Twin Disc TA-90-8501, Operator'S Manual

Page 1: ...hift er Shift er Shift er Shift T T T T Tr r r r ransmission ansmission ansmission ansmission ansmission Components TA 90 8501 Transmission 8 FLW 2302 0 Torque Converter TDEC 400 Electronic Control Document Number 1020510 TWIN DISC TWIN DISC TWIN DISC TWIN DISC TWIN DISC INCORPORA INCORPORA INCORPORA INCORPORA INCORPORATED TED TED TED TED ...

Page 2: ... 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 ...

Page 3: ...Document Number 1020510 Revison 1 May 2002 Power Shift Transmission System Operator s Manual ...

Page 4: ......

Page 5: ...inion 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 pla...

Page 6: ...1300 6 1500 6 0 8 0 4 1600 4 2000 6 0 12 0 4 2200 w cooler 12 0 30 0 4 2600 4 3400 w cooler 20 0 40 0 10 000 11 500 6 0 12 0 11 500 HD 13 800 w Radiator 10 0 24 0 w o Radiator 10 0 20 0 16 000 w Radiator 14 0 32 0 w o Radiator 14 0 28 0 Fluid Couplings 14 5 HC HM HU HUC 2 0 4 0 17 5 HC HM HU HUC 2 0 4 0 21 HC HM HU HUC 2 0 6 0 27 HC HM 4 0 8 0 27 HUD w Radiator 8 0 32 0 w o Radiator 8 0 28 0 Power...

Page 7: ...ications 15 General 15 Description 16 Sump 16 Pump 16 Regulator Valve Assembly 17 Range Selector Valve 17 Special Features 18 Specifications 19 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 Contro...

Page 8: ... Elect Control 133 238008A Schematic Hydraulic 134 229578E Diagram Piping 135 1019876 page 1 of 6 Transmission Parts 136 1019876 page 2 of 6 Transmission Parts 137 1019876 page 3 of 6 Transmission Parts 138 1019876 page 4 of 6 Transmission Parts 139 1019876 page 5 of 6 Transmission Installation 140 1019876 page 6 of 6 Transmission Installation 141 X237074A Clutch Assembly 1 4 7 142 X237073A Clutch...

Page 9: ... 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 to...

Page 10: ... any authorized Twin Disc distributor or service dealer 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 ...

Page 11: ...e 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 Lifting Bolt Holes Most Twin Disc products have provisions for attaching lifting bolts The holes provided are always of adequate size and number to safely lift the Twin Disc product These lifting points must not be used to lift the com...

Page 12: ...Because of the possible danger to person s or property from accidents which may result from the use of manufactured products it is important that correct procedures be followed Products must be used in accordance with the engineering information specified Proper installation maintenance and operation procedures must be observed Inspection should be made as necessary to assure safe operations under...

Page 13: ...ed changes are made to reflect advancing technology and improvements in state of the art Individual product service bulletins are issued to provide the field with immediate notice of new service information For the latest service information on Twin Disc products contact any Twin Disc distributor or contact the Product Service Department Twin Disc Incorporated Racine Wisconsin 53405 3698 USA or by...

Page 14: ...er Shift Transmission System Operator s Manual 1020510 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 ...

Page 15: ... are electronically controlled by a Twin Disc model TDEC 400 control Model Identity Numbers and Letters TA 90 8501 BOM 67425 T Transmission A No drop box output and input are axially in line 9 Nine speeds forward 0 No reverse 85 Transmission model series 01 Basic model number Assigned in consecutive sequence to identify specific modifications or gear ratios 8 FLW 2302 0 BOM 67288 8 type 8 Twin Dis...

Page 16: ...ssemblies 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...

Page 17: ...mounted on the left of the transmission housing viewed from the rear control the application of the transmission clutches The valves are controlled by electronically modulated signals These valves are identical and are identified as 1 2 3 4 5 and 6 These solenoid numbers are referenced in the electronic control system drawing to aid technicians in troubleshooting the system The lockup clutch in th...

Page 18: ...ing 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 ea...

Page 19: ... 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 ClutchApply Pressure CL Within 12 psi 83 kPa of main at end caps Transmission Lube Pressures 35 60 psi 24...

Page 20: ... load 1950 rpm No load 1960 rpm Converter stall speed 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...

Page 21: ...vers 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 ...

Page 22: ...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 If the oil temperature is at operating temperature 80 100 o C the oil level can be checked With the engine at low idle fo...

Page 23: ...anual 1020510 Basic System Description This section describes the function and relationship of the following major components in your power transmission system q Remote mounted transmission TD90 8501 q Engine mounted torque converter 8FLW 2302 0 q Electronic control system TDEC 400 ...

Page 24: ...RANSMISSION OIL FILTER DIFF PRESS SWITCH SWITCH INPUTS LIQUID CRYSTAL DISPLAY VIA J1939 POWER SOURCE TRANSMISSION ENGINE MISCELLANEOUS TDEC 400 24VDC NEUTRAL DISCONNECT OIL LEVEL KEY SWITCH SYSTEM OIL J1939 BUS OUTPUTS J1939 BUS INPUTS WORK MODE SWITCH RANGE SELECTOR WORK MODE POT LOCKUP OFF SWITCH TRAN INPUT SPEED SYSTEM OIL TEMP TRAN OUTPUT SPEED TRANS FILTER DIFF PRESS SWITCH STATUS OIL LEVEL S...

