INCORPORA
TED
INCORPORATED
Oper
ator
s
Opera
tors
Manual
Power Shift
Transmission
Components:
TA-90-8501 Transmission
8-FLW-2302-0 Torque Converter
TDEC-400 Electronic Control
NOTICE
Twin Disc, Incorporated makes no warranty or guaranty of any
kind, expressed, implied or otherwise, with regard to the
information contained within this manual. Twin Disc,
Incorporated has developed this manual through research and
testing of the information contained therein. Twin Disc,
Incorporated assumes no responsibility for any errors that may
appear in this manual and shall not be liable under any
circumstances for incidental, consequential or punitive damages
in connection with, or arising out of, the use of this manual. The
information contained within this manual is subject to change
without notice.
Document Number
1020510
Revison 1
May, 2002
Twin Disc, Incorporated warrants all assembled products and parts, (except component products or parts on which written warranties
issued by the respective manufacturers thereof are furnished to the original customer, as to which Twin Disc, Incorporated makes no
warranty and assumes no liability) against defective materials or workmanship for a period of twenty-four (24) months from the date of original
shipment by Twin Disc, Incorporated to the original customer, but not to exceed twelve (12) months of service, whichever occurs first. This is the
only warranty made by Twin Disc, Incorporated and is in lieu of any and all other warranties, express or implied, including the warranties
of merchantability or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc,
Incorporated.
The original customer does not rely upon any tests or inspections by Twin Disc, Incorporated or on Twin Disc, Incorporated*s
application engineering.
B.
The exclusive remedy provided by Twin Disc, Incorporated whether arising out of warranty within the applicable warranty period as
specified, or otherwise (including tort liability), shall at the sole option of Twin Disc, Incorporated be either the repair or replacement
of any Twin Disc, Incorporated part or product found by Twin Disc, Incorporated to be defective and the labor to perform that work
and to remove and reinstall (or equivalent credit). In this context, labor is defined as the flat rate labor hours established by Twin Disc,
Incorporated in the published Twin Disc Flat Rate Schedule, required to remove, disassemble, inspect, repair, reassemble, reinstall and
test the Twin Disc, Incorporated product only. Under no circumstances, including a failure of the exclusive remedy, shall Twin Disc,
Incorporated be liable for economic loss, consequential, incidental or punitive damages. The above warranty and remedy are subject
to the following terms and conditions:
1.
Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc,
Incorporated within sixty (60) days after completion of the in-warranty repair.
2.
The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted from abuse,
neglect, improper maintenance or accident.
3.
The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc,
Incorporated.
4.
The warranty is void unless the product or part is properly transported, stored and cared for from the date of shipment to
the date placed in service.
5.
The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product
or part with installations properly engineered and in accordance with the practices, methods and instructions approved or
provided by Twin Disc, Incorporated.
6.
The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal, and otherwise identical
with components of the original equipment. Replacement parts or products not of Twin Disc origin are not warranted by Twin
Disc, Incorporated.
C.
As consideration for this warranty, the original customer and subsequent purchaser agree to indemnify and hold Twin Disc, Incorporated
harmless from and against all and any loss, liability, damages or expenses for injury to persons or properly, including without limitation,
the original customer*s and subsequent purchaser*s employees and property, due to their acts or omissions or the acts or omissions of
their agents, and employees in the installation, transportation, maintenance, use and operation of said equipment.
D.
Only a Twin Disc, Incorporated authorized factory representative shall have authority to assume any cost or expense in the service, repair
or replacement of any part or product within the warranty period, except when such cost or expense is authorized in advance in writing
by Twin Disc, Incorporated.
E.
Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials without being obligated to
incorporate such changes in products of prior manufacture. The original customer and subsequent purchasers will not use any such
changes as evidence of insufficiency or inadequacy of prior designs or materials.
F.
If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts will be furnished on a
no-charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete
unit.
December 14, 2001
TDWP0002
GENERAL UNITS
Model Series
Powershift Transmissions
1000, 1100, 1300, 1400
1600, 2000, 2600, 3100
2800
3600
8500
6-1300, 6-1500
8-1400, 8-1450, 8-1600
8-1700, 8-1800, 8-1750, 8-1850
4-2000
8-2300
Fluid Couplings
R&R
14.0
14.0
14.0
14.0
14.0
24.0
30.0
18.0
36.0
72.0
6.0
6.0
8.0
6.0
8.0
6.0
8.0
12.0
12.0
20.0
6.0
6.0
12.0
20.0
6.0
8.0
12.0
30.0
40.0
12.0
10.0
10.0
24.0
20.0
14.0
14.0
32.0
28.0
2.0
2.0
2.0
4.0
4.0
4.0
6.0
8.0
8.0
8.0
32.0
28.0
1.0
1.0
1.0
1.0
2.0
2.0
2.0
3.0
3.0
3.0
4.0
4.0
4.0
6.0
2.0
2.0
2.5
3.0
4.0
5.5
2.0
6.0
6.0
8.0
10.0
10.0
10.0
14.0
Clutches Only
1.0
1.0
1.0
1.5
2.0
2.0
1.0
3.0
3.0
3.0
4.0
4.0
4.0
6.0
TDWP0002A
Table of Contents
Table of Contents
Introduction ...........................................................9
General Information ............................................................................ 9
Replacement Parts ............................................................................ 10
Preventative Maintenance/Troubleshooting ................................. 11
Safety .................................................................................................. 12
Sources of Service Information ...................................................... 13
Warranty .............................................................................................. 14
Operation ..............................................................21
Checking Oil Level ............................................................................ 22
Basic System Description ................................................................ 23
Transmission Component Summary ............................................ 29
Transmission Hydraulic System ..................................................... 30
Power Flow Through Transmission System ................................. 33
D.C. Power Supply............................................................................. 35
Electronic Control System Overview ............................................. 36
TDEC-400 Electronic Control System Components..................... 40
System Operation .............................................................................. 45
Fracturing rig Operating Modes ..................................................... 46
Operational Problems ....................................................................... 50
Table of Contents
Troubleshooting ..................................................61
General ................................................................................................ 61
Pressure and Flow Test Kit .............................................................. 62
Troubleshooting Discussion ........................................................... 63
Problems that Show No Fault Messages in the Display .............. 64
Problems that Show Fault Messages in the Display .................... 85
Display Faults ..................................................................................... 87
Diagnostic Test ................................................................................ 101
Introduction
Introduction
General Information
This publication provides the information necessary for the operation and
maintenance of the Twin Disc, Incorporated equipment specified on the cover
of this manual. Specific engineering details and performance characteristics
can be obtained from the Product Service Department of Twin Disc,
Incorporated, Racine, Wisconsin, USA.
Operation and maintenance personnel responsible for this equipment should
have this manual at their disposal and be familiar with its contents. Applying
the information in the manual will result in consistent performance from the
unit and help reduce downtime.
Special Tools
Engineering drawings are available for the fabrication of special tools that
should be used during disassembly and assembly of a unit. Repair of this
equipment should not be attempted without special tools. Twin Disc does
not manufacture these tools for general use.
Introduction
Replacement Parts
Parts Lists
Engineering assembly drawings are provided in appropriate sections of this
manual to facilitate ordering spare or replacement parts. Current bill of
materials are available from Twin Disc or the nearest Authorized Twin Disc
Distributor.
Ordering Parts
Parts Shipment
Furnish the complete shipping information and postal address. All parts
shipments made from the factory will be FOB factory location, USA. State
specifically whether the parts are to be shipped by freight, express, etc. If
shipping instructions are not specified, the equipment will be shipped the
best way, considering time and expense. Twin Disc, Incorporated will not
be responsible for any charges incurred by this procedure.
