Hyster C214 (H400HD-EC, H450HD-EC, H450HDS-EC, H500HD-EC) Internal Combustion Engine Trucks Service

Hyster C214 (H400HD-EC, H450HD-EC, H450HDS-EC, H500HD-EC) Internal Combustion Engine Trucks Service Repair Manual

TE-13 & TE-17 TRANSMISSION DESCRIPTION & OPERATION, WITH FULL FLOW VALVE H16XM-12, H18XM-12, H20XM-12, H22XM-12 (H400HD, H450HD, H500HD, H550HD) [B236]; H16XM-12EC, H18XM-12EC, H22XM-12EC (H400HD-EC, H450HD-EC, H500HD-EC) [C214]

PART NO. 4069309

1300 SRM 1608

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

TE-13 & TE-17 Transmission

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

General ...........................................................................................................................................................

Operation............................................................................................................................................................

Hydraulic Operation......................................................................................................................................

Clutch Release ...............................................................................................................................................

Neutral Selection ...........................................................................................................................................

Cooling and Lubrication................................................................................................................................

Control System...................................................................................................................................................

General ...........................................................................................................................................................

APC216 Controller.........................................................................................................................................

Self Test .....................................................................................................................................................

Protection Modes .......................................................................................................................................

Limp Home Mode ..................................................................................................................................

Shut Down Mode ...................................................................................................................................

Transmission Exceed Codes .................................................................................................................

Fault Codes ................................................................................................................................................

Description ............................................................................................................................................

Fault Log Mode..........................................................................................................................................

Access.....................................................................................................................................................

Exit ........................................................................................................................................................

Clear ......................................................................................................................................................

Fault Rectification .....................................................................................................................................

Transmission Control Valve..........................................................................................................................

Transmission Control Valve Repair .........................................................................................................

Oil Pressure Check....................................................................................................................................

Check by Air Pressure...............................................................................................................................

Pressure Specifications .............................................................................................................................

Pressure, Speed, and Temperature Sensors.................................................................................................

Pressure Sensor.........................................................................................................................................

Test ........................................................................................................................................................

Speed Sensor..............................................................................................................................................

Test ........................................................................................................................................................

Temperature Sensors ................................................................................................................................

Test ........................................................................................................................................................

Dana Dashboard Software.................................................................................................................................

Description .....................................................................................................................................................

Connection .....................................................................................................................................................

Transmission Test and Calibration...................................................................................................................

Precautions ....................................................................................................................................................

Stall Test ........................................................................................................................................................

Description.................................................................................................................................................

Stall Test Procedure ..................................................................................................................................

Inching Calibration .......................................................................................................................................

Description.................................................................................................................................................

Brake and Inching Pedal Adjustment ......................................................................................................

Inching Pedal Sensor Adjustment ............................................................................................................

Inching Pedal Sensor Calibration.............................................................................................................

Electrical Specifications.....................................................................................................................................

APC216 Display Information ............................................................................................................................

General ...........................................................................................................................................................

©2012 HYSTER COMPANY

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Table of Contents

TE-13 & TE-17 Transmission

TABLE OF CONTENTS (Continued) General Information Group ..........................................................................................................................

Fault Codes ....................................................................................................................................................

Indication of Protection Modes .....................................................................................................................

Test Function Group......................................................................................................................................

Digital Input Test ..........................................................................................................................................

Analog Input Test ..........................................................................................................................................

Speed Sensor Test..........................................................................................................................................

Output Test ....................................................................................................................................................

Voltage Test....................................................................................................................................................

Calibration Group..........................................................................................................................................

Calibration Mode.......................................................................................................................................

Clutch Filling Calibration.........................................................................................................................

Heat Up Mode............................................................................................................................................

Inching Pedal Sensor Calibration.............................................................................................................

Inching Pedal Sensor Adjustment........................................................................................................

Inching Pedal Sensor Calibration ........................................................................................................

