SINGLE-SPEED POWERSHIFT TRANSMISSION DESCRIPTION AND OPERATION13, SAFETY PRECAUTIONS MAINTENANCE AND REPAIR When lifting parts or assemblies, make sure that all slings, chains, or cables are correctly fastened and balanced before lifting. Make sure that the crane, cable, or chain has the capacity to lift the weight, Do not lift heavy parts by hand. Use a lifting mechanism Wear safety glasses. DISCONNECT THE BATTERY CABLES before doing any maintenance or repair on electric lift trucks. Always use correct blocks to prevent the unit or parts from rolling or falling Keep the unit and working area clean, and in order. Use correct tools for the job. Keep tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs. Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs. Make sure you check the WARNING and CAUTION notes in the instructions. Batteries generate flammable gas when they are being charged Keep fire and sparks away from the area, Make sure the area has ventilation,CONTENTS INTRODUCTION General . DESCRIPTION AND OPERATION General . Torque Converter . Description Operation . Clutch Assemblies . Description Operation . Hydraulic System . General . Oil Pump and Front Cover .. Torque Converter Regulator . Oil Cooler By-Pass Control Valves... +++ General . Differential .. Oil Flow Diagrams Neutral . Forward ........ Forward-Inching Reverse . This section is for the following models: S/H25-35XL, H40-60XL_ NOTE: This transmission can be identified by the transmission filter being located on the side of the transmission. The Hyster T41,T42, and 43 transmissions have the filter on top of the transmission, © HYSTER COMPANY 1981NOTESINTRODUCTION GENERAL ‘This section has the description and operation of the single speed powershift transmission. DESCRIPTION AND OPERATION GENERAL The single speed powershift transmission has four assemblies, the control valve and the differential main parts: the torque converter, the clutch 1. TORQUE CONVERTER HOUSING 2. Ol PUMP 3. FORWARD GEAR “ f 4. FORWARD CLUTCH 3 5. FORWARD HUB 10. TRANSMISSION HOUSING 6. CONTROL VALVE 11. REVERSE HUB 7, OUTPUT GEAR 12. REVERSE CLUTCH 8. RING GEAR 13. REVERSE GEAR 9. PINION 14. FRONT COVER FIGURE I. TRANSMISSIONTORQUE CONVERTER Description The torque converter has an impeller, a turbine, a stator and a one direction clutch. The impeller hasa set of curved blades and is fastened to the flywheel The turbine also has blades, and is connected to the input shaft (Forward clutch housing) of the transmission by splines. The stator is between the turbine and the impeller. The one direction clutch permits the stator to turn with engine rotation but prevents it from rotating in the opposite direction. TURBINE IMPELLER STATOR ONE DIRECTION CLUTCH STATOR TUBE INPUT SHAFT eoRene FIGURE 2. TORQUE CONVERTER Operation The torque converter has two main functions. It works as a fluid clutch to smoothly transfer power 2 from the engine to the transmission. Also, the torque converter multiplies torque. The torque of the engine is increased by the torque converter when the additional torque is needed to move the lift truck. If the need for additional torque is low, the torque converter works as a fluid clutch. VORTEX FLOW ROTARY FLOW FIGURE 3. TYPES OF FLOW The impeller has a set of curved blades that send the oil out from the center of the impeller when the impeller turns. The oil is rotating when it kaves the impeller. Because the impeller is curved, the ol flows into the outer edge of the turbine. The oil moves the turbine in the direction of the engine rotation. The oil then flows from the outside to the center of the turbine. The turbine blades change the direction of the oil flow so that the oil that leaving thecenter of1. IMPELLER 2. STATOR 3. OIL FLOW 4, TURBINE FIGURE 4, OIL FLOW THROUGH TORQUE CONVERTER the turbine is going the direction opposite of engine rotation, See Figure 4. The stator is between the turbine and impeller in the center of the torque converter. When the oil hits the stator blades, the one-direction clutch prevents the stator from turning against the engine rotation. The blades of the stator change the direction of the oil so that the oil enters the impeller in the direction of engine rotation, The stator permits the torque converter to increase the torque of the engine. The force of the oil entering the impeller from the stator helps the impeller and engine turn. When the lift truck starts moving, the turbine starts turning, The centrifugal force of the rotating turbine sends the oil that is in the turbine against the oil flow from the impeller. The oil moving in this direction decreases the amount of oil flow to the impeller from 1. OUTER RACE 2. ROLLERS 3. SPLINES ON INNER RACE FIGURE 5. ONE DIRECTION CLUTCH the stator. Because the flow to the impeller decreases, the additional force on the impeller decreases. Less torque is available when less torque is needed. When the lift truck is traveling at a constant speed on level ground, the turbine and impeller turn at approximately the same speed. The centrifugal force of the oil is the same for both the impeller and turbine. The oil does not flow through the stator and no additional torque is transferred. The rotating oil hits the back of the stator blades and turns the stator in the direction of engine rotation. The one direction clutch permits the stator to turn with engine rotation, The impeller, turbine, stator and oil rotate as a unit when there is no load on the turbine. FIGURE 6. LIFT TRUCK AT CONSTANT SPEED - NO TORQUE MULTIPLICATIONS, 3When the lift truck starts up a ramp, the turbine has. a resistance to turning, The centrifugal force of the oil in the turbine decreases. The oil again flows from the impeller through the turbine and stator and enters the impeller with force. The torque converter again increases torque when torque is needed. CLUTCH ASSEMBLIES Description The transmission has two clutch assemblies, a Forward clutch and a Reverse clutch. The Forward clutch housing has the input shaft and is driven directly by the torque converter. The Forward and Reverse gears are always engaged with each other. Also, the Forward and Reverse clutch hubs are always engaged with the output gear. Each clutch assembly has a housing, piston, friction discs and separator plates. The friction dises and separator plates are installed in the housing in a sequence. Each friction disc is next to a separator plate. The separator plates have a smooth surface while the friction discs have a friction material on the surface. The hub in each clutch assembly engages with the inner splines of the friction discs. The outer splines of the separator plates engage with the grooves in the clutch housing, A pressure plate holds the friction discs and separator plates in the housing, A group of return springs keeps the piston retracted against the housing. There is enough clearance in the clutch assemblies to let the friction discs rotate freely when a clutch assembly is not engaged. Pabenn . SPRING ASSEMBLY Se SNAP RING SEPARATOR PLATE FRICTION DISC. PRESSURE PLATE SNAP RING THRUST WASHER NEEDLE BEARINGS SPACER HUB. PLASTIC WASHER THRUST WASHER, SEAL RINGS FORWARD CLUTCH ‘O-RING PISTON SEAL PISTON RETAINER FIGURE 7. CLUTCH ASSEMBLYEach shaft in the transmission has oil passages that connect the clutch assemblies to the control valve. There are also oil passages in the transmission housing and the clutch assemblies for the lubrication and cooling of the clutch assemblies. There are seal rings on one end of both clutch shafts to seal the oil passages. Operation When the Forward clutch is engaged, the Forward clutch hub rotates in the direction of engine rotation. The Forward clutch hub rotates the output shaft and pinion in the opposite direction. In REVERSE, the Forward gear rotates the Reverse gear and the Reverse clutch assembly. Since the Reverse clutch is now engaged, the output gear and pinion are driven by the Reverse clutch. In REVERSE, the output shaft rotates in the same direction as the Forward gear (input shaft). HYDRAULIC SYSTEM General ‘The powershift transmission has its own hydraulic system. An oil pump is installed on the front cover of the transmission and is driven by the torque 2 ENGAGED Nor. ENGAGED 3 FORWARD PeNa INPUT SHAFT FORWARD CLUTCH REVERSE CLUTCH OUTPUT SHAFT 3 Not ENGAGED ENGAGED REVERSE FIGURE 8. CLUTCH OPERATIONconverter (engine). The oil for the system is kept in the transmission sump. The oil pump causes the oil to flow through a screen in the sump and then through the spin on filter. (There is a relief valve in the oil filter that opens at 48 to 62 kPa [7 to 9 psi] when the filter has a restriction.) Oil will also flow through a restriction in the front cover to the torque converter. From the filter the oil flows to the control valve through passages in the transmission housing. At the control valve the oil flows to the main regulator spool and the inching spool. Oil from the main regulator spool flows to the circuits for the torque converter and lubrication. Oil from the inching spool flows to the direction spool, clutch assemblies and the modulation spools. OIL PUMP AND FRONT COVER The oil pump is installed on the front cover of the transmission. The front cover has passages for oil flow, a regulator for the torque converter circuit and a by-pass valve for the oil cooler. The oil pressures for the pump, torque converter and oil cooler circuits are checked at the front cover. Torque Converter Regulator Oil flows to the torque converter through a restriction in the front cover and whenever the main regulator opens. The torque converter regulator stays closed until the pressure to the torque converter increases to 758 to 896 kPa (110 to 130 psi) at 2000 rpm. When the torque converter regulator opens, some of the oil flows to the sump for cooling, and lubrication of the clutches. Oil Cooler By-Pass The oil cooler by-pass works as.a relief valve for the oil cooler circuit. When the oil pressure is more than, 345 to 483 kPa (50 to 70 psi) at 2000 rpm the ball will ‘move from the seat. Oil that flows past the by-pass flows into the sump. CONTROL VALVE General The control valve is installed on the top of the transmission. Holes in the control valve gasket permit oil to flow from the valve body to passages in the transmission housing, The control valve has the inching spool, direction spool, modulation spools and the main regulator. A Neutral start switch is also installed on the control valve. The direction spool is SEAL BUSHING OIL PUMP BODY GEAR SET ‘STATOR SUPPORT SEAL FRONT COVER OIL COOLER BYPASS O-RING PLUG TORQUE CONVERTER REGULATOR 12. BEARING 13. GASKET 14. FITTING == 3 SSeenemaune FIGURE 9. OIL PUMP AND FRONT COVER,SUCTION 2. OIL COOLER BY-PASS 3, FROM TORQUE CONVERTER 4, TO OIL COOLER 5. CHECK PORT - TORQUE CONVERTER 6. TO TORQUE CONVERTER 7. TORQUE CONVERTER REGULATOR, 8. ORIFICE FOR TORQUE CONVERTER 9. FROM OIL PUMP 10. MAIN REGULATOR (CHECK PORT) FIGURE 10, OIL P. contolled by the movement of the direction control lever. The position of the inching spool is controlled by the inching pedal, Main Regulator (See Figure 11) ‘The main regulator controls the oil pressure for the hydraulic operation of the transmission. The maximum pressure of the system is 965 to 1103 kPa, (140 to 160 psi) with the engine at 2000 rpm and the oil at 50°C (120° F). Oil that flows through the main regulator flows to the torque converter circuit. Inching Spool Assembly (See Fiugre 11) The inching spool assembly is in two pieces; an inching spool and an inching spool plunger. A spring keeps the two pieces apart. Oil flows to the inching spool from the oil pump, through the filter and past the main regulator. Oil that flows past the inching spool flows to the direction spool. During operation, the inching spool will decrease the oil pressure to the direction spool as the inching spool plunger is extended. When the inching spool plunger is completely extended the oil pressure to the IN FRONT COVER direction spool is zero. The oil that normally flows to the direction spool now drains into the transmission through the torque converter circuit Direction Spool (See Figure 11) The direction spool controls which clutch piston cavity receives the oil from the inching spool. The spool has three positions: FORWARD, NEUTRAL, and REVERSE. The direction spool operates a Neutral start switch. The switch permits the engine to start only when the direction spool is in the NEUTRAL position. The oil flow from the inching spool does not flow by the direction spool when the direction spool isin NEUTRAL. When the direction, spool is moved, oil flows to and from the clutch assemblies and also to the modulation spools Modulation Spools and Accumulator (See Figure 11) There are two modulation spools that help control the shock when changing directions. The modulation spools are in the same bore with the main regulator. A spring is installed between the two modulation spools to keep them against their stops, 1MAIN REGULATOR 12 4 SPRING SPRING RETAINER PIN MODULATION SPOOL O-RING PLUG 1 a ii ae a 8 9 10. " 12. 13, 14 INCHING SPOOL INCHING PLUNGER RETAINING CLIP SEAL DIRECTION SPOOL NEUTRAL START SWITCH DETENT BALL FIGURE 11. CONTROL VALVE SPOOLS ‘The accumulator isa piston that fits ima cavity in the transmission case. When the direction spool is moved from FORWARD to REVERSE, oil flows to the Reverse piston cavity and the Reverse modulation spool. The Reverse modulation spool moves and permits oil to flow to one end of the cavity for the accumulator. As the cavity begins to fill, the oil on the other side of the piston flows past the other modulation spool to drain. The movement of the accumulator piston helps decrease clutch pressure to permit smooth application of the clutch. The clutch pressure will increase to the maximum limit after the accumulator piston has moved to the end of the cavity. The modulation spools and accumulator work the same for Forward and Reverse direction changes.DIRECTION SPOOL INCHING SPOOL PLUNGER MODULATION SPOOLS MAIN REGULATOR INLET FROM PUMP TO INCHING SPOOL TO REVERSE MODULATION ‘SPOOL 8. TO ACCUMULATOR (REVERSE) 9. TO FORWARD MODULATION ‘SPOOL 10. TO ACCUMULATOR (FORWARD) 11, FROM MAIN REGULATOR 12, TO DIRECTION SPOOL 13, TO REVERSE CLUTCH 14, TO FORWARD CLUTCH ose 15, DRAIN Megsenn 2 ToRave gonventen 1. TRANSMISSION HOUSING 7. OIL COOLER RETURN 2. CAPSCREW HOLES 8. REVERSE CLUTCH PRESSURE 3. TO TORQUE CONVERTER 9. REVERSE CLUTCH COOLING 4. DRAIN 10. FORWARD CLUTCH COOLING 5. TO TORQUE CONVERTER REGULATOR 11, FORWARD CLUTCH PRESSURE 6. INLET TO CONTROL VALVE FROM 12. ACCUMULATOR (REVERSE) PUMP 13, ACCUMULATOR (FORWARD) FIGURE 13. OIL PASSAGES IN TRANSMISSION CASEPLUG RORS SPOOL SPOOL TRANSMISSION HOUSING ACCUMULATOR PISTON FROM FORWARD MODULATION 5. FROM REVERSE MODULATION FIGURE 14. ACCUMULATOR SSeeavemawns BEARING CONE BEARING CUP SPECIAL SPACER TRANSMISSION HOUSING . SHIMS PINION CAPSCREW CASE 12, THRUST WASHER 13. AXLE GEAR 20. 14, THRUST WASHER, 21 18. PINION GEAR. 22. 16. SPIDER 23. 17. BOLT 24. 18. RING GEAR 25. 19. CASE 26. washer 22 NUT ADJUSTMENT NUT BEARING CAP CASE FOR RING GEAR PILOT BEARING SNAP RING 10 FIGURE 15. DIFFERENTIALDIFFERENTIAL The hypoid ring and pinion gears muliply the torque from the transmission and change the direction of power. The differential assembly permits the drive wheels to turn at different speeds when the lift truck is turning a corner. ‘The hypoid ring and pinion gears are installed in the case for the ring gear. The case for the ring gear is fastened to the transmission housing. The pinion is installed in the transmission housing. There is also pilot bearing in the case for the ring gear on the H40- 60XL units, The S/H25-35XL units do not use a pilot bearing for the pinion, ‘The output gear for the transmission is installed on the pinion. The output gear is always engaged with the Forward and Reverse clutch hubs. NOTESOIL FLOW DIAGRAMS ‘The following is a description of the oil flow through the hydraulic system in four different conditions. In. each condition, the engine is running, NEUTRAL (See Figure 16) Oil from the pump flows through the filter to the main regulator and the inching spool. The oil flows past the inching spool to the direction spool. Since the direction spoolis in the NEUTRAL position, the oil stops at the direction spool. The oil that flows to the main regulator moves the main regulator. Oil flows past the main regulator to the torque converter. The torque converter regulator controls the oil pressure to the torque converter. Excess oil in the torque converter circuit flows into the clutch cooling circuit. Oil from the torque converter flows into the oil cooler. A by-pass valve for the oil cooler controls the oil pressure toa maximum of 345to 483, kPa (50 to 70 psi) at 2000 rpm. The oil from the oil cooler flows to the clutch cooling and lubrication circuit 2 Ol PUMP. TORQUE CONVERTER TORQUE CONVERTER REGULATOR OIL COOLER BY-PASS OIL COOLER |. MAIN REGULATOR ”. REVERSE MODULATION SPOOL |. FORWARD MODULATION SPOOL, ACCUMULATOR INCHING SPOOL. DIRECTION SPOOL. FORWARD CLUTCH |. REVERSE CLUTCH . FILTER . REVERSE CLUTCH PRESSURE CHECK PORT . FORWARD CLUTCH PRESSURE CHECK PORT . MAIN REGULATOR CHECK PORT . OIL COOLER BY-PASS CHECK PORT |. TORQUE CONVERTER REGULATOR CHECK PORTie Ui |, AE 7 : ; ® vl it ” ir ; J) 0 it " D Aa 1 An : . " » Hl suction PUMP PRESSURE (i cuuren pressure Ty [opaue convener "fie v PRES R F MR coouin Conan 8 Oh FIGURE 16. OIL FLOW IN NEUTRAL if]FORWARD (See Figure 17) Oil flows to the main regulator, inching spool, torque converter and direction spool as described in NEUTRAL position. With the direction spool in FORWARD position, oil flows through the direction spool to the Forward clutch piston. At the same time oil also flows tothe Forward modulation spool. As the Forward cluich engages, the Forward modulation spool shifts to permit oil to flow to the accumulator. The accumulator fills quickly because the direction spool was in NEUTRAL. 4 lL PUMP TORQUE CONVERTER TORQUE CONVERTER REGULATOR OIL COOLER BY-PASS OIL COOLER |. MAIN REGULATOR . REVERSE MODULATION SPOOL . FORWARD MODULATION SPOOL ‘ACCUMULATOR INCHING SPOOL DIRECTION SPOOL . FORWARD CLUTCH |. REVERSE CLUTCH FILTER . REVERSE CLUTCH PRESSURE CHECK PORT FORWARD CLUTCH PRESSURE CHECK PORT MAIN REGULATOR CHECK PORT OIL COOLER BY-PASS CHECK PORT TORQUE CONVERTER REGULATOR CHECK PORT4 I secon [iB rune pressure euronrnessne wma euemveren MB coounc Cioran w 1S co FIGURE 17. OIL FLOW IN FORWARD.FORWARD INCHING (See Figure 18) The inching condition occurs when the operator pushes on the inching pedal. As the operator pushes on the inching pedal, the inching spool plunger extends from the control valve. When the inching spool plunger extends, the spring tension on the inching spool is decreased. As the spring tension decreases, the inching spool moves to decrease the flow of oil to the direction spool. When the inching spool plunger is fully extended the inching spool stops the flow of oil to the direction spool. During inching, the oil that does not flow to the direction spool drains into the transmission sump. 16 ‘Ol PUMP TORQUE CONVERTER TORQUE CONVERTER REGULATOR: . OIL COOLER BY-PASS . OIL COOLER MAIN REGULATOR REVERSE MODULATION SPOOL |. FORWARD MODULATION SPOOL ACCUMULATOR INCHING SPOOL DIRECTION SPOOL FORWARD CLUTCH REVERSE CLUTCH FILTER REVERSE CLUTCH PRESSURE CHECK PORT FORWARD CLUTCH PRESSURE CHECK PORT MAIN REGULATOR CHECK PORT OIL COOLER BY-PASS CHECK PORT TORQUE CONVERTER REGULATOR CHECK PORTHL rune pressune auren pressure ‘Tongue converter PRessune HE crn MB coouns © craw FIGURE 18, OIL FLOW IN FORWARD-INCHING ”REVERSE (See Figure 19) ‘The hydraulic operation in REVERSE is similar to FORWARD except for the position of the direction control lever. With the direction control lever in the REVERSE position, oil now flows to the Reverse clutch and moves the Reverse modulation spool at the same time. The oil from the Forward clutch assembly flows to the drain circuit through the direction spool. The oil that flows past the Reverse modulation spool begins to fill the end of the accumulator that is empty. The movement of the Reverse modulation spool causes the Forward modulation spool to move to the drain position. The Reverse clutch will be completely engaged after the accumulator piston has moved to the other end of the bore. The extra time it takes to fill the accumulator helps control the shock when changing directions. Seenonsons "1 12. 13, 14. 15. 16. 17. 18. 19, OlL PUMP TORQUE CONVERTER TORQUE CONVERTER REGULATOR . OIL COOLER BY-PASS . OIL COOLER |. MAIN REGULATOR REVERSE MODULATION SPOOL FORWARD MODULATION SPOOL ‘ACCUMULATOR INCHING SPOOL DIRECTION SPOOL FORWARD CLUTCH REVERSE CLUTCH FILTER REVERSE CLUTCH PRESSURE CHECK PORT FORWARD CLUTCH PRESSURE CHECK PORT MAIN REGULATOR CHECK PORT OIL COOLER BY-PASS CHECK PORT TORQUE CONVERTER REGULATOR CHECK PORTHii ruwe pressure Dlcuren pressure TORQUE CONVERTER ” Ml coounc Conan + 6 1 lo FIGURE 19. OIL FLOW IN REVERSEHyster Easy Language Program mi HYSTER COMPANY OS MM recnicar pusucations 1300 SRM 75 3/83 (10/81) (6/81) 500 AP Litho in U.S.A.