TECHNICAL TRAINING TEXT

TRANSMISSION
CLARK HR 24000 SERIES
MEGA 200 / 200-III LOADERS

4028-7052E
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 TECHNICAL TRAINING TEXT
GENERAL DESCRIPTION

THEORY OF OPERATION

The HR Model consists of a torque converter and powershifted transmission in one package
mounted directly to the engine.
The shift control valve assembly may be mounted directly on the side of converter housing or
front transmission cover, or remote mounted and connected to transmission by means of
flexible hoses.
The function of the control valve assembly is to direct oil under pressure to the desired
directional and speed clutch. A provision is made on certain models to neutralize the
transmission when brakes are applied. This is accomplished through use of a brake actuated
shutoff valve. The speed and direction clutch assemblies are mounted inside transmission
case and are connected to output shaft of converter either by direct gearing or drive shaft.
The purpose of speed or directional clutches is to direct power flow through gear train to
provide desired speed range and direction.
With engine running, converter charging pump draws transmission sump through removable
oil suction screen and directs it through oil filter and pressure regulating valve.
The pressure regulating valve maintains pressure to transmission control cover for actuating
direction and speed clutches. This requires a small Portion of the total volume of oil used in
the system. The remaining volume of oil is directed through torque converter circuit to oil
cooler and returns to transmission for positive lubrication. This regulator valve consists of a
hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to
hold valve in a closed position. When a specific pressure is achieved, valve spool works
against spring until a port is exposed along side of bore. This sequence of events provides
proper system pressure.
After entering converter housing oil is directed through stator support to converter blade
cavity and exits in the passage between the turbine shaft and converter support. The oil then
flows out of converter to oil cooler. After leaving cooler, oil is directed to a lubricating fitting on
transmission and through a series of tubes and passage lubricates transmission bearings and
clutches. The oil then gravity drains to transmission sump.
The hydraulic torque converter basically of three elements and their related parts to multiply
engine torque. The engine power is transmitted from engine flywheel to impeller element
through impeller cover. This element is the pump portion of hydraulic torque converter and is
primary component which starts oil flowing to other components which results in torque
multiplication. This element can be compared to a centrifugal pump in that it picks up fluid at
its center and discharges at its outer diameter.
The torque converter turbine is mounted opposite the impeller and is connected to outer or
inner shaft of torque converter. This element receives fluid at its outer diameter and
discharges at its center. Fluid directed by impeller out into the particular design of blazing in
turbine and reaction member is the means by which hydraulic torque converter multiplies
torque.

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 TECHNICAL TRAINING TEXT

The reaction member of the torque converter is located between and at the center or inner
diameters of the impeller and turbine elements. Its function is to take the fluid which is
exhausting from the inner portIon of the turbine and change its direction to allow correct entry
for recirculation into the impeller element.
The torque converter will multiply engine torque to its designed maximum multiplication ratio
when the output shaft is at zero RPM. Therefore, we can say that as the output shaft is
decreasing in speed the torque multiplication is increasing.
The shift control valve assembly consists of a valve body with selector spools. A detent ball
and spring in the selector spools provides one position for each speed range. A detent ball
and spring in the direction spool provides three positions, one for each forward, neutral and
reverse.
With the engine running and the directional control lever in the neutral position, oil pressure
from the regulating valve is blocked at the control valve, and the transmission is in neutral.
Movement of the forward and reverse spool will direct oil, under pressure to either the
forward or reverse direction clutch as desired.
When either directional clutch is selected to the opposite clutch is relieved of pressure and
vents back through the direction selector spool. The same procedure is used in the speed
selector.
The direction or speed clutch assembly consists of a drum with the internal splines and a
bore to receive a hydraulically actuated piston. The piston is oil tight'by the use of sealing
rings. A steel disc with external splines is inserted into the drum and rests against the piston.
Next, a friction disc with splines at the inner diameter is inserted. Discs are alternated until
the requested total is achieved. A heavy back-up plate is then inserted and secured with a
snap ring. A hub with 0.D. splines is inserted into the splines of a discs with teeth on the inner
diameter. The discs and hub are free to increase in speed or rotate in the opposite direction
as long as no pressure is present in that specific clutch.
To engage the clutch, as previously stated, the control valve is placed in the desired position.
This allows oil under pressure to flow from the control valve, through a passageway, to a
chosen clutch shaft. This shaft has a drilled passageway for oil under pressure to enter the
shaft. Oil pressure sealing rims are located on the clutch shaft. These rings direct oil under
pressure to a desired clutch. Pressure of the oil forces the piston and discs against the heavy
hack-up plate. The discs, with teeth on the outer diameter, clamping against discs with teeth
on the inner diameter, enables the hub and clutch shaft to be locked together and allows
them to drive as a unit.
There are bleed balls or bleed orifices in the clutch piston, depending upon the model, which
allow quick escape for oil when the pressure to the piston is released.