Page 25: ...25 Twin Disc Incorporated Operation Power Shift Transmission System Operator s Manual 1020510 Figure 2 Hydraulic Torque Converter ...

Page 26: ...26 Twin Disc Incorporated Operation Power Shift Transmission System Operator s Manual 1020510 Figure 3 Power Shift Transmission Engine Side Side B ...

Page 27: ...27 Twin Disc Incorporated Operation Power Shift Transmission System Operator s Manual 1020510 Figure 4 Power Shift Transmission Side and Top View ...

Page 28: ...28 Twin Disc Incorporated Operation Power Shift Transmission System Operator s Manual 1020510 Figure 5 Power Shift Transmission Opposite Input Side A ...

Page 29: ...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 RemoteMountedTransmission The remote mounted transmission contain...

Page 30: ...ascaded to meet the demands of the next area Hydraulic system components and their functions are as follows TransmissionSump 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 pro...

Page 31: ...he remaining flow into the torque converter circuit supply cavity Cold Oil Relief A cold oil relief valve is located in the regulator valve body that senses pressure at the torque converter pressure supply cavity Excessive pressure causes the valve to open and bypass oil back to the oil pump suction cavity which protects the torque converter circuit from excessive pressure ConverterRegulatorValve ...

Page 32: ...sure to apply the desired clutch packs When another range is selected the valve coils for the new range are energized and the valve coils for the previous range are de energized allowing the passage of clutch apply oil to the sump thus releasing the clutch These valves are powered with signals that are capable of controlling the pressures at intermediate levels for improved shift quality Converter...

Page 33: ...utput 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 Lockup Clutch Drive The lo...

Page 34: ...ch 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 i...

Page 35: ...irectly to the battery negative The electronic control is active when applied voltage is between 10 and 28 volts dc Note The 10 amp input power circuit protection device must not exceed the time current characteristics of anATO type fuse If the installed device is larger or slower responding than specified the wiring could be damaged and the system made inoperable Interruption of Power 1 Interrupt...

Page 36: ...e Figure 1 in Operation The electronic control system consists of the following components 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 Transmission Range Selector The transmission range selector is customer supplied and is used to selec...

Page 37: ...arameters 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 rig s J1939 data bus The J1939 Data Bus is a communication link designed into the fracturing rig Refer to the...

Page 38: ...ansmission oil level switch q Relay customer supplied to remove power from disconnectable clutch valve coils when in neutral q Dedicated ground connection to the battery negative q Dedicated fused 10 Amp 24 volt battery power q Fracturing rig key switch The S A E J1939 Data Bus Inputs Are q Transmission range selector signal q Work mode or Hydraulic Test mode command if applicable q Potentiometer ...

Page 39: ...nsmission range valve clutch coils used to engage the proper clutches to provide the transmission range desired q Electrical current to the lockup clutch valve coil used to apply the converter lockup clutch as needed The S A E J1939 Data Bus Output Signals Are q Signals to the display unit indicating the transmission range and direction q Transmission input and output speed q Transmission system o...

Page 40: ...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 ...

Page 41: ...on 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 turbin...

Page 42: ...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 engin...

Page 43: ...at 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 w...

Page 44: ...etween 5 and 11 ohms depending on temperature The control is programmed with the appropriate resistance of each of the valves and the wires to from the valve and checks the external circuits continuously If it detects a value that is out of range it shows a display message on the display to alert the operator to check the circuit and the valve This will alert the operator if a wire is cut or short...

Page 45: ... Manual 1020510 System Operation Start Up 1 Select N on the range selector This de energizes the neutral disconnect relay which opens the contacts disconnecting all power from the transmission solenoids 2 Activate the start switch to supply electrical power to the starter circuit ...

Page 46: ...ircuit when a gear range has been selected with the range selector The electronic control does a self test sequence and upon passing this looks at the various input signals If N has been selected with the range selector the operator is allowed to start the engine The electronic control continuously monitors the various inputs and outputs to prevent improper operation of the transmission system Whe...

Page 47: ...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 c...

Page 48: ...work mode will be ignored Operation in the work mode requires that the input speed remain below a predetermined level Speed increases beyond that level will result in the transmission being automatically be placed in Neutral Upon entering the work mode and a range selected the appropriate input section clutch will be engaged and the low range output section clutch Solenoid 4 will be engaged at a l...

Page 49: ...n of the controller integrity and function of the external circuits and provide a means to energize clutches individually Fifteen separate tests can be individually selected and performed via the display unit Please refer to Troubleshooting for the correct troubleshooting procedures This mode is entered by simultaneously depressing the up and down arrow switches on the display unit while powering ...

Page 50: ...0 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 ...

