AMT Technical Training. Automatic Mechanical Transmission

Содержание

Слайд 2

Kindly attention： 1.The course will take you approx 45 minutes 2.Please

Kindly attention：
1.The course will take you approx 45 minutes
2.Please linsten carefully,and

we will have a test
3.Please refer to the remarks at the bottom
4.Keep your cellphone on mute condition
Слайд 3

Catalog Components Service standard Trouble-shooting and solutions

Catalog

Components

Service standard

Trouble-shooting and solutions

Слайд 4

System overview

System overview

Слайд 5

Following information display on LCD and cluster: Current gears， Current mode(Auto/Manual)

Following information display on LCD and cluster:
Current gears， Current mode(Auto/Manual)
Normal/Economical(Shifting pattern

under auto Mode)
Fault light
Buzzer in cluster will work under following conditions：
Reverse gear request to ECU
After system self-learning
Illogical gears request from shifting lever
System fault

System overview

Human-computer interface

Слайд 6

System layout １ECU 2 Electrohydraulic unit ３TCU 4 Cluster ５Econ/Norm button ６brake switch ７Shift lever ８Accelerator

System layout

１ECU 2 Electrohydraulic unit ３TCU 4 Cluster
５Econ/Norm button ６brake switch ７Shift lever ８Accelerator

Слайд 7

System introduction On the basis of the original manual transmission gearbox

System introduction

On the basis of the original manual transmission gearbox and

clutch to add auxiliary hydraulic power control unit , Which retains all the advantages of clutch and mechanical gearbox (weight, strength and reliability, low power consumption), and to have automatic transmission.
Eliminated clutch pedal and shift wires, gear lever machines were replaced by an electronic joystick marked with (+/-/ N / R) reduce costs, improve the system reliability.
Improved user interface, less operation to improve the driving safety , especially in urban conditions.
Shifting point will alter with the vehicle and driver’s willing.
Слайд 8

Shift lever position with three stable and three unstable position, the

Shift lever position with three stable and three unstable position, the

position signal was transformed by the Hall sensor into electrical signals.

Shift lever

Manual （semi-auto mode）
Automatic(Eco)：
Automatic(Norm) ：

System introduction

Слайд 9

Shift to Neutral during running APP sensor released Vehicle speed requirement System introduction

Shift to Neutral during running

APP sensor released
Vehicle speed <80KM/H

requirement

System introduction

Слайд 10

Shift to Reverse Brake pedal was depressed Vehicle speed Requirement R System introduction

Shift to Reverse

Brake pedal
was depressed
Vehicle speed
<2Km/h

Requirement

R

System introduction

Слайд 11

Possible following situation may cause when the driver try to move

Possible following situation may cause when the driver try to move

shift lever without depressing the brake pedal.

Shift lever instructions

System will automatically switch to Neutral gear once the driver’s door opens

System introduction

Слайд 12

Knowledge prepration Three types of operation on transmission are replace by

Knowledge prepration

Three types of operation on transmission are replace by Actuator

( Electrohydraulic mechanism )

Clutch release fork

Engage direction

Select direction

Слайд 13

Electrohydraulic Mechanism

Electrohydraulic Mechanism

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ECU Brake switch -----------? Clutch speed --- --- --- ? Clutch


ECU<-------------?
Brake switch -----------?
Clutch speed --- --- --- ?
Clutch fork position--?
Gear

selected position?
Gear engaged position?
Fluid pressure----------?
Shift lever input--------?
Driver’s door switch--?
Ignition switch ---------?
----- ??Gear selection solenoid valve 1
----- ??Gear selection solenoid valve 2
----- ??Gear engage solenoid valve 1
----- ??Gear engage solenoid valve 2
----- ??Clutch solenoid valve
<--- ??Instrument