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 TECHNICAL TRAINING TEXT

24000
HR MODEL 4 SPEED LONG DROP

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 TECHNICAL TRAINING TEXT
CLUTCH AND GEAR ARRANGEMENT OF TRANSMISSION

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 TECHNICAL TRAINING TEXT
HYDRAULIC CURCUIT OF TORQUE CONVERTER
AND TRANSMISSION

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 TECHNICAL TRAINING TEXT
ELECTRIC CONTROL VALVE

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 TECHNICAL TRAINING TEXT
ELECTRIC CONTROL VALVE ASSEMBLY
LESS DECLUTCH – HORIZONTAL SOLENOID

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 TECHNICAL TRAINING TEXT
TRANSMISSION CLUTCH MODULATION
The device is to shift clutch smoothly, and the modulating time is 2 seconds.

Forward clutch modulation (Example)

1. Initial stage: As the pressure of “B” is higher than that of “A”, the regulator spool is
moved to the right and connects pressure oil to the drain port, at this time the pressure
rises suddenly and then it is lowered to a pressure of 1.4 kg/cm2 (20 lb/in2 ).
2. Middle stage: Some oil is filled up an accumulator cavity with the difference in pressure
between “A” and “B”, and the pressure of is kept until the oil is filled completely. At this
time the accumulator spool is moved against the spring force, and the pressures of “A”
and “B” rises slowly.
3. Final stage: When the accumulator stops operating, pressure of “A” and “B” becomes
equal with no oil flow through orifice and then the working pressure of clutch rises
vertically to reach the specified clutch pressure.
4. Reverse clutch and modulator are connected to the drain port.

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 TECHNICAL TRAINING TEXT

Notes
Hose Line Operating Requirements:
1. Pressure Lines – Suitable for operation from ambient to 250 ?[121?] continuous
operating temperature.
Must withstand 300 PSI[2068 kPa] continuous pressure, with 600 PSI [4137 kPa]
intermittent surges.
Ref. S.A.E. Spec. No. J517, 100R1 Hydraulic Hose Specifications.
2. See Lubrication Specifications.
3. See hose lines used must conform to S.A.E. Spec. No J 1019 Tests and Procedures
for High Temperature Transmission Oil Hose.
Port “L” – Converter Outlet Temperature
Port is to be used for Converter Outlet Temperature pick-up. Gauge is to be located
in the Operator Compartment. See Oil Temperature Gauge Specifications.

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 TECHNICAL TRAINING TEXT
Port “M” – Converter Outlet Pressure

Pressure must be measured during normal vehicle “Production Line” test.

Converter outlet pressure equals the total pressure drop of the Heat Exchanger,
Heat Exchanger Lines and back pressure of the transmission lubrication system.

Test Conditions:
1. Converter Outlet Oil Temperature 82°~104°C (180°~220°F).
2. Transmission in Neutral.

Operating Specifications:

25 psi [173 kPa] Min. pressure at 2000 RPM engine speed and a max. of 70 psi [483 kPa]
outlet pressure at a no-load governed speed.
Ports “A”, “F”, “K”, “L”, and “M”
These ports can be used for field “Trouble Shooting” or vehicle “Production Line” tests.
Ports “F”, “L”, and “M”
These ports are to be used as check points for normal vehicle “Production Line” test.
Port “F” – Clutch Pressure
It is recommended that clutch pressure be monitored by a gauge having an indicator dial
range of 0 to 400 psi [0 to 2758 kPa] and located in the Operator Compartment.
Ports “G” and “H” – Back-up Warning
These ports are provided for installation of Back-up Pressure Switch for Warning Light or
Horn.

