1300399, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThis section has a description and the operatingprinciples of the single speed powershift transmis-sion. The section is in two parts. The first part de-scribes the mechanical components of the transmis-sion. The second part describes the hydraulic op-eration of the transmission.MECHANICAL DESCRIPTIONGENERALThe transmission has a housing, torque converter,oil pump, control valve and three shaft assembliesand a ring gear, pinion and differential assembly.The impeller is connected to the flywheel of theengine by a flexible disc. A flange on the impellerengages with the oil pump for the transmission andoperates the pump when the engine is running.The turbine fits inside the impeller and engageswith the input shaft of the transmission. The statoralso fits inside the impeller and engages with thestator tube on the transmission.TORQUE CONVERTER(SEE FIGURE 1)The torque converter is installed between the en-gine and the transmission. The torque converterhas three main parts: an impeller, a turbine and astator.OIL PUMPThe transmission has its own hydraulic system. Anoil pump is installed on the cover of the transmis-sion inside the torque converter housing. The oilpump is driven by the impeller of the torque con-verter. The transmission cover has passages foroil to flow to and from the oil pump.SHAFT ASSEMBLIES (SEE FIGURE2)The three shaft assemblies are: (1) the input shaft(with forward clutch assembly), (2) the reverseclutch shaft and (3) the countershaft.Input ShaftThe input shaft is driven by the engine through thetorque converter and rotates in the direction of en-gine rotation. The input shaft has the forward clutchassembly. The clutch is installed in the forwardclutch housing and has a piston, friction discs, sepa-rator plates, a pressure plate and a return spring.The teeth on the forward clutch housing are en-gaged with the teeth on the reverse clutch housing.The hub for the forward clutch is engaged with thecountershaft gear.FIGURE 1. TORQUE CONVERTERReverse Clutch ShaftThe reverse clutch shaft is installed next to the in-put shaft. The teeth on the reverse clutch housingare engaged with the teeth on the forward clutchhousing. During operation, the reverse clutch shaftrotates in the opposite direction of engine rota-tion. The reverse clutch assembly has a piston,friction discs, separator plates, a pressure plateand a return spring. The hub for the reverse clutchis engaged with the countershaft gear.CountershaftThe countershaft connects the direction clutches tothe pinion shaft. The small gear on the counter-shaft is engaged with the drive gear for the pinion.The pinion, in turn, drives the ring gear and differ-ential assembly.Ring Gear, Pinion and DifferentialThe ring gear and pinion provides a gear reduc-tion and changes the direction of the power flow.The differential permits the drive wheels to turn atdifferent speeds when the lift truck is turning a cor-ner.FIGURE 2. ARRANGEMENT OF THE SHAFTSgrooves in the clutch housing. A pressure plateholds the friction discs and separator plates in thehousing. A return spring keeps the piston retractedagainst the housing. There is an orifice in each pis-ton. The orifice releases any oil pressure in thepiston housing caused by centrifugal force afterthe clutch is disengaged. There is enough clear-ance in the clutch assemblies to let the friction discsrotate freely when a clutch assembly is not engaged.FIGURE 3. CLUTCH ASSEMBLIESClutch Assemblies (See Figures 3 and 4)The two clutch assemblies use the similar partsand operate in the same manner. The friction discsand separator plates are installed in the housing ina sequence. Each friction disc is next to a separa-tor plate. The separator plates have a smooth sur-face while the friction discs have a friction mate-rial on the surface. The hub in each clutch assem-bly engages with the inner splines of the frictiondiscs. The outer splines of the separator plates en-gage with theFIGURE 4. OPERATION OF THECLUTCH ASSEMBLIESHYDRAULIC OPERATIONTORQUE CONVERTERThe torque converter has two main functions. Itworks as a fluid clutch to transfer power from theengine to the transmission. Also, the torque con-verter multiplies torque. The torque of the engineis increased by the torque converter when addi-tional torque is needed to move the lift truck. If theneed for additional torque is low, the torque con-verter works as a fluid coupling.The impeller has a set of curved blades that sendthe oil out from the center of the impeller when theimpeller turns. The oil is moving at high speedwhen it leaves the impeller. Because the impelleris curved, the oil flows into the outer edge of theturbine. The oil pushes the turbine in the directionof the engine rotation. The oil then flows from theoutside to the center of the turbine. The turbineblades change the direction of the oil flow so thatthe oil leaving the center of the turbine is going inthe direction opposite of engine rotation. See Fig-ure 7. The stator is between the turbine and impel-ler in the center of the torque converter. When theoil hits the stator blades, the one-direction clutchprevents the stator from turning against the enginerotation. The blades of the stator change the direc-tion of the oil so that the oil enters the impeller inthe direction of engine rotation. The stator permitsthe torque converter to increase the torque of theengine. The force of the oil entering the impellerfrom the stator helps the impeller and engine turn.As the speed of the lift truck increases, the oil fromthe turbine flows toward the impeller. The centrifu-gal force of the rotating turbine sends the oil that isin the turbine against the oil flow from the impel-ler. The oil moving in this direction decreases theamount of oil flow to the impeller from the stator.Because the oil flow to the impeller decreases,the additional force on the impeller decreases. Lesstorque is available as the speed of the lift truck in-creases.When the lift truck is traveling at a constant speedon a level surface, the turbine and impeller turn atapproximately the same speed. The centrifugalforce of the oil is the same for both the impellerand turbine. The oil does not flow through the sta-tor and no additional torque is transferred. Therotating oil hits the back of the stator blades andturns the stator in the direction of engine rotation.The one direction clutch permits the stator to turnwith engine rotation. The impeller, turbine, statorand oil rotate as a unit when there is no load on theturbine.FIGURE 5. OIL FLOW THROUGH THE TORQUE CONVERTERFIGURE 6. ONE DIRECTION CLUTCHWhen the lift truck starts up a ramp, the turbine hasa resistance to turning. The centrifugal force of theoil in the turbine decreases. The oil again flowsfrom the impeller through the turbine and statorand enters the impeller with force. The torque con-verter again increases torque when the turbine speedis less than the impeller speed.gasket permit oil to flow from the valve body topassages in the transmission housing. The controlvalve has several regulators and spools to controlthe oil pressure and oil flow in the transmission.The control valve has the pressure regulators for:(1) system pressure, (2) clutch pressure and (3)torque converter pressure. (The cold oil reliefvalve for the oil cooler is in the front cover for thetransmission. The pressure regulators for the lu-brication circuit are in the output end of the hous-ing.) The control valve uses three spools for modu-lation of oil pressure to the clutch assemblies.These spools are: (1) a drain spool, (2) a modula-tion valve and (3) an accumulator. On units with adirection control lever, there are two manuallyoperated spools in the control valve: (1) an inch-ing spool and plunger, and (2) a direction spool.On units with a Monotrol pedal, the direction spoolis actuated by oil from two solenoid valves in-stalled on the control valve. On all units the inch-ing plunger is actuated by the inching/brake pedal.SHAFT ASSEMBLIES (SEE FIGURE 4)The input shaft and the reverse clutch shaft haveoil passages that connect the clutch assemblies tothe control valve and the lubrication circuit. Sealrings are installed on the shafts to make sure theoil flows to the correct passages. The oil flow toengage a clutch enters at the groove in the shallot.The oil flow for lubrication enters the ports at theend of the shaft.CONTROL VALVEGeneral (See Figure 7)The control valve is installed on the top of thetransmission housing. Holes in the control valveFIGURE 7. CONTROL VALVE

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