HỘP SỐ DANA TE27,32 mek o hyd eng

Mechanic / Hydraulic function TE27/32 Mechanic / Hydraulic function Mechanic / Hydraulic function Oil specifications Converter/Transmission Oil System Capacity (Approximate: measured at 600 RPM input speed and oil temp between 60 and 70°C, Short drop 60L Long drop 75L Lines and cooler not included neutral) Oil Type ONLY ATF Dexron III approved viscosity at 40°C: 33 → 38 cSt viscosity at 100°C: → cSt flash point: 160°C pour point: max –42°C Oil change 1000 hours Filtration x Spin On 1000 hours life first change: 50-250 hrs or after rebuild Mechanic / Hydraulic function Temperature specifications Normal operating temperature 70 - 120°C measured at the converter outlet port Maximum transmission oil temperature 120° C Pressure specifications Charging pump flow: dual pump 75.8 l/min @ 2000 rpm - lubrication and cooling 92.8 l/min @ 2000 rpm - clutch filling, lube & cooling Transmission regulated pressure measured at port 31 : 600 RPM @ 17 bar 2650 RPM @ 25,5 bar Mechanic / Hydraulic function Clutch pressure @ 2200 RPM 21.5 - 25.5 bar Filter bypass Set to 4.1 to 4.5 bar Lube pressure 1.76 - 2.64 bar @ 73 l/min converter flow Internal leakage @ 1000 RPM Forward/Reverse l/min 1st 10.5 l/min 2nd/3rd/4th l/min Mechanic / Hydraulic function Safety valve Cracking pressure 9.0 bar Converter out pressure (to cooler) Minimum bar @ 2000 RPM and maximum 5.0 bar in normal unloaded driving Pump flow System pump flow : 101,9 l/min @ 2000 RPM Lube pump flow : 86,3 l/min @ 2000 RPM Mechanic / Hydraulic function Oil circurit specifications HYDRAULIC COOLER LINES SPECIFICATIONS Minimum 32 mm internal diameter for hoses and fittings Suitable for operation from ambient to 120° C continuous operating temperature Must withstand 30 bar continuous pressure and 45 bar intermittent surges Conform SAE J1019 and SAE J517, 100RI Mechanic / Hydraulic function Mechanic / Hydraulic function The control valves functionality The control valve is equipped with electrically controlled Variable Flow Solenoids (VFS), 2pcs ON/ OFF solenoids and one pressure feedback sensor which all are connected to the controller APC200 The control valve contents also of a several spools and springs and all this components gives full modulation which results in a smooth gear shift From the pump comes the oil through the oil filter and parallel to the filter is a bypass valve A pressure regulator will reduce the pressure and the line will split in two directions The VFS operates with a pressure of to bars and therefore a pressure reducer is positioned before, that will decrease the pressure to 12 bars After each VFS is an accumulator The accumulator have the function to take a way all small oil pressure peaks before the oil goes in to the intensifiers, which increase the pressure with a ratio of 5:1 That means that to 30 bar will be available for the clutches VFS 1/3, VFS 2/4 provide the 1st and 3rd clutch, 2nd and 4th clutch with clutch pressure and the on/off range solenoid select between 1st and the 3rd clutch, 2nd and 3rd clutch There is one more on/off solenoid for the total neutral and that is only activated in forward and reverse When Error code is shown in the display the total neutral solenoid is not activated and the oil is dumped to the sump The control valve has a pressure feed back sensor which will detect and protect the transmission if the oil pressure are too low or if it is a pressure when it not should be there If it should be an Error code the transmission goes to neutral and a failure code will be displayed on the APC200 and on the display in the cabin if the machine has this function installed Mechanic / Hydraulic function