AMT Electrical Control Components

Слайд 15

Input signal TCU APP sensor Brake switch Mode switch(M/A) Econ/Norm button

Input signal

TCU

APP sensor

Brake switch

Mode switch(M/A)
Econ/Norm button
Shift Up/down(+/-) switch

Vehicle speed sensor

Engine

speed sensor

Coolant temperature sensor

Слайд 16

Input signal TCU Gear engage position sensor Gear selection sensor Clutch

Input signal

TCU

Gear engage position sensor
Gear selection sensor

Clutch fork position sensor

Friction disc

speed sensor of Clutch

Driver door switch

Ignition switch

Fluid pressure sensor

Слайд 17

Output signal TCU Clutch solenoid valve(EV0) Even gears engage solenoid valve(EV2)

Output signal

TCU

Clutch solenoid valve(EV0)

Even gears engage solenoid valve(EV2)

1-2 gears selection solenoid

valve(EV3)

5-R gears selection solenoid valve(EV4)

Odd gears engage solenoid valve(EV1)

Relay of pump

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System specification

System specification

Слайд 19

System will be woke up in two ways： — Open the

System will be woke up in two ways：
— Open the driver's

side door: The system will automatically wake up and hydraulic pump will run to supply enough pressure for starting.
— Turn on the ignition switch.

System wake up

Слайд 20

Engine start control Start requirement： Once TCU receives the brake (except

Engine start control

Start requirement：

Once TCU receives the brake (except Neutral gear)

and the start signal, it will automatically ground the control wire and run the starter.
After starting conditions are met, TCU simultaneously through CAN bus to send a start signal to allow engine control system (ECU) to start.

Emergency start:
Battery with low energy fails to start engines but with enough electric power to run the pump supplying enough fluid pressure to shift operations, that is gears can still be engaged.
Set the transmission under Manual mode and pull vehicle to certain low speed, shift the gear manually to 1st/2nd gear.

Слайд 21

Vehicle can start to move on 1st & 2nd gear Starting

Vehicle can start to move on 1st & 2nd gear

Starting move

Driver

release brake pedal and stepping on the accelerator pedal, the system will gradually engage the clutch. When the system detects the engine speed with the clutch rotational speed synchronized, the clutch will be fully engaged. Different gears in different APP and speeds ,the engagement will vary to ensure rapid and smooth start.

Tip +
Tip －

Слайд 22

Shift process under Manual Mode Shift process When vehicle is running

Shift process under Manual Mode

Shift process

When vehicle is running and the

clutch engaged, driver can manually shift gears.

Three stages: Stage 1: engine decrease torque output Stage 2: shift process Stage 3: increase engine torque output

Shift request will only be accepted by ECU when it does not cause the overspeed or stall.

Слайд 23

Control intervention under Manual Mode In Manual mode, TCU will control

Control intervention under Manual Mode

In Manual mode, TCU will control the

gears automatically avoid overspeed or stall under following situations:
Downshift intervention: higher gear when the driver began to slow down, the system will automatically help the driver to downshift.
Upshift intervention: System will automatically upshift avoid overspeed.

Attention: that these two cases the system is still in manual mode, the following, the main reason is to help the driver to take control rather than driving engine for the purpose of protection, engine protection should be the engine control system (EMS) functions.

Слайд 24

Auto mode Shift lever can switch to automatic mode at any

Auto mode

Shift lever can switch to automatic mode at any time(If

condition is met).Once automatic mode is activated ,the letter “AUTO” will be shown in cluster. At the same time the meter will display under the E button is in the state of economic model or the ordinary mode 。

In automatic mode, there are two sets of shift curve, it has considered economy and power to meet the different driving needs.

Слайд 25

When the driver stepped on the accelerator to fully open, TCU

When the driver stepped on the accelerator to fully open, TCU

will downshift one or two gears to increase the torque.

Accelerator Pedal Position（ >90%）

Kick down

Слайд 26

Deceleration TCU will automatically downshift during deceleration and the gears above

Deceleration

TCU will automatically downshift during deceleration and the gears above 2nd

gear.

For example, in 5th gear, clutch engaged and accelerator pedal released, when the engine speed reach idle speed, the system will automatically downshift from 5th to 4th , to avoid the engine speed drops below the target idle speed which led to stall.
When a downshift depends on the following parameters: stalls, engine idling, the brake pedal and engine deceleration rate.
Continuous deceleration until the vehicle stopped, TCU will be automatically shift to Neutral, and disengage the clutch.

Auto clutch engagement During the downhill and the vehicle speed increase, if the gear engaged during running and APP was released, when the reach a certain speed, the clutch will automatically engage to provide engine braking.

Слайд 27

System security features

System security features

Слайд 28

When the vehicle stopped but the engine working and engage gear

When the vehicle stopped but the engine working and engage gear

(such as 1st , 2nd and Reverse).
When the driver‘s door open, if the driver stepped on the brakes or APP, the system will remain the current gear.
If the driver's side door open and the driver has not stepped on the brake or accelerator more than three seconds, the system will automatically switch to Neutral gear dashboard displays the current operating mode and N.
If the driver does not take any action (except depress the brake pedal) more than three minutes, the system will automatically switch to Neutral gear dashboard displays the current operating mode and N.
If the driver depresses the brake more than 10 minutes without any operation, the system will automatically select the Neutral. Dashboard displays the current operating mode and Neutral.

System security features

Слайд 29

Emergency start during brake switch is broken If the TCU detected

Emergency start during brake switch is broken
If the TCU detected brake

switch is broken, Ignition key remains in the starting position about 10 seconds before starting vehicle. After the start, TCU will inform the driver by warning lights.

System security features

Слайд 30

System control theory APP sensor Brake switch Dash panel Door switch

System control theory

APP sensor

Brake switch

Dash panel

Door switch

Shift lever

Vehicle speed

TCU

ECU

Engine

Hydraulic system

solenoid valves

Transmission

shifting mechanism and position sensor

Clutch
Position sensor

Transmission and speed sensor

Слайд 31

Components

Components

Слайд 32

Shift components

Shift components

Слайд 33

Shift gears Shift pin Selection gear 5-R shift fork 3-4 shift fork

Shift gears

Shift pin

Selection gear

5-R shift fork

3-4 shift fork


Слайд 34

Hydraulic actuator SQR 513 transmission hydraulic actuator location （Bracket of hydraulic actuator must be remove）

Hydraulic actuator

SQR 513 transmission hydraulic actuator location
（Bracket of hydraulic actuator must

be remove）
Слайд 35

Power Unit Hydraulic power unit provides power to hydraulic. Motor Accumulator

Power Unit

Hydraulic power unit provides power to hydraulic.

Motor

Accumulator

Gear pump

Low pressure fluid

hose

High pressure pipe

Fluid tank

Слайд 36

Pump 12V DC。 System pressure: >46 bar stop TCU 30 31

Pump

12V DC。
System pressure:
<36 bar run
>46 bar stop

TCU

30

31

Слайд 37

Tank 150 micrometer filter was fitted in exports of tank. Fluid

Tank

150 micrometer filter was fitted in exports of tank.

Fluid level standard
Relief

system pressure using X431 and then observe the liquid level inside the tank.

Pressure fluid manufacturer: -TUTELA CAR CS SPEED PN:EW.0011602.A

Слайд 38

Accumulator Capacity:250 cm3

Accumulator

Capacity:250 cm3

Слайд 39

Valve body Valve body has follow functions： Control gear engage and

Valve body

Valve body has follow functions：
Control gear engage and detach。
Control gear

selection
Control clutch engage and detach

Components:
1. Clutch solenoid valve(EV0)
2. Even gear engage valve(EV2)
3. Odd gear engage valve(EV1)
4. 1-2 selection gears solenoid valve(EV3)
5. 5-R selection gears solenoid valve(EV4)
6. Gear engage position sensor
7. Gear selection position sensor
8. Press sensor（0-70 bar）
9. Valve body

Слайд 40

Valve body Joint Mounting location

Valve body

Joint

Mounting location

Слайд 41

Clutch actuator

Clutch actuator

Слайд 42

Clutch actuator assembly 1. Release cable 2. Clutch actuator body 3.