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 TECHNICAL TRAINING TEXT
CONVERTER LOCK-UP OPTION

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 Forward First Mega 200 & M200-III Back-up
"N" Terminal of Alarm
Starter Controller and Lights

Fuse 7

T/M CONTROL RELAY

0.85G

0.85BW
87a 0.5WB 85 0.5B
30
0.85Y 87 86 87
0.85Y (2) 0.85WL 0.85WR
(1) 0.85G
0.5B 86 87a
30
0.85Y

85
(1)
0.85Y 0.85YL 87a
30
0.85B (1) (25) 87
0.85YB 87a
(9) 30
87a 85 0.5B
87 KICK 1 2 3 4
30 F N R
87 86 (4) DOWN STEP STEP STEP STEP
0.5B 86 0.5Br
(3) 0.85RL
0.5B 86 7{49a}
(2) 0.5Y 85
(2) 0.85RL
85 4(53a)
0.85B
87a 0.85Br
0.5LW 23
30
0.85GY 87 0.5Gr
(5) 19
0.5B 86
(F4) 0.85L 0.5Y
85 18
0.85B 87a 0.5W
(3) EXIT3
0.85WB 30 0.85RL
87 0.5W
(6) FOWARD CUT OFF SW 16
(F) (4) 86
0.5B 0.5LB 0.5LY 0.5LY
0.85B 20
85 3
(15) 2 0.5LY 0.5WG
1 21
0.85BW 0.5BrW 0.5LB 87a
30 0.5LY FOWARD CUT OFF SW COMBINATION SWITCH
(R) (16) 0.5R 87
(5)
30 (7)
0.85B 87 0.5B 85 86 0.5LW
0.85BW
(8)
0.5B 86 0.5LW
85 0.5WG

HATF120.eps
 Forward Second Mega 200 & M200-III Back-up
"N" Terminal of Alarm
Starter Controller and Lights

Fuse 7

0.85G T/M CONTROL RELAY

0.85BW
87a 85
0.5WB 0.5B
30
0.85Y 87 86 87
0.85Y (2) 0.85WL 0.85WR
(1) 0.85G
0.5B 86 87a
30
0.85Y

85
(1)
0.85Y 0.85YL 87a
30
0.85B (1) (25) 87
0.85YB 87a
(5) 30
87a 85 0.5B
87 KICK 1 2 3 4
30 F N R
87 86 (4) DOWN STEP STEP STEP STEP
(3) 0.5B 86 0.5Br
0.85RL
0.5B 86 7{49a}
(2) 0.5Y 85
(2) 0.85RL
85 4(53a)
0.85B
87a 0.85Br
0.5LW 23
30
0.85GY 87 0.5Gr
(5) 19
0.5B 86
(F4) 0.85L 0.5Y
85 18
0.85B 87a 0.5W
(3) EXIT3
0.85WB 30 0.85RL FOWARD CUT OFF SW
87 0.5W
(6) (4549-9413) 16
(F) (4) 86
0.5B 0.5LB 0.5LY 0.5LY
0.85B 20
85 3
(15) 2 0.5LY 0.5WG
1 21
0.85BW 0.5BrW 0.5LB 87a
30 0.5LY FOWARD CUT OFF SW
(R) (16) 87
(5) 0.5R (2549-9101) COMBINATION SWITCH
30 (7)
0.85B 87 0.5B 85 86 0.5LW (2549-9085)*2/2
0.85BW
(8)
0.5B 86 0.5LW
85 0.5WG

HATF130.eps
 Back-up
Forward Second with Kick Down Button Down Mega 200 & M200-III "N" Terminal of Alarm
Starter Controller and Lights

Fuse 7

0.85G T/M CONTROL RELAY

0.85BW
87a 85
0.5WB 0.5B
30
0.85Y 87 86 87
0.85Y (2) 0.85WL 0.85WR
(1) 0.85G
0.5B 86 87a
30
0.85Y

85
(1)
0.85Y 0.85YL 87a
30
0.85B (25) 87
(1) 0.85YB
(9) 87a
87a 30
85 0.5B
30 87 KICK 1 2 3 4
86 F N R
87 (4) DOWN STEP STEP STEP STEP
86 0.5Br
(3) 0.5B 0.85RL
0.5B 86 0.5Y 7{49a}
(2) 85
0.85RL
85 4(53a)
0.85B
(2) 87a 0.85Br
0.5LW 23
30
0.85GY 87 0.5Gr
(5) 19
0.5B 86
(F4) 0.85L 0.5Y
85 18
0.85B 0.5W
(3) 87a
30 EXIT3
0.85WB 0.85RL
87 0.5W
(6) FOWARD CUT OFF PRESSURE SW 16
(F) 0.5B 86 0.5LB 0.5LY 0.5LY
0.85B 20
85 3
(4) 2 0.5LY 0.5WG
(15)
21
0.85BW 0.5BrW 1
0.5LB 87a
30 0.5LY FOWARD CUT OFF SELECTOR SW COMBINATION SWITCH
(R) (16) 0.5R
(5) 87
87a 30 (7)
0.85B 0.5B 85 86 0.5LW
87
0.85BW (8)
0.5B 86 0.5LW
85 0.5WG