Solenoid activating TE27/32 Transmission gear Activated on/off solenoids Activated VFS solenoids Activated Clutch Forward Forward Forward Forward Total neutral Total neutral Total neutral, 2/4 Total neutral,1/3, 2/4 Forward,1/3 Forward, 2/4 Forward, 1/3 Forward, 2/4 4an Forward 3an Forward 2an Forward 1an Forward Neutral Neutral Neutral Neutral Neutral Total neutral Total neutral Total neutral,2/4 Total neutral 1/3 2/4 Forward, Reverse , 1/3 Forward, Reverse , 2/4 Forward, Reverse , 1/3 Forward, Reverse , 2/4 Forward, Reverse , 1/3, 2/4 4an 3an 2an 1an No Reverse Reverse Reverse Reverse Total neutral Total neutral Total neutral, 2/4 Total neutral 1/3 2/4 Reverse,1/3 Reverse, 2/4 Reverse, 1/3 Reverse, 2/4 4an Reverse 3an Reverse 2an Reverse 1an Reverse Mechanic / Hydraulic function Total neutral Mechanic / Hydraulic function VFS fwd VFS 2/4 VFS rev VFS 1/3 Mechanic / Hydraulic function Forward 1st Mechanic / Hydraulic function VFS fwd VFS 2/4 VFS rev VFS 1/3 Mechanic / Hydraulic function Forward 2nd Mechanic / Hydraulic function VFS fwd VFS 2/4 VFS rev VFS 1/3 Mechanic / Hydraulic function Forward 3rd Mechanic / Hydraulic function VFS fwd VFS 2/4 VFS rev VFS 1/3 Mechanic / Hydraulic function Forward 4th Mechanic / Hydraulic function VFS fwd VFS 2/4 VFS rev VFS 1/3 Mechanic / Hydraulic function Reverse 1st Mechanic / Hydraulic function Measure ports on the control valve G A65 55 F F 64 B 54 N 59 H C60/62 50/52 K Checkport 4/4 SPEED (TE32) 31a Regulator pressure (before total neutral) 51 VFS reverse 50/52 VFS 3rd /1st 54 VFS FWD 55 VFS 2ND/4TH 56 System pressure (after Total Neutral) 57 Pilot pressure 58 Range clutches 59 Direction clutches 61 Pressure intensifier rev 60/62 Pressure intensifier 1st/3rd 64 Pressure intensifier FWD 65 Pressure intensifier 2nd /4th 56 D 51 E 61 L J 57 M 31a 58 Mechanic / Hydraulic function Removing the control valve Removing the control valve Suggestion: Use two long studs into the transmission to eliminate the risk to drop the valve in disassembling and assembling Make sure that the area around the valve is clean and that no dirt can fall into the valve during the disassembly procedure Unscrew the hex bolts (marked pink on drawing) until you feel that the tension is out of the bolt Do not remove them! Unscrew the 15 other bolts (with internal hex) some turns When all bolts are loose, you should be able to move the valve a bit Installing the control valve First fasten all bolts (21 pieces hand tight) according to the numbers you find on the drawing Repeat the same procedure but now with a torque wrench Settings of the torque wrench 20 to 25 Nm If possible, leave the valve for an intervening period of at least 20 Fasten all bolts a second time according to the procedure described above NOTE Mechanic / Hydraulic function 20 19 21 18 17 16 15 11 13 10 12 14 Mechanic / Hydraulic function Electrical specifications • The resistance in the VFS coils in the control valve (F /R /2-4 / 1-3) should be 4,35 ±0,35 measured @ 25°C •The resistance in the on / off solenoids 3-1 and 4-2 should be 28 ±2 measured @ 20°C ... are connected to the controller APC200 The control valve contents also of a several spools and springs and all this components gives full modulation which results in a smooth gear shift From the... function The control valves functionality The control valve is equipped with electrically controlled Variable Flow Solenoids (VFS), 2pcs ON/ OFF solenoids and one pressure feedback sensor which... function Solenoid activating TE27/32 Transmission gear Activated on/off solenoids Activated VFS solenoids Activated Clutch Forward Forward Forward Forward Total neutral Total neutral Total neutral,