Page 51: ...ng 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 Transmission ConverterOverhaulInterval A complete overhaul of the transmission and converter should be accomplished at the same time as a scheduled engine overhaul This is...

Page 52: ...tem Checking Oil Level The oil level in the transmission must be checked before each use Procedure for checking oil is as follows 1 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 ...

Page 53: ...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 If the oil temperature is at operating temperature 80 100 o C the oil level can be checked With the engine at low idle for 5 minutes the transmission in neutral the low level sight gauge should be completely full and the hot oil level sight gauge should show 1 4 to 1 2 full...

Page 54: ...r every 1200 hours of operation Change the oil filter after each 300 hours of operation or sooner if the filter pressure indicator shows TRAN OIL FILTER in the display Note The TRAN OIL FILTER message is triggered by a switch that senses pressure drop across the filter As the filter fills with contamination the pressure drop increases A filter may show an TRAN OIL FILTER message under cold oil con...

Page 55: ...uirements of MIL L 2104E OilViscosity 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...

Page 56: ...support six inches back from each connector The cable or harness must be secured at 18 inch intervals to its own frame supports between the cable or harness ends 2 Keep cable or harness away from hot surfaces moving parts and oil locations 3 Attach cable or harness to machine making the connector the highest point of the cable If not possible install cable or harness with drip loop 4 Protect cable...

Page 57: ...lation or removal 11 Whenever mating connectors always inspect each for damage or defects For example bent pins pushed back sockets broken keys etc 12 Check that sure seal connectors have clip clamps in place 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 s...

Page 58: ...e connections chafing etc Correct leaks and replace damaged parts Lines hoses etc which show evidence of chafing should be replaced rerouted and or otherwise protected to prevent further damage ExternallyMountedComponents Periodically inspect split lines between housing halves and between externally mounted components such as valves and covers for leakage or damage Repair leaks and or replace dama...

Page 59: ...distance from the fracturing rig tires Gages must be installed while the engine is not running Pressure checks are made with the engine running the transmission in neutral and the fracturing rig parking brakes on No one must be allowed in front of nor behind the fracturing rig nor near the fracturing rig tires Check main and lube system pressures as follows 1 Select desired check point and install...

Page 60: ...60 Twin Disc Incorporated Power Shift Transmission System Operator s Manual 1020510 Preventative Maintenance ...

Page 61: ...trol 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 diag...

Page 62: ...urately test and troubleshoot the hydraulic system of this Twin Disc unit The kit contains pressure gauges hoses adapters and flow meters Contact the Twin Disc Service Department Racine Wisconsin for specific information concerning this test kit One principle of troubleshooting is to start with the simple and move to the more difficult Check the simple items first Run the simple test first Then mo...

Page 63: ...ncludes the following topics q Problems that do not produce a fault message in the display q Problems that do produce a fault message in the display q Pressure testing for troubleshooting q Recommended testing following field service repairs This should be performed after the installation of any major components such as transmission or torque converter ...

Page 64: ...oting 1 Display is blank with the ignition in the on position Possible causes No dc Power to the Display Verify that the proper dc voltage 24 volts is supplied to the transmission display connector FailedDisplay 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 Replac...

Page 65: ...output driveshaft now rotates properly low oil level was the cause of malfunction If oil level is high and does not drop when the engine is running either the oil level was set over full or the main pump is not supplying oil FailedMainPump Since the output driveline will not rotate it is possible that the pump is not supplying oil Check main pressure with a pressure gage at the transmission main p...

Page 66: ...the input drive shaft should come to a stop quickly If R is selected three clutches are deliberately engaged thus stalling the torque converter If the input drive shaft stops and the output driveshaft does not move when D1 is selected the transmission may be locked up internally or the oil fracturing pump may be locked up If the drive shaft does not come to a stop when shifted out of N and the out...

Page 67: ...t driveline comes to a stop when N is deselected remove the output drive shaft from the transmission to verify that the transmission is not the cause of the problem With the transmission output drive shaft removed the transmission input shaft should rotate in N and any Drive range The transmission output flange should rotate when any Drive range is selected by using the upshift button on the range...

Page 68: ...e and or the output driveline rotates run Test 8 and check pressure to the applied clutch packs These can be checked by upshifting to D2 and D4 Valves 2 and 4 are energized in D2 and valves 2 and 5 are energized in D4 These tests should only be done with the engine at idle speed If the clutch pressures are good when engaged and the drive shaft into the transmission doesn t stop when R is selected ...

Page 69: ...the transmission does not stop when D is selected and the output drive line does not rotate then the range clutch pack is slipping internally Dark or burnt oil is confirmation of clutch damage Remove the transmission for repair If the range clutch pressure is acceptable when engaged and the drive shaft into the transmission does stop when D is selected and the output driveline flange does not rota...

Page 70: ...at 1950 RPM Values will vary somewhat with oil temperature Pressure well below specification will produce poor converter performance Check the converter pressure regulator for a broken spring or stuck spool Check the transmission lube pressure as well Low lube pressure is an indication of low transmission main pump flow Replace the main pump Low Engine Power With Nselected fullyadvancetheenginethr...

Page 71: ... pump Disconnect the hose at the outlet side of the scavenge pump and direct it to a bucket Start the engine and observe if oil is coming from the pump Initiallythehoseshouldrunfulluntiltheoilfromtheflywheelhousing is evacuated While the hose is running full catch the oil in a 2 liter or gallon container and measure the time to fill the container At 700 RPM the pump should deliver 21 3 liter minut...

Page 72: ...noid With the engine running at low idle go into Test 8 and select LOCKUP to verify that the converter lockup clutch pressure is following the pressure versus current Observe main pressure at the same time Follow the instructions as outlined in the electronic test mode section If lockup clutch pressure is low but main pressure remains normal replace the proportional valve on the converter LockupCl...

Page 73: ...Scavenge from Engine Flywheel Follow engine flywheel scavenge checks as outlined in step 5 Low Oil Flow Through the Converter and Cooler Measure transmission main and lube pressures and converter outlet pressure Low pressure especially low lube pressure is an indication of low oil flow through the torque converter Replace the transmission main pump on the torque converter Cooler Not Working Proper...

Page 74: ...ngs Check all hoses and fittings for leaks Repair as needed Seal Leak Between Engine and Torque Converter Check the engine oil If the transmission continues to lose oil and the engine gains oil it is likely that the engine crankshaft oil seal at the rear of the engine is leaking The converter must be removed from the truck and the engine crankshaft oil seal replaced ...

Page 75: ...engine cranking system and power supply is discussed here as the transmission control system criteria calls for the engine cranking to only occur when the transmission is in neutral The customer supplied neutral disconnect relay circuit is between the range selector and the oil well fracturing rig starting circuit A comprehensive testing of this circuit is necessary when troubleshooting engine cra...

Page 76: ...well fracturing rig pump Look for bad universal joint assemblies Verify that the universal joints are phased properly universal joint yokes at each end of the center section must be parallel with each other Inspect cross and bearing journals for brinelling or other damage With the range selector in the N position run the engine speed up slowly If there is vibration present in the speed range the d...

Page 77: ...LL SYSTEM CABLES CONNECTED AND TIGHT CONNECT AND TIGHTEN DOES OUTPUT DRIVE SEE NEXT CHART TITLED DRIVESHAFT WON T TURN DISPLAY SHOWS D IF AFTER 30 SECONDS DISPLAY REMAINS BLANK REPLACE DISPLAY UNIT No Yes Yes Yes No No 24 VOLTS PIN 1 TO 2 ON 6 PIN CONNECTOR AT DISPLAY Yes CHECK FOR BROKEN WIRES No Possible causes No D C power to display loose cables failed display Figure 6 Troubleshooting Flowchar...

Page 78: ...ESSURE PORT X REMOVE OIL TO PROPER LEVEL 185 minimum CHECK FOR OIL PUMP SUCTION LEAKS See Trouble Shooting Discussion BELOW 185 PSI REPAIR SUCTION LEAKS REPLACE OIL PUMP Yes No TRANSMISSION IN NEUTRAL IS DRIVESHAFT TURNING PUT SELECTOR IN RANGE IS DRIVESHAFT TURNING No Yes RUN PRESSURE TEST TO DIAGNOSE TRANSMISSION IS HYDRAULICLY LOCKED UP RUN PRESSURE TEST TO DIAGNOSE No Yes ENGINE OFF DOES TRANS...

Page 79: ...CE FAULTY RANGE VALVE IF ALL PRESSURES ARE NORMAL ONE OR MORE CLUTCH IS SLIPPING REMOVE TRANSMISSION MAIN NORMAL OTHER ZERO SWAP LOW PRESSURE RANGE VALVE WITH ANOTHER RANGE VALVE MAIN NORMAL OTHERS NORMAL MAIN NORMAL OTHERS LOW ENGINE AT IDLE DOES TRANSMISSION DRIVESHAFT STOP IN REVERSE THIS IS NORMAL IN WARM UP Yes No REMOVE AND REPAIR TRANSMISSION NO CHANGE Yes Possible Causes Failed range clutc...

Page 80: ...E IF ALL PRESSURES ARE NORMAL ENGAGED CLUTCH IS SLIPPING REMOVE TRANSMISSION MAIN NORMAL CLUTCH ZERO SWAP AFFECTED RANGE CLUTCH VALVE WITH A KNOWN GOOD RANGE CLUTCH VALVE MAIN NORMAL CLUTCH NORMAL MAIN NORMAL CLUTCH LOW ENGINE AT IDLE DOES TRANSMISSION INPUT DRIVESHAFT STOP IN A DRIVE RANGE RUN PRESSURE TEST 8 EXTRA CLUTCH MAY BE APPLIED Yes REMOVE AND REPAIR TRANSMISSION NO CHANGE SELECT A DIFFER...

Page 81: ...D AGREE WITH ENGINE STALL TORQUE SPECIFICATION EXPECT 2000 to 2050 RPM RUN TEST 8 ON LOCK UP CLUTCH AND RANGE CLUTCH VALVES PERFORM CONVERTER SCAVENGE PUMP TEST See Fig 14 IDENTIFY AND CORRECT PROBLEM WITH TORQUE CONVERTER No Yes Yes SERVICE ENGINE Pass Fail MEASURE LOCKUP AND MAIN PRESSURE IN TEST 8 REPLACE CLUTCH RANGE VALVE ON CONVERTER INTERNAL LEAKAGE REMOVE AND REPAIR CONVERTER LOCK UP CLUTC...

Page 82: ...GES Possible causes Worn clutch pack slow range clutch valve improper pressure improper speed signal defective temperature sensor CHECK FOR DARK OR BURNED SMELLING OIL RUN TEST 5 TEST 6 and TEST 7 AND VERIFY INTEGRITY AND ACCURACY OF TRANSMISSION TEMPERATURE SENSOR PERFORM PRESSURE TEST Figure 11 Troubleshooting Flowchart ...

Page 83: ...RUNS HOT Possible causes Too much oil in transmission poor scavenge from engine flywheel low oil flow thru converter and cooler cooler not working properly ADJUST TRANSMISSION OIL TO PROPER LEVEL PERFORM TORQUE CONVERTER SCAVENGE TEST PERFORM PRESSURE TEST INSPECT AND REPAIR COOLING SYSTEM Figure 12 Troubleshooting Flowchart ...

Page 84: ... BUCKET IDLE ENGINE AT 700 RPM AND MEASURE OIL FLOW RATE BY MEASURMENT AND TIME NOTE FLOW RATE OIL FLOW REMAINS STEADY AT PUMP RATED CAPACITY APPROXIMATELY 5 6GPM 700 RPM AFTER A SHORT TIME OIL FLOW SHOULD INCLUDE SOME AIR AND MEASURED FLOW RATE SHOULD SLOW CONVERTER LEAKAGE EXCESSIVE REMOVE AND REPAIR CONVERTER CLEAN PUMP INLET SCREEN AND EXAMINE DEBRIS FOR POSSIBLE ORIGIN Low Flow but converter ...

Page 85: ...efinitions General The control system is designed to maintain safe operation in all modes of operation The system also runs special software routines in conjunction with the main program to check system integrity For example if a range is engaged a test routine checks that the correct range clutch valves are turned on and that all others are off If not the system reacts by going to neutral At the ...

Page 86: ...LECTOR FAULT N A Test via J1939 bus TRAN SYS FAULT TranSol1 BD COMBO Transmission Range Clutch valve coil 1 TRAN SYS FAULT TranSol1 CIRCUIT Transmission Range Clutch valve coil 1 TRAN SYS FAULT TranSol2 BD COMBO Transmission Range Clutch valve coil 2 TRAN SYS FAULT TranSol2 CIRCUIT Transmission Range Clutch valve coil 2 TRAN SYS FAULT TranSol3 BD COMBO Transmission Range Clutch valve coil 3 TRAN S...

Page 87: ...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 Trouble...

Page 88: ... electronic control to repower act as if the power was turned off then on If a position other than N has been selected a SELECT NEUTRAL fault message will appear Possible causes A The code may appear briefly when electrical power is removed from the control during activation of the starter or when the run switch is turned off This is a normal response to input power dropping off B Battery voltage ...

Page 89: ... transmission system TRAN SYS FAULT Message INPT SPD Log Code This fault message will be displayed if the control recognizes an open or short in the transmission input speed sensor circuit The transmission output speed sensor signal will be used to determine the engagement of the torque converter lockup clutch based on the range that the transmission is in The display message will not be cleared u...

Page 90: ...ission input speed sensor that is out of adjustment or damaged The sensor is located on the upper left side of the transmission The sensor can be adjusted as follows A Remove the transmission input speed sensor B Thoroughly clean the transmission input speed sensor or replace if damaged C Align the gear seen through the transmission input speed sensor hole so the gear tooth is in the middle of the...

Page 91: ...and the control power cycled by the key switch The circuit can be checked by removing the J4 cable and checking terminals J3J1 and J3J2 If the measured impedance is not proper at these points the cable must be disconnected at the sensor to determine the location of the fault The proper coil impedance is 5 to 11 ohms TRAN SYS FAULT Message NEUTRAL FAULT Log Code This fault message will be displayed...

Page 92: ...from the control There should be no circuit between either of these terminals and the chassis ground which is J4X3 If the measured impedance is not proper at these points the cable must be disconnected at the sensor and at the transmission junction to determine the location of the fault Note If both the transmission input speed sensor and the transmission output speed sensor fail simultaneously wh...

Page 93: ...roblem is a transmission output speed sensor that is out of adjustment or damaged The sensor is located near the output shaft of the transmission The sensor can be adjusted as follows A Remove the output speed sensor B Thoroughly clean the output speed sensor or replace if damaged 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 ...

Page 94: ... data agrees Troubleshooting Test 3 and Test 4 can be used to test the opening and closing of individual relay contacts and the J1939 data from the selector A closed switch has approximately 0 OHMS of resistance An open switch has resistance too large to be measured TRAN SYS FAULT Message TranSol 1 through 6 Log Code BD COMBO Status Code This fault message will be displayed if the control detects ...

Page 95: ...he chart that follows The proper impedance for each coil is 5 to 11 ohms Table 2 Transmission Solenoid Listing Log Code Solenoid Energized Connector Contacts Approximate Resistance Ohms TranSol1 1 J4 J4S1 and J4S2 5 to 11 TranSol2 2 J4 J4N2 and J4 N3 5 to 11 TranSol3 3 J4 J4M2 and J4M3 5 to 11 TranSol4 4 J4 J4L1 and J4L2 5 to 11 TranSol5 5 J4 J4P1 and J4T1 5 to 11 TranSol6 6 J3 J3K1 and J3 J3 5 to...

Page 96: ...esistance is measured into the valve and there is no connection to the chassis reconnect the harness to the valve a Unplug the J4 cable from the electronic control b Measure the resistance between the contacts shown Resistance value should be the same as measured at the valve itself If the resistance is very high there is a fault in one of the harnesses from the control to the valve or there is a ...

Page 97: ...H StatusCode 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 ...

Page 98: ...L PWR PROB LOW HIGH HIGH LOW REPLACE CONTROL CAUSE ACTION PWR PROB CHECK VOLTAGE SUPPLY RUN TEST 2 CHECK CHARGING SYSTEM RUN TEST 2 SELECT NEUTRAL FILTER DIFFERENTIAL PRESSURE HIGH WARM OIL OR CHANGE FILTER CHECK J1939 BUS OIL FILT PLUGGED LOG CODE I1 I24 I15 ACC PEDL I16 INTERNAL CONTROL PROBLEM J1939 DATA SIGNAL MISSING NEUTRAL NOT SELECTED VOLTAGE TOO LOW VOLTAGE TOO HIGH Figure 14 Troubleshoot...

Page 99: ...TEST 5 LOCKUP LOCKUP VALVE COIL IMPEDANCE TRAN SYS FAULT RUN TEST 4 NEUTRAL FAULT NEUTRAL DISCONNECT SWITCH TRAN SYS FAULT RESISTANCE 1000 TO 1300 OHMS RUN TEST 5 OUT1 SPD TRANSMISSION OUTPUT SPEED SENSOR TRAN SYS FAULT ADJUST OR REPLACE SENSOR OUT1 SPD FREQ TRANSMISSION OUTPUT SPEED SENSOR TRAN SYS FAULT RUN TEST 3 SELECTOR FAULT RANGE DIRECTION SELECTOR SWITCHES OPEN SHORT CIRCUIT OPEN SHORT TRA...

Page 100: ...ACE RUN TEST 5 SYSTEM TEMPERATURE CIRCUIT BAD TRAN SYS OVR HEAT INVESTIGATE HOT OIL OR SENSOR RUN TEST 7 SYST TMP SYSTEM TEMPERATURE HIGH SIGNAL INVESTIGATE COLD OIL OR SENSOR RUN TEST 7 SYSTEM TEMPERATURE LOW SIGNAL CIRCUIT HIGH LOW DISPLAY FAULT DISPLAY FAULT J1939 MESSAGE LOSS DISPLAY TEST CHECK J1939 BUS CHECK CABLE IF GOOD REPLACE DISPLAY COM FAILURE Figure 16 Troubleshooting Flowchart ...

Page 101: ... 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 fracturin...

Page 102: ...st 11 Speed Out Test NO NO Test 12 Warranty Date and Software Hardware Version NO NO Test 13 Adjust Display NO NO Test 14 Sensor Calibration NO NO Test 15 Fault Log NO NO Test Running Engine Required Stopped Engine Required Test 1 Display Test NO NO Test 2 Power Supply Test NO NO Test 3 Range Direction Selector Test NO YES Test 4 Discrete Switch Test NO YES Test 5 GP4 Controller Boundary Scan Test...

Page 103: ...multaneously depressing the up and down arrow button Test 2 Power Supply Test The following sub menu items will be displayed SUPPLYPOWER INTERNAL POWER EXIT TEST These are scrolled through by depressing the up or down arrow button To enter one of the tests simultaneously depress both the up and down arrow button Once entered the sub menu test may be exited by pushing the up arrow button SUPPLY POW...

Page 104: ...the display matches the position of the selector The following positions can be tested q Upshift q 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 Test 4 Discrete Switch Test The following sub menu switches will be listed by depressing the up arrow button OIL FILT OIL LEVEL LOCKUP OFF ...

Page 105: ...st be removed from neutral to run this test DESELECT NEUTRAL will be displayed if the selector is left in neutral The display will show TESTING followed by TEST PASSED if all functions are normal Depressing the up arrow button or moving the selector to neutral will terminate the test and display EXIT TEST If a fault is detected in a speed sensor circuit the top half of the display will indicate wh...

Page 106: ...ted to ground LeadAor lead B connected to positive voltage or Leads A and B connected together low coil resistance Control Figure 17 Valve Coil Fault Schematic If a miscellaneous sensor circuit voltage is found to be out of range during the testing the out of range sensor circuit will be indicated on the display ACC PEDL or SYST TMP If one of these sensors is found to be out of range Test 7 should...