Clutch actuator assembly

1. Release cable
2. Clutch actuator body
3. Clutch cable position

sensor
4. System air bleed bolt

Clutch solenoid valve (EV0)

2

1

3

4

Слайд 43

Data stream in X431 concerning clutch

Data stream in X431 concerning clutch

Слайд 44

Clutch cable position sensor Function: feedback the clutch cable position signal to TCU

Clutch cable position sensor

Function: feedback the clutch cable position signal to

TCU
Слайд 45

Gear engage and selection solenoid valves

Gear engage and selection solenoid valves

Слайд 46

Gear engage solenoid valves Even gear engage valve(EV2) Odd gear engage valve(EV1)

Gear engage solenoid valves

Even gear engage valve(EV2)

Odd gear engage valve(EV1)

Слайд 47

Gear selection valves 1-2 gears selection solenoid valve(EV3) 5-R gears selection solenoid valve(EV4)

Gear selection valves

1-2 gears selection solenoid valve(EV3)

5-R gears selection solenoid valve(EV4)

Слайд 48

Summary of solenoid valves

Summary of solenoid valves

Слайд 49

Pressure sensor Function :Monitor system pressure

Pressure sensor

Function :Monitor system pressure

Слайд 50

Pressure sensor What is special meaning that the range from 36-46

Pressure sensor

What is special meaning that the range from 36-46 bar?

TCU

+ -

Pressure output voltage characteristics

Voltage(V)

Pressure (bar)

Слайд 51

Maintenance specification ——AMT system self-learn

Maintenance specification

——AMT system self-learn

Слайд 52

System maintenance services Replace or assemble parts must perform the following

System maintenance services

Replace or assemble parts must perform the following functions

in whole or in part:

After replace the following parts: clutch actuator, tank, pump, high pressure pipe, pressure sensors, accumulators and other major parts, Bleed the system 3, and then take gear self-learn one time, 3 to 5 times the clutch self-learning. Finally check the oil level according to the method.

Слайд 53

Service should be taken after parts replacement

Service should be taken after parts replacement

Слайд 54

——Guide of dismount and assemble Maintenance specification

——Guide of dismount and assemble

Maintenance specification

Слайд 55

Pressure Fluid Abnormal pressure fluid add into system will cause a

Pressure Fluid

Abnormal pressure fluid add into system will cause a serious

situation and miss the warranty!
Слайд 56

Before removing the AMT ASSM, selection shaft must be released. Remove

Before removing the AMT ASSM, selection shaft must be released. Remove

the cover
Rotate the selection shaft 90° with flat screwdriver .(both directions can be rotated)

Dismount select shaft

Слайд 57

Mount guide First of all, after cleaning and coating sealant, should

Mount guide

First of all, after cleaning and coating sealant,
should ensure

a good seal interfaces
Adjust the transmission gear selector position to
Neutral
Fasten the bolts
Assemble the release cable
Слайд 58

Remove cover Select shaft must be adjusted to the self-locking pole

Remove cover
Select shaft must be adjusted to the self-locking pole position,

then press it down, such as the right picture. Hear the "click," engagement is finish.
Assemble the cover

Assemble select shaft

Слайд 59

Fault code

Fault code

Слайд 60

Fault code

Fault code

Слайд 61

Trouble-shooting and solutions

Trouble-shooting and solutions

Слайд 62

Problem I: The vehicle shivers noticeably upon releasing the accelerator pedal

Problem I: The vehicle shivers noticeably upon releasing the accelerator pedal

at the first, second or third gear or slightly depressing the brake pedal, with low comfort level.
Failure code: P0500 (Vehicle speed sensor failure)
Testing and solution: Start the engine, and use the dianalyzer software to collect the data at real time. The vehicle speed signal is detected in TCU, but none in ECU. It is judged that the harness from the sensor to the ECU fails.
By testing with a multi-meter, it is found that TCU Pin 36 and ECU Pin 44 are in closed circuits. So ECU is in poor contact with its interface. Slightly bend the ECU Pin 44, and after connection, start the engine. The problem is thereby solved.
Слайд 63

Problem II: The transmission failure lamp is lit during movement, and

Problem II: The transmission failure lamp is lit during movement, and

the failure code P0715 (friction disc revolution sensor open circuit) is indicated, with the gearshift disabled.
Testing and solution: Revolution signal failure; TCU issues the gear locking command. Remove the revolution sensor, and add a 0.2mm shim. Thereafter, upgrade TCU data to its latest version （CAA05QN0）, and carry out the gear self-learn and clutch engagement point self-learn.

Add a 0.2mm shim here.

Слайд 64

Problem III: Friction disc revolution sensor failure; the gear is locked

Problem III: Friction disc revolution sensor failure; the gear is locked

at the first/second gear, allowing no shift to higher gears. After the failure code is eliminated and the self-learn conducted, this problem appears again later.
Causes:
1.Disproportionate speed ratio: Under certain operating conditions (for example, from first gear to the reverse gear, or from the reverse gear to the neutral gear), the radial run-out may occur on the shaft on which the signal wheel is mounted in the transmission, leading to the abnormality of signals collected by the clutch speed sensor. This case may bring an incorrect proportion among the engine revolution, clutch revolution and vehicle speed, consequently resulting in the wrong report by TCU and the activation of the safe operation mode.
2. No signals from the clutch revolution sensor: Under certain operating conditions (for example, from first gear to the reverse gear, or from the reverse gear to the neutral gear), the severe radial run-out may occur on the shaft on which the signal wheel is mounted in the transmission, leading to the mutual interference between the signal wheel and the senor and also the damages of the senor, which further causes no signal output, to consequently result in the wrong report by TCU and the activation of the safe operation mode.
3. Serious skidding of the clutch: Owing to the serious wear of the clutch, there is a significant deviation in the proportion among the engine revolution, clutch revolution and vehicle speed under certain working conditions.
Слайд 65

4. Clutch position sensor failure (in this case, P1810 and P0715

4. Clutch position sensor failure (in this case, P1810 and P0715

will be indicated at the same time): Some vehicles are not made accessible to such a technical upgrade that a waterproof pad is provided for the clutch position sensor, which leads to the water ingress into the sensor, consequently resulting in this problem.
5. transmission internal failure, for example, the disabled gear locking function (in this case, P1818 or P0720 will be indicated at the same time): The speed ratio does not conform to the actual gear.
6. Other electric failures (may be accompanied by the failure code 1810): The harness is damaged or improperly earthed.
Solutions:
Renew TCU, and calibrate it to CAA04OH0 version: This problem corresponds to Problem I (the disproportionate speed ratio), and the solution is to largely increase the judgment threshold value.
Repair of transmission: If there is interference between the transmission signal wheel and the senor, and the sensor is damaged, the recovery by software is impossible, but the only way is to repair the transmission.
3. Water ingress in the clutch position sensor: Replace this sensor and provide waterproof pad (this pad will be supplied together with the sensor).
4. Clutch skidding: Replace the clutch, and use a diagnoser to initiate the TCU.
Слайд 66

Problem IV: Oil leakage in the oil pot Causes: 1. The

Problem IV: Oil leakage in the oil pot
Causes: 1. The

vent on the pot cover is blocked: during the service, in the oil pot, the negative pressure will be produced at low temperature while positive pressure at high temperature, leading to the expansion and breakage of the pot.
2. The sealing ring on the pot cover is not removed after it is fitted: leading to the blocking of the vent. This problem is frequently reported in the after-sales service.

Solutions:
1. Replacement of the oil pot cover
2. The sealing ring on the pot must be removed: This ring is used to prevent the oil leakage in the speed selector during transportation, and must be removed after the pot is fitted onto the vehicle; otherwise, the pressure in the pot may become abnormal, which will consequently influence the oil return, or increase air bubbles in the hydraulic oil to adversely affect the system pressure.

Cover blocked

Cover not blocked

Sealing ring not removed

Слайд 67

Problem V: There is trip stop or failure of gear engagement

Problem V: There is trip stop or failure of gear engagement

in the vehicle, and the failure code P1810 or P1743 is indicated.
Causes:
At the initial design of AMT, neither Chery nor Marelli has taken waterproof requirements into account. In actual application, the speed selector is mounted at a low position, which usually brings the sensor to be in contact with water spattered from the road. The entry of water into the sensor may cause abnormal signal output.

Solution: Marelli has conducted engineering modification, namely, providing a sealing ring in the clutch position sensor to improve its waterproof performance.

Add a sealing ring here

Слайд 68

Problem VI: One of direct gears is always missing in the

Problem VI: One of direct gears is always missing in the

operation, for example, the transmission directly moves from the second gear to the fourth gear, with the third gear skipped, but can directly move from the fourth gear to the third gear. Sometimes, a failure code P1810 will be indicated; when the vehicle is stopped, all gears will work correctly.

Causes:
1. The synchronizer of the transmission is excessively worn, and can’t work. If serious , the sound of collision of teeth may be heard. This case mostly occurs in vehicles produced prior to 2007.
2. The transmission synchronizer is separated.
3. One of direct gears is always missing during the operation.
Solution:
1. In the first case, relevant parts must be replaced.
2. In the second case, only the reassembly of the transmission is required.

Слайд 69

Problem VII 1. No depression of the accelerator pedal is required

Problem VII
1. No depression of the accelerator pedal is required

in the engagement of the first gear when the vehicle moves.
2. The vehicle shivers seriously at the beginning of movement, but restores its normal operation after the move-up.
Causes:
1. The clutch engagement point self-learn is not conducted, or the system is not disconnected from the power supply after the self-learn is finished. (Note: The data can be only successfully written into TCU 10s after the ignition switch is turned off after the each self-learn is finished.)
2. The clutch is not replaced until it skids due to the excessive wear. After the replacement, TCU is not initialized via a diagnoser.
3. The clutch friction plate is uneven, including new parts. (This case may occur at self-learn of the engagement point. The return values after each learn are different, which can be used for judgment.)
4. There is water ingress in the clutch position sensor.
5. The clutch and TCU calibrations are misused.
Solutions:
1. Relevant personnel in the service station shall learn how to use the diagnoser. Each time after any part is replaced, the self-learn (clutch engagement point self-learn, gear self-learn) shall be conducted. The power supply shall be disconnected for 10s after the self-learn.
2. Replace the Valeo clutch and upgrade the TCU calibration to CAA05QM5: CAA04QHO is used together with Changchun Yidong clutch, while CAA05QM5 is used together with Valeo clutch. No confusion is allowed; otherwise, the vehicle may move up automatically, or does not move after refueling, or gears can’t be shifted smoothly.
Слайд 70

Problem VIII: After the transmission is shifted to the first gear

Problem VIII:
After the transmission is shifted to the first gear

and the vehicle is stopped, the neutral gear is engaged automatically and immediately.
Possible causes:
1. The cab door lamp switch is disabled. (Move the roof lamp switch to its middle position, and if the lamp is lit suddenly, this fault can be identified.)
Solutions:
1. Replace the door switch.
Слайд 71

Thank you very much!

Thank you very much!

Слайд 72

Pratice Check resistence of each solenoid valve。 Remove gear selection/gear engage

Pratice

Check resistence of each solenoid valve。
Remove gear selection/gear engage sensor/ clutch

sensor and how it works
Perform how to check the oil level.
Gear and clutch self-learn
- Предыдущая
Мастер-класс по космической живописи Встреча в космосе
Следующая -
Политическая система общества

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