HATF110.eps
 Forward Third Mega 200 & M200-III Back-up
"N" Terminal of Alarm
Starter Controller and Lights

Fuse 7

T/M CONTROL RELAY

0.85G
(2544-9020)*9

0.85BW
87a 85
0.5WB 0.5B
30
0.85Y 87 86 87
0.85Y (2) 0.85WL 0.85WR
(1) 0.85G
0.5B 86 87a
30
0.85Y

85
(1)
0.85Y 0.85YL 87a
30
0.85B (1) (25) 87
0.85YB 87a
(5)
87a 85 0.5B 30
87 KICK 1 2 3 4
30 F N R
87 86 DOWN STEP STEP STEP STEP
0.5B 86 0.5Br
0.85RL
0.5B 86 0.5Y 7{49a}
(2) 85
(2) 0.85RL
85 4(53a)
0.85B
87a 0.85Br
0.5LW 23
30
0.85GY 87 0.5Gr
(5) 19
0.5B 86
(F4) 0.85L 0.5Y
85 18
0.85B 87a 0.5W
(3) EXIT3
0.85WB 30 0.85RL FOWARD CUT OFF SW
87 0.5W
(6) (4549-9413) 16
(F) (4) 86
0.5B 0.5LB 0.5LY 0.5LY
0.85B 20
85 3
(15) 2 0.5LY 0.5WG
1 21
0.85BW 0.5BrW 0.5LB 87a
30 0.5LY FOWARD CUT OFF SW
(R) (16) 87
(5) 0.5R (2549-9101) COMBINATION SWITCH
30 (7)
0.85B 87 0.5B 85 86 0.5LW (2549-9085)*2/2
0.85BW
(8)
0.5B 86 0.5LW
85 0.5WG

HATF140.eps
 Forward Fourth Mega 200 Back-up
"N" Terminal of Alarm
Starter Controller and Lights

Fuse 7

T/M CONTROL RELAY

0.85G
(2544-9020)*9

0.85BW
87a 85 0.5B
0.5WB
30
86 87
0.85Y 0.85Y 87 (2) 0.85WL 0.85WR
(1) 0.85G
0.5B 86 87a
30
0.85Y

85
(1)
0.85Y 0.85YL 87a
30
0.85B (25) 87
(1) 0.85YB 87a
(9)
87a 85 0.5B 30
87 KICK 1 2 3 4
30 F N R
87 86 (4) DOWN STEP STEP STEP STEP
0.5B 86 0.5Br
(3) 0.85RL
0.5B 86 0.5Y 7{49a}
(2) (2) 85
0.85RL
85 4(53a)
0.85B
87a 0.85Br
0.5LW 23
30
0.85GY 87 0.5Gr
(5) 19
0.5B 86
(F4) 0.85L 0.5Y
85 18
0.85B 87a 0.5W
(3) EXIT3
0.85WB 30 0.85RL
87 0.5W
(6) FOWARD CUT OFF PRESSURE SW 16
(F) (4) 86
0.5B 0.5LB 0.5LY 0.5LY
0.85B 20
85 3
(15) 2 0.5LY 0.5WG
1 21
0.85BW 0.5BrW 0.5LB 87a
30 0.5LY FOWARD CUT OFF SELECTOR SW
(R) (16) 0.5R 87 COMBINATION SWITCH
(5)
30 (7)
0.85B 0.5B 85 86 0.5LW
0.85BW 87
(8)
0.5B 86 0.5LW
85 0.5WG

HATF100.eps
 Reverse 1 Mega 200 & M200-III
Back-up
"N" Terminal of Alarm
Starter Controller and Lights

