assembly(13) matches the "FRONT"side ofthe stator (9). NOTE:The grooves on the O.D. ofth e oute r ring (12) matchthe lugs in the center of thestator (9).

7. Insert the stator (9} in thecenter of the turbine (8) sothat the "FRONTil side ofthe s tat or (9) fa c e s thefront cover assembly (4).Lay the impeller (7) overthe turbine (8) and stator(9). Match the "0" sten­ciled on the imp e 11e r (7)with the "0" stamped onthe front side of the frontcover as sembly (4). Fastenthe assembly together withthe ten bolts (3) and nuts(2) placed in the holes inthe front cover assemblywhich are not punch markedas described in Step 2 underSec t ion "C" Disas semb1yof the Tor que Converter.If a new front cover as­sembly (4) is used, insertthe bolts (2) and nuts (3)in the same position as

4. In ser t the thrust washers(11) on e a c h sid e of thes tat a r (9) sot hat thenotches in the washers (11)match the lugs in the stator(9). The 4 grooves in thewa s he r (11) should face

17

-_._- ._---------

shown below in Fig. 14. 9. Install the two 1/4" plugs(1) in the front cover as­sembly (4).

-_

10. Inst all the converter strapsas describedin Step 7 underSection B - - "Disa ssemblyProcedure for the ReservoirHousing Assembly." Fastenconverter to converterstraps.

F. Assembly of the ReservoirHousing. {Refer to Fig. 7)

1. Lay the housing (13) on abench with the clutch sidedown. Install shaft bearing(12) in the housing makingsure that the race is flushwith the bottom of the col­lector block (9) recess in thehousing.

2. Insert the collector block(9) in the housing with thec ham fer e d e dg e facingdown and hold in place withtwo short capscrews. Thisis done to keep the bearingin place until after the out­put shaft (29) has been in­stalled.

3. Turn the housing (13) overand block it up about 411 offthe bench. Install oil seal(28). The lip of the sealshould face toward the insideof the housing•

4. Lightly tap or press theoutput shaft (29) into posi­tion. Make certain that theshaft flange does not touchthe 4 casting lugs in thehousing. Grind off the lugsif clearance is required.

5. Turn the housing over againwith the clutch side down.Remove the collector block(9) and place it in its properpo s i ti on with the cham­fered edge up. Be surethat the collector block doesnot rock or bind in the hous­ing recess. If the fit is sat­isfactory, remove for nextstep of installation.

•• CONVERTER BOLTS •• STRAP BOLTS •• HUB BOLTS

Fig. No. 14Converter Bolt Circle

8. Whenever the torque con­verter or engine is dis­assembled and rep air e d,dial indicate the engine fly­wheel, flywheel housing,clutch flywheel and clutchhousing as shown in Fig. No.15 shown below.

MAX. T.I.R. LIMITSEngine ABC D EFlywheel .008 .008 .005 .008 .008

ClutchFlywheel .011 .011 .005 .010 .010

Fig. No. 15Dial Indicator Check Points

18

6. Place the snap ring (11) inthe groove around the out­put shaft (29) next to theshaft bearing (12). Next,install a new seal ring (10)on the shaft.

7. C0v e r the seal ring (10)with a high grade of greaseand place the c oLl e c torblock (9) in position withthe chamfered e d g e up.Be sure not to damage thering when setting the blockinto position. A damagedring may cause a loss ofpressure in the high pres­sure system, or leakage atclutch housing. Fig. No. 16

Indicating Clutch Flywheel Housing

10. With the two (2) dowels (32)in place on the output shaft,fasten the clutch flywheel(31) to the input shaft withthe 5special capscrews (30).Torque the caps crews to 43foot pounds. Attach a dialindicator to the housing andindicate the run-out of theflywheel surface and pilotbearing bore as shown inFig. 17. The run-out on theflywheel should not exceed.010 T.loR. and the run-outon the pilot bearing boreshould not exceed .005 T.I.R.

8. Place the "0" ring (8) overthe chamfered edge of thecollector block (9)00 Slipthe pump (2) over the out­put shaft (29) and secure itto the h 0 u sin g with twocapscrews (4) 2-3/4" longand two c a p s c r e w s (5)2-5/8" long. Noticing thevaried t hi ck n e s s of thecap s c r ew bosses in thepump housing should helpyou determine where eachcapscrew should be placed.Use a new Dynaseal wash­er (6)with each capscrewand torque to 16-18 footpounds. Lockthecapscrewsin place with #16gauge wire(7) .

9. Turn the housing over onthe engine flywheel side andblock it up so that the out «

put shaft does not touch thebench. Attach a dial indi­cator to the i npu t s ha ftflange and indicate the ma­chined surface s at the hous­ing as shown in Fig. 16.The run-out of the indicatedsurfaces should not exceed.011 T.I.R. (Total IndicatedReading).

Fig. No. 17Indicating Flywheel

19

11. Pack the pilot bearing (33)with a high grade of greaseand install it in the flywheelwith the open side of thebearing down. As shown inFig. 18, use a pilot shaft andinstall the driven memberand clutch cover assembly.Secure in place with 8 cap­screws and torque to 36 footpounds.

each. If the fingers opposeeach other, they will causethe pump to bind and breakwhen the capscrews holdingthe reservoir housing as­semb1y to the engine aretightened.

14. Remove plug (41) from tee(40) and insert a 200 poundoil pressure gauge. Also,insert a tee in the line be­tween the filter and orifice(17) on Models HA and HAHand, between the oil coolerand orifice on Models HF,HR, HU and HH. Place an­other 200 pound pressuregauge in this partlcular tee.

15. Make all the necessary con­nections required to put the"PAYLOADER" back intooperation.

16. Fill the torque convertersystem with Type" A" trans­mission fluid as outlined inItem D under Section III -Service and Maintenance.

Fig. No. 18Clutch Assembly

17. Put the "PAYLOADER" un­der full loa d and take areading of the pre s sur egauges in the high and lowpressure lines. The highpressure gauge should readbetween 40and 50 P.S.I. andthe low pressure gaugeshould read between 25 and30 P.S.I.

12. Install the bottom cover (26)and the L.H. cover plate (15)which contains the orificeand relief valve.

13. With the converter (1) se­curely in place, mount thereservoir housing assemblyon the engine. CAUTION:Be sure that the fingers inthe pump (2) and the fingersin the converter fit side by

18. Ref e r t 0 Sec t ion IV - -"Trouble Shooting" if thepressure readings do notmeet those specified above.

HA HA HA HAH HAH HF HR HU HH26900 2A-2978 2A-29849 51929 4A-1342 85061 43800 14A-l00l 18A-l00lthru And And Up thru And And And thru thru

Model &: SIN 2A-2977 Up 3A-1l31 4A-1341 Up Up Up 14A-1363 18A-1448And Up 15A-l00l 19A-l00l

thru thru

PART NO.15A-1l19 19A-1133

135311 Cover X X X X X X138532 Cover X X X134152 Plunger X X X X X X X138531 Spring XX X X X X X X X116716 Plug X X X X114851Washer X X

X X X X20