TE transmissions training program

Август 12, 2022

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TE transmissions training program

Содержание

2. Basic connverter /transmission theory movie
3. TE transmissions Electronic controlled modulation Clutch overlap control Inching control
4. Electronic controlled modulation (E.C.M.) Controller
5. Modulated build up of pressure in the clutch Electronic controlled modulation (E.C.M.) Controller different modulation pressure
6. Modulated build up of pressure in the clutch Controller different modulation energy different modulation in power
7. Overlap control Controller
8. Electronic controlled inching Controller
9. TE13/17 transmission
10. TE 13 & TE17
11. 340 F T E 13 3 XX - XX Converter specific ¨dash number¨ Model Wheel Group
12. Converter/Transmission Oil System Capacity 16,5L Lines and cooler not included Oil Type ? Only ATF Dexron
13. Ratios Technical specifications TE 13 & TE17
14. Temperature specifications Normal operating temperature 70 - 120°C at temperature check port 71 converter out Maximum
15. At 2200 RPM 24 – 29 Bar Converter : 1.0 -4.0 l/m Each range clutch :
16. Safety valve cracking pressure 7,5 bar Converter out pressure (to cooler) 3.0 – 3.5 bar. at
17. Pump flow At 2200 RPM : 90 to 110 lpm TE 13 & TE17
18. Electrical specifications TE 13 & TE17
19. HYDRAULIC COOLER LINES SPECIFICATIONS. Minimum 19 mm internal diameter for lines and fittings. Suitable for operation
20. TE 13 & TE17
21. Additional signals Speed sensors Engine speed combined with oil temperature pick up located at pump gear
22. Wiring schematics TE 13 & TE17 Total neutral
23. Wiring schematics TE 13 & TE17
24. Control valve Variable force solenoids (VFS) VFS0 for forward VFS1 for 2nd VFS2 for reverse VFS3
25. Solenoid activation TE 13 & TE17
26. Electronic controlled modulation (E.C.M.) TE13-17
27. Operation of transmission TE 13 & TE17 The transmission is controlled by an APC200 box. This
28. Operation of transmission TE 13 & TE17 Range selection When 1 st clutch is selected ,
29. Operation of transmission TE 13 & TE17 Total neutral selection Total neutral is only selected by
30. TE 13 & TE17 37 90 -110 lpm @ 2200 RPM
31. Neutral TE 13 & TE17
32. TE 13 & TE17 90 -110 lpm @ 2200 RPM 37
33. TE 13 & TE17
34. TE 13 & TE17 90 -110 lpm @ 2200 RPM 37
35. TE 13 & TE17
36. TE 13 & TE17 90 -110 lpm @ 2200 RPM 37
37. TE 13 & TE17
38. TE 13 & TE17 90 -110 lpm @ 2200 RPM 37
39. TE 13 & TE17
40. Check ports TE 13 & TE17
41. Check ports TE 13 & TE17 Port 42 2nd clutch Port 46 Pressure check port solenoid
42. Check ports TE 13 & TE17 To cooler Port 37 Safety valve pressure Safaty valve mmmpressure
43. Check ports TE 13 & TE17 Safaty valve pressure Engine
44. Check ports TE 13 & TE17 Port 46 Rev. clutch Rev. clutch Pump Pressure Port 35
45. Check ports TE 13 & TE17 Pressure To cooler Port 32
46. Check ports Control valve TE 13 & TE17 VFS REV Port 55 VFS 2nd Port 51
47. Control valve installation instruction Removing the valve 1.Make sure that the area around the valve is
48. Control valve installation instruction Installing the valve 1.Unscrew the 7bolts (marked green with a star on
49. 27* 26* 15* 16 18 25 24 22 12 20 21 23* 5 4 11 19
50. Control valve installation instruction TE 13 & TE17 15 9 8 7 10 11 12 13
51. Speed sensor installation TE 13 & TE17 Combined engine speed sensor and temperature Turbine, drum and
52. Speed sensor installation TE 13 & TE17
53. Speed sensor installation TE 13 & TE17
54. Speed sensor installation TE 13 & TE17
55. TE32 transmission
56. Overview TE32 TE32 : short drop 4 speed Fwd/Rev
57. TE32 Transmission Layout
58. 1X.X T E 32 4 X X - XX Converter specific ¨dash number¨ Model Wheel Group
59. TE32 Technical specifications Ratio TE32418
60. TE32 Technical specifications Output flange rotation – (transmission forward clutch engaged) Model Output Short Drop Opposite
61. Speed pick-up : - Engine speed combined with temperature located on pump drive gear Turbine speed
62. TE32 Technical specifications Converter/Transmission Oil System Capacity (Approximate: measured at 600 RPM input speed and oil
63. Normal operating temperature 70 - 120°C at temperature check port converter out Maximum allowed transmission temperature
64. At 1800 RPM 20.5 - 24.5 bar Fwd/Rev max 4 l/min 1st max 9.2 l/min 2nd/3rd/4th
65. Savety valve cracking pressure 8.8-9.6 bar Converter out pressure (to cooler) 5 bar min. at 2000
66. Variable force solenoids(VFS) VFS 2nd/4th - VFS 1st/3rd - VFS Fwd -VFS Rev Coil resistance 4.35
67. Speed sensors Type Magneto resistive sensor. Sensing distance up to 1.8 mm Sensor signal generates a
68. HYDRAULIC COOLER LINES SPECIFICATIONS. Minimum 32 mm internal diameter for lines and fittings. Suitable for operation
69. TE32
70. Additional signals Speed sensors Engine speed combined with oil temperature pick up located at pump gear
71. Wiring schematics TE 32
72. Wiring schematics TE 32
73. TE32 Solenoids activated Transmission gear Forward 4 Forward 3 Forward 2 Forward 1 Neutral 4 Neutral
74. Electronic controlled modulation (E.C.M.) TE27-32
75. Operation of transmission TE32 The transmission is controlled by an APC200 box. This unit has a
76. Operation of transmission TE32 Range selection When 1 st clutch is selected , the 3rd/1st and
77. Operation of transmission TE32 Neutral selection When neutral is selected (1st, 2nd, 3rd or 4th) ,
78. Operation of transmission TE32 Pressure switch The control valve also has a pressure switch installed between
79. TE32 VFS 1/3 VFS 2/4
80. TE32 Total neutral
81. TE32 VFS 1/3 VFS 2/4
82. TE32 Forward 1st
83. TE32 VFS 1/3 VFS 2/4
84. TE32 Forward 2nd
85. TE32 VFS 1/3 VFS 2/4
86. TE32 Forward 3rd
87. TE32 VFS 1/3 VFS 2/4
88. TE32 Forward 4th
89. TE32 VFS 1/3 VFS 2/4
90. TE32 Reverse 1st
91. Connections - top view To remote filter from pump 2 To remote filter from pump 1
92. Pressure check 1st clutch port 41 Oil level check port 1/4 NPT Checkports - left view
93. Checkports - right view TE32 Reg. Pressure port 31 Converter In Pres port 37 To cooler
94. Checkports - front view TE32 2nd clutch port 42 Rev clutch port 46 4th clutch port
95. Checkports - rear view TE32 From filter 1 Conv out press port 32 Temp switch Converter
96. Speed sensor location TE32 Engine speed & transmission temperature sensor Drum speed sensor Output speed sensor
97. Checkports control valve 66/61 49/51 F 54 59 58 31b 57 65 55 56 50/52 60/62
98. Control valve replacement Removing the valve 1.Make sure that the area around the valve is clean
99. TE32 20 18 19 17 15 3 7 11 13 16 14 2 5 10 12
100. TE 32 Speed sensor installation
101. TE 32 Speed sensor installation
102. TE 32 Speed sensor installation
103. APC200 CONTROLLER
104. Overview Link with the transmission APC200 APC200 display modes APC200 diagnostics System calibration
105. Transmission Input signals Speed sensors Engine speed Turbine speed Drum speed Output speed Pressure feedback switch
106. Control valve Proportional solenoids (VFS = “Variable Force Solenoid”) VFS0 for forward VFS1 for 2nd/4th (if
107. APC 200 Device for shifting Spicer Off Highway Products ECM powershift transmissions (TE transmissions) ECM ->
108. Block diagram APC 200 Controller
109. Block diagram APC 200 : inputs Controller 10 digital inputs 6 (7) analogue inputs Ani0 Pressure
110. Block diagram APC 200 : outputs (1/3) Controller 4 digital outputs Do0 RSP Drive Solenoid +
111. Block diagram APC 200 : outputs (2/3) Controller Do0 and Do3 : RSP Drive Solenoid =
112. Block diagram APC 200 : outputs (3/3) Controller 7 analogue outputs Closed loop current regulation for
113. Block diagram APC 200 : example Controller
114. PSU = Power Supply Unit Version : 12V or 24V Two power lines PPWR : permanent
115. Bootstrap and reset circuit Bootstrap: Special mode, controller wants to receive serial data, to program the
116. Functions Manual / automatic shifting Electronic modulation Overlap control Electronic inching Start 1st / 2nd Limit
117. Functions on wiring diagram Controller
118. Communication CAN 2.0 B Communicate with different controllers and PC RS 232 To flash a new
119. Parameter setting 1 approved drive-line = 1 APT-file Approved drive-line = Specific type of vehicle +
120. Display 4 red 7-segment LED digits 3 status LED lamps D -> yellow, test modes E
121. Display modes Controller
122. “GPOS” display Reflects the actually engaged transmission direction and range Display modes Controller
123. Display modes “VSPD” display Shows the vehicle speed in km/h or MPH, with a resolution of
124. “dist” display Shows the distance travelled in km or miles, with a resolution of 0.1 km
125. Display modes Controller
126. “CPOS” display Reflects the actually shiftlever position Display modes Controller
127. “Espd” display Shows the measured engine speed in RPM Display modes Controller
128. “Tspd” display Shows the measured turbine speed in RPM Display modes Controller
129. “Ospd” display Shows the measured output speed in RPM Display modes Controller
130. “Srat” display Reflects the current speed ration ( Tspd / Espd ), which is an important
131. “TQ I” display Reflects the measured torque (turbine torque) at the transmission input side in Nm
132. “Ttmp” display Shows the transmission sump temperature in °C Display modes Controller
133. “Ctmp” display Shows the Converter out temperature in °C Display modes Note : due that the
134. Display modes Controller
135. “Err” display Shows all existing error codes (none blinking error code) and error codes detected in
136. Error codes list Controller
137. Diagnostics Controller
138. Diagnostics Note : for the firmware version, the display is using a scrolling text moving to
139. Diagnostics Digital input test Digital input reference 0 1 2 3 4 5 8 9 6
140. Diagnostics Analog input test 1st value (kΩ or V) of the 1st 4 analog inputs No
141. Diagnostics Speed sensor test C informs the sensor is a current sensor, value is expressed in
142. Diagnostics Output test Analog output Current of 997 mA Analog output 3 on wire 8 Note
143. Diagnostics Voltage test Voltage switched power Voltage sensor power supply 22.7 volt 8.1 volt Controller
144. Calibration APC200-Transmission Menu structure overview Transmission calibration (clutch filling) Heat mode Calibration of the analogue inputs
145. Menu structure overview
146. Transmission calibration (clutch filling) Introduction What? Is determining volume of oil that is needed to fill
147. Transmission calibration (clutch filling) Introduction How ? Direction (FWD/REV)clutches are calibrated by fully activating 2nd range
148. Transmission calibration (clutch filling) Introduction A transmission calibration has to be performed : when the vehicle
149. Transmission calibration (clutch filling) How ? (1/3) Enter the calibration menu by pressing the S-button on
150. Transmission calibration (clutch filling) How ? (2/3) If all these conditions are met, the APC will
151. Transmission calibration (clutch filling) How ? (3/3) When all clutches have been calibrated, the APC200 displays
152. Heat mode (1/3) Goal : warm up transmission in a fast way (stall) Specific to heat
153. Heat mode (2/3) Perform the following scheme to warm up the transmission : When the sumpt°
154. Heat mode (3/3) Note : When the converter out temperature would exceed 120°C, the engine speed
155. Other messages during calibration (1/5) 1. Calibration condition messages
156. Other messages during calibration (2/5) 1. Calibration condition messages (part 2)
157. Other messages during calibration (3/5) 2. Calibration error messages E1.25 : during calibration, early touch detect.
158. Other messages during calibration (4/5) 2. Calibration error messages continued E1.10 : during calibration, shift inhibit.
159. Other messages during calibration (5/5) 2. Calibration error messages continued E2.14 : calibration failed ,fill time
160. Calibration of analogue imputs Example : brake pedal (1/4) Enter the calibration menu by pressing the
161. Calibration of analogue imputs Example : brake pedal (2/4) Then, the APC asks for the mid
162. Calibration of analogue imputs Example : brake pedal (3/4) Finally, the APC asks for the full
163. Calibration of analogue imputs Example : brake pedal (4/4)
164. TE transmission field experience TE13/17 field campaign Speed sensor changes Case studies
165. TE transmission field experience TE13/17 field campaign Clutch end plate snapring jumps out of groove, causing
166. TE transmission field experience Speed sensor changes. Cracked speedsensor housing causes potting material to swell which
167. TE transmission field experience Case studies 1. Vehicle stops error 00.50 action 1 : Change APC
168. TE transmission field experience Case studies 2. Vehicle has a delay when downshifting, no error codes
169. TE transmission field experience Case studies 3. Tel call : machine sometimes shows 20.60error code action
170. TE transmission field experience Case studies 4. Tel call : unit shocks when 4th is selected
171. TE transmission field experience Case studies 5. Tel call : failure code 20/61 with engine not
172. TE transmission field experience Case studies 6. Tel call : error code 42/04 (speed ratio (Turbine/Output)
174. Скачать презентацию

Слайд 2

Basic connverter /transmission theory
movie

Слайд 3

TE transmissions
Electronic controlled modulation
Clutch overlap control
Inching control

Слайд 4

Electronic controlled modulation (E.C.M.)
Controller

Слайд 5

Modulated build up of pressure in the clutch
Electronic controlled modulation (E.C.M.)
Controller

different modulation pressure to time.

Слайд 6

Modulated build up of pressure in the clutch
Controller
different modulation
energy
different modulation in

power

Слайд 7

Overlap control
Controller

Слайд 8

Electronic controlled inching
Controller

Слайд 9

TE13/17 transmission

Слайд 10

TE 13 & TE17

Слайд 11

340 F T E 13 3 XX - XX
Converter specific ¨dash

number¨
Model Wheel Group
Converter freewheel
(optional)
Engine mount specific ratio/drop
With converter
numbers of gears
Electronically controlled model
Model number
Transmission input rating x
100Nm

Model designation

TE 13 & TE17

Слайд 12

Converter/Transmission Oil System
Capacity 16,5L Lines and cooler not included
Oil Type ? Only

ATF Dexron III approved
viscosity at 40°C: 33 → 38 cSt
viscosity at 100°C: 7 → 8 cSt
Oil change? 1000 hours
Filtration ? integral spin on change every 1000 hours first change or after rebuild : 100 hours

Technical specifications

Слайд 13

Ratios
Technical specifications
TE 13 & TE17

Слайд 14

Temperature specifications
Normal operating temperature 70 - 120°C at temperature check port

71 converter out
Maximum allowed transmission temperature 120° C

Pressure specifications

Transmission regulator pressure :
25 -30 bar at 2200RPM

TE 13 & TE17

Слайд 15

At 2200 RPM 24
–
29 Bar
Converter : 1.0 -4.0 l/m
Each range

clutch : 1.5-4.5 l/m
Each directional clutch : 5.5-9.0 l/m

Clutch pressures

Filter bypass

valve set at 3.9 bar

Lube pressure

In neutral 0 : 2.8-3.4 Bar at 80 l/m flow
In FWD 0 – REV 0 : 1.2-1.8 Bar at 80l/m flow

Internal leakage

TE 13 & TE17

Слайд 16

Safety valve
cracking pressure 7,5 bar
Converter out pressure (to cooler)
3.0 – 3.5

bar. at max stall speed

TE 13 & TE17

Слайд 17

Pump flow
At 2200 RPM : 90 to 110 lpm
TE 13 &

TE17

Слайд 18

Electrical specifications
TE 13 & TE17

Слайд 19

HYDRAULIC COOLER LINES SPECIFICATIONS.
Minimum 19 mm internal diameter for lines and

fittings.
Suitable for operation from ambient to 120° C continuous operating temperature.
Must withstand 30 bar continuous pressure and 45 bar intermittent surges.
Conform SAE J1019 and SAE J517, 100RI.