Fuse 7

T/M CONTROL RELAY

0.85G

0.85BW
87a 0.5WB 85 0.5B
30
0.85Y 87 86 87
0.85Y (2) 0.85WL 0.85WR
(1) 0.85G
0.5B 86 87a
30
0.85Y

85
(1)
0.85Y 0.85YL 87a
30
0.85B (1) (25) 87
0.85YB 87a
(9)
87a 85 0.5B 30
87 KICK 1 2 3 4
30 (4) F N R
87 86 DOWN STEP STEP STEP STEP
(3) 0.5B 86 0.5Br
0.85RL
0.5B 86 0.5Y 7{49a}
(2) 85
(2) 0.85RL
85 4(53a)
0.85B
87a 0.85Br
0.5LW 23
30
0.85GY 87 0.5Gr
(5) 19
0.5B 86
(F4) 0.85L 0.5Y
85 18
0.85B 87a 0.5W
(3) EXIT3
0.85WB 30 0.85RL
87 0.5W
(6) FOWARD CUT OFF PRESSURE SW 16
(F) (4) 86
0.5B 0.5LB 0.5LY 0.5LY
0.85B 20
85 3
(15) 2 0.5LY 0.5WG
1 21
0.85BW 0.5BrW 0.5LB 87a
FOWARD CUT OFF SW COMBINATION SWITCH
30 0.5LY
(R) (16) 87
(5) 0.5R
30 (7)
0.85B 0.5B 85 86 0.5LW
0.85BW 87
(8)
0.5B 86 0.5LW
85 0.5WG

HATF150.eps
 Reverse 2 Mega 200 & M200-III Back-up
"N" Terminal of Alarm
Starter Controller and Lights

Fuse 7

T/M CONTROL RELAY

0.85G

0.85BW
87a 0.5WB 85 0.5B
30
0.85Y 87 86 87
0.85Y (2) 0.85WL 0.85WR
(1) 0.85G
0.5B 86 87a
30
0.85Y

85
(1)
0.85Y 0.85YL 87a
30
0.85B (1) (25)
0.85YB 87 87a
(9)
87a 87 85 0.5B 30
87 KICK 1 2 3 4
30 F N R
87 86 (4) DOWN STEP STEP STEP STEP
(3) 0.5B 86 0.5Br
0.85RL
0.5B 86 0.5Y 7{49a}
(2) 85
(2) 0.85RL
85 4(53a)
0.85B
87a 0.85Br
0.5LW 23
30
0.85GY 87 0.5Gr
(5) 19
0.5B 86
(F4) 0.85L 0.5Y
85 18
0.85B 0.5W
(3) 87a
30 EXIT3
0.85WB 0.85RL
87 FOWARD CUT OFF PRESSURE SW 0.5W
(6) 16
(F) (4) 86
0.5B 0.5LB 0.5LY 0.5LY
0.85B 20
85 3
(15) 2 0.5LY 0.5WG
1 21
0.85BW 0.5BrW 0.5LB 87a
30 0.5LY FOWARD CUT OFF SW
(R) (16)
0.5R 87 COMBINATION SWITCH
(5)
30 (7)
0.85B 0.5B 85 86 0.5LW (2549-9085)*2/2
0.85BW 87
(8)
0.5B 86 0.5LW
85 0.5WG

HATF160.eps
 Reverse 3 Mega 200 & M200-III
Back-up
"N" Terminal of Alarm
Starter Controller and Lights

Fuse 7

0.85G
T/M CONTROL RELAY

0.85BW
87a 0.5WB 85
0.5B
30
0.85Y 86 87
0.85Y 87 (2) 0.85WL 0.85WR
(1) 0.85G
0.5B 86 87a
30
0.85Y

85
(1)
0.85Y 0.85YL 87a
30
0.85B (1) (25)
0.85YB 87 87a
(9) 30
87a 85 0.5B
87 KICK 1 2 3 4
30 F N R
87 86 DOWN STEP STEP STEP STEP
(4) 86 0.5Br
(3) 0.5B 0.85RL
0.5B 86 0.5Y 7{49a}
(2) 85
(2) 0.85RL
85 4(53a)
0.85B
87a 0.85Br
0.5LW 23
30
0.85GY 87 0.5Gr
(5) 19
0.5B 85 86
(F4) 0.85L 0.5Y
18
0.85B 0.5W
(3) 87a
30 EXIT3
0.85WB 0.85RL
87 0.5W
(6) FOWARD CUT OFF PRESSURE SW 16
(F) (4) 86
0.5B 0.5LB 0.5LY 0.5LY
0.85B 20
85 3
(15) 2 0.5LY 0.5WG
1 21
0.85BW (16) 0.5BrW 0.5LB 87a FOWARD CUT OFF SW
30 0.5LY COMBINATION SWITCH
(R) 87a 0.5R 87
(5)
30 (7)
0.85B 0.5B 85 86 0.5LW
0.85BW 87
(8)
0.5B 86 0.5LW
85 0.5WG

HATF170.eps