This section is for the following models: H16XM-12, H18XM-12, H20XM-12, H22XM-12 (H400HD, H450HD, H500HD, H550HD) [B236]; H16XM-12EC, H18XM-12EC, H22XM-12EC (H400HD-EC, H450HD-EC, H500HD-EC) [C214]

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1300 SRM 1608

Description

General This manual provides information on the operation and diagnostics of the TE-13 and TE-17 transmission with full flow valve as equipped on these series of lift trucks. The difference between models TE-13 and TE-17 is in the torque converter and the number of discs in the clutches. Model TE-13 is fitted on trucks with the 142 kW engine option, Model TE-17 is fitted on trucks with the 164 kW engine option.

The repair procedures for the transmission and the control valve are shown in TE-13 & TE-17 Transmission Repair, With Full Flow Valve 1300 SRM 1603.

Electrical system diagrams are shown in the Diagrams manual for your lift truck.

Description GENERAL The transmission transfers engine power from the engine flywheel to the drive wheels, and to the hydraulic pumps that are attached to the transmission.

The engine flywheel is connected to the torque converter through drive plates. See Figure 1.

The flexing properties of the drive plate reduce transfer of axial forces between the engine crankshaft and the torque converter. A gear on the torque converter housing drives the transmission pump and the attached pumps for the lift truck hydraulic system. The torque converter housing, transmission, and attached pumps turn at proportional engine speed.

The oil pressure generated by the transmission pump is used for lubrication, internal cooling, and hydraulic control of the transmission. Without oil pressure, the transmission cannot function.

The torque converter hydraulically connects the engine flywheel with the transmission input shaft. It functions as a fluid clutch to smoothly transfer power from the engine to the transmission, and as a torque multiplier when speed difference between engine and transmission input shaft increases. The torque converter has a specific torque multiplication factor which matches the engine power characteristics.

Speed difference between engine and transmission input shaft is a measure of engine power being transferred.

With increasing speed difference (= increasing stall), also an increasing amount of heat is generated in the converter. The heat generated is removed by the transmission lubrication oil, which flows through the torque converter. However, oil flow through the torque converter is strongly reduced under stall conditions, which raises oil temperature in the converter even further. A temperature switch at the converter exit port provides protection against overheating by sending a signal to the transmission controller to have the clutches released. Resulting load removal and reinstatement of the oil flow will lower oil temperature. When oil temperature is acceptable again, the controller will allow re-engagement of the clutches.

The different speed ratios between input shaft and drive shaft are obtained by engaging and disengaging the different clutches. Clutch engagement is controlled by the APC216 Control System, which activates and deactivates solenoids in the control valve.

Three groups of gears are continuously engaged with each other: the input gears, the interconnecting gears, and the output gears. See Figure 2.

1

Description

1300 SRM 1608

A. INPUT GEARS B. INTERCONNECTING GEARS C. OUTPUT GEARS Figure 2. Gear Engagement If clutches belonging to one group would be engaged simultaneously, the transmission would lock. Erroneous clutch engagement is prevented by the transmission control system.

1.

2.

3.

4.

5.

6.

7.

8.

9.

DRIVE PLATE TORQUE CONVERTER PUMP DRIVE GEAR TRANSMISSION PUMP INPUT GEAR INTERCONNECTING GEAR CLUTCH TRANSMISSION FILTER TRANSMISSION INPUT SHAFT

Different speeds are obtained by engaging either the forward or the reverse clutch, and by engaging the 1st, 2nd, or 3rd speed clutch.

When the transmission is in NEUTRAL, the forward clutch and the reverse clutch are disengaged, while one of the speed clutches remains engaged.

The clutches consist of a hub which carries friction discs with internal splines, and a drum which carries steel discs with external splines. See Figure 3.

Figure 1. Transmission Input Section The friction discs and the steel discs are alternately installed. By pressurizing the clutch piston, the friction discs and the steel discs are clamped together, which causes the hub and the drum to rotate as one unit. When hydraulic pressure is released, the return springs force the piston back against the clutch housing and allows the hub and drum to rotate independently. The drum, steel discs, piston, spacer, and return springs rotate at the same speed. The hub and friction discs rotate at the same speed.

2

1300 SRM 1608

1.

2.

3.

4.

5.

6.

7.

8.

Description

INTERCONNECTING GEAR CLUTCH DRUM, 3RD GEAR PISTON SEALS CLUTCH DRUM, FWD GEAR INTERCONNECTING GEAR OIL SEALS PRESSURE SUPPLY, 3RD CLUTCH PRESSURE SUPPLY, FWD CLUTCH

9.

10.

11.

12.

13.

14.

15.

16.

CLUTCH HUB, FWD GEAR FRICTION DISCS, FWD GEAR PISTON PISTON SPRING SPACER CLUTCH END PLATE CLUTCH HUB, 3RD GEAR PISTON SPRING SET STEEL DISC

Figure 3. Clutch Components

3

Operation

1300 SRM 1608

Operation HYDRAULIC OPERATION The transmission sump is the main reservoir for the transmission oil. The sump screen keeps large particles from entering the transmission pump. The pump is driven by gears that connect with the torque converter housing. The pump transfers oil through the transmission filter, and further to the 28.5 to 31.5 bar (413.3 to 456.8 psi) pressure regulator valve. See Figure 4.

The 28.5 to 31.5 bar (413.3 to 456.8 psi) pressure regulator valve regulates system pressure, by relieving excess oil through the torque converter, oil cooler, and lubrication system. See Cooling and Lubrication. System pressure is used to fill and pressurize the clutches.

System pressure is admitted to the clutches through proportional valves and selector valves, which receive electrical signals from the APC216.

The proportional valves admit and release oil pressure according a varying signal from the APC216.

The varying signal allows a controlled engagement and release of the clutches. To dampen hydraulic vibration, the oil channels directly after the proportional valves have each been provided with a dampening spool.

In the supply channels for the speed clutches (1st/3rd and 2nd gear) the actual clutch pressure is measured

by a sensor. The APC216 uses this pressure signal and the signals from speed sensors to control engagement and release of the different clutches during shifting.

If the APC216 does NOT receive the proper signals, then the proportional valves will be deactivated, causing all clutches to release immediately.

The selector valves receive an ON or OFF signal to divert pressure to the correct clutch.

• The 1st/3rd selector valve diverts pressure to the 1st clutch when activated.

• The 1st/3rd selector valve diverts pressure to the 3rd clutch when NOT activated.

• The Forward/Reverse selector valve diverts pressure to the Forward or Reverse clutch, according activation of the relevant solenoid.

When the signal is OFF, the Forward/Reverse selector valve is in the neutral position, draining both the forward and reverse clutches and blocking any pressure supply from the proportional valve.

Table 1 provides an overview of the activated solenoids and clutches for the different transmission speeds. Neutral selection is by disengagement of both the forward and reverse clutch. Trucks with a MONOTROL® pedal will only shift to NEUTRAL by applying the hand or service brake, or when the operator has left his seat.

Legend for Figure 4 NOTE: THE CIRCLED NUMBERS IN THE HYDRAULIC DIAGRAM REFERENCE THE PRESSURE CHECK PORTS IN TABLE 3, TABLE 4, AND PRESSURE, SPEED, AND TEMPERATURE SENSORS. A. LUBRICATION B. LOW PRESSURE

C. HIGH PRESSURE D. DRAIN

1. CONTROL VALVE

2. DAMPING SPOOL

4

1300 SRM 1608

Operation

Figure 4. Hydraulic Diagram

5

Operation

1300 SRM 1608 Table 1. Gear Selection and Activated Valves for VFS Control Valve

Direction

Speed

Activated Proportional Valves

Activated Selector Valves

Activated Clutches

Forward

1st

FWD/REV + 1st/3rd

Forward + 1st

Forward + 1st

Forward

2nd

FWD/REV + 2nd FWD/REV

Forward + 2nd

Forward + 2nd

Forward

3rd

1st/3rd

Forward

Forward + 3rd

Neutral

1st

-----

1st

1st

Neutral

2nd

-----

2nd

2nd

Neutral

3rd

-----

-----

3rd

Reverse

1st

FWD/REV + 1st/3rd

Reverse + 1st

Reverse + 1st

Reverse

2nd

FWD/REV + 2nd FWD/REV

Reverse + 2nd

Reverse + 2nd

Reverse

3rd

1st/3rd

Reverse + 3rd

Reverse + 3rd

CLUTCH RELEASE When clutch pressure is released, the clutch spring returns the piston into the clutch housing and pushes hydraulic oil back to sump through the shift spool. For an improved clutch release of the 1st speed clutch, a 0.9 mm hole has been drilled in its piston. The volume of oil escaping through this hole during clutch engagement is irrelevant compared with oil supply capacity.

NEUTRAL SELECTION Neutral selection is obtained by disengaging both the forward clutch and reverse clutch. The signal from the APC216 controller to select neutral is generated by each of the following inputs: • Neutral position of the gear shift selector.

• Park brake engagement.

• Fully depressed inching pedal.

• Seat NOT occupied.

• Sensor inputs causing the APC216 controller to engage neutral.

NOTE: Trucks equipped with a MONOTROL® pedal do not have a shift lever with a neutral position.

NOTE: The transmission will automatically shift to neutral a few seconds after the operator has left the seat.

6

NOTE: The speed clutch will remain engaged according to the position of the gear shift lever, or will engage according to the gear selection made by the automatic drive mode.

COOLING AND LUBRICATION Heat is primarily generated at the torque converter and at the clutch plates during transmission operation. The heat generated by mechanical friction at gears, shafts and bearings is relatively low.

Heat generated in the torque converter relates directly to the degree of stall, i.e. the speed difference between engine and turbine. In a stall situation most of the supplied engine power is transferred into heat.

This heat accumulates in the torque converter because of the reduced oil flow during a stall situation.

With increasing turbine speed, the volume of added heat reduces, while simultaneously the increased oil flow more rapidly transfers the accumulated heat.

Heat generated at the clutch plates varies with the actually available engine power at time of clutch engagement and the duration of clutch engagement.

During normal operation, the transmission control system determines the duration of clutch engagement. During inching it is the driver who controls the added heat in the clutch by varying engine power and clutch engagement. The transmission control system will close the forward or reverse clutch when a certain amount of generated heat has been exceeded.

1300 SRM 1608

Control System

Only a minor portion of the total transmission pump supply is used for clutch filling. The majority of transmission oil supply is used for the cooling and lubrication circuit that functions at a pressure that is lower than system pressure. See Hydraulic Diagram. The pressure regulator valve admits oil that is not required for clutch filling. The safety valve reduces oil pressure to 9 bar (131 psi) to protect the torque converter and oil cooler. The normal oil flow is through the torque converter, the transmission oil cooler and to the transmission lubrication port.

The volume of oil and the oil flow resistance causes that the initial 9 bar (131 psi) supply pressure is reduced to 1.55 to 2.25 bar (22.4 to 32.6 psi) at the transmission lubrication port. Flow resistance increases during torque converter stall or when oil temperature is low. When the transmission is at operating temperature and no load is applied, the

volume of lubrication oil is 64 liter (17 gal) at 1500 rev/min.

From the transmission lubrication port the oil flows into channels in the different shafts, which lead to the shaft bearings for lubrication, and to the inside of the clutch packs where the oil absorbs the heat that is generated at the clutch plates.

To speed the warming-up process, a thermostat valve is installed between the torque converter outlet port and the transmission radiator. The thermostat starts opening at 87°C (188.6°F) and is completely opened at 102°C (188.6°F). At temperatures below 87°C (215.6°F), oil flow is directly returned to the transmission. At temperatures above 102°C (215.6°F), the entire oil flow from the outlet port passes through the transmission radiator before it is returned to the transmission.

Control System GENERAL The control system of the transmission consists of the APC216 controller, several switches, and sensors.

The sensors provide information to the APC216 controller and to the hydraulic control valve, which regulates pressures according to signals from the APC216 controller.

APC216 CONTROLLER The APC216 controller has software that controls the operation of the transmission and performs the following functions: • Self-testing and troubleshooting.

• Functional control of the transmission.

– Automatic shifting gear selection.

– Inching.

• Entering a protection mode when required: – Improper pressures, temperatures, and speeds.

– No operator present.

– Parking brake applied.

– Gear or direction change at improper speeds.

• Logging a fault code when circumstances have exceeded certain values.

• Allowing diagnostics and calibration with a laptop (Dana Dashboard software).

Depending on the signals of the shift lever and various switches and sensors, the APC216 controller activates or deactivates the solenoids and VFS in the control valve, which transfer hydraulic oil pressure

to the clutches in the transmission. If an input signal does not comply with the programming of the APC216, the APC216 controller will record the fault and react by activating a protection mode. All recorded events are stored as fault codes and are shown on the hourmeter/fault code display when the fault occurs. Faults can also be retrieved and read at a later time, making it possible to trace intermittent problems.

Protection modes and self tests are part of the APC216 programming and cannot be influenced.

The APC216 controller is located in the side console of the cab and has a display and push buttons to call off information. Normally, the gauges and displays on the instrument panel are used to read transmission-related information. For diagnostics and settings, it is recommended to use the Dana Dashboard software system. Refer to APC200 Operation for the instructions on how to access and retrieve information from the APC216 controller when the Dana Dashboard software is not available.

Self Test A series of checks is done at power-up. If the APC216 controller fails these checks, it will shut off all outputs. The transmission cannot be operated until the problem is resolved or repaired. A fault code will be displayed.

7

Control System

Protection Modes Limp Home Mode The transmission shifts to NEUTRAL if a fault is detected on the following: • Outputs for solenoids, VFS, or pressure switch • Engine speed sensor • Two out of three transmission speed sensors (turbine, drum, or output speed sensor).

To continue driving, place the shift lever in NEUTRAL, and reengage a direction. When Limp Home Mode has been entered, the user can operate the transmission in either direction in 1st and 2nd gear only, and inching is disabled.

Shut Down Mode If an intolerable combination of faults is detected, the Shut Down Mode will be entered. The APC216 controller puts the transmission in NEUTRAL by putting all VFS signals at zero pressure and by switching OFF the total neutral solenoid, cutting off pressure to the clutches. Intolerable faults are also referred to as Redundant Shutdown Path (RSP) errors.

1300 SRM 1608 If the engine and/or transmission controller detects a fault, the hourmeter/fault code display will show a fault code instead of the engine running hours.

Fault codes starting with ‘E’ refer to engine fault codes.

• Fault code number(s)

Fault codes starting with ‘t’ refer to transmission exceed and fault codes, which are listed in APC200 Fault Code Guide 1300 SRM 1435.

When more than one fault occurs at the same time, the fault codes will be displayed in succession. When circumstances have changed and all faults have ceased to exist, the hour meter/fault code display will show engine running hours again.

Fault code E-CON and t-CON indicate a communication problem.

Transmission Exceed Codes During operation of the lift truck, the APC216 controller may display transmission exceed codes on the hourmeter/fault code display. These exceed codes show that the request made by the operator will not be executed because of certain circumstances.

APC200 Fault Code Guide 1300 SRM 1435 lists the transmission exceed codes with a description of the encountered circumstances.

Fault Codes

Display fault code E-CON is shown when the following occurs: • The engine controller does not reply to the engine identification request or request for fault codes.

• The engine controller stops sending one of the regular messages, such as engine RPM or engine coolant temperature.

Description Under normal conditions, the hour meter/fault code display on the instrument cluster shows engine running hours. The maximum hours that can be displayed is 9999.9 hours.

• Hourmeter reading

8

Display fault code t-CON is shown when the instrument cluster does not receive a cyclic message or receives incorrect error messages from the APC216 controller.

Fault codes that appear as tE123 are for faults that occur during calibration of the transmission.

1300 SRM 1608

Control System

Fault Log Mode

Clear

Access

To clear the fault codes logged in the display, proceed as follows:

The instrument cluster has a memory that records each fault as it occurs. The faults that have occurred can be reviewed at a later point in time by entering into the fault log mode. Proceed as follows to enter into the fault log mode: 1. Apply the parking brake.

2. Turn the key switch to ON, but do not start the lift truck.

3. Turn the key switch OFF and ON three times, switching one time per second. After the first OFF and ON cycle, the display will show a ‘1’.

After the second OFF and ON cycle, the display will show a ‘2’. After the third OFF and ON cycle, the display will show a ‘3’.

The display is now in fault log mode. When no faults have been recorded, the LCD display shows ‘clear’.

When faults have been recorded, the display shows a letter and four numbers for each fault code. For engine fault codes, the letter is ‘E’. For transmission fault codes, the letter is ‘t’.

After the fault code, three numbers are shown which represent the following: • Fault code • Hourmeter reading at last occurrence • Hourmeter reading at first occurrence • Number of occurrences of current fault Each number is shown for three seconds, after which the following number is shown. The faults will be shown in the opposite sequence of occurrence: the most recent fault first and the initial fault last. When all recorded fault codes have been shown, the display will continue to repeat the recorded fault codes until the user exits the fault log mode.

Exit To exit the fault log mode, turn the key switch OFF and then ON, leaving the key switch ON for more than two seconds. The cluster will also exit to normal mode when the parking brake is released or when the engine is started.

1. Access the fault log mode. See Access.

2. Clear the fault log by cycling the ignition key OFF and ON three more times. This is a repetition of the procedure to access the fault log mode.

See Access.

If the data-erasing process is successful, the display will show ’clear’. If the data-erasing process is not successful, the display will show the fault codes in the memory, shown in the order by the time of the occurrence. To return to the normal mode, follow the procedure as described in Exit. To retry erasing stored fault codes, follow Step 2 of the procedure to clear fault codes.

Fault Rectification Fault codes are listed in APC200 Fault Code Guide 1300 SRM 1435, which provides an explanation of the fault, the resulting action of the APC216 controller, and checks for troubleshooting. Each fault code represents a specific defect or malfunction.

In most cases, the suggested solution is to check electrical functionality between the APC216, the wiring and sensors, solenoids, or switches.

Before disassembling components for test purposes, connect the Dana Dashboard software. The screen ‘Dashboard-Monitor’ allows verification of the functionality of speed sensors, the pressure switch, and the shift lever. If several possible defects are indicated, Dana Dashboard software may narrow down the number of possible defects, preventing unnecessary removal of components that function correctly.

To rectify problems with switches, solenoids, and sensors, look up their actual location, and test the component. The location of the solenoids are shown in the section Transmission Control Valve. The location of sensors and switches are shown in the section Pressure, Speed, and Temperature Sensors. Test values of solenoids and sensors are shown in the section Temperature Sensor (In Speed Sensor) Resistance Versus Temperature.

9

Control System

1300 SRM 1608

Note that the Dana Dashboard software and the APC200 Fault Code Guide 1300 SRM 1435 have wire references and input references that relate to the APC216.

Refer to APC200 Wire Number to Hyster Wire Number Conversion for the conversion from APC216 wire numbers to Hyster wire numbers.

To determine the exact location of a harness problem, refer to the APC200 Fault Code Guide 1300 SRM 1435.

TRANSMISSION CONTROL VALVE

A hydraulic schematic of the control valve is included in the Hydraulic Diagram. See Figure 4.

The transmission control valve consists of two separator plates, the regulator valve and the full flow valve. See Figure 5 The function of the separator plates is to provide the proper hydraulic connection between transmission housing, regulator valve and full flow valve.

The Regulator Valve houses all pressure regulating valves. See Figure 6. The filter by-pass valve is incorporated in the filter element.

Functioning of the control valve depends on available pump supply pressure and the activation of the electrical solenoids by the APC216 controller.

The Full Flow Valve houses all solenoids and pressure sensors. See Figure 7 and Table 2. The pressure sensors measure applied pressure in the clutches for 1st, 2nd and 3rd gear. The pressure signal is used by the APC216 to control activation of the proportional solenoids. Activation of the selector valve solenoids is through an on/off signal from APC216.

1. GASKET 2. SEPARATOR PLATE

3. REGULATOR VALVE 4. FULL FLOW VALVE

The transmission control valve is located at the front of the transmission. It contains the pressure sensors, all solenoids and most of the check ports.

Figure 5. Control Valve Components

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1300 SRM 1608

Control System

1. SAFETY VALVE, 9 bar (131 psi) 2. PORT 12, FROM COOLER 3. CONVERTER BYPASS VALVE, 5 bar (73 psi)

4. PRESSURE REGULATOR, 28.5 to 31.5 bar (413.3 to 456.8 psi) 5. SUMP TEMPERATURE SENSOR

Figure 6. Regulator Valve Components Table 2. Solenoid Description Connector

Description

1.

CPS177

Reverse Selector Solenoid

2.

CPS176

Forward Selector Solenoid

3.

CPS167

1st/3rd Gear Selector Solenoid

CPS168

1st/3rd Gear Proportional Solenoid

CPS174

Forward/Reverse Proportional Solenoid

6.

CPS175

2nd Gear Proportional Solenoid

7.

CRP14

2nd Gear Pressure Sensor

8.

CRP13

1st/3rd Gear Pressure Sensor

4.

5.

Figure 7. Solenoid Locations

11

Control System

Transmission Control Valve Repair Repairs to the control valve are limited to replacing solenoids and gaskets. Hydraulic components of the control valve may be inspected, but cannot be adjusted and are not available for replacement.

For details on control valve repairs or replacement, refer to the manual TE-13 & TE-17 Transmission Repair, With Full Flow Valve 1300 SRM 1603.

Oil Pressure Check Most of the transmission oil pressures can be measured at the side of the control valve. See Figure 9, which lists the check port numbers and their descriptions. Additional check ports for transmission oil pressures are at different locations on the transmission. See, Figure 10, Figure 11, Figure 12, and Table 4. The port numbers mentioned at each check port correspond with the port numbers as shown in Figure 4. Figure 4 also shows the nominal pressure values.

1300 SRM 1608 breather to avoid accidental pressurization of the transmission housing. Remove air pressure supply immediately when a big internal leak is apparent.

When applying air pressure to the clutch test ports, make sure that the related solenoids for selector valves and proportional valves are activated and that the system pressure supply line is sufficiently filled with oil.

With the transmission control valve removed, air pressure can be applied to the clutch ports indicated in Figure 8.

The oil pressures are not adjustable. If a pressure is out of specification, its cause must be established.

If a pressure reducing valve causes the problem, replace the spring and or the spool. If the failure persists, it may be necessary to replace the entire regulator valve

Check by Air Pressure It is possible to use air pressure to establish clutch piston movement and / or obvious piston leaks.

Air pressure should be approximately 14 bar (200 psi). Temporarily remove the transmission

12

1. REGULATOR 2. 3RD CLUTCH 3. FORWARD

4. 2ND CLUTCH 5. REVERSE 6. 1ST CLUTCH

Figure 8. Transmission Control Valve Ports

1300 SRM 1608

Control System Legend for Figure 9 Legend Item No.

Port Number

Description

1.

45

Forward Clutch Pressure

2.

46

Reverse Clutch Pressure

3.

33

Pressure Cooler Return

4.

43

3rd Clutch Pressure

5.

31

System Pressure

6.

42

2nd Clutch Pressure

7.

66

FWD/REV Regulated Pressure

8.

67

1st/3rd Regulated Pressure

9.

41

1st Clutch Pressure

Figure 9. Check Ports, Control Valve

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2.

3.

4.

TEMPERATURE SWITCH TURBINE SPEED SENSOR OUTPUT SPEED SENSOR PORT 46, REVERSE CLUTCH

5. PORT 12, FROM COOLER 6. PORT 46, REVERSE CLUTCH 7. PORT 45, FORWARD CLUTCH

8. DRUM SPEED SENSOR 9. ENGINE SPEED SENSOR 10. PORT 35, PUMP SUPPLY

Figure 10. Ports and Sensors, Top View

13

Control System

1. PORT 34, LUBRICATION 2. BREATHER 3. ENGINE SPEED SENSOR

1300 SRM 1608

4. PORT 35, PUMP SUPPLY 5. DRUM SPEED SENSOR 6. PORT 46, REVERSE CLUTCH

7. PORT 45, FORWARD CLUTCH 8. SUMP TEMPERATURE SENSOR

Figure 11. Ports and Sensors, Left View

1. OUTPUT SPEED SENSOR 2. DAMPING SPOOL 3. PORT 43, 3RD SPEED CLUTCH

4.

5.

6.

7.

PORT 33, COOLER RETURN TURBINE SPEED SENSOR TEMPERATURE SWITCH PORT 11, TO COOLER

8. PORT 34, LUBRICATION 9. PORT 32, COOLER SUPPLY 10. PORT 37, SAFETY VALVE

Figure 12. Ports and Sensors, Right View

14

1300 SRM 1608

Control System

NOTE: The thread for check ports 45 and 46 is M12 x 1.5, O-ring.

All other control valve check ports are provided with threads M10 x 1, O-ring.

Pressure Specifications The relief pressures in the transmission are influenced by the volume and viscosity of the oil passing through the relief valves. Smaller supply volumes and lower viscosity result in lower system pressures.

Larger supply volumes and higher viscosity result in higher system pressures. The volume of oil flowing

through the relief valves depends on engine speed.

Viscosity depends on the oil quality, and decreases with higher temperatures. Make sure the oil quality meets the required specification and has been replaced at the correct interval. Temperature of the oil must be 82 to 93°C (180 to 200°F) for correct pressure measurement. See Table 3 for pressure specifications.

In the cooling and lubrication circuit, the torque converter causes additional flow resistance with increasing speed difference between the engine and the transmission input shaft.

Table 3. Pressure Specifications Description

Port

Pressure Specification

In Filter Element

4.5 bar (65 psi)

Safety Valve

37

7.5 bar (109 psi) minimum at 600 rpm.

Regulator Pressure

31

Filter Bypass Valve

26 bar (377 psi) minimum at 700 rpm.

31 bar (450 psi) maximum at 2300 rpm.

26 bar (377 psi) minimum at 700 rpm.

41, 42, 43, 45, and 46

30 bar (435 psi) maximum at 2200 rpm.

Torque Converter Out

32

3 to 3.5 bar (43 to 51 psi) at stall speed.

Lubrication Pressure

33

1.5 to 2.3 bar (22 to 33 psi) at 1500 rpm, Neutral selected.

Clutch Pressure

15