Hydraulic cooler line specifications

TE 13 & TE17

Слайд 20

TE 13 & TE17

Слайд 21

Additional signals
Speed sensors
Engine speed combined
with oil temperature pick up

located at pump gear
Turbine speed located on input gear forward
Drum speed located on low drum
Output speed located on output gear
Pressure feedback sensor
Oil temperature
Converter out temperature switch

TE 13 & TE17

Слайд 22

Wiring schematics
TE 13 & TE17
Total
neutral

Слайд 23

Wiring schematics
TE 13 & TE17

Слайд 24

Control valve
Variable force solenoids (VFS)
VFS0 for forward
VFS1 for 2nd
VFS2 for reverse
VFS3

for 1st / 3rd
Pressure reducer
Pressure intensifiers for each VFS

TE 13 & TE17

Слайд 25

Solenoid activation
TE 13 & TE17

Слайд 26

Electronic controlled modulation (E.C.M.)
TE13-17

Слайд 27

Operation of transmission
TE 13 & TE17
The transmission is controlled by an

APC200 box. This unit has a microprocessor that receives certain inputs (gear selector position, speed sensors,…), which are processed and will give output signals to the control valve.
Operation of the valve
Regulated pressure (25-30 bar) is directed to the total neutral shift spool and the pressure reducer that will decrease the pressure to 10 bar.
This reduced pressure will be used to supply the variable force solenoids(VFS), total neutral solenoid and 3rd/1st solenoid.
The VFS will give an output pressure curve from 0 to 6 bar proportional to a current from 1000 mA to 0 mA. The pressure intensifiers with a ratio of 5:1 will multiply this pressure curve so that a curve from 0 to 30 bar is available for each directional and range clutch. Between each VFS a pressure intensifier is placed and an accumulator to dampen any hydraulic vibration.
Directional selection
When a direction (forward or reverse) is selected , total neutral solenoid is activated and the required directional VFS will provide a pressure rise from 0 to 6 bar. The directional clutch is then fed with modulated pressure supplied through the pressure intensifier.

Слайд 28

Operation of transmission
TE 13 & TE17
Range selection
When 1 st clutch is

selected , the 3rd/1st solenoid is activated and 1st/3rd VFS will provide a pressure curve from 0 to 6 bar. The pressure intensifier will multiply this pressure and will feed 1st clutch via the activated 3rd/1st spool.
When 2nd clutch is selected the 2nd VFS will provide a pressure curve from 0 to 6 bar . this pressure is fed to 2 nd clutch via the pressure intensifier, at the same time 1st/3rd VFS will decrease pressure from 6 to 0 bar, thus allowing the release of 1 st clutch in a controlled fashion, which will provide clutch overlap.
When 3rd clutch is selected the 3rd/1st solenoid is not activated. The 1st/3rd VFS will provide a pressure curve from 0 to 6 bar and will feed 3rd clutch via a pressure intensifier and the deactivated 3rd/1st spool. At the same time the 2nd VFS will decrease pressure from 6 to 0 bar providing the clutch overlap.
Neutral selection
When neutral is selected (1st, 2nd or 3rd) , the total neutral solenoid is activated and the VFS’s for forward and reverse are fed by a 1000mA current, which will result in a 0 bar output, thus providing 0 bar pressure to the forward and reverse clutch. The range clutches 1, 2 or 3 remain activated by their respective VFS.

Слайд 29

Operation of transmission
TE 13 & TE17
Total neutral selection
Total neutral is only

selected by the APC200 in case a severe error is detected which will cause a shutdown
When total neutral is selected, the total neutral solenoid is not activated and as a result no pressure is supplied to the pressure intensifiers.
Pressure switch
The control valve also has a pressure switch installed between the total neutral shift spool and the pressure intensifiers supply. This switch will verify that a minimum pressure of 12 bar to the various pressure intensifiers is supplied only when the total neutral solenoid is activated. This information is an input of the APC200 box.
If a pressure is detected below 12 bar the controller will put the transmission in total neutral which causes a shut down.

Слайд 30

TE 13 & TE17
37
90 -110 lpm @ 2200 RPM

Слайд 31

Neutral
TE 13 & TE17

Слайд 32

TE 13 & TE17
90 -110 lpm @ 2200 RPM
37

Слайд 33

TE 13 & TE17

Слайд 34

TE 13 & TE17
90 -110 lpm @ 2200 RPM
37

Слайд 35

TE 13 & TE17

Слайд 36

TE 13 & TE17
90 -110 lpm @ 2200 RPM
37

Слайд 37

TE 13 & TE17

Слайд 38

TE 13 & TE17
90 -110 lpm @ 2200 RPM
37

Слайд 39

TE 13 & TE17

Слайд 40

Check ports
TE 13 & TE17

Слайд 41

Check ports
TE 13 & TE17
Port 42 2nd clutch
Port 46
Pressure check

port solenoid

Port 31
Pressure check port regulator

Port 43 3rd clutch

From cooler

Port 71
Converter out temp.

Port 41 1st clutch

Magnetic drain
plug

Слайд 42

Check ports
TE 13 & TE17
To cooler
Port 37
Safety valve
pressure
Safaty valve
mmmpressure
Safaty

valve
pressure

Слайд 43

Check ports
TE 13 & TE17
Safaty valve
pressure
Engine

Слайд 44

Check ports
TE 13 & TE17
Port 46
Rev. clutch
Rev. clutch
Pump
Pressure
Port 35

Слайд 45

Check ports
TE 13 & TE17
Pressure
To cooler
Port 32

Слайд 46

Check ports Control valve
TE 13 & TE17
VFS REV
Port 55
VFS 2nd
Port

VFS 1st/3rd
Port 50/52

VFS FWD
Port 54

Слайд 47

Control valve installation instruction
Removing the valve
1.Make sure that the area around

the valve is clean and that no dirt can fall into the valve during the disassembly procedure.
2.Unscrew the 7 bolts (marked green with a star on the drawing 1) until you feel that the tension is out of the bolt. Do not remove them!
3.Unscrew the 20 other bolts (marked blue on drawing 1) some turns. When all bolts are loose, you should be able to move the valve a bit
4.Remove 2 bolts (marked blue on drawing 1 )and replace with aligning studs.
5.Remove the 15 bolts (marked pink on drawing 2)
6.Remove the remaining bolts (marked blue on drawing 1) and remove valve, note the sandwich plate between valve and housing

TE 13 & TE17

Слайд 48

Control valve installation instruction
Installing the valve
1.Unscrew the 7bolts (marked green with

a star on drawing 1) untill all tension is out of the bolt. Do not remove them!
2. Using aligning studs, install valve, sandwich plate and a new gaskets.
3. Hand tighten all bolts(marked blue and green on drawing 1) according to the sequence you find on the drawing 1.
4. Torque all bolts in the same sequence as on drawing 1 to a torque of 25Nm
5. Hand tighten the 15 bolts(marked pink on, drawing 2 ) and torque to 25Nm to the sequence as shown on drawing 2
Retorque all bolts (drawing 1 and 2) again to the sequences as shown
7. Recalibrate the transmission

TE 13 & TE17

Слайд 49

27*
26*
15*
16
18
25
24
22
12
20
21
23*
5
4
11
19
13
6
1*
3
10*
9*
14
7
2
8
17
Control valve installation instruction
TE 13 & TE17

Слайд 50

Control valve installation instruction
TE 13 & TE17
15
9
8
7
10
11
12
13
14
6
5
4
3
2
1

Слайд 51

Speed sensor installation
TE 13 & TE17
Combined engine speed sensor and temperature
Turbine,

drum and output (x3)speed sensor

Слайд 52

Speed sensor installation
TE 13 & TE17

Слайд 53

Speed sensor installation
TE 13 & TE17

Слайд 54

Speed sensor installation
TE 13 & TE17

Слайд 55

TE32 transmission

Слайд 56

Overview
TE32
TE32 :
short drop
4 speed Fwd/Rev

Слайд 57

TE32
Transmission Layout

Слайд 58

1X.X T E 32 4 X X - XX
Converter specific ¨dash number¨
Model

Wheel Group specific ratio
Mounting type
Engine mount =T even n° :long drop
Remote mount =RT odd n° : short drop
Mid mount =MT numbers of gears
Electronically controlled model transmission input rating ( x 100Nm)

Model designation

Слайд 59

TE32
Technical specifications

Ratio TE32418

Слайд 60

TE32
Technical specifications

Output flange rotation – (transmission forward clutch

engaged)
Model Output
Short Drop Opposite
Long Drop Same
Drop :
- Long Drop 624.6mm
- Short Drop 317.8mm

Слайд 61

Speed pick-up :
- Engine speed combined with temperature located on

pump drive gear
Turbine speed located on input gear
- Drum speed located on forward drum
- Output speed located on output shaft gear

Technical specifications

Слайд 62

TE32
Technical specifications

Converter/Transmission Oil System
Capacity (Approximate: measured at

600 RPM input speed and oil temp between 60 and 70°C, neutral) ? Short drop 60L ? Long drop 75L Lines and cooler not included
Oil Type ? ONLY ATF Dexron III approved
viscosity at 40°C: 33 → 38 cSt
viscosity at 100°C: 7 → 8 cSt
flash point: min 160°C
pour point: max –42°C
Oil change ? 1000 hours
Filtration ? 2 x Spin On
change every 1000 hours
first change: 100 hrs or after rebuild

Слайд 63

Normal operating temperature 70 - 120°C at temperature check port converter

out
Maximum allowed transmission temperature 120° C

TE32

Temperature specifications

Transmission regulator pressure :
600 RPM 22.5-24.5 bar
2200 RPM 23.5-25.5 bar

Pressure specifications

Слайд 64

At 1800 RPM 20.5 - 24.5 bar
Fwd/Rev max 4 l/min
1st max

9.2 l/min
2nd/3rd/4th max 4 l/min

TE32

Clutch pressures

Filter bypass

valve set at 4.1 to 4.5 bar

Lube pressure

0.9 – 1.4 bar at 100 l/min. lube flow.(+/-1000RPM)

Internal leakage @ 1800 RPM

Слайд 65

Savety valve
cracking pressure 8.8-9.6 bar
Converter out pressure (to cooler)
5 bar min.

at 2000 RPM and max. 8.5 bar at no load governed speed.

Pump flow

System pump flow : 108-128 l/min at 2200 RPM.
Lube pump flow : 80-95 l/min at 2200 RPM.

TE32

Слайд 66

Variable force solenoids(VFS)
VFS 2nd/4th - VFS 1st/3rd - VFS Fwd -VFS

Rev
Coil resistance 4.35 ± 0.35 OHMS. at 25° C
On/Off Solenoids
Total neutral , 1st/3rd & 2nd/4th range solenoids
Coil resistance 12V - 28 ± 2 . OHMS at 20° C
Coil resistance 24V - 87 ± 2 . OHMS at 20° C

TE32

Electrical specifications

Слайд 67

Speed sensors
Type Magneto resistive sensor.
Sensing distance up to 1.8 mm
Sensor

signal generates a square current with a fixed amplitude changing between 7 and 14 mA.

TE32

Drum speed sensor

Turbine and output (x2) speed sensor

Combined engine speed sensor and temperature

Слайд 68

HYDRAULIC COOLER LINES SPECIFICATIONS.
Minimum 32 mm internal diameter for lines and

TE32

Hydraulic cooler line specifications

Слайд 69

TE32

Слайд 70

Additional signals
Speed sensors
Engine speed combined
with oil temperature pick up

located at pump gear
Turbine speed located on input gear
Drum speed located on forward drum
Output speed located on output gear
Pressure feedback sensor
Oil temperature
Converter out temperature switch

TE 32

Слайд 71

Wiring schematics
TE 32

Слайд 72

Wiring schematics
TE 32

Слайд 73

TE32
Solenoids activated
Transmission gear Forward 4 Forward 3 Forward 2 Forward 1 Neutral 4 Neutral 3 Neutral 2 Neutral 1 Reverse

4 Reverse 3 Reverse 2 Reverse 1

Activated on /off solenoids Total neutral Total neutral Total neutral, 2/4 selector Total neutral, 1/3, 2/4 selector Total neutral Total neutral Total neutral, 2/4 selector Total neutral, 1/3, 2/4 selector Total neutral Total neutral Total neutral, 2/4 selector Total neutral, 1/3, 2/4 selector

Activated Clutches Forward, 4th Forward, 3rd Forward, 2nd Forward, 1st 4th 3rd 2nd 1st Reverse, 4th Reverse, 3rd Reverse, 2nd Reverse, 1st

Activated VFS’s Reverse, 1/3 Reverse, 2/4 Reverse, 1/3 Reverse, 2/4 Forward, Reverse, 1/3 Forward, Reverse, 2/4 Forward, Reverse, 1/3 Forward, Reverse, 2/4 Forward, 1/3 Forward, 2/4 Forward, 1/3 Forward, 2/4

Слайд 74

Electronic controlled modulation (E.C.M.)
TE27-32

Слайд 75

Operation of transmission
TE32
The transmission is controlled by an APC200 box. This

unit has a microprocessor that receives certain inputs (gear selector position, speed sensors,…), which are processed and will give output signals to the control valve.
Operation of the valve
Regulated pressure (22.5-25.5 bar) is directed to the total neutral shift spool and the pressure reducer that will decrease the pressure to 10 bar.
This reduced pressure will be used to supply the variable force solenoids(VFS), total neutral solenoid , 3rd/1st solenoid and 4th/2nd solenoid.
The VFS will give an output pressure curve from 0 to 6 bar proportional to a current from 1000 mA to 0 mA. The pressure intensifiers with a ratio of 3.5:1 will multiply this pressure curve so that a curve from 0 to 20 bar is available for each directional and range clutch. Between each VFS a pressure intensifier is placed and an accumulator to dampen any hydraulic vibration.
Directional selection
When a direction (forward or reverse) is selected , total neutral solenoid is activated and the required directional VFS will provide a pressure rise from 0 to 6 bar. The directional clutch is then fed with modulated pressure supplied through the pressure intensifier.

Слайд 76

Operation of transmission
TE32
Range selection
When 1 st clutch is selected , the

3rd/1st and 4th/2nd solenoids are activated. The 1st/3rd VFS will provide a pressure curve from 0 to 6 bar. The pressure intensifier will multiply this pressure and will feed 1st clutch via the activated 3rd/1st spool.
When 2nd clutch is selected, The 3th/1st VFS will decrease pressure from 6 to 0 bar, thus releasing the 1 st clutch in a controlled fashion. At the same time the 4th/2nd VFS will provide a pressure curve from 0 to 6 bar . This pressure is fed to 2 nd clutch via the pressure intensifier, which will provide clutch overlap.
When the shift is finalised the 3rd/1st solenoid is deactivated.
When 3rd clutch is selected the 3rd/1st solenoid is not activated. The 1st/3rd VFS will provide a pressure curve from 0 to 6 bar and will feed 3rd clutch via a pressure intensifier and the deactivated 3rd/1st spool. At the same time the 4th/2nd VFS will decrease pressure from 6 to 0 bar providing the clutch overlap.
When the shift is finalised the 4th/2nd solenoid is deactivated.
When 4th clutch is selected , the 4th/2nd VFS will provide a pressure curve from 0 to 6 bar and will feed 4th clutch via a pressure intensifier and the deactivated 4th/2nd spool. At the same time the 3rd/1st VFS will decrease pressure from 6 to 0 bar providing the clutch overlap

Слайд 77

Operation of transmission
TE32
Neutral selection
When neutral is selected (1st, 2nd, 3rd

or 4th) , the total neutral solenoid is activated and the VFS’s for forward and reverse are fed by a 1000mA current, which will result in a 0 bar output, thus providing 0 bar pressure to the forward and reverse clutch. The range clutches 1, 2,3 or 4 remain activated by their respective VFS.
Total neutral selection
Total neutral is only selected by the APC200 in case a severe error is detected which will cause a shutdown
When total neutral is selected, the total neutral solenoid is not activated and as a result no pressure is supplied to the pressure intensifiers.

Слайд 78

Operation of transmission
TE32
Pressure switch
The control valve also has a pressure

switch installed between the total neutral shift spool and the pressure intensifiers supply. This switch has 2 functions :
It will verify that a minimum pressure of 12 bar to the various pressure intensifiers is supplied only when the total neutral solenoid is activated. This information is an input of the APC200 box and if a pressure is detected below 12 bar the controller will put the transmission in total neutral which causes a shut down.
It will verify if only 1 direction clutch and 1 range clutch is activated when the shift is finalised. If detection is made that 2 direction clutches or 2 range cluthes are hydraulically activated it will provide an input signal to the APC200 which will put the transmission in total neutral which causes a shutdown.

Слайд 79

TE32
VFS 1/3
VFS 2/4

Слайд 80

TE32
Total neutral

Слайд 81

TE32
VFS 1/3
VFS 2/4

Слайд 82

TE32
Forward 1st

Слайд 83

TE32
VFS 1/3
VFS 2/4

Слайд 84

TE32
Forward 2nd

Слайд 85

TE32
VFS 1/3
VFS 2/4

Слайд 86

TE32
Forward 3rd

Слайд 87

TE32
VFS 1/3
VFS 2/4

Слайд 88

TE32
Forward 4th

Слайд 89

TE32
VFS 1/3
VFS 2/4

Слайд 90

TE32
Reverse 1st

Слайд 91

Connections - top view
To remote filter from pump 2
To

remote filter from pump 1

Oil fill ¾ npft

TE32

Слайд 92

Pressure check 1st clutch port 41
Oil level check port
1/4 NPT
Checkports

- left view

TE32

Слайд 93

Checkports - right view
TE32
Reg. Pressure port 31
Converter In Pres

port 37

To cooler

Fwd clutch port 45

From cooler

From filter 2

Слайд 94

Checkports - front view
TE32
2nd clutch port 42
Rev clutch
port 46
4th clutch
port 44
Lube

press
port34

Слайд 95

Checkports - rear view
TE32
From filter 1
Conv out press port 32
Temp switch
Converter

out

3rd clutch port 43

Слайд 96

Speed sensor location
TE32
Engine speed & transmission temperature sensor
Drum speed sensor

Output speed sensor

Turbine speed sensor

Слайд 97

Checkports control valve
66/61
49/51
F
54
59
58
31b
57
65
55
56
50/52
60/62
64
TE32

Слайд 98

Control valve replacement

Removing the valve
1.Make sure that the area around the

valve is clean and that no dirt can fall into the valve during the disassembly procedure.
2.Unscrew the 4 hex bolts (marked pink on drawing) until you feel that the tension is out of the bolt. Do not remove them!
3.Unscrew the 15 other bolts (marked blue) some turns. When all bolts are loose, you should be able to move the valve a bit.
4.Remove 2 bolts (marked blue)and replace with aligning studs;
5.Remove the remaining bolts (marked blue) and remove valve
Installing the valve
1.Unscrew the 4 hexbolts (marked pink on drawing) untill all tension is out of the bolt.
Do not remove them!
2. Using aligning studs, install valve and a new gasket.
3. Hand tighten all bolts(21) according to the sequence you find on the drawing.
4. Torque all bolts 2X in the same sequence as on the drawing to 25Nm
5. Recalibrate the transmission

TE32

Слайд 99

TE32
20
18
19
17
15
3
7
11
13
16
14
2
5
10
12
21
8
4
1
6
9

Слайд 100

TE 32
Speed sensor installation

Слайд 101

TE 32
Speed sensor installation

Слайд 102

TE 32
Speed sensor installation

Слайд 103

APC200 CONTROLLER

Слайд 104

Overview
Link with the transmission
APC200
APC200 display modes
APC200 diagnostics
System calibration

Слайд 105

Transmission Input signals
Speed sensors
Engine speed
Turbine speed
Drum speed
Output speed
Pressure feedback switch
Sump

temperature sensor
Converter out temperature switch

Слайд 106

Control valve
Proportional solenoids (VFS = “Variable Force Solenoid”)
VFS0 for forward
VFS1 for

2nd/4th (if used)
VFS2 for reverse
VFS3 for 1st / 3rd
Pressure reducer
Pressure intensifiers for each VFS (“boosters”)
Selector solenoid 1st/3rd
Selector solenoid 2nd/4th(if used)
Total neutral solenoid

Слайд 107

APC 200
Device for shifting Spicer Off Highway Products ECM powershift transmissions

(TE transmissions)
ECM -> Electronic Controlled Modulation
a transmission control technology, available on a range of transmission models
ECI -> Electronic Controlled Inching
to run at very low controlled speed at virtually any engine speed
Overlap control
Self diagnostics
Throttle by Wire – engine control
CAN Network Integration

Controller

Слайд 108

Block diagram APC 200
Controller

Слайд 109

Block diagram APC 200 : inputs
Controller
10 digital inputs
6 (7) analogue inputs
Ani0

Pressure feedback switch (resistance)
Ani1 Sump temperature (resistance)
Ani2 Converter out temperature switch (voltage)
Ani3 Aux f.ex. brake pedal (voltage)
(Ani4 Aux1 of anal. outputs (-pin) (reference voltage 5V))
Ani5 Aux2 of anal. outputs (-pin) f.ex. servo feedback (voltage)
Ani6 Aux3 of anal. outputs (-pin) f.ex. throttle pedal (voltage)
⇒ input 0 to 2 have a fixed use
⇒ input 3, 5 and 6 can be linked to external devices
4 speed inputs

Слайд 110

Block diagram APC 200 : outputs (1/3)
Controller
4 digital outputs
Do0 RSP Drive

Solenoid +
Do1
2nd/4th selector (VFS1 is used for 2nd & 4th) on 4-speed
can be used for warning lamp on 3-speed transm. (Kalmar)
Do2 1st/3rd selector (VFS3 is used for 1st & 3rd)
Do3 RSP Drive Solenoid -

Слайд 111

Block diagram APC 200 : outputs (2/3)
Controller
Do0 and Do3 : RSP

Drive Solenoid = “Total neutral” solenoid
RSP = Redundant ShutDown Path
⇒ need of a fully reliable device to cut off pressure of all clutches in case of important failures (shutdown)
Scheme :

Слайд 112

Block diagram APC 200 : outputs (3/3)
Controller
7 analogue outputs
Closed loop current

regulation for the VFS’s :
VFS0 (fwd)
VFS1 (2nd/4th)
VFS2 (rev)
VFS3 (1st/3rd)
Aux1 to Aux3 : open loop current regulation
VFS4+ (servomotor engine control A)
VFS5+ (servomotor engine control B)
VFS6+ (analogue brake valve)
Remark servomotor : hardware version with H-bridge requested

Слайд 113

Block diagram APC 200 : example
Controller

Слайд 114

PSU = Power Supply Unit
Version : 12V or 24V
Two power lines
PPWR

: permanent power
Connected directly to the battery
SPWR : switched power
Connected via key contact to the battery

Controller

Слайд 115

Bootstrap and reset circuit
Bootstrap:
Special mode, controller wants to receive serial data,

to program the firmware into the program memory
While in bootstrap all output functions are hold off
Start : during power up both buttons pressed
Reset circuit : watchdog & supply supervisor will reset the CPU if either the feedback from the watchdog is outside 10% of timing tolerance or if the CPU has “forgotten” to re-trigger the watchdog trigger

Controller

Слайд 116

Functions
Manual / automatic shifting
Electronic modulation
Overlap control
Electronic inching
Start 1st / 2nd
Limit vehicle

speed
Reduce vehicle speed (by use of an input)
Limit engine speed
Direction change protection (speed and engine RPM)
Declutch (in normal mode : neutral / in inching : offset pressure)
Engine control
Seat orientation
Hydro lever function in neutral

Controller

Слайд 117

Functions on wiring diagram
Controller

Слайд 118

Communication
CAN 2.0 B
Communicate with different controllers and PC
RS 232
To flash a

new firmware (main program)
To download the parameter settings (APT-file)
To edit specific parameters (GDE-file)

Controller

Слайд 119

Parameter setting
1 approved drive-line = 1 APT-file
Approved drive-line =
Specific type

of vehicle + specific engine + specific transmission ( + axle + tires )

Controller

Слайд 120

Display
4 red 7-segment LED digits
3 status LED lamps
D -> yellow,

test modes
E -> yellow, faults
F -> red, APC 200 in reset conditions (f.ex. bootstrap)
2 push buttons
M -> which information group
S -> item within group

Controller

Слайд 121

Display modes
Controller

Слайд 122

“GPOS” display
Reflects the actually engaged transmission direction and range
Display modes
Controller

Слайд 123

Display modes
“VSPD” display
Shows the vehicle speed in km/h or MPH,

with a resolution of 0.1 km/h or 0.1 MPH

Controller

Слайд 124

“dist” display
Shows the distance travelled in km or miles, with

a resolution of 0.1 km or 0.1 miles

Display modes

Note : the distance can be reset by pushing the “s” button during 3
seconds when being in this display mode.

Controller

Слайд 125

Display modes
Controller

Слайд 126

“CPOS” display
Reflects the actually shiftlever position
Display modes
Controller

Слайд 127

“Espd” display
Shows the measured engine speed in RPM
Display modes
Controller

Слайд 128

“Tspd” display
Shows the measured turbine speed in RPM
Display modes
Controller

Слайд 129

“Ospd” display
Shows the measured output speed in RPM
Display modes
Controller

Слайд 130

“Srat” display
Reflects the current speed ration ( Tspd / Espd

), which is an important factor in automatic shifting

Display modes

Controller

Слайд 131

“TQ I” display
Reflects the measured torque (turbine torque) at the

transmission input side in Nm

Display modes

Controller

Слайд 132

“Ttmp” display
Shows the transmission sump temperature in °C
Display modes
Controller

Слайд 133

“Ctmp” display
Shows the Converter out temperature in °C
Display modes
Note :

due that the converter out temperature is measured by a
temperature switch : 50 on the display means below 120° C
150 on the display means above 120° C

Controller

Слайд 134

Display modes
Controller

Слайд 135

“Err” display
Shows all existing error codes (none blinking error code)

and error codes detected in the past (blinking error code).

Display modes

(blinking)

(none blinking)

(end of faults)

Note : when an error is active,
the error led will be blinking

Controller

Слайд 136

Error codes list
Controller

Слайд 137

Diagnostics
Controller

Слайд 138

Diagnostics
Note : for the firmware version, the display is using a

scrolling text moving to the left (continuously).

Display test

Controller

Слайд 139

Diagnostics
Digital input test
Digital input reference
0
1
2
3
4
5
8
9
6
7
10
11
12
13
Note : input 10 till 13 are

the 4 analog
inputs, which could be used as
digital inputs

Digital input 3 on wire 17

input not active

Controller

Слайд 140

Diagnostics
Analog input test
1st value (kΩ or V) of the 1st 4

analog inputs

No . meaning the value is in Ω

A . meaning the value is in Volts

Analog input 3 on wire 47 (47 – 30 pins on connector A = B17)

Controller

Слайд 141

Diagnostics
Speed sensor test
C informs the sensor is a current sensor, value

is expressed in Hz or kHz (ex.: c2.45)

1st value (kHz) of the 4 speed sensors

Speed sensor 0 on wire 22

Controller

Слайд 142

Diagnostics
Output test
Analog output
Current of 997 mA
Analog output 3 on wire

Note : 0 till 6 are
analog
outputs, and
7 till 10 are
digital
outputs.

output active

Digital output 1 (7 – 6 = 1 ) on wire 10

Controller

Слайд 143

Diagnostics
Voltage test
Voltage switched power
Voltage sensor power supply
22.7 volt
8.1 volt
Controller

Слайд 144

Calibration APC200-Transmission
Menu structure overview
Transmission calibration (clutch filling)
Heat mode
Calibration of the

analogue inputs :
Throttle pedal
Brake pedal
Hydro lever
Servo motor

Слайд 145

Menu structure overview

Слайд 146

Transmission calibration (clutch filling) Introduction
What?
Is determining volume of oil that is needed

to fill up the clutch, untill clutch plates start to transfer torque.
This start of torque transfer is the point when the programmed modulation curve starts to act.
Since each transmission, clutch ,valve and VFS has its own tolerances, this fill capacity needs to be determined on newly assembled units and every time any of these components is changed.

Слайд 147

Transmission calibration (clutch filling) Introduction
How ?
Direction (FWD/REV)clutches are calibrated by fully activating

2nd range clutch, and then by gradually increasing the pressure signal from the directionalVFS untill a drop in turbine RPM is noted. This drop in turbine RPM is the touch detection i.e. the point at which the clutch starts to transfer torque. This VFS signal is stored in the memory of the APC200 and is used as the start point for the modulation which was predetermined during prototype testing.
Range clutches (1st, 2nd,3th and 4th ) are calibrated by fully activating forward clutch and then by gradually increasing the pressuure signal to the corresponding range VFS as above.

Слайд 148

Transmission calibration (clutch filling) Introduction
A transmission calibration has to be performed :
when

the vehicle is built at the OEM
after 2000 hours driving in gear (forward or reverse)
when the valve is changed
when an overhaul of the transmission is done
when the transmission is repaired / replaced
when the APC200 is replaced
when firmware and APT-file are updated
Goal :
guarantee the best shift quality during the complete life of the transmission

Слайд 149

Transmission calibration (clutch filling) How ? (1/3)
Enter the calibration menu by pressing

the S-button on the APC200 display for 15 s during power up of the APC :
Push the S-button to trigger the transmission calibration
Before the calibration can be started, a number of conditions need to be fulfilled :
parking brake has to be activated
sump temperature has to be > 60°C (cfr. Heat mode)
engine speed has to be kept within 800 ± 200 rpm (note: if the APC has control over the engine, the speed will be adapted automatically)

Слайд 150

Transmission calibration (clutch filling) How ? (2/3)
If all these conditions are met,

the APC will ask to shift to forward to start the calibration :
The transmission calibration now starts. This is indicated on the APC200-display :
etc. (‘c1’ = clutch 1 I.e. fwd ; ‘M1’ = mode 1 of the calibration)

Слайд 151

Transmission calibration (clutch filling) How ? (3/3)
When all clutches have been calibrated,

the APC200 displays :
This means the calibration has been completed success-fully. Normal duration : about 15 min.
Now switch off the ignition key of the vehicle and let the APC power down.
When restarting the vehicle, the calibration results will be activated automatically.
Important : by selecting REVERSE, the calibration is stopped immediately (APC powers down).

Слайд 152

Heat mode (1/3)
Goal : warm up transmission in a fast way

(stall)
Specific to heat mode :
fwd/rev can be selected while the parking brake is on
disables inching and declutch
the highest gear is forced (3rd or 4th)
How ? Push M-button when ‘trAn’ is on the display :
Push the S-button to trigger the heat mode : actual sumpt°

Слайд 153

Heat mode (2/3)
Perform the following scheme to warm up the transmission

:
When the sumpt° is above 60°C, the indication on the APC display starts blinking.
Now push the M-button until you come back to ‘trAn’

Слайд 154

Heat mode (3/3)
Note : When the converter out temperature would exceed

120°C, the engine speed will be limited to half throttle (if APC has engine control) or the transmission will be forced to neutral (when APC has no engine control).

Слайд 155

Other messages during calibration (1/5)
1. Calibration condition messages

Слайд 156

Other messages during calibration (2/5)
1. Calibration condition messages (part 2)

Слайд 157

Other messages during calibration (3/5)
2. Calibration error messages
E1.25 : during calibration,

early touch detect.
Possible causes :
Too much clutch drag because of too thick oil, recalibrate at higher temperature 90 -100 °C)
Sticking or burnt clutch which causes turbine to drop before pressure is applied,
E1.26 : during calibration,no touch detect.
Possible causes :
VFS faulty (no out put pressure)
Slipping clutch or too high internal leakage

Слайд 158

Other messages during calibration (4/5)
2. Calibration error messages continued
E1.10 : during

calibration, shift inhibit.
Possible causes :
Caused by shutdown e.g; in combination with 20/60 error;
Resolve cause of shutdown before recalibation

Слайд 159

Other messages during calibration (5/5)
2. Calibration error messages continued
E2.14 : calibration

failed ,fill time out.
Possible causes :
Turbine speed does not decrease caused by too high internal leakage and or slipping clutch
E2.16 : calibration failed , turbine pull down too early.
Possible causes :
Faulty turbine speed sensor

Слайд 160

Calibration of analogue imputs Example : brake pedal (1/4)
Enter the calibration menu

by pressing the S-button on the APC200 display for 15 s during power up of the APC.
When having ‘trAn’ on the display, push the M-button until you see
Push the S-button to trigger the brake pedal calibration
The APC now asks for the idle position of the brake pedal (no play in the pedal anymore) :
Push the S-button to confirm the position.

Слайд 161

Calibration of analogue imputs Example : brake pedal (2/4)
Then, the APC asks

for the mid position of the brake pedal (point where the brakes start to operate) :
With hydraulic brakes : this point corresponds to the moment the brakes start ‘sissing’
With dry brakes : push the pedal a little bit, just enough to make the position led stop blinking (if blinking, there is not enough position difference / former position). When doing so, the midpoint is automatically clipped at 5%.
Push again the S-button to confirm the position.

Слайд 162

Calibration of analogue imputs Example : brake pedal (3/4)
Finally, the APC asks

for the full brake position :
Apply full brake and press the S-button to confirm.
If the calibration has been successful, the APC display will show
Now switch off the contact key. The calibration values are automatically stored into the APC200.

Слайд 163

Calibration of analogue imputs Example : brake pedal (4/4)

Слайд 164

TE transmission field experience
TE13/17 field campaign
Speed sensor changes
Case studies

Слайд 165

TE transmission field experience
TE13/17 field campaign
Clutch end plate snapring jumps out

of groove, causing slipping clutch.
Only cluthes in combination with a spacer between endplate and snapring are affected
Fix is a one piece endplate
Population : all units built prior to April 2004

Слайд 166

TE transmission field experience
Speed sensor changes.
Cracked speedsensor housing causes potting material

to swell which results in speed sensor touching the gear.
solved by changing potting material and new speed sensors moulds
Latest version is recognisable by a coloured ring around the housing
Installation : refer to drawing

Слайд 167

TE transmission field experience
Case studies
1. Vehicle stops error 00.50
action 1

: Change APC and calibrate
error E1.25 and E2.14 in 2nd
vehicle only drives in second
action 2 : changed valve and recalibrate
error 20.60 before calibration can start
action 3 : measure cluch pressure ( 0 bar), measure lube pressure (0bar), check pump (OK) found sandwich plate on valve not fitted during exchange, refitted sandwich plate and recalibrate
error E1.25 and E2.14
vehicle only drives in 2nd and blocks in 1st and 3rd
action 4 : replace transmission, faulty unit had a burnt 2nd clutch
Comments, A 20/60 error indicates a system pressure fault, 1st step should be to check system pressure

Слайд 168

TE transmission field experience
Case studies
2. Vehicle has a delay when downshifting,

no error codes
action 1 : replace speed sensors and valve
no improvement
action 2 : test drive confirms that downshiftspeedpoints are lower than on similar vehicle, recalibrate throttle switch
No improvement
action 3 : test drive shows that speed ratio and turbine speeds are correct when down shift is made, indicating a changed converter characteristic which causes loss of tractive effort ; measure stall speed which shows only 1200 RPM i.o. 1800 RPM.
Replace transmission which shows a failed converter freewheel
Comments: the delay was not clearly understood. This case proofs that basic converter/transmission troubleshooting is still valid (measure stall speed),

Слайд 169

TE transmission field experience
Case studies
3. Tel call : machine sometimes shows

20.60error code
action 1 : recalibrate transmission
Error codes : E1.26; E2.14
vehicle symptons : slips in third, oil is contaminated
replace transmission which shows a 3 rd clutch failure
commnets, The 20/60 appeared only when 3rd clutch is selected, this indicates a high 3rd clutch leakage? The symptons confirm this; behind the 20/60 error a 42.05 should have been found, but this was not checked.
A 20/60 only on TE32 can also indicate that two range or direction cluthes are engaged at the same time. Pressure checks should confirm this .

Слайд 170

TE transmission field experience
Case studies
4. Tel call : unit shocks when

4th is selected and goes back to 3rd , no error codes
action 1 check 4th clutch pressure : 5 bar
action remove transmission and send for repair
nothing found wrong, reinstalled unit and is OK… for 2 days when
problem reappears
action 2 : check CPOS and GPOS on APC200
CPOS shows only FWD 3
action 3 : replace cab control
Problem solved
comments : The cab control had an intermittent fault causing 4th to engage and disengage; this causes the VFS 4/2 to rise and fall in pressure quickly which explains the 5 bar measured . The suspected 4 th clutch failure should have been confirmed by error codes.

Слайд 171

TE transmission field experience
Case studies
5. Tel call : failure code 20/61

with engine not running
pressure switch blocked in closed position.
Action 1 : replace pressure switch
problem solved
comment : 20/61 indicates system pressure when it should not be there. Since engine is not running there can be no system pressure indicating a jammed switch
If 20/61 occurs with engine running it is most probably caused by a faulty engine speed sensor which generates 0 RPM

Слайд 172

TE transmission field experience
Case studies
6. Tel call : error code 42/04

(speed ratio (Turbine/Output) too low
action 1 replace turbine speed sensor
Problem solved
comment : too low speed ratio is a wrong speed measurement or a wrong ratio. Since a wrong ratio is least likely the turbine or output speed sensor are at fault
42/05 error (speed ratio too high) can be caused by the same speed sensors if this fault appears in all speeds/directions. If it only appears in one speed or one direction you have to assume a slipping clutch.

TE transmissions training program

Содержание

Basic connverter /transmission theorymovie

TE transmissions Electronic controlled modulationClutch overlap controlInching control

Electronic controlled modulation (E.C.M.)Controller

Modulated build up of pressure in the clutchElectronic controlled modulation (E.C.M.)Controller

Modulated build up of pressure in the clutchControllerdifferent modulationenergydifferent modulation in

Overlap controlController

Electronic controlled inchingController

TE13/17 transmission

TE 13 & TE17

340 F T E 13 3 XX - XX Converter specific ¨dash

Converter/Transmission Oil System Capacity 16,5L Lines and cooler not includedOil Type ? Only

RatiosTechnical specificationsTE 13 & TE17

Temperature specificationsNormal operating temperature 70 - 120°C at temperature check port

At 2200 RPM 24 –29 BarConverter : 1.0 -4.0 l/mEach range

Safety valvecracking pressure 7,5 barConverter out pressure (to cooler)3.0 – 3.5

Pump flowAt 2200 RPM : 90 to 110 lpmTE 13 &

Electrical specificationsTE 13 & TE17

HYDRAULIC COOLER LINES SPECIFICATIONS.Minimum 19 mm internal diameter for lines and

TE 13 & TE17

Additional signalsSpeed sensorsEngine speed combined with oil temperature pick up

Wiring schematicsTE 13 & TE17Total neutral

Wiring schematicsTE 13 & TE17

Control valveVariable force solenoids (VFS)VFS0 for forwardVFS1 for 2ndVFS2 for reverseVFS3

Solenoid activationTE 13 & TE17

Electronic controlled modulation (E.C.M.)TE13-17

Operation of transmissionTE 13 & TE17 The transmission is controlled by an

Operation of transmissionTE 13 & TE17Range selection When 1 st clutch is

Operation of transmissionTE 13 & TE17Total neutral selection Total neutral is only

TE 13 & TE173790 -110 lpm @ 2200 RPM

NeutralTE 13 & TE17

TE 13 & TE1790 -110 lpm @ 2200 RPM37

TE 13 & TE17

TE 13 & TE1790 -110 lpm @ 2200 RPM37

TE 13 & TE17

TE 13 & TE1790 -110 lpm @ 2200 RPM37

TE 13 & TE17

TE 13 & TE1790 -110 lpm @ 2200 RPM37

TE 13 & TE17

Check portsTE 13 & TE17

Check portsTE 13 & TE17Port 42 2nd clutchPort 46 Pressure check

Check portsTE 13 & TE17To coolerPort 37Safety valve pressureSafaty valve mmmpressureSafaty

Check portsTE 13 & TE17Safaty valve pressureEngine

Check portsTE 13 & TE17Port 46Rev. clutchRev. clutchPumpPressurePort 35

Check portsTE 13 & TE17PressureTo coolerPort 32

Check ports Control valveTE 13 & TE17VFS REVPort 55 VFS 2ndPort

Control valve installation instructionRemoving the valve 1.Make sure that the area around

Control valve installation instructionInstalling the valve 1.Unscrew the 7bolts (marked green with

27*26*15*161825242212202123*5411191361*310*9*1472817Control valve installation instructionTE 13 & TE17

Control valve installation instructionTE 13 & TE17159871011121314654321

Speed sensor installationTE 13 & TE17Combined engine speed sensor and temperatureTurbine,

Speed sensor installationTE 13 & TE17

Speed sensor installationTE 13 & TE17

Speed sensor installationTE 13 & TE17

TE32 transmission

OverviewTE32TE32 : short drop 4 speed Fwd/Rev

TE32Transmission Layout

1X.X T E 32 4 X X - XXConverter specific ¨dash number¨Model

TE32Technical specifications Ratio TE32418

TE32Technical specifications Output flange rotation – (transmission forward clutch

Speed pick-up : - Engine speed combined with temperature located on

TE32Technical specifications Converter/Transmission Oil System Capacity (Approximate: measured at

Normal operating temperature 70 - 120°C at temperature check port converter

At 1800 RPM 20.5 - 24.5 barFwd/Rev max 4 l/min1st max

Savety valvecracking pressure 8.8-9.6 barConverter out pressure (to cooler)5 bar min.

Variable force solenoids(VFS)VFS 2nd/4th - VFS 1st/3rd - VFS Fwd -VFS

Speed sensorsType Magneto resistive sensor.Sensing distance up to 1.8 mm Sensor

HYDRAULIC COOLER LINES SPECIFICATIONS.Minimum 32 mm internal diameter for lines and

TE32

Additional signalsSpeed sensorsEngine speed combined with oil temperature pick up

Wiring schematicsTE 32

Wiring schematicsTE 32

TE32Solenoids activatedTransmission gear Forward 4 Forward 3 Forward 2 Forward 1 Neutral 4 Neutral 3 Neutral 2 Neutral 1 Reverse

Electronic controlled modulation (E.C.M.)TE27-32

Operation of transmissionTE32 The transmission is controlled by an APC200 box. This

Basic connverter /transmission theory
movie

TE transmissions
Electronic controlled modulation
Clutch overlap control
Inching control

Electronic controlled modulation (E.C.M.)
Controller

Modulated build up of pressure in the clutch
Electronic controlled modulation (E.C.M.)
Controller

Modulated build up of pressure in the clutch
Controller
different modulation
energy
different modulation in

Overlap control
Controller

Electronic controlled inching
Controller

340 F T E 13 3 XX - XX
Converter specific ¨dash

Converter/Transmission Oil System
Capacity 16,5L Lines and cooler not included
Oil Type ? Only

Ratios
Technical specifications
TE 13 & TE17

Temperature specifications
Normal operating temperature 70 - 120°C at temperature check port

At 2200 RPM 24
–
29 Bar
Converter : 1.0 -4.0 l/m
Each range

Safety valve
cracking pressure 7,5 bar
Converter out pressure (to cooler)
3.0 – 3.5

Pump flow
At 2200 RPM : 90 to 110 lpm
TE 13 &

Electrical specifications
TE 13 & TE17

HYDRAULIC COOLER LINES SPECIFICATIONS.
Minimum 19 mm internal diameter for lines and

Additional signals
Speed sensors
Engine speed combined
with oil temperature pick up

Wiring schematics
TE 13 & TE17
Total
neutral

Wiring schematics
TE 13 & TE17

Control valve
Variable force solenoids (VFS)
VFS0 for forward
VFS1 for 2nd
VFS2 for reverse
VFS3

Solenoid activation
TE 13 & TE17

Electronic controlled modulation (E.C.M.)
TE13-17

Operation of transmission
TE 13 & TE17
The transmission is controlled by an

Operation of transmission
TE 13 & TE17
Range selection
When 1 st clutch is

Operation of transmission
TE 13 & TE17
Total neutral selection
Total neutral is only

TE 13 & TE17
37
90 -110 lpm @ 2200 RPM

Neutral
TE 13 & TE17

TE 13 & TE17
90 -110 lpm @ 2200 RPM
37

TE 13 & TE17
90 -110 lpm @ 2200 RPM
37

TE 13 & TE17
90 -110 lpm @ 2200 RPM
37

TE 13 & TE17
90 -110 lpm @ 2200 RPM
37

Check ports
TE 13 & TE17

Check ports
TE 13 & TE17
Port 42 2nd clutch
Port 46
Pressure check

Check ports
TE 13 & TE17
To cooler
Port 37
Safety valve
pressure
Safaty valve
mmmpressure
Safaty

Check ports
TE 13 & TE17
Safaty valve
pressure
Engine

Check ports
TE 13 & TE17
Port 46
Rev. clutch
Rev. clutch
Pump
Pressure
Port 35

Check ports
TE 13 & TE17
Pressure
To cooler
Port 32

Check ports Control valve
TE 13 & TE17
VFS REV
Port 55
VFS 2nd
Port

Control valve installation instruction
Removing the valve
1.Make sure that the area around

Control valve installation instruction
Installing the valve
1.Unscrew the 7bolts (marked green with

27*
26*
15*
16
18
25
24
22
12
20
21
23*
5
4
11
19
13
6
1*
3
10*
9*
14
7
2
8
17
Control valve installation instruction
TE 13 & TE17

Control valve installation instruction
TE 13 & TE17
15
9
8
7
10
11
12
13
14
6
5
4
3
2
1

Speed sensor installation
TE 13 & TE17
Combined engine speed sensor and temperature
Turbine,

Speed sensor installation
TE 13 & TE17

Speed sensor installation
TE 13 & TE17

Speed sensor installation
TE 13 & TE17

Overview
TE32
TE32 :
short drop
4 speed Fwd/Rev

TE32
Transmission Layout

1X.X T E 32 4 X X - XX
Converter specific ¨dash number¨
Model

TE32
Technical specifications

Ratio TE32418

TE32
Technical specifications

Output flange rotation – (transmission forward clutch

Speed pick-up :
- Engine speed combined with temperature located on

TE32
Technical specifications

Converter/Transmission Oil System
Capacity (Approximate: measured at

At 1800 RPM 20.5 - 24.5 bar
Fwd/Rev max 4 l/min
1st max

Savety valve
cracking pressure 8.8-9.6 bar
Converter out pressure (to cooler)
5 bar min.

Variable force solenoids(VFS)
VFS 2nd/4th - VFS 1st/3rd - VFS Fwd -VFS

Speed sensors
Type Magneto resistive sensor.
Sensing distance up to 1.8 mm
Sensor

HYDRAULIC COOLER LINES SPECIFICATIONS.
Minimum 32 mm internal diameter for lines and

Additional signals
Speed sensors
Engine speed combined
with oil temperature pick up

Wiring schematics
TE 32

Wiring schematics
TE 32

TE32
Solenoids activated
Transmission gear Forward 4 Forward 3 Forward 2 Forward 1 Neutral 4 Neutral 3 Neutral 2 Neutral 1 Reverse

Electronic controlled modulation (E.C.M.)
TE27-32

Operation of transmission
TE32
The transmission is controlled by an APC200 box. This