Page 107: ... PEDL and transmission input temperature SYST TMP can be displayed during this test The accelerator pedal position will be displayed with a percent of full travel such as 25 that is obtained from the oil well fracturing rig s J1939 Data Bus Note that if the oil well fracturing rig is not equipped with a work mode switch it may not have an accelerator pedal potentiometer The oil temperatures will d...

Page 108: ...play shall show the identifier of the coil commanded on This test will allow individual transmission or converter clutch valve coils to be energized at any level for pressure testing The following list identifies the selectable menu The display will flash DESELECT NEUTRAL if the selector is not moved out of the Neutral position when the test is entered LOCKUP Converter Lockup Clutch Valve Coil Tra...

Page 109: ... 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...

Page 110: ...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...

Page 111: ...n is pushed or the selector is moved to the neutral position This test should only be performed for short periods of time to allow the transmission system oil temperature to cool sufficiently During the operation of test 9 it is necessary to have all personnel and any obstacles clear of the oil well fracturing rig If the oil well fracturing rig pump is not sufficiently loaded the transmission outp...

Page 112: ...test ADJUST BACKLITE ADJUST CONTRAST FACTORY DEFAULT and EXIT TEST If ADJUST BACKLITE is selected three options are ADJUST BRITENES SET MIN VALUE and EXIT SUB MENU If ADJUST BRITENES is selected the display will indicate ADJUST NOW and the brightness level can be adjusted by the up and down arrow buttons The SET MIN VALUE will apply the lowest allowable setting to the brightness EXIT SUB MENU will...

Page 113: ... contents Note The acronym NVM refers to the Non Volatile Memory in the control ALL FAULTS Record of all faults written to NVM SPEED Record of Speed Sensor faults written to NVM SENSORS RANGE Record of Range Direction Selector faults written SELECTOR to NVM SWITCHES Record of Discrete Switch faults written to NVM MISC SENSORS Record of Miscellaneous analog Sensor faults written to NVM COILS Record...

Page 114: ...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 sele...

Page 115: ...y displayed test from the menu selection v This shape shows exactly what is seen in the display ACTION v This shape shows an action that must be accomplished SEC v This shape shows a time delay that is programmed v Press down button to scroll through menu selection in order shown v Cycle power to exit testing 2 SEC DELAY 5 SEC DELAY PRESS UP BUTTON TO EXIT SUB MENU IF FAILED REPLACE CONTROL SUPPLY...

Page 116: ... OIL FILT OPEN OR CLOSED OIL LEVEL FULL OR EMPTY 4 SWITCH TEST EXIT TEST RUN TEST 5 SCAN TEST ENGINE OFF DESELECT NEUTRAL MOVE SELECTOR FROM NEUTRAL TESTING INPT SPD OPEN OR SHORT OUT1 SPD OPEN OR SHORT LOCKUP FAULT 1 OR FAULT 2 TranSol FAULT 1 OR FAULT 2 ACC PEDL SYSTTMP TEST PASSED OR PRESS UP BUTTON OR SELECT NEUTRAL PRESS UP BUTTON TO CONTINUE THRU TEST NEUT DIS OPEN OR CLOSED MODE SEL OPEN OR...

Page 117: ...COIL TEST MOVE SELECTOR FROM NEUTRAL FULL ON EXIT TEST TranSol EXIT SUB MENU PRESET MODULATE COIL ID XX XXA COIL ID XX XXA COIL ID FULL ON SELECT NEUTRAL 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 EXIT TEST 8th 8th ENGAGED DESELECT NEUTRAL MOVE SELECTOR FROM NEUTRAL MOVE SELECTOR TO NEUTRAL TURN VEHICLE POWER...

Page 118: ...EASE PRESS BOTH TO EXIT 12 VERSN WARRANTY EXIT TEST WARRANTY DATE HARDWARE VERSION SOFTWARE VERSION NOT STARTED DDMMMYY XXXXXXXX XXX OR PRESS UP BUTTON TO EXIT 13 ADJST DISPLAY ADJUST BRITENES EXIT TEST FACTORY DEFAULT ADJUST CONTRAST ADJUST BACKLITE WORKING ADJUST NOW WORKING ADJUST NOW EXIT SUB MENU SET MIN VALUE 10 COMM TESTS EXIT TEST RS232 CONNECT RX TO TX RS232 BAD LINK PRESS UP ARROW OR SEL...

Page 119: ...ENSORS EXIT SUB MENU CLEARING SHORT LG END OF LOG NO LOG FAULTS OR SCROLL THRU FAULTS WITH UP OR DOWN ARROW DEPRESS BOTH SWITCHES TO EXIT TEST CLEAR SHORT FAULTS BY HOLDING UPARROW FOR SIX SECONDS AT BEGINNING OF LIST SCROLL THRU FAULTS WITH UP OR DOWN ARROW DEPRESS BOTH SWITCHES TO EXIT TEST AFTER 2 SECONDS FAULT DATE AND TIME WILL SCROLL 14 SENSR CALIBRTN EXIT TEST Note Sensor information comes ...