Twin Disc, Incorporated having stipulated the bill of material number on the
units nameplate absolves itself of any responsibility resulting from any
external, internal or installation changes made in the field without the express
written approval of Twin Disc. All returned parts, new or old, emanating
from any of the above-stated changes will not be accepted for credit.
Furthermore, any equipment which has been subjected to such changes will
not be covered by a Twin Disc warranty.
10
Introduction
Preventative Maintenance/Troubleshooting
Frequent reference to the information provided in this manual regarding daily
operation and limitations of this equipment will assist in obtaining troublefree operation. Schedules are provided for the recommended maintenance
of the equipment and, if observed, minimum repairs (aside from normal wear)
will result.
In the event a malfunction does occur, a troubleshooting table is provided to
help identify the problem area and lists information that will help determine
the extent of the repairs necessary to get a unit back into operation.
These lifting points must not be used to lift the complete power unit.
Lifting excessive loads at these points could cause failure at the lift
point (or points) and result in damage or personal injury.
11
Introduction
Safety
General
Safe practices must be employed by all personnel operating and servicing
this unit. Twin Disc, Incorporated will not be responsible for personal injury
resulting from careless use of hand tools, lifting equipment, power tools, or
unaccepted maintenance/operating practices.
12
Introduction
13
Introduction
Warranty
Equipment for which this manual was written has a limited warranty. For
details of the warranty, refer to the warranty statement at the front of this
manual.
14
General
(Reference - Twin Disc Application # AN4019)
The Twin Disc TA-90-8501 transmission is a hydraulically actuated power shift
transmission, providing nine speeds forward. Used with this transmission is a
Twin Disc torque converter model 8-FLW-2302-0. The transmission and torque
converter are electronically controlled by a Twin Disc model TDEC-400 control.
15
Description
There are two main sections of the transmission, a countershaft input section,
and a planetary output section. The input section consists of three gearedtogether clutch shafts and a driven front output shaft. A 9-inch ball dump clutch
is directly connected to, and driven by the input shaft, and when engaged, is
directly connected to the front output shaft. The outer member of this clutch
pack (gear driver) meshes with the input members of two shaft mounted clutches.
These clutches are 10.5 inch and are the S type. When one of the input section
clutches is engaged, power is transmitted to the front output shaft either directly
or through the driven gears, and to the input members of the planetary output
section. There are three clutch pack assemblies in the planetary output section.
The high range clutch is a 12.5-inch and is of the LD type. When engaged, the
output shaft rotates at the same speed as the front output shaft in the input
section of the transmission. There are two 23-inch planetary clutch assemblies
(non dump valve) that connect to the output flange through planetary reduction
gearsets. These are referred to as the low range and intermediate range clutch
pack assemblies
The hydraulic torque converter is a single stage Type 8 design with an integral
lockup clutch, and stator freewheel. The lockup clutch is hydraulically controlled
in conjunction with the electronic control.
Sump
The bottom of the transmission housing serves as the sump for all oil used in
the transmission/ torque converter system. A suction strainer is installed in the
sump to prevent debris from being drawn into the pump inlet.
Pump
The hydraulic system dual pump assembly is located on the rear of the torque
converter on a pump mount to the right of center as viewed from the rear. The
two pumps are of the positive displacement gear-type and are driven directly
by the engine. The pump inlets draw oil through a suction strainer. The oil from
the pumps is directed through filters and regulator valves and supplies pressure
for clutch apply, torque converter and lube. The pumps run at engine speed.
A scavenge pump is on the rear of the torque converter on a pump mount to the
left of center as viewed from the rear. The scavenge pump draws oil from the
bottom of the engine flywheel and converter housings and returns the oil to the
transmission sump.
16
17
Special Features
Clutches
Hardened steel plates and organic fiber friction plates are used on all clutches.
The 9-inch (input section) clutch is a ball-dump type clutch. The two 10.5-inch
clutches (input section) are of the S dump valve configuration. The high range
(output section) 12.5-inch clutch is of the LD dump valve configuration. The two
23-inch (output section) are modulatable non dump valve clutches. All of the
clutches are hydraulically actuated, spring-released, and oil cooled.
Bearings
The input section clutch shafts and the front output shaft are supported with
tapered roller bearings. These bearings (in conjunction with shims) are used
to control the end play of the shafts. The planetary shafts are supported with
caged needle bearings, and end float is controlled by thrust washers. The ring
gear float is controlled with lube ring assemblies on each side. The high range
clutch is supported on the front output shaft with a ball bearing, and the end
thrust is controlled by this bearing and a ball bearing in the sun gear on the
opposite end. The allowable float is controlled with shims between the sun
gear and the clutch hub. The output shaft and planetary carrier is supported by
a double tapered roller bearing set.
18
Specifications
Normal Temperature Range:
180-220 F (82-104 C)
Low Speed Pressures:
Run at 715 rpm
Main Pressure (X):
185 psi (1276 kPa) minimum at regulator.
Clutch Apply Pressure (CL):
180 psi (1241 kPa) minimum at end caps and within 5 psi (34 kPa) of each
other.
Transmission Lube Pressure:
15 psi minimum (103 kPa) at lube regulator (G).
2 psi (14 kPa) minimum at clutch lube ports.
Converter outlet pressure (W):
30 psi minimum (207 kPa)
High Speed Pressures:
Run at 1950 rpm
Main Pressure (X):
235-255 psi (1620-1758 kPa) at main regulator.
Clutch Apply Pressure (CL):
Within 12 psi (83 kPa) of main at end caps.
Transmission Lube Pressures:
35-60 psi (241-417 kPa) at lube regulator (G).
5-20 psi (34-138 kPa) at clutch lube test ports.
Converter outlet pressure (W):
45 to 55 psi (310-379 kPa)
19
1950 rpm
1960 rpm
1953 rpm
TDEC-400 CONTROL
Furnished with the transmission is the TDEC-400 electronic control. The control
provides shifting for the transmission/converter system and is necessary to
coordinate the function of the fracturing rig, torque converter and transmission
in the oil well servicing application. The control operates on 24 volts dc provided
by the fracturing rigs battery.
20
Operation
Operation
This section covers operation of the transmission, torque converter, and the
associated hydraulic and electronic control system and their relationship to the
engine and fracturing rig. The following paragraph (prior to start-up) provides
information the fracturing rig operator needs to know to inspect the transmission
and start the engine.
21
Operation
Visually inspect the transmission, converter and drive line for security of
mounting. Inspect plumbing and electrical components for security of
attachment and/or leaks. Leakage must be corrected.
2.
Oil level check: It is best to check the oil level after the oil well fracturing
rig has been parked with the engine not running for at least 8 hours (or
overnight). The fracturing rig should be parked on a level surface.
a.
With the engine not running, the low level sight gauge should show
full, and the hot oil level sight gauge may be full. Add oil if the low
level sight gauge does not show full.
b.
Start the engine. With the engine at low idle for 1 minute, the
transmission in neutral, and with cold oil (10~35 oC) the oil level
should be visible in the low level (lower) sight gauge. Add oil as
necessary until it is seen in the low level sight gauge before
operating the oil well fracturing rig. Note that there is a low oil
level sight gauge on the front of the transmission by the hot oil
level sight gauge, and one on the rear of the transmission.
c.
d.
If a sump heater is used when the fracturing rig is parked, the oil
temperature after the engine is idling for one minute will determine
which of the above procedures should be followed.
Do not operate the transmission with oil levels above or below the
recommended settings. Either condition can result in overheating or
loss of power and damage to the equipment. When following this oil
check procedure be sure the fracturing rig is secured from moving.
22
Operation
23
POWER
SOURCE
MISCELLANEOUS
SWITCH INPUTS
NEUTRAL DISCONNECT
OIL LEVEL
KEY SWITCH
TDEC 400
TRANSMISSION
OIL FILTER
DIFF. PRESS.
SWITCH
ENGINE
CONTROLLER
TRANSMISSION
INPUT AND
OUTPUT SPEED
SENSORS
CONVERTER LOCKUP
CLUTCH VALVE COIL
SYSTEM OIL
TEMPERATURE
SENSOR
TRANSMISSION
RANGE CLUTCH
VALVE COILS
ENGINE
TORQUE CONVERTER
WITH LOCK UP CLUTCH
TRANSMISSION
J1939 BUS
INPUTS
WORK MODE SWITCH
RANGE SELECTOR
WORK MODE POT
LOCKUP OFF SWITCH
LIQUID CRYSTAL
DISPLAY (VIA J1939)
Operation
24
24VDC
Operation
25
Operation
26
Operation
27
Operation
28
Operation
Torque Converter
The torque converter is direct mounted to the engine flywheel housing, and its
input member rotates with the flywheel. The transmission system oil pumps
are geared to the input member, providing oil flow for transmission system
operation. Two pumps are mounted in tandem on the right of the torque converter
when viewed from the rear. They both provide oil flow for the operation of the
transmission system, and the other pump on the left side of the torque converter
as viewed from the rear, pumps normal torque converter drainage back to the
transmission oil sump (scavenge pump). A pump drive pad is located near the
bottom on the centerline for customer use.
There is one internal clutch in the torque converter. It is the lockup clutch that
connects the engine flywheel to the fluid turbine or converter output shaft. This
clutch is controlled by the electronic controller, based on conditions. There are
pressure testing ports located on the torque converter that can be used in trouble
shooting certain problems. See Figure 2 in Operation.
29
Operation
Transmission Sump
The sump is located in the bottom of the transmission housing and serves as a
reservoir for all oil used in the system. Oil level is checked with the sight glass
on the right rear of the transmission. Please refer to Preventative Maintenance
for oil level check and filling procedures. A suction screen installed in the reservoir
prevents debris from being drawn into the pump inlet. This screen is not
serviceable from the outside.
Pumps
The system oil pumps are assembled together in tandem. They are positive
displacement gear-type pumps, rated at 68 gpm (257 L/min) for the front
element and 52 gpm (197 L/min) for the rear element at 1900 rpm engine
speed. The converter and flywheel housing scavenge pump is rated at 15.3
gpm (57.9 L/min) at 1900 rpm engine speed.
30
Operation
31
Operation
32
Operation
Converter Drive
When in converter drive, converter fluid is moved by the impeller blades and
directed against the turbine wheel blades, driving the turbine wheel assembly.
Since the turbine wheel assembly is spline connected to the output shaft, the
output shaft is driven.
After the fluid passes through the turbine wheel blades, it is redirected to the
impeller wheel blades by the stator blades. When output torque requirements
exceed input torque, the freewheel unit on the stator is locked up. However,
when output torque requirements are equal to, or less than, input torque, the
stator freewheels.
The pumps run at engine speed.
33
Operation
Freewheel Function
When the lockup clutch is engaged, the freewheel assembly allows the stator
to freewheel. This improves the unit efficiency. The freewheel assembly locks
the stator to the stator carrier during converter operation. This allows the torque
converter to multiply engine torque.
Transmission
Power flow is from the engine through the torque converter output shaft to the
input yoke on the front of the transmission input shaft. The 2-5-8 clutch input
gear drives the 1-4-7 and the 3-6-9 input gears that are solidly connected to
their shafts by an interference tapered fit. If one of these three clutches are
engaged, they cause the front section output shaft to rotate. The 2-5-8 clutch
output is directly connected to this shaft, and the other two clutches are connected
through gears. The front section output shaft is spline connected to the sun
gear for the low range (1-2-3) planetary assembly, the sun gear for the
intermediate range (4-5-6) planetary assembly, and to the clutch hub for the
high range (7-8-9) clutch. When the low (1-2-3) range clutch is engaged, the
low range ring gear becomes anchored to the housing and cannot rotate. The
low range sun gear causes the low range planet gears to rotate inside of the
stalled ring gear, causing the planetary carrier to rotate. The transmission output
shaft is an integral part of this planetary carrier and therefore rotates at the
same speed. When the intermediate range (4-5-6) clutch is engaged, the
intermediate range ring gear becomes anchored to the housing and cannot
rotate. The intermediate range sun gear causes the intermediate range planet
gears to rotate inside of the stalled ring gear, causing the planetary carrier to
rotate. The intermediate range planetary carrier is directly connected to the
low range ring gear. The low range sun gear and the intermediate range sun
gear are connected and rotating together, resulting in the low range planetary
carrier being driven at a faster speed than when the low range ring gear was
grounded. When the high range (7-8-9) clutch is engaged, the intermediate
range carrier, the low range ring gear, and the low range sun gear are rotating
at the same speed as the front input section output shaft, thus the low range
carrier also must rotate at this speed. In order to have power to the oil well
fracturing pump, one input section clutch and one output (planetary section)
clutch must be engaged.
34
Operation
Interruption of Power
1.
2.
The control system will be in neutral (N) on power up. This means that
after regaining power from some power fault, the electronic control will
place the transmission in N even if the transmission output shaft is
rotating.
35
Operation
Cables
Two cables connect the components of the electronic control system to each
other, and also to the sensors, valves, and switches that are located on the
various components in the power transmission system.
36
Operation
Display Unit
The display unit provides information to the operator about what range the
transmission is in, and is also used while troubleshooting system problems. It
also displays messages that may be generated by the electronic control sensing
abnormal conditions in the transmission system. The display unit contains the
switches that enable the diagnostic testing of the transmission system.
Electronic Control
The electronic control contains the computer memory that has been
programmed with the desired fracturing rig function parameters. The electronic
control relies on information provided by several discreet input devices, and
provides signals to several outputs that result in the fracturing rig performing in
the desired manner. The electronic control also monitors and responds to some
signals from the fracturing rigs J1939 data bus.
The J1939 Data Bus is a communication link designed into the fracturing rig.
Refer to the Society of Automotive Engineers (S.A.E.) Recommended Practice
J1939 for detailed information. Electronic signals are communicated to the
J1939 Data Bus by various controllers on the fracturing rig. The transmission
control system uses this data bus to receive information from other fracturing
rig controls, and to send information to other fracturing rig controls. The display
data is communicated from the control via the data bus.
37
Operation
38
Operation
Based on all discreet input signals and J1939 Data Bus input signals, the
electronic control sends signals out to various devices that cause the fracturing
rig operation. The outputs are sent discreetly and also via the J1939 Data
Bus.
Electrical current to the lockup clutch valve coil used to apply the
converter lockup clutch as needed
39
Operation
R-1 (Warm-Up)
This range is selected by downshifting from neutral. Solenoids are energized
to select the 2-5-8 input section clutch, and the 1-2-3, and 4-5-6 planetary
clutches in the output section. This results in the transmission shafts being
locked up, stalling the torque converter output shaft. The lockup clutch is not
allowed in the Warm-up mode.
N--NEUTRAL
Torque converter lockup clutch and transmission range clutches are disengaged.
Neutral (N) will always be selected while starting the engine and during power
up of the electronic control system. A customer supplied neutral disconnect
relay will be de-energized and the neutral disconnect switch contacts opened.
Neutral will be achieved if the instant neutral switch is used to disconnect the
pump from the engine.
D-1
First range is engaged. This range is achieved by upshifting from neutral or
downshifting from D-2. The transmission input shaft will turn at 4.47 times the
transmission output shaft. Torque converter lockup clutch is automatically
applied based on turbine speed.
40
Operation
D-2
Second range is engaged. This range is achieved by upshifting from D-1 or
downshifting from D-3. The transmission input shaft will turn at 3.57 times the
transmission output shaft. Torque converter lockup clutch is automatically
applied based on turbine speed.
D-3
Third range is engaged. This range is achieved by upshifting from D-2 or
downshifting from D-4. The transmission input shaft will turn at 2.85 times the
transmission output shaft. Torque converter lockup clutch is automatically
applied based on turbine speed.
D-4
Fourth range is engaged. This range is achieved by upshifting from D-3 or
downshifting from D-5. The transmission input shaft will turn at 2.41 times the
transmission output shaft. Torque converter lockup clutch is automatically
applied based on turbine speed.
D-5
Fifth range is engaged. This range is achieved by upshifting from D-4 or
downshifting from D-6. The transmission input shaft will turn at 1.92 times the
transmission output shaft. Torque converter lockup clutch is automatically
applied based on turbine speed.
D-6
Sixth range is engaged. This range is achieved by upshifting from D-5 or
downshifting from D-7. The transmission input shaft will turn at 1.54 times the
transmission output shaft. Torque converter lockup clutch is automatically
applied based on turbine speed.
D-7
Seventh range is engaged. This range is achieved by upshifting from D-6 or
downshifting from D-8. The transmission input shaft will turn at 1.25 times the
transmission output shaft. Torque converter lockup clutch is automatically
applied based on turbine speed.
41
Operation
D-8
Eighth range is engaged. This range is achieved by upshifting from D-7. This
is the maximum range allowed in this application, even though one additional
range is available in the transmission. The transmission input shaft will turn at
1.00 times the transmission output shaft. Torque converter lockup clutch is
automatically applied based on turbine speed.
D-9
Ninth range is engaged. The transmission input shaft will turn at 0.798 times
the transmission output shaft. Torque converter lockup clutch is automatically
applied based on turbine speed. This range is not allowed in this transmission
application via a customer inhibit.
Signals are provided by the customer supplied range selector.
N (neutral) must be selected before the starter is engaged (so that clutches are
not being unexpectedly engaged when the engine starts).
A customer supplied neutral disconnect relay is de-energized by the range
selector, so the electronic control is not able to energize most of the solenoids
when the selector is in N. This provides a redundant neutral for safety - the
control cannot engage transmission clutches when the selector is in N.
42
Operation
Speed Sensors
A voltage signal is generated as each tooth of a gear moves past the sensor.
This results in an ac voltage signal with a frequency determined by the frequency
of a tooth passing the sensor. The control is programmed with the number of
teeth on the gear under the sensor and converts the frequency of pulses to
determine gear/shaft RPM. The input speed sensor is calibrated to measure
torque converter output speed (equals transmission input speed). The sensor
is mounted on the left front side of the transmission (when viewed from the
rear). The output speed sensor measures output speed of the transmission.
The control uses the input and output speed information when determining
transmission range, engagement of the lockup clutch, and work mode functions.
Resistance of the sensors is approximately 1100 ohms. The control does not
measure the voltage of the speed sensor signals; it only uses the frequency of
the pulses. The amplitude (voltage) of the signal is determined by the velocity
of the gear tooth as it passes the sensor and the gap between the gear tooth
and the end of the sensor. The sensor must be close to the gear to generate a
signal that is large enough to reach the control where the frequency is measured.
Measuring the voltage of the speed sensor signal would only be useful for
verifying that the sensor is generating a signal.
The control checks resistance of speed sensor circuits frequently. If the value
is found to be out of range, a display message is shown on the display to alert
the operator. This could indicate a fault in a wire to the sensor or in the sensor
itself. The control also calculates what range is engaged based on what
solenoids are energized and the transmission ratio. It alerts the operator if it
does not receive a frequency signal from one of the sensors when it expects to
see a signal. For example, the control will show a display message if it sees a
signal indicating output speed, a range is engaged, and it sees no signal from
the turbine/transmission input speed sensor.
Display
The dot matrix liquid crystal display (LCD) is usually installed on the control
panel for the oil fracturing rig. It indicates the transmission range that the control
has engaged. It is also used to inform the operator if the control has detected a
fault in one of the external circuits, and is used during the diagnostics test to
communicate with the operator. Two membrane switches are housed in the
display for diagnostic purposes. The diagnostic test mode is entered by
simultaneously depressing these up and down arrow buttons while cycling
power to the control via the key switch.
43
Operation
44
Operation
System Operation
Start Up
1.
2.
Activate the start switch to supply electrical power to the starter circuit.
45
Operation
46
Operation
Examples of Operation
Basic: The oil well fracturing rig has been positioned and plumbed for pumping
into an oil well. The operator starts the engine . A downshift is selected to lock
the transmission shafts to allow for heating of the transmission system oil prior
to begin pumping mud into the oil well. The control looks at all of the inputs and
decides it is appropriate to engage the clutches necessary for R-1 or warm-up.
The oil temperature is monitored, and when appropriate, an upshift to Neutral
is selected, or the instant neutral switch is actuated, placing the transmission
into neutral. When it is time to begin pumping mud, the upshift button is actuated
until the desired transmission range is reached. This could be done at any
engine speed desired. If the transmission input speed is high enough, the
torque converter lockup clutch may be automatically engaged by the control.
Upshifts or downshifts can be made based on the needs for more or less flow
into the well. The control energizes two transmission range clutch valves to
engage two clutch packs in the transmission. See drawing number 1019142 in
Engineering Drawings. Two clutch packs must be engaged in the transmission
to transmit power to the oil well fracturing rig pump. There is no automatic
shifting of the transmission in this application. The torque converter lockup
clutch can be disabled by the disable request switch. The oil well fracturing rig
mud pump can be disconnected from the engine at any time by use of the
instant neutral switch on the selector.
47
Operation
48
Operation
49
Operation
Operational Problems
If the normal operation of the fracturing rig is not occurring. Please refer to
Troubleshooting for the correct troubleshooting procedures. A clear
understanding of the normal operation of the fracturing rig systems is essential
to understand and troubleshoot any problems.
50
Preventative Maintenance
Preventative Maintenance
General
Lubrication
Lubrication for the TA-90-8501 transmission and the 8-FLW-2302-0 torque
converter is accomplished by a full pressure system utilizing oil in the
transmission sump. The transmission sump is the reservoir for all oil used in
the hydraulic and lubrication systems. No lubrication is required beyond a daily
check of the transmission oil level with the sight gauges.
51
Preventative Maintenance
Hydraulic System
52
Visually inspect the transmission, converter and drive line for security of
mounting. Inspect plumbing and electrical components for security of
attachment and/or leaks. Leakage must be corrected.
2.
Preventative Maintenance
Oil level check: It is best to check the oil level after the oil well fracturing
rig has been parked with the engine not running for at least 8 hours (or
overnight). The fracturing rig should be parked on a level surface.
a.
With the engine not running, the low level sight gauge should show
full, and the hot oil level sight gauge may be full. Add oil if the low
level sight gauge does not show full.
b.
Start the engine. With the engine at low idle for 1 minute, the
transmission in neutral, and with cold oil (10~35 oC) the oil level
should be visible in the low level (lower) sight gauge. Add oil as
necessary until it is seen in the low level sight gauge before
operating the oil well fracturing rig. Note that there is a low oil
level sight gauge on the front of the transmission by the hot oil
level sight gauge, and one on the rear of the transmission.
c.
d.
If a sump heater is used when the fracturing rig is parked, the oil
temperature after the engine is idling for one minute will determine
which of the above procedures should be followed.
Do not operate the transmission with oil levels above or below the
recommended settings. Either condition can result in overheating or
loss of power and damage to the equipment. When following this oil
check procedure be sure the fracturing rig is secured from moving.
53
Preventative Maintenance
Adding Oil
The oil fill plug is located on the front face of the transmission on the left side as
viewed from the rear. Refer to Figure 5 in Operation. Add or remove oil as
needed to set proper level. Note that an optional oil fill plug is located on the
left side of the planetary section below the valves.
Do not operate the transmission with oil levels above or below the
recommended settings. Either condition can result in overheating or
loss of power and damage to the equipment. When following this oil
check procedure be sure the fracturing rig parking brakes are on. The
fracturing rig wheels should also be blocked or the fracturing rig parked
up against an immovable object.
54
Preventative Maintenance
Recommended Oil
Oil Classification
Use specified engine oil viscosity grade that meets one of the API service
classification: CF, CF-2, CG-4, or CH-4 per SAE J138a and the requirements
of Caterpillar TO-2 and Allison C4 specifications or the requirements of MIL-L2104E.
Oil Viscosity
The approved viscosity for this application is SAE 10W. Some multi-viscosity
oils (SAE 15W40) have also been approved in this transmission. Contact Twin
Disc for approval.
Filter Requirement
A filter is to be installed between the main pump outlet and pressure regulating
valve. Provision is made for the filter and it is shown on the hydraulic schematic.
The Twin Disc part number for replacement filter elements is 1016502.
55
Preventative Maintenance
56
1.
2.
Keep cable or harness away from hot surfaces, moving parts and oil
locations.
3.
4.
Protect cable or harness with grommet, loom or flex guard at any rub
point, particularly when passing through a sheet metal hole.
5.
6.
7.
When mating connectors, make sure they will mate properly. Coat pins
and sockets only with dielectric compound to seal out moisture and
corrosive substances (Twin Disc part number MA890 or Dow 4
Compound.) Locate and use the connector orientation key.
Preventative Maintenance
8.
9.
Cable or harness bend radius must not be less than twenty times the
cable diameter.
10.
11.
12.
13.
Check the cable or harness tie downs. Keep cable securely fastened to
machine frame.
14.
Check the condition of the cable or harness at any rub point and wherever
the cable passes through a sheet metal hole.
15.
57
Preventative Maintenance
58
Preventative Maintenance
Select desired check point and install 0-300 psi (0-2000 kPa) pressure
gauge to check main and clutch apply pressures, and 0-100 psi (0-800
kPa) pressure gauge for lube system.
2.
Start the engine, and shift to Warm-Up and bring the engine up to 1500
rpm. Allow the transmission oil to heat to 80 to 100 C.
3.
59
Preventative Maintenance
60
Troubleshooting
Troubleshooting
General
This section of the maintenance manual has been prepared to assist
maintenance personnel in troubleshooting the power shift transmission and
control. When troubleshooting the equipment, always remember to consider
the entire power package of the oil well fracturing rig. Interaction between the
transmission, the engine, and the oil well fracturing rig functions are all part of
the troubleshooting process. It is suggested that you take some time to
understand the operational characteristics of the transmission power system
to more accurately diagnose the problem at hand. See Figures 1, 2, 3, 4, and
5 in Operation.
61
Troubleshooting
62
Troubleshooting
Troubleshooting Discussion
The troubleshooting discussion includes the following topics:
q
63
Troubleshooting
Failed Display
If the cable connections are tight but the display is still blank, the display
is defective. The oil well fracturing rig will still operate if the control unit is
functioning properly.
Replace the display unit.
64
Troubleshooting
2.
65
Troubleshooting
66
Troubleshooting
67
Troubleshooting
3.
68
Troubleshooting
4.
Oil well fracturing rig output driveshaft only moves in some ranges
Possible causes:
69
Troubleshooting
5.
Oil well fracturing rig will not properly drive the pump in the upper
transmission ranges when the pumping load should allow
operation in these ranges.
Possible Causes:
70
Troubleshooting
Failed Converter
If the pump continues to deliver a solid stream of oil and the pump is
delivering as expected , it is likely that the leakage from the torque
converter is greater than normal and the scavenge pump can not keep
up. The torque converter must be removed for repair. Raise engine rpm
to approximately 1000 rpm and run for several minutes. Repeat the oil
flow measurement at this engine rpm. A solid oil stream at this rpm
supports the decision to remove the torque converter because of
excessive leakage.
71
Troubleshooting
6.
Lockup Clutch
If lockup clutch pressure is low and main pressure drops significantly as
lockup is applied, then an internal leak in the lockup clutch apply section
is likely. The converter must be removed for repair.
72
Troubleshooting
7.
73
Troubleshooting
8.
74
Troubleshooting
9.
75
Troubleshooting
10.
76
Troubleshooting
IS FUSE OR CIRCUIT
BREAKER CLOSED?
REPLACE FUSE OR
RESET BREAKER
No
Yes
24 VOLTS PIN 1 TO 2 ON 6
PIN CONNECTOR AT
DISPLAY?
No
Yes
No
Yes
No
Yes
IF AFTER 30 SECONDS,
DISPLAY REMAINS BLANK,
REPLACE DISPLAY UNIT
77
Troubleshooting
Yes
REPAIR PUMP
No
No
No
Yes
185 minimum
No
REPAIR
SUCTION
LEAKS
REPLACE
OIL PUMP
TRANSMISSION IN NEUTRAL, IS
DRIVESHAFT TURNING
Yes
No
Yes
No
Yes
RUN PRESSURE
TEST TO
DIAGNOSE
TRANSMISSION IS DAMAGED
INTERNALLY AND MUST BE
REMOVED
No
TRANSMISSION IS
HYDRAULICLY LOCKED
UP, RUN PRESSURE
TEST TO DIAGNOSE
Troubleshooting
No
DIAGNOSE SELECTOR
Yes
Yes
MAIN - NORMAL
OTHER - ZERO
REPAIR OR REPLACE
FAULTY RANGE VALVE
No
MAIN - NORMAL
OTHERS - LOW
MAIN - NORMAL
OTHERS - NORMAL
79
Troubleshooting
No
DIAGNOSE SELECTOR
Yes
Yes
MAIN - NORMAL
CLUTCH- NORMAL
MAIN - NORMAL
CLUTCH- ZERO
REPAIR OR REPLACE
APPROPRIATE RANGE
CLUTCH VALVE
MAIN - NORMAL
CLUTCH - LOW
SWAP AFFECTED
RANGE CLUTCH VALVE
WITH A KNOWN GOOD
RANGE CLUTCH VALVE
NO CHANGE
80
Troubleshooting
No
INVESTIGATE CAUSE OF
ENGINE MALFUNCTION
Yes
Yes
SERVICE
ENGINE
Fail
Pass
Test 8, Select
LOCKUP,followed by
FULL ON. Both pressures
normal no evidence of
slight engine lug
down when lock-up
is applied
81
Troubleshooting
PERFORM PRESSURE
TEST
82
Troubleshooting
ADJUST TRANSMISSION
OIL TO PROPER LEVEL
PERFORM TORQUE
CONVERTER SCAVENGE
TEST
PERFORM PRESSURE
TEST
83
Troubleshooting
REPLACE PUMP
84
Troubleshooting
85
Troubleshooting
Status Code
TEST
CONTROL ERROR
I1 thru I24
N/A
PWR PROB
I15
I16
HIGH
LOW
PWR PROB
SELECT NEUTRAL
N/A
ACC PEDL
HIGH
ACC PEDL
LOW
INPT SPD
OPEN
INPT SPD
SHORT
N/A
LOCKUP
CIRCUIT
NEUTRAL FAULT
N/A
N/A
OUT1 SPD
OPEN
OUT1 SPD
SELECTOR FAULT
TranSol1
TranSol1
TranSol2
TranSol2
TranSol3
TranSol3
TranSol4
TranSol4
TranSol5
TranSol5
TranSol6
TranSol6
SYST TMP
SYST TMP
SYST TMP
DISPLAY FAULT
SHORT
N/A
BD COMBO
CIRCUIT
BD COMBO
CIRCUIT
BD COMBO
CIRCUIT
BD COMBO
CIRCUIT
BD COMBO
CIRCUIT
BD COMBO
CIRCUIT
CIRCUIT
HIGH
LOW
COM FAILURE
86
Troubleshooting
Display Faults
Note: The following Fault Messages, Log Codes, and Status
Codes are arranged and listed in alphabetical order.
The TDEC-400 Display unit is a sealed non field serviceable device with two
cable connectors and a backlit dot matrix LCD screen.
Possible display faults include segments that dont come on, stay on when they
should not, blank display, and no backlight.
One of the cable connectors is used to supply 24 volts DC and a signal from
the oil well fracturing rig light switch. The other connector attaches to the oil
well fracturing rig J1939 Data Bus. If the wiring that supplies the power is
damaged, there will not be any information displayed on the display screen.
If the connection to the oil well fracturing rig J1939 Data Bus is damaged or
missing, the display will show COM FAILURE.
Controller Test 1 is used to check the display pixels.
Controller Test 13 is used to adjust the blacklight brightness and contrast of the
display.
Note: Refer to the System Control Drawing 1019142 in
Engineering Drawings for cable and pin locations that are
identified in the Troubleshooting instructions. Note that
pin connections are identified by cable number and pin
matrix number. For example, J2C2 refers to the cable at
Junction block 2, column C, row 2.
87
Troubleshooting
88
A.
B.
C.
D.
E.
Key switch contacts are not disconnecting during the start cycle.
Troubleshooting
TRAN OIL FILTER Fault Message -OIL FILT PLUGGED Log Code
This fault message will be displayed if the hydraulic system filter differential
pressure switch indicates a high pressure drop across the filter for more than
30 seconds. The message will be cleared when the switch indicates a normal
pressure drop for at least five seconds. This message will not affect the operation
of the transmission system.
89
Troubleshooting
B.
C.
Align the gear seen through the transmission input speed sensor hole
so the gear tooth is in the middle of the hole.
D.
Screw the transmission input speed sensor into the hole until it just
contacts the gear tooth.
E.
F.
Use jam nut to lock the transmission input speed sensor in place (50 inlbs, 5.7 Nm).
*
90
Troubleshooting
91
Troubleshooting
B.
The present transmission range will be held until the operator selects
neutral.
C.
The above actions will be maintained until the fault is corrected and the control
is repowered by cycling the key switch.
92
Troubleshooting
B.
C.
Align the gear seen through the output speed sensor hole so the gear
tooth is in the middle of the hole.
D.
Screw the output speed sensor into the hole until it just contacts the
gear tooth.
E.
F.
Use jam nut to lock the output speed sensor in place (50 in-lbs, 5.7
Nm).
*
93
Troubleshooting
94
Troubleshooting
So lenoid
Energized
Co nnector
Co ntacts
Approximate
Resistance
Oh ms
T ranSol1
J4
5 to 11
T ranSol2
J4
J4N2 and J4 N3
5 to 11
T ranSol3
J4
5 to 11
T ranSol4
J4
5 to 11
T ranSol5
J4
5 to 11
T ranSol6
J3
J3K1 and J3 J3
5 to 11
95
Troubleshooting
Unplug the pigtail of the indicated valve and measure the resistance of
the solenoid valve itself. Expected resistance values are listed in Table
2. Place ohmmeter leads on the two sockets corresponding to the
solenoid in question. See Table 2. A proper ohmmeter reading for the
solenoid is shown in the chart. Also verify that the solenoid leads are not
shorted to the chassis by measuring resistance between the connector
and the transmission housing, there should be no connection.
96
A.
B.
b.
c.
d.
Troubleshooting
TRAN SYS OVR HEAT Message -- SYST TMP Log Code CIRCUIT
Status Code
This fault message will be displayed if the transmission temperature signal is
well outside of the range that would indicate a possible oil temperature condition.
Operation of the oil well fracturing rig will continue. The display message will
not be cleared until the fault is corrected and the controller is repowered by
cycling the key switch.
TRAN SYS OVR HEAT Message -- SYST TMP Log Code HIGH
Status Code
This fault message will be displayed if the transmission temperature signal is
above the normal transmission operating level. Normal operation of the oil well
fracturing rig will continue. The fault message will clear from the display when
the transmission temperature returns to normal, however a code will be logged
into the control memory.
TRAN SYS OVR HEAT Message -- SYST TMP Log Code LOW
Status Code
This fault message will be displayed if the transmission temperature signal is
below the normal transmission operating level. Normal operation of the oil well
fracturing rig will continue. The fault message will clear from the display when
the transmission temperature returns to normal, however a code will be logged
into the control memory.
97
Troubleshooting
LOG CODE
CONTROL
ERROR
I1 - I24
INTERNAL
CONTROL
PROBLEM
REPLACE
CONTROL
I15
HIGH
VOLTAGE TOO
HIGH
CHECK
CHARGING
SYSTEM
RUN TEST 2
LOW
VOLTAGE TOO
LOW
CHECK
VOLTAGE
SUPPLY
RUN TEST 2
NEUTRAL NOT
SELECTED
SELECT
NEUTRAL
FILTER
DIFFERENTIAL
PRESSURE
HIGH
WARM OIL OR
CHANGE FILTER
J1939 DATA
SIGNAL
MISSING
CHECK J1939
BUS
PWR PROB
PWR PROB
I16
STATUS
CODE
SELECT
NEUTRAL
TRAN OIL
FILTER
TRAN SYS
FAULT
OIL FILT
PLUGGED
HIGH
ACC PEDL
LOW
CAUSE
ACTION
98
Troubleshooting
LOG CODE
STATUS
CODE
OPEN
TRAN SYS
FAULT
INPT SPD
TRAN SYS
FAULT
INPT SPD
FREQ
SHORT
TRAN SYS
FAULT
LOCKUP
TRAN SYS
FAULT
NEUTRAL
FAULT
CIRCUIT
OPEN
CAUSE
ACTION
TRANSMISSION
INPUT SPEED
SENSOR
RESISTANCE
1000 TO 1300
OHMS
RUN TEST 5
TRANSMISSION
INPUT SPEED
SENSOR
ADJUST OR
REPLACE
SENSOR
LOCKUP
VALVE COIL
IMPEDANCE
OPEN CIRCUITRESISTANCE
SHOULD BE 5
TO 11 OHMS
RUN TEST 5
NEUTRAL
DISCONNECT
SWITCH
RUN TEST 4
TRANSMISSION
OUTPUT SPEED
SENSOR
RESISTANCE
1000 TO 1300
OHMS
RUN TEST 5
TRAN SYS
FAULT
OUT1 SPD
TRAN SYS
FAULT
OUT1 SPD
FREQ
TRANSMISSION
OUTPUT SPEED
SENSOR
ADJUST OR
REPLACE
SENSOR
TRAN SYS
FAULT
SELECTOR
FAULT
RANGE/
DIRECTION
SELECTOR
SWITCHES
RUN TEST 3
TRANSMISSION
RANGE CLUTCH
VALVE COIL #
OPEN CIRCUITRESISTANCE
SHOULD BE 5
TO 11 OHMS
RUN TEST 5
TRANSMISSION
RANGE CLUTCH
VALVE COIL #
WRONG COILS
ENERGIZED
SHORT
CIRCUIT
TRAN SYS
FAULT
TranSol#
BD
COMBO
99
Troubleshooting
TRAN SYS
OVR HEAT
COM
FAILURE
LOG CODE
SYST TMP
STATUS
CODE
CAUSE
CIRCUIT
SYSTEM
TEMPERATURE
CIRCUIT BAD
REPAIR OR
REPLACE
RUN TEST 5
HIGH
SYSTEM
TEMPERATURE
HIGH SIGNAL
INVESTIGATE
HOT OIL OR
SENSOR
RUN TEST 7
LOW
SYSTEM
TEMPERATURE
LOW SIGNAL
INVESTIGATE
COLD OIL OR
SENSOR
RUN TEST 7
ACTION
DISPLAY
FAULT
DISPLAY TEST
DISPLAY
FAULT
J1939
MESSAGE
LOSS
CHECK J1939
BUS
100
Troubleshooting
Diagnostic Test
General
See Figure 14 in Troubleshooting.
A test routine is included within the control to aid in troubleshooting the external
components of the control system. It is also helpful in troubleshooting the
transmission and torque converter.
The troubleshooting mode is entered by simultaneously depressing the up and
down arrow buttons on the display unit face while applying power to the control
by turning the key switch off and back on.
The following chart shows the required engine running status for the available
tests.
Oil well fracturing rig brakes should be applied during all testing.
101
Troubleshooting
Test
Running
Engine
Required
Stopped
Engine
Required
Test 1:
Display Test
NO
NO
Test 2:
NO
NO
Test 3:
NO
YES
Test 4:
NO
YES
Test 5:
NO
YES
Test 6:
YES
NO
Test 7:
NO
NO
Test 8:
YES
NO
Test 9:
YES
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
102
Troubleshooting
103
Troubleshooting
Upshift
Downshift
To exit Test 3, momentarily depress the up arrow button. The control will return
to the main menu at the same point that it was when the test was entered.
104
Troubleshooting
105
Troubleshooting
If a fault is detected in a valve coil circuit during the testing, the top half of the
display will indicate which coil is being tested, (LOCKUP, TranSol1, TranSol2,
TranSol3, TranSol4, TranSol5, or TranSol6) and the bottom half of the display
will indicate one of the following: FAULT 1, or FAULT 2. Refer to the sketch
below as a guide.
FAULT 1 - Lead A or lead B open; or Lead B connected to ground.
FAULT 2 - Lead A connected to ground; Lead A or lead B connected to
positive voltage; or Leads A and B connected together (low coil
resistance)
Control
106
Troubleshooting
C. The data value will be displayed until the up or down arrow button is pressed,
and when EXIT TEST is selected, the control is returned to the main menu.
Note: The resistance of the temperature sensor should be
between 800 and 1800 ohms, and should measure
approximately 968 ohms at 77 F.
107
Troubleshooting
108
LOCKUP
TranSol1
TranSol2
TranSol3
TranSol4
TranSol5
TranSol6
EXIT TEST
Troubleshooting
After selection of an individual coil, a sub menu will be displayed, showing the
following options: FULL ON, MODULATE, PRESET, and EXIT SUB MENU.
If FULL ON is selected, the selected coil will be powered with full on current.
The display will show the coil selected and display FULL ON. Depressing the
up arrow button will turn the coil off and go back to the sub menu.
If MODULATE is selected, the selected coil can be toggled on in increments of
5% of full current with the use of the up arrow button. It can be reduced in
increments of 5% of full current with the use of the down arrow button. The
display will identify the coil selected, the percentage of full current, and the
current value. (Example: TranSol2 55% .13A) The test can be terminated by
reaching 100% with the use of the up arrow button, or by simultaneously
depressing both the up and down arrow buttons at any time. These actions will
both result in EXIT SUB MENU being displayed.
If PRESET is selected, current to the selected coil will be ramped linearly from
zero to full current in 15 seconds, and then from full current to zero current over
the next 15 seconds. This cycle will be continuously repeated until the up arrow
button is pushed. This will turn the current to zero, and return the control to the
sub menu listing the choices. While the cycling is continuing, the display will
identify the coil, the percentage of full current, and the current level.
If the range selector is moved into the neutral position after FULL ON,
MODULATE, or PRESET has been selected, the test will be terminated, current
turned off, and DESELECT NEUTRAL will be displayed.
109
Troubleshooting
Table 4 shows expected pressure values for the electric modulating valves tested
in troubleshooting Test 8. The oil temperature range is between 100 F and
180 F, and the system main pressure is 250 psi or less, and SAE 10W oil is
used. The pressure at an intermediate setting is not affected by the main supply
pressure, but will level off when main pressure is reached. The important things
to consider when testing a valve are that there should not be any pressure at
zero current, and full pressure when 100 is displayed. The orientation of the
axis of the valve coil with respect to the horizontal plane affects the
resulting pressure. The maximum pressure results when the coil axis is
vertical with the coil end up. Conversely, the minimum pressure results
when the coil axis is vertical with the coil end down. A plot of pressure vs.
current should result in a reasonably smooth line from minimum current to
maximum current.
Table 4. Proportional Valve Pressure Chart
Current
% of full
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
110
Pressure
minimum
0
0
0
0
0
0
0
3
10
30
52
74
93
112
135
155
177
195
218
230
241
Pressure
maximum
0
0
0
0
0
0
15
29
46
70
90
110
129
148
170
189
210
230
246
255
255
Troubleshooting
Selecting N
111
Troubleshooting
112
Troubleshooting
SPEED
SENSORS
RANGE
SELECTOR
SWITCHES
MISC SENSORS
COILS
POWER
SUPPLIES
INTERNAL
FAULTS
COMM FAULTS
EXIT TEST
113
Troubleshooting
When any selection is made other than EXIT TEST, the sub menu of SHORT
LOG LIST, LONG LOG LIST, and EXIT SUB MENU will be displayed.
Selecting the SHORT LOG LIST will allow scrolling (by using the up and down
arrow buttons) through any faults that had been logged into memory since the
memory was last cleared. The logged code, date, and time for any faults logged
for the category selected, will be displayed, followed by the message END OF
LOG. If no messages have been logged, the message NO LOG FAULTS will
be displayed. The short log list can be cleared by depressing and holding the
up arrow button for six seconds when at the beginning of the fault list. If this is
done, the message CLEARING SHORT LG will be displayed while the clearing
is occurring. Once cleared, the message, NO LOG FAULTS will appear.
Selecting the LONG LOG LIST will allow scrolling through any faults that had
been logged into memory (by using the up and down arrow buttons). The
logged code, date, and time for any faults logged for the category selected, will
be displayed, followed by the message END OF LOG. This list of faults can
not be cleared. If the allocated memory capacity is exceeded, the first in
faults will be overwritten. If no faults have occurred, NO LOG FAULTS will be
displayed. Simultaneously depressing both up and down arrow buttons will
exit the sub menu, and EXIT SUB MENU must be selected to return to the
main menu. Selecting EXIT TEST will return the control to the main menu. Exit
the Test Mode by cycling the key switch off and back on.
114
Troubleshooting
DISPLAY
ACTION
SEC
1 DSPLAY
TEST
1 DSPLAY
TEST
2 SEC
DELAY
ALL DOTS
ON
5 SEC
DELAY
ALL DOTS
ON
PRESS UP OR
DOWN
ARROW OR
BOTH TO EXIT
TO MAIN
MENU
CHECKSUM
XXXX
2 POWER
TEST
SUPPLY
POWER
X.XX V
INTERNAL
POWER
TEST
PASSED
OR
EXIT TEST
PRESS UP
BUTTON
TO EXIT
SUB MENU
XXXXX
FAILED
IF FAILED
REPLACE
CONTROL
115
Troubleshooting
3 SLECTR
TEST
PRESS UP
BUTTON
TO EXIT
SUB MENU
OR
INVALID
POSITION
4 SWITCH
TEST
OIL FILT
OPEN OR CLOSED
OIL LEVEL
FULL OR EMPTY
NEUT DIS
OPEN OR CLOSED
MODE SEL
OPEN OR CLOSED
LU OFF
OPEN OR CLOSED
EXIT TEST
5 SCAN
TEST
ENGINE
OFF
RUN TEST
DESELECT
NEUTRAL
INPT SPD
OPEN OR SHORT
MOVE
SELECTOR
FROM
NEUTRAL
OUT1 SPD
OPEN OR SHORT
LOCKUP
FAULT 1 OR FAULT 2
EXIT TEST
TESTING
OR
TEST
PASSED
PRESS UP BUTTON
OR SELECT
NEUTRAL
TranSol#
FAULT 1 OR FAULT 2
ACC PEDL
SYSTTMP
PRESS UP BUTTON
TO CONTINUE THRU
TEST
116
Troubleshooting
INPT SPD
XXXX RPM
7 SENSOR
RD TEST
EXIT TEST
8 COIL
TEST
EXIT TEST
DESELECT
NEUTRAL
FULL ON
LOCKUP
MOVE
SELECTOR
FROM
NEUTRAL
SYST TMP
XXX OC
ACC PEDL
XX%
TranSol#
EXIT
TEST
MODULATE
PRESET
EXIT SUB
MENU
SELECT
NEUTRAL
COIL ID
FULL ON
COIL ID
XX% .XXA
COIL ID
XX% .XXA
PRESS UP
ARROW OR
SELECT N
PRESS UP OR DOWN
ARROW TO CHANGE
5% PRESS BOTH OR
SELECT N TO EXIT
PRESS UP
ARROW OR
SELECT N
9 STALL
TEST
8th
DESELECT
NEUTRAL
MOVE
SELECTOR
FROM
NEUTRAL
8th
ENGAGED
EXIT TEST
SELECT
NEUTRAL
117
Troubleshooting
RS232
CONNECT
RX TO TX
PRESS UP
ARROW OR
SELECT N
EXIT TEST
11 SPEED
OUT TEST
EXIT
SOFTWARE
VERSION
12 VERSN
WARRANTY
HARDWARE
VERSION
WARRANTY
DATE
EXIT TEST
ADJUST
BACKLITE
13 ADJST
DISPLAY
XXXXXXXX
XXX
DDMMMYY
PRESS UP
BUTTON
TO EXIT
OR
NOT
STARTED
ADJUST
BRITENES
ADJUST
NOW
SET MIN
VALUE
WORKING
EXIT SUB
MENU
2
SEC
PRESS UP TO INCREASE
PRESS DOWN TO
DECREASE
PRESS BOTH TO EXIT
ADJUST
CONTRAST
ADJUST
NOW
FACTORY
DEFAULT
WORKING
2
SEC
EXIT TEST
Troubleshooting
14 SENSR
CALIBRTN
EXIT TEST
15 FAULT
LOG
DEPRESS BOTH
SWITCHES TO
EXIT TEST
ALL
FAULTS
SPEED
SENSORS
RANGE
SELECTOR
SHORT
LOG LIST
SCROLL THRU
FAULTS WITH UP
OR DOWN
ARROW
CLEAR SHORT
FAULTS BY
HOLDING UPARROW
FOR SIX SECONDS
AT BEGINNING OF
LIST
OR
NO LOG
FAULTS
SWITCHES
CLEARING
SHORT LG
MISC
SENSORS
COILS
LONG
LOG LIST
POWER
SUPPLIES
SCROLL THRU
FAULTS WITH UP
OR DOWN
ARROW
INTERNAL
FAULTS
COMM
FAULTS
EXIT
SUB MENU
EXIT TEST
AFTER 2 SECONDS
FAULT, DATE, AND
TIME WILL SCROLL
DEPRESS BOTH
SWITCHES TO
EXIT TEST
END OF
LOG
119
Troubleshooting
120
Main pressure
Converter outlet
Lube
Lockup clutch
Clutch 1
Clutch 2
Clutch 3
Clutch 4
Clutch 5
Clutch 6
Troubleshooting
121
Troubleshooting
none
Solenoid energized
2
3
4
5
---
--
--
Clutch 2
Clutch 3
Clutch 4
----
VENT
---
---
VENT
Clutch 5
--
--
--
--
--
Clutch 6
Flow from
vented
port
--
--
--
--
--
Record
Pressure
Main
Converter
Lock up
Lube
Lock-up
Clutch 1
122
--
VENT
---
---
---
---
--
--
--
----
----
----
VENT
--
VENT
VENT
---
Troubleshooting
Min
Clutch
1
Clutch
2
Clutch
3
Clutch
4
10
15
20
25
30
15
35
29
40
10
46
45
30
70
50
52
90
55
74
110
60
93
129
65
112
148
70
135
170
75
155
189
80
177
210
85
195
230
90
218
246
95
230
255
Main
Pressure
Lube
Pressure
Clutch
5
Clutch
6
Lock
up
Max
123
Troubleshooting
124
Troubleshooting
________ Tested By
Description
Test 1
Display check
Test 2
Test 3
Test 4
Switch tests
Test 5
Test 7
Results
125
Troubleshooting
Main pressure
Lube regulator
126
Engine RPM
Oil temp
____________________ Deg C
Main pressure
Lube regulator
Troubleshooting
none
Solenoid energized
2
3
4
5
Lock-up
--
--
--
--
--
--
--
Clutch 1
Clutch 2
Clutch 3
Clutch 4
-----
VENT
---
---
-----
-----
-----
Clutch 5
Clutch 6
Flow from
vented
port
---
VENT
---
Record
Pressure
Main
Lock up
Converter
Lube
VENT
VENT
---
---
VENT
---
---
---
--
---
VENT
--
127
Troubleshooting
128
Current
% of Full
Min
Clutch
1
Clutch
2
Clutch
3
Clutch
4
Clutch
5
Clutch
6
Lock
up
Max
10
15
20
25
30
15
35
29
40
10
46
45
30
70
50
52
90
55
74
110
60
93
129
65
112
148
70
135
170
75
155
189
80
177
210
85
195
230
90
218
246
95
230
255
Main
Pressure
Lube
Pressure
Troubleshooting
Test Port
Pressure
PSI
Comments
Test 9
2
6
________
Downshift
N to R
4
5
2
________
Upshift
N to 1
1
4
________
Upshift
1 to 2
2
4
________
Upshift
2 to 3
3
4
________
Upshift
3 to 4
1
5
________
Upshift
4 to 5
2
5
________
Upshift
5 to 6
3
5
________
Upshift
6 to 7
1
6
________
Upshift
7 to 8
2
6
________
129
Troubleshooting
130
Engineering Drawings
Engineering Drawings
1019142
238008A
(Schematic, Hydraulic)
229578E
(Diagram, Piping)
1019876 (page 1 of 6)
(Transmission Parts)
1019876 (page 2 of 6)
(Transmission Parts)
1019876 (page 3 of 6)
(Transmission Parts)
1019876 (page 4 of 6)
(Transmission Parts)
1019876 (page 5 of 6)
(Transmission Installation)
1019876 (page 6 of 6)
(Transmission Installation)
X237074A
(Clutch Assembly, 1, 4, 7)
X237073A
(Clutch Assembly, 3, 6, 9)
X229489F
(Clutch Assembly, 2, 5, 8)
1018460
(Valve Assembly)
X229460P
X229823B (page 1 of 3)
131
Engineering Drawings
132
X229823B (page 2 of 3)
X229823B (page 3 of 3)
1018360 (partial)
#1020510 R1 05/02
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