Maintenance and Service Manual %, 24000 Sr Powershift —@-— Transmission 7 R-HR & LFHR MODEL a = ae 3 SPEED LONG DROP i oy {LOCK-UP & FREEWHEEL) CLARIC-HURTE> | 31189,248 RHR & LHRZ4-9 LO 1292Service Publications 1-77 at 1-40, Rt. 18, Box 38 Statesville, NC 28677 TOWING OR PUSH STARTING Batore towing the vehicle, be sure to lift the (NOTE: if the transmission has 4 wheel drive, rear wheels off the ground or disconnect the iscannect both front and rear drivelines, driveline to avoid damage to the trans Because of the design of the hydraulic mission during towing, system, the engine cannot be started by pushing or towing, ‘Seah Clk Eaterore Comps, ERT, 1982 ‘Ungubaned seneal al gee renee nnd Deer tuen spar of me wert mayb reprominedin any oor vader soy mens wheat chet ‘erie ermiogon of Bik Faumen Comesry.FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the CLARK-HURTH COMPONENTS product. Extreme care has been exercised in the design, selection af materials and manufacturing af thass units. The slight outlay in personal atiention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principle of operation, trauble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully anduse it asa reference when performing maintenance and repair operations, Whenever repair or replacement of component parts is required, only Clark Hurth Components-approved paris as listed in the applicable parts manual should be used. Use of “willfit” or non-approved parts may endanger proper operation and performance of the equipment, Clark Hurth Components does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design ...... Fig. ‘Converter and Transmission Case Group Fig.B Converter Group » Fig. ‘Three Speed Clutch and Geer Group ceseeeeeeees Fig.D (Cluteh Group coe eens Fig Control Valve AsseMBIY. obec cece eee ceeeee Fig F ‘Charging Pump and Reguisting Valve Group ....... Fig. G External Plumbing and Pressure Check Points ..... 2... Fig. H Assembly Instructions: ...... voter eeeer creer Figel Speed Sensor Installation beceteeeetetereeeeees Fig DISASSEMBLY OF TRANSMISSION tees cad REASSEMELY OF TRANSMISSION ........ . a CLEANING AND INSPECTION - <5 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL 52 TOWING OR PUSH STARTING ..... cece vere BB SPECIFICATION AND SERVICE DATA... . wes 88 LUBRICATION 53 TROUBLE SHOOTING GUIDE 54 CLUTCH AND GEAR ARRANTEMENT . 55 POWER FLOW «2.0.0 e cece cece eee SBST ELECTRIC SOLENOID CONTROL 0... 6.csceecceeesseeeeeeeee CONTROL WIRING DIAGRAM .....0.6cc08 ee) DRIVE PLATE INSTALLATION, ..00.0000ccscceeusutvevee .. 60 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE .. RMODELSECTION 22.2... ee cones BB LHR SECTION .. #3 NOTE: Metric Dimensions Shown in Brackets [ |.HOW THE UNITS OPERATE The transmission and hydraulic tarque portion of the power train enacts am important rele in franamitting ‘engine pawer te the to first understand their function and how they operate. iving wheels, In order to properly maintain and service these units it is important The transmission end torque converter function together and operate through 2 commen hydraulic system. It is necessary te consider both units the study of their function and operation. To supplement the text below, and fer reference use therewith, the following illustrations are provided: ‘SECTIONAL VIEWS AND PARTS IDENTIFICATION Basie BEGIN ees eoecee sada Burtatindecnadias ds tian se, FRA Converter and Transmission Cove GrOWP sees cases esersisterorernoaey Fa Converter Group Fie ‘Three Speed Clutch ant Gear Grou coneeerceserereee Fig CHUN GOD oe css cesar scene tetaseeseeneenssesnetinneaneenene Fine Gontal Valve Assembiy Fa Charging Purpan Requiating Valve Group . . cee FIG External Pubing and Prosaune CheskePOINES 6.6505 Fig. ‘asec instructions a Fig. Speed Serser Installation oon Fig The R, HR, and MHR Model Transmissions are of three basic designs. The R Model consists of s separate torque converter, mounted to the engine with the powershift trans: ‘mission ramotely mounted and esnnected 12 the torque converter with » drive shat The HR Model consists of a torque converter and powarshifted transmission im ene package mounted directly to the engine, The MHR version is 2 mid-mount torque converter and transmission assembly connected to the engine by meens of » drive sheft. (See Fig. A for basie design silhawetta,) ‘The shift control valve assembly may be mounted directly on the side of the converter housing or front transmission cover, or remote mou function of the cantral valve assembly is to direct oil under prevaure to the desired directional and speed and connected to the trantmission by means of flexible hoses. The This is accomplished thraugh use of « brake sctuated shutoff velve. The speed end direction clutch assem bblias are mounted inside the transmission cave and are conneciod te the eviput shaft of the converter either by direct gearing or drive chsh. The purpose of the speed or directional clutches is to direct the power flow through the gear train t0 provide the desired speed range and dicection. ‘An axle ditconnee! is optional and is locared on the ovrput shaft, The drive 10 the fren or rear axle can be disconnected or connected by manual shiftingWith the engine running, the converter charging pump draws cil from the tranamission sump through the removable oll suction screen and directs it through the oil filler and the pressure regulating valve, reuulsting valve miinisins pretcoie bo the Inemtmision conirel saver for’ astusting the direc- speed clutches, This requires « small portion of the total volume of ail used in the The remaining volume of oil is directed through the torque converter circuit to the ell cooler and returns to the tranemission for positive lubrication, This regulalor valve consists of « hardened valve spool operating ina clotaly fited bore. The valve spool is spring loaded to hold the valve in a cloted position. When a specific pressure is achieved, the valve spoot works sasinst the spring until a port is exposed along the side of the bore. This sequence of events provides the proper system pressure, After entering the converter housing the ail is directed through the stator support to the converter blade cavity and exits in the passage betweon the turbine shaft and converler support. The cil then flows evt of the converter to tha ail eacler. After leaving the cooler, the cil | Wd 10 & lubricating fitting on the transmiasion and through a serles of tubes and panages lubricates the transmission beerings and clutches, The oil then gravity drains to the transmission sump. The hydraulic torque converter consists basically of three elements and their related parts to: multiply engine torque. The engine power is iransmitied from the engine flywheel to she impeller element threugh the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary com. ponent which starts the oil flowing to the other components which results in torque multiplication. This els ‘ement can be compared to « centrifugal pump in that it picks up fluid at its center and discharges ati diameter, ‘The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter, This element receives fivid at itt outer diameter and discharges at its center, Fluid diracted bby the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque. ‘The reaction member of the iorque converter is located between and ai the center or inner diameters of the impeller and turbine elements. lis function ia to lake the fluid which is exhausting from the inner portion of the turbine and change ifs direction fo allow correct entry for recirculation into the impeller element. The torque converter will multiply engine torque to its designed maximum multiplication ratio when the out put shaft is at zero RPM. Therefore, we can say that as the ovtput shaft ix decreasing in speed the torque ‘The shift contral valve assembly consists of a valve body with selector valve speols. A derent bail and spring in the selector spool provides one position for each speed range, A detent ball end spring in the direction spec! provides three positions, one each for forward, neviral and reverse, With the engine running and the directional control lever in neutral position, oll pressure from the regulat- i is blocked at the control valve, and the transmission is in neutral. Movement of the forward and rect oil, under pressure to either the forward or reverse direction clutch as desired When either directional renin ut be mrad wes gE a, ‘hath pms erie ary ane eit cen a 8 a IDA WPavepa ates INGTE: Nee ut sarvich Beton while making fltah prezere cheeks Unis having bra ae fund dachaiching in foraurd arr reverse wl ine ge «000 reading ALWAYS USE PARKING BRAKE WHEN MAX. [WO CLUTCH PRESEURE CHECKS ‘RECOMMENDED LUBRICANTS FOR CLARK HURTH COMPONENTS POWER SHEFFED "TRANSMISSION AND TOROUE CONVERTERS Paving enhiont Temporary ‘cenauk Spann Masia an apieble machin ‘oder sion canal. Toraoe Convene ‘Tarte dwt rte yen at omuiiune 348 abo 9 Gene ‘Coch il eel DALY we wg rnin ‘Soba Ras ad gu ur 150" He 980" 1D ST)S° CL Molnae cli oo FULL Mae Rie Pa wwe rkemmnassane | Seale Rome | i ut (el eft teramfasion to LOW mak. fal Rar engine 9 08608 RPMI sre Convene ane Recheck ines with engin running at 560800 RIA and mc 0 beng lve Si eval cheek. BRIG GIL LEVEL TO wen w eee deceue sant iprers eee omen Serer hay tures Ona Slnatbmeerass rope Tanntaigay "ore BOM oat ‘camo even #0 asamp sae, iar EN Seman see ee “Normal drain periods and fihar change intervats are for average environmental and duty-cycie canditions. Severe ‘or sustained high epersting temperatures or very dusty atmospheric conditions will cause accelerated deterioration and comamination. For extreme. conditions judgment must be used to determine the required change intervals. —sa—TROUBLE SHOOTING GUIDE For The FR & HR Model, 24000 Transmission The following data Is presented at an wid to locating the source ef difficulty In» malfunctioning unit. It is acenary te consider the terque converter charging Pump, transmission, oil cooler, and connacting: lines a a complete system when running down the soures cof trouble since the proper operation of any unit thare- in depends greatly on the condition and operations of the ethers. By studying the principles of operation together vith date in thir section, it may be possible to correct any malfunction which may accur in the nystam. TROUBLE SHOOTING PROCEDURE BASICALLY CON. SISTS OF TWO CLASSIFICATIONS: MECHANICAL AND HYDRAUIC. (MECHANICAL CHECKS Iycrealic mengpat, te Gllowing mechentel checks alle standpoint ng rachel skould be mader 1. A check should be made fo be ture all control lever linkage is properly connected and adjusted st all sonnaeting paint 2. Check shift levers and rads for binding or nestrle- tions in travel that would prevent full engagement Shift lovers by hand at eantral valve, if full engage- ant cannot be obtained, difficulty may be in contra! cover and valve esuembly. HYDRAULIC CHECKS Before checking on the torque converter, trantmis- sion, and allied hydraulle system for pressures and rate of oll flow, Ht is aaaentiel that the following pre- liminary cheeks be made: ‘Check oil level in: transmission. This thauld be done ‘ith oll temparatures of 189 to 200° F. (62,2-93,2°C]. DG NOT ATTEMPT THESE CHECKS WITH COLD Oil, To bring the oll temperature to this specification i a mesessary ta either work he machine of “stall” aut the converter. Whare: the formar mean is impractical, the latter meant should be employed as. follows: Engage shift levers in forward and high speed and apply brakes, Accelarate engine half to three-quarter throttle. Hold stall until desired convecter ovtlet temperature is eoached, CAUTION: FULL THROTTLE STALL SPEEDS FOR AN EXCESSIVE LENGTH OF TUME WILL OVERHEAT THE CONVERTER, LOW CLUTCH PRESSURE Caose Low oll bevel Clutch pressure regulating valve spool stuck open. Faulty cherging pump. Broken or worn chrich shaft ar piston sasling rings. Clutch piston bleed valve stuck open. peepee Ready 1. Fill to propar level. 2. Clean valve spool and housing. 3. Replace pump. 4. Replace sealing rings. 5. Clean bleed valves thoroughly, LOW CONVERTER CHARGING PUMP OUTPUT 1. Low oil Jovel 2. Suetion verean plugged. 3. Air leaks at pump intake hose and connections or collapsed hove. (24000 ely) 4, Defective oil pump. 1, il te proper lnvel, 2. Clean suction screen, 3. Tighten all connections ar replace hove Hf necessa 4, Roplace pump. 1, Worm ell seating rings. 2. Worn oil pump. 3. Lew oil leval 4 Pump sveiion line taking ale. (R24000 only) 1, Remave, disassemble, and rebuild converter asseen= 2. Replace. ill to proper level A. Check all line connections: and tighten securely. 1. Worn oll pump. 2. Woen er damaged beari 1. Replace. 2. A complete dieaeamibly il bs maceaary fe deter ‘mine whet Bearing ie faulty. LACK OF POWER 1. Low engine RFM st converter at 2. See “Ovechoating™ and make seme checks. 1, Tune engine check governor. 2. Make corrections 8 explained in “Overheating.”—s5————s7—yoinig punuod 4 yin Bug OE ain BauENeY OL yatnig pug 92 Jolla @NOREH cH Weld Pug dz Whe PEMD da olla ISL dt ‘OazIuNSSaud S3HOLNTD. —58— TOULNOD GIONSTOS 91419313 NOISSIWNWYL 033ds £ 00OFZ‘DOAbZ ONY D0AZ1- WVHOWIC ONIYIM OHXLNCO GIONS TOS SIMLII13 ONY “SNVEL dds ¢ —sa—DRIVE PLATE INSTALLATION Moscure the "AX dimension (fate Cite meter] and order Brive Biate Kit listed below. Note four (f) kits have these (3] intsnnecia Intermaciate crive plates. tive plates ond one (1) drive plate and wald nut aesnmély. Two (2) kite wit four ALIGNMENT HOLES. (DRIVE PLATE AND: 8 wa Asam —, ” G1 Ly ‘a mremacoiare hour cincur Oia FDINTENMEDIATE Shive nutes BREED eee rie Teacname mine + evawoour $23 [22 | " Dimension (Bok Crete Dlometar " Dinansion (Holt Crea Blametar 11.30" (288.500 wen] Biomater grup? (7 13.50" [342,900 men] Chameter vie Wo, 802338 L ‘AS ine sonny 13.126" (932.378 rn) Ouamater a cee ysa.976 mm) Otsmener it No, 602216, beh a 13.80" [42,900 me Oamoser och kit wil inchide the feloming parts: Belaarls : waneean 47.00" [431,806 men] Biamerer 1 Backing Ring. ses Ke Wo, 2264 3 Each Ki wil include he tollowina pans: 10 tochwanher. 3 ntermediat Dive tes. 10 Stud nate $) Orie Pots and Weld Nut Assembly. + Insrveuon Sheot 1 Backing Rog 10 Sis, 10 Lachwathorw, 10 Stud Nats. 1) Iruetion Sheet. Drive Plata installation Procedure 2 TO FACILITATE ASSEMBLY, ALION SMALL HOLES IN DRIVE PLATES — SEE ILLUSTRATION ABOVE, Clean tapped Noles anc studs thoroughly with Loctite 7E6 Scivent. Must bw true of any grease or ell, Spray Loctite 747 Primer “Tin tapnedholeaandon studs and allow tadry. Apply Loctite 262 Threadlociarto beth tappadholes anet[16 MC thread} reud end. Asemble to standout shown. Remove excess Loctite after asserably. Allow $0 minwis minianum before inatabing an engine. NOTE: I Loctite 747 Primer “T™ ig not used, allow 28 nours for the thrandiocker to cure bilare installing on engine. Peaiban drive plate end weald nut saxembly on impeller cover stud with weld nuts toward cover. Align intermediate drive plate and backing ing with studs in imsiter saver. NOTE: Two eimpies 120" apert in bucking ring muvl be wut [toward engine flywheel. Install Wweshers and stud nuts, With a calibrated torque wrench, tighten nuts 28 19 28 ft, fa. torque [35.3 ~ 38.3 Nm}.eA 6. a TRANSMISSION TO ENGINE INSTALLATION PROCEDURE Remove all burrs from flywheel mounting face and nose pilot bore, Clean drive plate surface with solvent, Check engine Sireheet and housing for conform: ance to standard SAE. #3-S.A.E. J-927 tolerance specifications for pilat bore size, pilot bore runcut ‘and mounting fece flatnass. Measure and record ‘engine crankshaft end play, Install two 2.50 [63, 50 mm] long trentmission to flywheel houring guide studs in the engine fy- wheel housing a8 shown. Rotate the angine flywheel to align « drive plate mounting screw hole with the flywheel housing access hole. Install a 4,00 [101, 60 mm] long drive plate locar ing stud .3750-24 fine thread in a drive plate nut Align the locating stud in the drive plate with the flywheel drive plete mounting screw hole posi Hioned in step No. 3. Sara plo an Sih Rpetel oe Install transmission 1a flywheel housing screws, Tighten screws fo specified torque. Remove trans mission to engine guide studs. Install remai screws and tighten to specified torque, Remove drive plate locating stud. Install drive plate attaching serew and washer, Snug screw but de net fighian, NOTE Fig. 4 in. stallation, install drive plate attaching washers and nuts, Tighten gach nut 28 to 30 ff. Ibs. torque [98.0 -40.6 Nm]. Some engine flywheel housings have » hole located en the. flywheel hous eumference in line with the drive plate screw accoss hole, A screwdriver or pry bir used to hold the drive plate against the flywhee! will facilitate stallation of the drive plate screws. Rotate the en- SH are installed torave each one 25 to 20 ft. Ibs. torque (38.8-40,8 Him]. This will require torquing wach screw ond rotating the engine flperheal until the full amount of eight (8) screws have been tightened. Mansure angina crankshaft end play after trensenis tion has been completely intialled on engine fly. wheel. This value must be within .067 [0,025mm] of the end play recorded in step No. 2. % Does not apply to unite having 3 intermediate deve plates. 586 Fig. 4. si(NOTES.R MODEL SECTION -8-FRONT COVER AND TRANSMISSION CASE GROUP ITEM DESCRIPTION ary ITEM DESCRIPTION aty 1 Input Flange Nut... ad 43° Frant Coverta Case Dowel Pin... ..... 1 2 InpurFlonge Washer 0s cee ese 1 hatch Presi Tube "0" Ring sos cess cess 3 Input Flange "0" Ring Goce) a8 Tube Sleeve. D4 4 Input Fange Gicreeunrinssunens 1 AG Glut Pressure Tube “O" Ring osc. 5 InputFange Oi Saal... : Ce 87 Tube Sieve... oe 1 6 mpuShaR Fon Boag cece vesiaeseee 1 4 Gute Presa Tube “O" Ring oid 7 Front Cover ieaee hae 1 49 TubeSleeve........ a7 B Breather... eapaaneaiasceT 50 Gutch Preseure Tube “O" Ring, cot 8 Rear Bearing Snap Ring . . wee DV BY Transmission Case Assembly ad 10 oor Beoting Washer... cise 62 Tube Sleeve we 1 11 input Shaft Roor Bosra. : C1 BB Gatch Pressure Tube “O" Ring 1 12 or Basing Revaring Fite vos ons 18 Rear Cover a Transmission Cose Gost ot 13 Retaining Piste Sorew & Lockwasher .... ae 55 Transmission Case to Rear Cover DowslPin,........ 7 14 Input Shafts. sce SI 86 Rar Cover Pipe Phd sssecssasevsssersoeevecns T 1S Bate fing... : SA BP ReweCoverscsssscssuserescstecnuecsuererncesd 16 Ravin lelr Gate Besring Assembly |... cscs sss 1 BB RewrGoverto CaseBcrew 20 17 Bearing Retaining Plate Nut. 2.0... re 1 59 eee Cover to Case Screw Lockwasher...... 20 $8 Ravers leer Gooe Thrust Pate Sincere 16) Trinimianin Cae to Reds Cover Dowel Pin sesso 19 Reveos Iter Gear . Soe PGE PREFIG ces esereserssesseseraeisersene T 20 Rivera et Gao Basing That ote so 1 pea ence ses seseenee a 21 er Shem Lok esc cece P88 Magnet Drath Pag 2 22 Front Cover Stsnve SB Bat 1 230 Slrevelip.. oo. ee see 1 65 Tube Clip ._ #: 4 i 2 ae Sioave Clip Scrow Washor _ ‘ a 1 66 Clip Retainer Screw . seers 1 25 Sleewe Clip Screw ree 1 G7) Clip izvainer Screw Lockwashar......... set 28 Sleove Op Sariv ccetcsesen 68 Suotion Tube Ascambiy-*0" Ring a 27 Shave Oip Seren Washer oes esssasceee ) 6B Suction Tube Assembly 1 26 SMIVECH seesesc ise seieseev reeset 70 Retsiner Screw Locka oo 2 79 Front Cover Sleeve. ~ . 1 7 Sustion Tube Retsiner Screw... . 2 30 Front Coverio Cane Screw Lockwaster COMPONENTS Statesville, North Caralina Brugge, Belgium Arco, Italy ‘Sao Paulo, Brazil OHT-0004 PRINTED IN U.S.A,