Page 120: ...ry helpful in determining the cause of and a solution to a problem A shortcut taken here to only measure the pressure that is of concern can result in erroneous conclusions Install quick connect fittings on the following ports Refer to Figures 2 through 5 in Operation q Main pressure q Converter outlet q Lube q Lockup clutch q Clutch 1 q Clutch 2 q Clutch 3 q Clutch 4 q Clutch 5 q Clutch 6 ...

Page 121: ...il temperature should be warmed to operating temperatures if possible If not this must be taken into consideration during the analysis of the results Use Test 8 to select the converter and transmission range clutch coil Use the FULL ON option when recording pressures in Table 5 in Troubleshooting Troubleshooting the proportional effects of the shift profiles requires that pressure versus current b...

Page 122: ...em Operator s Manual 1020510 Table 5 Pressure Data FULL ON Sub Menu Option Solenoid energized Record Pressure none 1 2 3 4 5 6 Lock up Main Converter Lube Lock up Clutch 1 VENT Clutch 2 VENT Clutch 3 VENT Clutch 4 VENT Clutch 5 VENT Clutch 6 VENT Flow from vented port ...

Page 123: ...sure MODULATE Option Pressure PSI Current of Full Min Clutch 1 Clutch 2 Clutch 3 Clutch 4 Clutch 5 Clutch 6 Lock up Max 0 0 0 5 0 0 10 0 0 15 0 0 20 0 0 25 0 0 30 0 15 35 3 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 ...

Page 124: ...his oil well fracturing rig is equipped with an oil filtering system with a filter bypass warning indicator During the following engine running tests be alert to the TRAN OIL FILTER fault warning on the transmission system display unit If the fault message is indicated and the engine is at idle it is important to change oil filter elements Repeat this as necessary to clean up the oil of contaminan...

Page 125: ..._______ Converter __________ Control __________ Date ________ Tested By __________ Location __________ Electronic Diagnostic Tests Engine not running See diagnostic test in the troubleshooting section of this manual Table 7 Diagnostic Test Test Description Results Test 1 Display check Test 2 Power Supply test Test 3 Range Selector Check Test 4 Switch tests Test 5 Speed sensors coil integrity Test ...

Page 126: ...ine rpm ____________________ 715 rpm Main pressure ____________________ 185 psi minimum Converter outlet pressure ____________________ 30 psi minimum Lube regulator ____________________ 5 psi minimum High Speed Pressure Test Warm oil to 100 C by shifting to Warm up and engine speed up to about 1200 to 1500 RPM When oil is hot shift to N and set engine speed at 1950 RPM Engine RPM _________________...

Page 127: ...the push button range selector Use FULL ON option Table 8 Solenoid Pressures Solenoid energized Record Pressure none 1 2 3 4 5 6 Lock up Main Converter Lube Lock up Clutch 1 VENT Clutch 2 VENT Clutch 3 VENT Clutch 4 VENT Clutch 5 VENT Clutch 6 VENT Flow from vented port Note Clutch apply pressures on disengaged clutch packs should be 0 psi Shaft lube pressures should not change when solenoids are ...

Page 128: ...E option and increase engagement to modulated clutch and record clutch pressure Table 9 Modulated Pressures Pressure PSI Current of Full Min Clutch 1 Clutch 2 Clutch 3 Clutch 4 Clutch 5 Clutch 6 Lock up Max 0 0 0 5 0 0 10 0 0 15 0 0 20 0 0 25 0 0 30 0 15 35 3 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...

Page 129: ...1 4 ________ Transmission should engage in 1st range Upshift 1 to 2 2 4 ________ Transmission should engage in 2nd range Upshift 2 to 3 3 4 ________ Transmission should engage in 3rd range Upshift 3 to 4 1 5 ________ Transmission should engage in 4th range Upshift 4 to 5 2 5 ________ Transmission should engage in 5th range Upshift 5 to 6 3 5 ________ Transmission should engage in 6th range Upshift...

Page 130: ...130 Twin Disc Incorporated Troubleshooting Power Transmission System Operator s Manual 1020510 Figure 23 Pressure vs Current Coil Up Graph Figure 24 Pressure vs Current Coil Down Graph ...

Page 131: ... your bill of material for part numbers specific to your model q 1019142 System Elect Control q 238008A Schematic Hydraulic q 229578E Diagram Piping q 1019876 page 1 of 6 Transmission Parts q 1019876 page 2 of 6 Transmission Parts q 1019876 page 3 of 6 Transmission Parts q 1019876 page 4 of 6 Transmission Parts q 1019876 page 5 of 6 Transmission Installation q 1019876 page 6 of 6 Transmission Inst...

Page 132: ...porated Engineering Drawings Power Shift Transmission System Operator s Manual 1020510 q X229823B page 2 of 3 Torque Converter Parts q X229823B page 3 of 3 Torque Converter Parts q 1018360 partial Valve Assembly solenoid ...

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Page 152: ... 1020510 R1 05 02 TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM ...