S MANOA WITH INBOARD FREEWHEEL aliVICL SM -124 10,000 AND11,500 HYDRAULIC TORQUE CONVERTER THREE-STAGE AVVAIIIN| Pe E>SM-124 SERVICE MANL MODEL CO 10,000 AND 11,500 HYDRAULIC TORQUE CONVERTER STANDARD THREE-STAGE WITH INBOARD FREEWHEEL ORIGINAL ISSUE—JANUARY 1966 REVISED ISSUE—JUNE 1970 REVISED ISSUE—NOVEMBER 1976 REVISED ISSUE—APRIL 1977 REVISED ISSUE—NOVEMBER 1977 REVISED ISSUE—AUGUST 1980 Twin Disc, Incorporated 1328 Racine Street Racine, Wisconsin, U.S.A. SERVICE INFORMATION Each series of Maintenance Manuals issued by Twin Disc, Incorporated is reviewed accuracy at regular intervals. When required, changes are made in the manual to provide the la information regarding current design and maintenance practices of the product, In addition, individual product Service Bulletins are issued to provide the field with immed notice of new service information. ‘These Service Bulletins are distributed to all the Twin Disc Distributorships throughout United States and in many foreign countries. To be sure you have the latest Service Information on your Twin Disc product, contact Twin Disc Distributor for Service Bulletins. or write to the Service Engineering Department, T Disc, Incorporated, Racine, Wisconsin, U.S.A.REVISION AND REISSUE DATA REVISION AUGUST 1980. Added new title and revision data pages and revised torque charts. Revised address on the hydraulic tester information A NOTE: "Flagging" indicates area revised.models LU- U,UUU and II, Section 1. Section IL Section II. Section IV. Section V. Section VI. Section VII. Section VIII. Section IX. Section xX. Section XI. Section X11. Section XIII Section XIV. Table of Contents Page INTRODUCTION... .. wena eee eee = 4 DESCRIPTION ...... tenes . 6 PRINCIPLES OF OPERATION ... . sees ence eeeee 12 LUBRICATION AND FLUID SYSTEM... 06-0... 20. 005 13 PREVENTIVE MAINTENANCE. .... 0-20-20 0e 000s eee eens 16 ‘TROUBLE SHOOTING 18 REMOVAL .......... . 23 POREASSEDMBES G5 fceg cscs sae uti gin cheng «ght fi 23 CLEANING AND INSPECTION ......... 00. 0.0.00005 . 8B ASSEMBLY = 4. (sr oy. GREECE Fe oo x neon 29 INSTALLATION ........ BT cenoe nna meni Kivi atm RECOMMENDED FLUIDS, OILS AND GREASES .........- oe 4 SPECIAL TOOLS ...... . fee veweaeeee +. 46 Eee aaapecenepsnarcne-onee veteeee ene eee 46 “IMPORTANT NOTICE. Because of the possible danger to person(s) or property from accident which may result from the use of manufactured products, it is important that correct procedure be followed: Products must be used in accordance with the engineering information specified i the catalog. Proper installation, maintenance, operation procedures must be observed. Inspectio should be made as necessary to assure safe operations under prevailing conditions. Proper guard and other suitable safety devices or procedures as may be desirable or as may be specified in safet codes should be provided, and are neither provided by Twin Disc, Incorporated nor are th responsibility of Twin Disc, Incorporated.”SIHHHCH COVER PLATE ASSEMB. OFERAIIG Sit SING cuurch PRESSURE F OUTPUT HOUSING Pipe FLANGE inpur'sy HAND-HOTE PLATE NEN clutch Driv PLATE ASSEMI Figure 1. Model CO-10,000 & 11,300 Series Three-Stuge ‘Vasque Converter (2/4 Front View)Models CO- 10,000 and 1 GREASE FITTING NAME AND. INSTRUCTION PLATE cuutcH HOUSING FiuTER LIFTING EYE BOLT ea FILTER BRACKET ASSEMBLY ‘OUTPUT HOUSING. REAR FLUID SEAL DRAIN LINE RESERVE TANK ASSEMBLY Figure 2. Model CO-10,000 & 11,500 Series Three-Stage Torque Converter (3/4 Rear VieHydraulic lorque Converter Section 1. INTRODUCTION 1. GENERAL. A. Scope. This maintenance manual con- tains instructions and illustrations for the opera- tion, removal, disassembly, assembly, and installa- tion of Twin Disc, Incorporated Hydraulic Torque Converter Mode! CO-10.000 and CO-11.500 Series. Engineering details and performance characteristics of the three-stage hydraulic torque converters may be obtained by writing to Twin Disc. Incorporated, Rockford Works. Rockford. Illinois. U.S.A B. Special Tools. The manual also con- tains engineering drawings for the fabrication of special tools that may be used during disassembly and assembly procedures. Twin Disc, Incorporated will not manufacture these tools for general use C. Parts List. A complete parts breakdown, with exploded view illustrations, is provided to facilitate the ordering of spare or replacement parts. D. Trouble Shooting. ‘The manual also con- tains a trouble shooting table which will assist in determining the cause of functional difficulties that may occur, Proper use of the symptom, cause, and remedy columns of the table will determine whether a simple repair can be accomplished on the torque converter or complete disassembly is necessary. 2. DISTRIBUTION. This maintenance manual should be made available to, and read in its entirety by, all personne! responsible for the operation or maintenance of the hydraulic torque converter. A thorough understand- ing and application of the material in this manual will result in lengthy and satisfactory service from the converter. 3. ORDERING PARTS. A. Source. Renewal Parts, repairs, and “Parts Operation Service Kits” may be obtained from your Authorized Twin Disc Distributor or Service Dealer. You can find him listed under POWER TRANSMISSION EQUIPMENT in the Yellow Pages of most metropolitan telephone directories. B. Method. It is highly imperative tt Model, Specification, and Serial Numbers unit be included when ordering a service part. numbers will always be found stamped on th verter instruction plate. Always give the number of the illustration containing the pa item number of the part, the description of th. and the quantity required. Do not use the “complete”, but state exactly each item w Do not designate the quantity by “sets”, but s the number of parts required NOTE If detail part numbers of the hydraulic torque converter are desired, write to ar address given in Paragraph 3A, and sub- mit the specification number. 4, PARTS SHIPMENT. A. ‘iethod. Specifically state wheth, parts are to he shipped by freight, express wheiever ordering spare or replacement pa ‘ng instructions are not specified on the we wis! use our own judgment and take int n tine as well as expense. Twin INRA aNY Nivua was way" YT INV NIT ANBA, 4 nee A ‘aunts + a + aAIWA INaA- avo amgHydraulic 18. MASTER CLUTCH SLIDING SLEEVE THROW- OUT BEARING. The masterclutch throw-out bearing is grease lubri- cated with a hand grease gun through a fitting and hose connection attached to the right side of the clutch housing. Use an approved grease as listed in Table IV, paragraph 50. Lubricate every 10 hours of operation or daily. 19. FLUID PRESSURE. ‘The auxiliary fluid pumpand its built-in relief valve control the converter charging fluid pressure. The pressure gauge, indicating the charging pressure, is is connected in a “tee” connection at the fluid filter outlet. If conditions are normal, and the air is properly vented from the converter circuit, the oil pressure will indicate full pressure (rated) immedi- ately upon starting the engine and engaging the master clutch. The pressure will drop to zero, when stopping the engine or disengaging the master clutch 20. FLUID TEMPERATURE. ‘The temperature is taken at the turbine housing. ‘The gauge is mounted next to the pressure gauge in the fluid filter and gauge mounting bracket. Normal temperature for operation is 180 degrees — 220 de- gtees F. Maximum temperature is 250 degrees F. 21. FLUID COOLING. It is recommended that the fluid be cooled with a hheat exchanger rather than a radiator, if the instal- lation lends itself readily to an exchanger instal- lation. Heat exchangers hold the fluid to a more desirable minimum than radiators and thereby cause less variance in fluid viscosity. Section V. PREVENTIVE MAINTENANCE 22. GENERAL. A. Lubrication. The unit lubrication was covered previously. A daily check should be made of the fluid and oil levels in the end plate sump, the output housing sump, and the reserve tank. B. Qverhaul Interval. Acomplete overhaul of the Model CO-10,000 and CO-11,500 series torque Converter should be made at the same time that the engine is overhauled. All parts showing signs of wear, fatigue, etc., should be replaced at this time. lorque Converter 23. OIL AND FLUID SYSTEMS. A. Oil Level. Check the oil level end plate sump and the output housing sump Check oil level when unit is static. Mainte level between the “low” and “full” marks gauge. Add oil as soon as the level drops be very near to the “low” mark, Use an appro. (paragraph 51, Table V) SAE 30 or 40 or the type of oil used in the engine crankcase. ( pacity is 1 qt. U.S. measure in the end plate and 4-1/2 qts. in the output sump. The oil is into the sumps through their oil level gay, breather assembly mounting nipples. B. Fluid Level. The converter circ the torque converter must contain a solid fluid to operate efficiently. Check the fluié in the reserve tank daily, with the fluid at op: temperature. Shutting down immediately after « ing the unit the level should be maintained “fall” mark. The fluid is poured in the tank t the fluid level-gauge-and-breather assembly ing nipple. The capacity of the converter circuit is 7 U.S. gals. less cooler and conn lines. C. Oil Change Interval. The lubricat in the end plate sump and spiral gear bearii output housing sump is changed every 1000 operation or every 3 months of operation, whi occurs first. (1) Draining. ‘The end plate st rained by removing the 1/2-inch pipe cap fr bottom of the clutch housing which connect the sump. ‘The output housing sump is drained by ing the 1/2-inch square-head pipe drain plug bottom of the housing. (2) Filling. The end plate sun the output housing sump are filled through th level gauge and breather assembly mounting ni ‘The end plate sump capacity is 1 U.S. quar output housing sump capacity is 4-1/2 U.S. « D. Converter Fluid Change Interval. converter fluid is changed every 1000 hrs. o ation or 3 months elapsed time, whichever : first. (1) Draining. The converter is d by removal of the socket head 1/2-inch pipe 1models CU-1U,UUU and I 13. CONVERTER CIRCUIT FLUID FLOW A. General. The converter internal fluid flow between the members of the converter, (impel- ler, turbine, and stators), was cove ed in paragraph 12. This paragraph will be devoted to the fluid circuit into and out of the converter B. Fluid Flow. The charging pump traws fluid from the reserve tank through the inlet strainer and displaces it through the fluid filter and into the end plate. A passage in the end plate routes the fluid through the seal carrier and into the cavity behind the impeller wheel A labyrinth seal formed by lands and grooves on the impeiler wheel and end plate confines the fluid, causing it to flow into the toroidal chamber through holes drilled in the front side (toward engine) of the impeller wheel The action of the impeller wheel imparts momentum and force to the fluid through the converter internal circuit increasing the pressure across the circuit. The converter outlet connection to the fiuid heat exchanger is at the outer diameter of the converter internal circuit, where the pressure is high. The fluid circulates through the heat exchanger and returns to the rear of the impeller wheel at the charging area (low pressure) to begin another cycle. ‘The pressure drop of differential between impeiler inlet to housing outlet is the cooling circulating pressure; the converter acts as its own cooling pump. The orifice bleed connected to the highest point in the cooling circuit vents the air from the circuit into the reserve tank and supplies a return for oil constantly displaced into the circuit from the charging pump. 14. FREEWHEEL OPERATION. The freewheel is a one way, or overrunning clutch. It is engaged and disengaged automatically. The cam, since it is connected to the impeller wheel, is turning at engine speed when the master clutch is engaged. The outer race is a part of the turbine wheel and is therefore turning at converter output shaft speed. When the engine (and cam) is turning faster than the converter output shaft the freewheel is disengaged. Under these conditions the freewheel rollers are at the low area on the cam and therefore do not apply pressure to the outer race. However, if the load should try to drive the output shaft faster than the input shaft the rollers move up the ramps of the cam and cause the freewheel to engage. Under this condition the rollers are connected solidly between the cam and outer race. It can be seen that under normal conditions (engine speed greater than output shaft speed) the frees ‘tot affect converter operation. When th tempts to back-drive through the converte connection exists between the engine an therefore, engine braking is available < verter output shaft Since the bladed com the converter ate being driven by the absorb some of its energy and add to braking. CAUTION When the freewheel is engaged, engine speed should be watched. § there is a direct mechanical conne, between engine and load, the en governor will not limit engine speed Section IV, LUBRICATION AND FLUID SYSTEM 15. GENERAL. The lubrication system in this series i from the converter fluid system. Two liquids are used; a converter fluid, see in paragraph 49, for the converter circuit cation of the seals and freewheel! unit; enj case oil (SAE 30-40 or as in engine) se an paragraph 51, for the flu'd pump drive parts drive, front ball bearing, rear doub bearing, and output shaft spherical roll lubrication. 16. END PLATE SUHP. ‘The end plate sump contains lubrication converter impeller ball bearing and fluid p The pump drive chain runs in the lubri carrying it around to wet the sprockets an ball bearing (converter impeller hub), these parts. A bayonet-type oil level breather assembly is mounted with a nip the clutch housing and into the end p. ‘The end plate sump holds 1 qt. of oil. 17. OUTPUT BEARING AND SPIRAL GE ING SUMP. This sump is filled with oil to a poir low the output shaft, so the rear turt double-row ball bearing and the output sh cal roller bearings are running submerge: