TE27 / TE32
Contents
1. 4 2 58 5 O E Q g 0 OE e 0 7 remote filter 2 E 52 gt pm gt cooler E E E 5 from cooler to transmission 1 pay 8 EE dE 275 I q 1 2 gH iP from remote filter 2 Hd 112 5 3 1 Cooler amp filter lines specifications Minimum 25 4 mm 1 0 inch internal diameter for lines and fittings Suitable for operation from ambient to 120 C 248 F continuous operating temperature Must withstand 30 bar 435psi continuous pressure and with 40 bar 652 psi intermittent surges e Conform SAE J1019 and SAE J517 100RI TE27 32 4 SD 03 2010 5 30 5 31 03 2010 i 2 VW TW 15008 2 AvmMOIH 240 5991690 06 paads suld Z 15 6027 5 081 paads suld Z dv 051607 592 690 081 wnq suld 576007 SNOLLINULSNI NOLLV2. Oil fill hole 14 VIEW TE27 32 4 SD 03 2010 7 66 Transmission Operation 7 4 CHECK POINTS continued Checkpoint Checkpoint Checkpoint Checkpoint Checkpoint Checkpoint Checkpoint Checkpoint Checkpoint Checkpoint O O FW 4214360R 31A System pressure diem 1st clutch pressure 2nd clutch pressure 3rd clutch pressure 44 4th clutch pressure AD PER FWD clutch pressure 46 uie REV clutch pressure unes FWD REV regulated pressure TA 1st 3rd regulated pressure DO 2nd 4th requlated pressure 31A 45 66 20 REV 46 GY 68 41 27 32 4 SD 03 2010 44 42 7 67 Transmission Operation 7 5 SPEED SENSOR STATIC STANDALONE TEST In order to be able to sense the currents a series resistor of e g 200 must be used This resistor is integrated in the controller but when the sensor is to be used it must be connected externally The idea is to connect the sensor to an external power source and measure the DC voltage across the series resistor The voltage
3. 1 6 Propottional valve 3rd 1Tst eoe tt ar anni 1 7 oro Mm 3 8 D 6 9 GARSCHE EE MIDI I I LT 6 10 Selector valve forWardireverse ir trn eed Ce eR PE E E Eve dde 1 11 gt e 1 12 oc 1 13 OPTI Gee 1 14 amp 1 15 Selector valve 15 3 9 1 15B Selector valve Ath 2nd u a 1 16 E 2 17 c 2 18 242 eL 2 19 2 20 accumulator spool 1 20 accumulator spool 204141 ae 1 20 accumulator spool 3 18 ee enne enne emnes nnns 1 21 Pin accumul ator e 3 22 jene 3 23 A 3 24 noL 3 25 VERE 2 26 m 2 27 amp 2 28 ERA
4. 12 444 400 44 30 5 4 SPEED SENSOR INSTALLATION nn aa nn nn Haren a 31 6 TRANSMISSION OPERATION 0 34 6 1 THE TRANSMISSION ASSEMBLY 34 6 1 1 The converter pump drive section and pressure regulating valve 35 6 1 2 The input shaft and directional 22 2 220 36 6 1 3 The range clutches cotra dann inch aras ue np RD cc 37 6 1 4The output section oorr 37 6 2 THE TRANSMISSION CONTROLS REFER TO HYDRAULIC DIAGRAM 38 6 3 ELECTRIC SOLENOID 5 aee sure en 39 6 4 POWERFLOWS ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT 40 6 4 1 Neuttral 1 40 6 4 2 Forward 1st speed 2 0 42 A A A TT 44 6 4 4 Forward 3rd 4 242 444 40 01080 nennen 46 6 4 5 Forward speed 23288555 ER 48 6 4 6 Reverse 1st 2 4 1111111 nsn 51 6 4 8 Reverse 3rd speed
5. 20 4 4 PROCEDURE FOR PERFORMING AUTOMATIC 21 ARA Introduction cs Goan E 21 4 4 2 running the automatic calibration 21 4 4 2 1 How to enter the calibration 4 04 15211 21 4 4 3 PERFORMING AN AUTOMATIC CALIBRATION 22 4 4 4 HEATING UP THE TRANSMISSION USING THE 23 4 4 5 CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS 25 TE27 32 4 SD 03 2010 4 4 5 1 Calibration condition 25 4 4 5 2 Calibration 25 4 4 6 PERFORMING A STALL TEST s ssssssnctessnsecnensessnnnncesnorcencadsacnavssdanasnaneredetusennninasnnnecsnnetnennd 26 5 INSTALLATION 8 222 22 2222 2 28 5 1 CONVERTER DRIVE COUPLING sua uan ei 28 5 2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 29 5 3 EXTERNAL PEUMBING u een Pene n 30 5 3 1 Cooler amp filter lines
6. 1 26 MCD O 1 27 4 28 TO ERR 4 29 O PI ds 1 TE27 32 4 SD 03 2010 3RD SPEED GEAR 8 91 03 2010 TE27 32 4 SD 3RD SPEED GEAR Item Description Qty 1 Gear 3rd M M 1 2 Gear 3rd speed driven ask rennen ende 1 TE27 32 4 SD 03 2010 8 92 REV 2ND SCHAFT GROUP TE27 32 4 SD 03 2010 8 93 REV 2ND SCHAFT GROUP Item Description Qty 1 jn 1 2 Seal Clutch piston OUter uii 1 3 Seal Clutch plstor INNER cie 1 4 Screen Not Sold Separate 1 5 Washer Belleville tte ner 7 6 Spacer Cl tclhi pisto 1 7 RING eb eae er ad 1 8 Disc Cl tch inner 7 9 Clutch 7 10 Plate Endet RE aci n 1 11 SNAPIING mM 1 12 jene 1 13 Clutch piston OUTER 1 14 Seal Clutch piston 4 1 15 Screen Sold Separate ctt trt er etl nennen 1 16 Ring s Retail iiio iie
7. ts uu 001 xoi 19 lt gt 21 31111 55438 Lang 588458 ogni SIDIND aon 304 IH 1296 5NDDVID ALIS rA 8100 H wi eq 72 IATA WoNTO3N 34055344 OF 9 4 31001 S Eu ania LNAWLYYdWOD 40175340 6 56 03 2010 TE27 32 4 SD Transmission Operation 6 4 9 Reverse 4TH speed continued MJ A mn V 13 ZEN io ZO EN gt lt FR 5 Jar N cu TE27 32 4 SD 03 2010 6 57 Transmission Operation 6 5 GEAR AND CLUTCH LAYOUT TE27 32 4 SD 03 2010 6 58 TE27 32 4 SD 03 2010 7 59 7 TROUBLESHOOTING GUIDE The following information is presented as an aid to isolate and determine the specific problem area in a transmission that is not functioning correctly When troubleshooting a transmission
8. 10 29 erc 10 30 ET 16 31 COPOS ER 16 32 EE 1 TE27 32 4 SD 03 2010 8 106 REMOTE FILTER ADAPTER GROUP TE27 32 4 SD 03 2010 8 107 REMOTE FILTER ADAPTOR GROUP Item Description Qty 1 p TEE m 1 2 Adapter Filter siii in 1 3 Assy Filter adapter 1 4 w M 1 5 Spool Safety valve se cee quee 1 6 oia nia 1 7 POP RIN nin 1 8 OO aaa ee A 1 9 ilu EL 2 10 UII 2 11 Cap JE ee epee rn 2 12 A 2 13 A A NUR 8 14 ai 8 Note 2 sets required TE27 32 4 SD 03 2010 8 108 9 ASSEMBLY INSTRUCTIONS TE27 32 4SD 03 2010 9 109 9 ASSEMBLY INSTRUCTIONS TE27 32 4 SD 03 2010 9 110 ASSEMBLY INSTRUCTIONS All lead in chamfers for oil seals pistonrings and O rings must be smooth and free from burrs Inspect at as sembly Add some grease to O rings before assembly Add
9. 27 32 4 SD 03 2010 9 113 ASSEMBLY INSTRUCTIONS INSTALLATION INSTRUCTIONS FOR TE27 32 VALVE Remove the valve Refer to Cleaning amp Inspection pages The area around the valve must be clean and free of any foreign material Unscrew 16 bolts marked with hexagonals on the drawing some turns When all bolts are loose you should be able to move the valve Replace 2 bolts by aligning studs Remove the remaining 14 hex bolts and valve from the transmission case Install the valve Install 2 aligning studs install new gasket and valve body Install 14 bolts and handtighten according to the number sequence on the drawing replace the studs by bolts Now torque all bolts twice to 20 25 Nm 15 18Lbs ft in the correct sequence Recalibrate the transmission 4214360R m 1 y A Y LI Wi 1 IST TE27 32 4 SD 03 2010 9 114 ASSEMBLY INSTRUCTIONS TE27 32 4 SD 03 2010 9 115 11 SPECIAL TOOLS TE27 32 4 SD 05 2004 11 190
10. 96 1ST SHAFT GEAR GROUP un ERU Re Era nOn EE REEL REA dada dr ENANS 98 OUTPUT SHAFT GROUP 100 REGULATOR VALVE GROUP iicccssecscinsasseasccnannsccsinsnaenasssnannoasaaneusnaassassanendsnecnpanaesdaassassnansaunaansinens 102 CONTROL VALVE GROUP 104 REMOTE FILTER ADAPTER GROUD codeine itc ni 106 9 ASSEMBLY INSTRUCTIONS siii rr na an 109 10 DISASSEMBLY OF TRANSMISSION UNDER 116 11 SPECIAL TOOL TE27 32 4 SD 03 2010 TOWING OR PUSHING Before towing the vehicle be sure to disconnect the driveline to avoid damage to the transmission during towing Note A Because of the design of the hydraulic system the engine cannot be started by pushing or towing Copyright DANA CORPORATION 1990 Unpublished material All rights reserved Limited Distribution No part of this work may be reproduced in any form under any means without direct written permission of the DANA CORPORATION TE27 32 4 SD 03 2010 5 FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER OFF HIGWAY PRODUCTS product Extreme care has been exercised in the design selection of materials and
11. NN RAM ERR 2 11 HQ 2 12 Lockwasher 2 13 1 14 1 15 A 1 16 A ORNATA NN RISORSE UTERE S RN 1 17 SIEVE 1 18 cto m 3 19 CAPS CROW Wis TS 3 20 Berna LIE 3 21 tdt 1 22 2 23 M 2 24 UESB PEE 2 25 A 14 26 9 27 LOCK WAS ET 23 28 gasket Converter to transmission 1 29 ta p iex oda decas 1 30 i de 1 31 1 32 Switch NN ERE EMI DIAS En ER ESSA 1 33 Adaptor Temperature SWItCh tno rt ntt exa RR 1 34 Sensor SPO io aea 1 35 goin 1 36 Sensor Speed 60 5 AR 1 37 Support Speed Pd eee dete eei ee Ed 2 38 M 2
12. 350H 350H 209 INVA 10111931 34055384 nv 34055384 LNAWLEVdWOD 80188340 6 44 03 2010 TE27 32 4 SD Transmission Operation 6 4 3 Forward 2nd speed continued TE27 32 4 SD 03 2010 6 45 Transmission Operation 6 4 4 Forward 3rd speed HOLD MIND MAD Cue amd 9 La 600 600 600 av ae 800 80 001 90 BLSHAINIaHnSSBud 9 Jeq 0019 3NTVA NOLLYINGOW Q3T108NO2 2INOHJD38 O fi 04651 N 105185 38155384 03124135 PIE WYYDVIC SA TWA NOISSINSNWUL Z 31 4231 ainssaid uoneonaqn anns 10 13925 lt gt udi tz ulus wd g tz 001 tdWnd 350 350H e xq lt gt INIVASSVE A8 lt gt 3NASSVd AB CBUH 146 SNOWED ALYS YOLWINOIY 34155384 Of T f 310801 S sna ININLYYANOD 8018340 6 46 03 2010 TE27 32 4 SD Transmission Operation 6 4 4 Forward 3rd speed continued TE27 32 4 SD 03 2010 6 47 Transmission Operatio
13. 4 0 2 Mil LIST T Land 69 N H H 350H 3504 08 51 H EA 3504 LA 1296 _ H INDD 2 2 INYA ALS f 5 100 N N 105186 105186 34055344 34055344 a 350H T T Se 300801 ux men 03103135 080235 3943 38 1NBWIBNdWO 10144340 WYYOWIC JAYA NOISSTWSNVUL Z 31 2231 6 52 03 2010 TE27 32 4 SD Transmission Operation 6 4 7 Reverse 2nd speed continued TE27 32 4 SD 03 2010 6 53 Transmission Operation MIND Hip Que ist LJ 6 4 8 Reverse 3rd speed Mi La LJ 600 600 600 600 600 600 a vw uis Qu N 109185 31055384 HIP aNZ 8 ERRE MES TO 129 001 9 3ATVA NOLLVINCOW 03110410 0815313 8 a e gt Ol fi 04 151 N 109185 34155384 03123135 PE 3583 48 10 IMAVECAH SATA 2631 2231 aunssaid ubi ainssaid uonesniqny 85 lt gt 411510 04411110 req sir Of
14. 0 25 A 012 00 i on 673 00 250 00 4 0 10 656 00 27 32 4 SD 05 2004 11 194 APPLICATION POLICY Capability ratings features and specifications vary depending upon the model type of service Applications approvals must be obtained from Spicer Off Highway Products Division We reserve the right to change or modify our product specifications configurations or dimensions at any time without notice SPICER OFF HIGHWAY PRODUCTS Ten Briele 3 B 8200 Sint Michiels Brugge Belgium
15. det 1 5 Shaft Gear tO P MP aeia Aida 1 6 SNAPIING 1 7 CROW MIT 2 8 Adaptor Suction 81 ee 1 9 Adaptor Suction transmission case 51 1 10 5 8 11 Hoses SUC ON Red 1 12 Clamp 2 13 tal 2 14 1101 5 8 15 8 16 Cap 5150 E 1 17 1 18 4 19 4 27 32 4 SD 03 2010 8 104 CONTROL VALVE GROUP TE27 32 4 SD 03 2010 8 105 CONTROL VALVE GROUP Item Description Qty 1 control valve 1 2 22 3 3 4 Pl g Restriction au ausm 4 5 i E MEE 1 6A Proportional valve 2 1 6B Proportional valve 2 414
16. Item Description Qty 1 PISTON 1 2 Seals ee 1 3 seal Piston INNER E E 1 4 Screen not sold seperate AA 1 5 Disc 11 6 Disc Clutch 11 7 Disc Clutch outer 2 8 Plate 1 9 1 10 Washer Belleville 15 11 Spacer Clutch PISION iii 1 12 Ret iner SPRING E 1 13 Ring 1 14 T E E nates 1 15 1 16 WEL 1 17 SHAPING susanne nennen 2 18 22 O tec 1 19 Ring 2 20 rro pe 1 21 Cap 3rd speed shaft rear crier neni anna 1 22 PAC PT CP TP 1 23 Irene 1 24 reeds 1 25
17. AT 44 1 QuE ISL N 105185 39155384 8 199 02 00 9 0 38085384 5 3153135 15814 1543 48 1990 OL 9 NOLLYIN CON 03110818402 WYYOWIC 1104 NOISSIWSN VUL Z 31 231 9925 uv 410510 0 19 2001 350 eq CD 183171 31111 55 4 8 350H 39055380 SIG 212 6 350 10059 17 lt gt IATA SSVd Ag 350H SIIN INW NOLAN 2 310801 saa LNAWLHVWOD 80148340 6 50 03 2010 27 32 4 SD Transmission Operation 6 4 6 Reverse 1st speed TE27 32 4 SD 03 2010 6 51 Transmission Operation 6 4 7 Reverse 2nd speed 410510 aunssaid 3025 ainssaid MO mind HOLD HOLD HOLD HOLM Hi Qut am uone niqm 11 EOM e kr a EA 600 600 600 600 600 600 9 wan 200 350H OS OS x OD 99
18. 4 4444445558 68 8 SECTIONAL VIEWS 8 PARTS IDENTIFICATION eeeee eren enne nennen nn nn nnn 69 TE27 32 4 SD 03 2010 TORQUE CONVERTER GROUP uuussuussansnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 70 TRANSMISSION CASE amp REAR COVER 72 TURBINE SHAFT GROUP sciences ris ernst rand Ru S RA SER NAA ARD GERNE 74 PUMP DRIVE GROUP Era e D ar 76 ADAPTOR SLEEVE GROUP asas sns a irral 78 WHEEL GROUP sirena dn n Le n D ead Ur as EF Cn EE CERE ED RE FI REEL ES 80 FLEX PLATE GROUP sins aaa nenn nn hin anne 82 FWD 8 REV 2ND AND 3TH OR 4TH CLUTCH SHAFT ASSY 84 FORWARD CLUTCH SHAFT 4 2 2 1 conan anna cnn renacer 86 SPEED CLUCTH SHAFT 1 1 88 A A 90 REV 2ND SCHAFT GROUD iini ha kun nena eno seo EUER XR ER CR DU TOO RETO NE RT ETC ROG 92 1ST SPEED CLUTCH SHAFT 94 SPEED CLUTCH SHAFT
19. br dle 1 17 TIL IM 1 18 Sensor Speed assy uoc ete 1 19 iesu 1 20 Support Speed Sersotr i cct tret A RR a 2 21 Caps rO EM 2 22 TUBE SUCION en 5 1 23 OQ TING ceret A rns A ERR ERR e 1 24 kockwash e EA 2 25 2 26 suizo a aa 1 27 Cover Oll asias 1 28 Oll bafa rrt 3 29 Lockwasher 6 30 2 3 31 A 3 32 ree nennen dition a once 1 33 M E 1 34 canes 4 35 4 27 32 4 SD 03 2010 8 74 TURBINE SHAFT GROUP 8 75 03 2010 TE27 32 4 SD TURBINE SHAFT GROUP Item Description Qty 1 Bearing Turbine shaft front ee na 1 2 Bearing Turbine shaft enne 1 3 Spacer Front icri reden Ee ec E ua ne 1 4 SOMA M N 1 5 Ring
20. 1 27 32 4 SD 03 2010 4TH SPEED CLUTCH SHAFT GROUP TE27 32 4 SD 03 2010 8 97 4TH SPEED CLUTCH SHAFT GROUP Item Description Qty 1 AA 1 2 Seal Pist n Oti 1 3 Seal Piston 1 4 Screen sold seperate oe innen ee 1 5 Disc Gl tch 11 6 Dise Clutch outer half nee anna 2 7 Disc Clutch oute 0 E 11 8 Plate zem M 1 9 1001 ER 1 10 Spacer Clutch u a Dear ei ee 1 11 Ret iner As 1 12 Se E 1 13 RING 1 14 eeren nenne 1 15 222 S 1 16 rene 1 17 A 1 18 eren 1 19 Ring P 2 TE27 32 4 SD 03 2010 1ST SHAFT GEAR GROUP 8 99 03 2010 TE27 32 4 SD 1ST SHAFT GEAR GROUP Item Description Qty 1 Gear a 1 2 Assy 1st speed 1 TE27 32 4 SD 03 2010 8 100 OUTPUT SHAFT GROUP 8 101 03 2
21. ADAPTOR SLEEVE GROUP TE27 32 4 SD 03 2010 8 79 ADAPTOR SLEEVE GROUP Item Description Qty 1 Sleeve Pump 1 2 NAPA A 1 TE27 32 4 SD 03 2010 8 80 WHEEL GROUP TE27 32 4 SD 03 2010 8 81 WHEEL GROUP Item Description Qty 1 Member Reaction 1 2 mee 1 3 Spacer Reaction membe iue etr ERR ee Ce eH EV Y 1 4 TU H s 1 5 1 6 1 7 eren 1 8 Screw Turbine 10 9 5 10 pa Hi Re 1 11 RATA m EE 1 12 SGU OW 32 13 siii 32 14 H b Impeller Em 1 15 1 16 SGD OW xni atit a 8 17 Ring Impeller hub derew back
22. E ETE E EE 1 6 Stator S ppotrt assy i c D 1 7 Screw Stator rear 7 8 ooi MT E 7 9 DOES me 1 10 eC 1 11 Seal Dil baffle cient irt ec T E EORR 1 12 Ring 40 Bo IET Tr 1 13 Ring Oll a 1 14 1 15 SNAP 1 16 Turbine a 1 TE27 32 4 SD 03 2010 PUMP DRIVE GROUP 8 77 03 2010 TE27 32 4 SD PUMP DRIVE GROUP Item Description Qty 1 Support Pump drive 3 2 Screw Bearing SUpport iiobis daten 4 3 ed ip 4 4 mm 4 5 Bera LLL 2 6 Screw 5 ET nannten nee 2 7 Bearing Pump drive gear eee een A 3 8 TOR A 3 9 Gear Aux Pump 2 10 Gear Charging pump uxo eu hern cett etd atte Rd X 1 11 Gear Impeller MUD ae ee 1 12 cc 1 27 32 4 SD 03 2010 8 78
23. OS OS 03153135 15814 CUYMYOS ainssaid uonesnign OD wud 0 12 um 001 3 0115518 8 310801 411510 NINDS 7 uly 9 178 ISOH 350H lt gt Land 3NWASSVd A8 cand 350H 9 350H 196 SNDDVID NWA ALYS W100 B HOLWINOSY C 2 C 8 350H S dice 10110830 6 42 03 2010 27 32 4 SD Transmission Operation 6 4 2 Forward 1st speed continued TE27 32 4 SD 03 2010 6 43 Transmission Operation MIND Hu Ne 6 4 3 Forward 2nd speed LJ 600 600 8 v ND 0 HLND 151 LJ 600 OS HLP ONZ 600 av av gt lt HDI Mi LJ 600 600 OD 03121115 0 0235 CHV MYO 0 80 31 014 NOISSINSNWULTEIL LZAL aunssaid NaHS lt ainssaid 411510 udi 0128 utur 2001 Land 350H 350H SIG
24. TE27 32 4 SD 03 2010 6 TRANSMISSION OPERATION 6 1 THE TRANSMISSION ASSEMBLY Basically the transmission is composed of five main assemblies 1 2 3 4 The converter pump drive section and pressure regulating valve The input shaft and directional clutches The range clutches The output section 5 pq The transmission control valve TE27 32 4 SD FWD 3 1 E 5 2 8 REV 209 N Bl 03 2010 6 34 Transmission Operation 6 1 1 The converter pump drive section and pressure regulating valve Engine power is transmitted from the engine flywheel to the impeller through the impeller cover This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication This element can be compared to a centrifugal pump that picks up fluid at its centre and discharges it at the outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque converter This element receives fluid at its outer diameter and discharges it at its centre The reaction member of the tor
25. ee ei 1 5 Disc Clutch Inner e aa aa 11 6 Disc Clutch 11 7 Plate TEA A 1 8 OMAP IMAG os E 1 9 Washer cannes nn 9 10 Spacer CIULCH PISTON 2 2 ertet een aan 1 11 Retainer 1 12 Ring RetalEier ae ae 1 13 Beann e 1 14 na 1 15 terete mere rere errr 1 16 Cleo m 1 17 PISTON iis X 2 18 Cap Bearlhg ote Lt 1 19 MOP RUNG 2 20 2 21 CORO 2 22 POP quom 1 23 CADSCHOW P 4 24 L ckw sher E 4 26 arn 1 26 Bearing eet bre dees d ln e ee 1 27 SHARING 1 28 Serene 1 29 rnm OE 1 30 1 31 DISC u a eens vances 1 32
26. AA RE n 54 6 4 9 Reverse ATH speed nenne erre Hanna ann an nn Haan Han aeai araa Ro x RR ERR RR 56 7 TROUBLESHOOTING GUIDE 1 tico coe ee ae acc 60 7 1 THE 5 5 60 7 2 THE INPUT SHAFT AND DIRECTIONAL 4 1211111 60 1 21 Stall 60 7 2 2 Transmission pressure 61 7 2 3 Mechanical and electrical 4 4 61 7 2 4 Hydraulic checks 61 7 2 5 Controller APC200 Please refer to functional description 61 7 3 TROUBLESHOOTING GUIDE nam hanh Rica Ru Rau nnd nn 62 1 3 1 Low clutch press te erre ret enne nonna or ann Hann a E ERR 62 7 3 2 Low charging pump output 62 7 3 3 aa smi Dg ga dag 62 1 34 NOISY CONVEerter 62 7 3 5 Lack of ce vecaduteacaeccdvessecacessanccsestancacesscevescesaesdeeresssdeaereeese 62 7 4 CHECK POINTS 63 7 5 SPEED SENSOR STATIC STANDALONE 8 22 122 44 67 7 6 FULL FLOW VALVE
27. 1 Recommended lubricants Dexron viscosity at 40 104 33 38 cSt 100 212 F 7 8cSt SUMP PREHEATERS Preheat the transmission fluid to the mimimum temperature for the oil viscosity used before engine startup 4 1 2 Normal oil change interval Drain and refill system every 1000 hrs for average environmental and duty cycle conditions Severe or sus tained high operating temperature or very dusty atmospheric conditions will result in accelerated detioration or contamination Judgement must be used to determine the required change intervals for extreme conditions Drain and refill system as follows drain with oil at 65 93 C 150 200 F 1 Drain transmission 2 Remove and discard filter Install new filter 3 Refill transmission to FULL mark 4 Runengine at 500 600 RPM to prime convertor and lines 5 Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil temperature is hot 82 2 93 3 C 180 200 F make final oil level check and adjust if necessary to bring oil level to FULL mark Note T IS RECOMMENDED THAT OIL FILTER BE CHANGED AFTER 100 HOURS OF OPERATION ON NEW REBUILT OR REPAIRED UNIT EXTENDED OIL CHANGE INTERVAL Extended oil service life may result when using synthetic fluids Appropriate change intervals should be deter mined for each transmission by measuring oil oxidation and wear metals over time to determine a baseline Wear metal
28. 11 SPECIAL TOOLS 485 00 431 50 135 00 20 00 2 00 5 00 20 00 40 00 50 00 i 412 00 413 00 160 00 gt 50 00 200 00 4 b Y lt gt 5 00 TE27 32 4 SD 05 2004 11 191 SPECIAL TOOLS 25 00 35 00 60 00 Bolt M10 x 40 9 Eyebolt M16 7 0 2 TI lt gt 240 2 00 0 20 050 50 00 060 00 gt 290 00 216 00 gt 10 x 45 4 PLACES 1 11 00 90 00 9 00 38 00 130 00 30 00 290 00 TE27 32 4 SD 05 2004 11 192 y SPECIAL TOOLS 91 469 WIN L IOS83A3 sepis u1oq OZ X GE ONN bL SZebv OS y OO SL A OO 87 4 OO c6 202 Y s30IS HILOS eddd NVHO X Z OO S OO OSL 00S u OO O6 m A 00 08 1 GeL 0 OO O9 OO POL OO O9 11 193 05 2004 TE27 32 4 SD SPECIAL TOOLS 3 00 0 15 6 00 0 25 75 00 54 00 52 00 0 15 7 7
29. 350H 350H SIG SIG lt gt 193011 3NWASSVd A8 Cr 212 350H 350 9 350 INWA 135 1100 H 10927 INIA YOLVINDIS 34155384 ININ LYVANOD 80118340 6 54 03 2010 TE27 32 4 SD Transmission Operation 6 4 8 Reverse 3rd speed continued TE27 32 4 SD 03 2010 6 55 Transmission Operation 6 4 9 Reverse 4TH speed ur HDI Ne LJ 600 OS OS 600 0 JSt HLND NU ND Ld 600 OD OD 4 Ld 600 600 600 OS OD 0312156 3583 33 WYYOWIC NOISSINSNWULTEIL LZAL aunssaid ainssaid MO uoneonigny Go uv 805 EHEN 410510
30. 5 UNI Port 16b From remote filter 1 Port 32 Pressure check port To cooler Temperature switch Temperature sensor Port 43 Pressure check port 3rd clutch REAR VIEW 03 2010 7 64 Transmission Operation 7 4 CHECK POINTS continued Pressure check Regulator Port 37 __ u h Pressure check port 4 Convertor in t ET ngine spee 8 sensor SO B Port 45 Pressure check port Fwd clutch TU Drum speed sensor ur E Port 12 From cooler Port 16A From remote filter Turbine speed sensor Output speed sensor Metric flange for 98 3 stick dia 25 4mm 4 Mounting holes M20 x 2 5 THD RIGHT VIEW 30mm DEEP NT bes 14 Y ESL Port 41 9 7 9 Pressure check port 48 1st clutch 4 o IE Ip H 1111 1 Oil level check port Ya NPT LEFT VIEW TE27 32 4 SD 03 2010 7 65 Transmission Operation 7 4 CHECK POINTS continued Port 13b Port 13a To remote filter To remote filter from pump 1
31. Serial number 3 2 WEIGHT DIMENSIONS OIL CAPACITY Weight dry 865 Kg 1903 Ib Max Length 1011 mm 39 8 Max With 703 mm 27 77 Max Heigth 982 mm 38 77 Oil capacity 60 liter 15 9 US Gallon without cooler and hydraulic lines Consult Operator s manual on applicable machine for system capacity TE27 32 4 SD 03 2010 3 12 Technical specifications 3 3 TIGHTENING TORQUES 3 3 1 Torque specifications for lubricated or plated screw threads GRADE 5 GRADE 5 NOM THD FINE THREAD COARSE THREAD SIZE TORQUE Lbs ft Nm TORQUE Lbs ft Nm 2500 9 11 12 2 14 9 8 10 10 8 13 6 16 20 21 7 27 1 12 16 16 3 21 7 26 29 35 2 39 3 23 25 31 2 33 9 41 45 56 61 37 41 50 2 55 6 64 70 87 95 57 63 77 85 91 100 123 136 82 90 111 122 128 141 174 191 113 124 153 168 223 245 302 332 200 220 271 298 Partnumber prefix GRADE 8 GRADE 8 FINE THREAD COARSE THREAD TORQUE Lbs ft Nm TORQUE Lbs ft Nm 2500 11 13 14 9 17 6 9 11 12 2 14 9 28 32 38 43 4 26 30 35 2 40 7 37 41 50 2 55 6 33 36 44 7 48 8 58 64 79 87 52 57 70 5 77 3 128 141 174 191 115 127 156 172 180 198 224 268 159 175 216 237 315 347 427 470 282 310 382 420 Partnumber prefix 18C 94G 96G 17C 93G 95G TE27 32 4 SD 03 2010 3 13 Technical specifications 3 3 1 Torque specifications for lubricated or plated screw threads continued NOM THD SIZE GRADE 8 8 GRADE 10 9 GRADE
32. all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION AM CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES FIRE HAZARDS AND INHALATION OF VAPOURS WHEN USING SOLVENT TYPE CLEANERS 2 1 1 BEARINGS Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles repeat above operation until bearings are thor oughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearing to avoid spinning DO NOT SPIN BEARINGS WHEN DRYING Bearings may be rotated slowly by hand to facilitate drying process 2 1 2 HOUSINGS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS AND SKIN RASHES WHEN USING ALKALI CLEANERS All parts cleaned must be thoroughly dried immediately by using moistere free compressed air or soft lintless absorbant wi
33. engine to idle 6 Go back to point 2 and repeat until the APC200 display shows a temperature above 60 C When the temperature is above 60 C the temperature indication on the display starts blinking Now you can switch to the automatic calibration by pressing the M button for several times until the APC200 displays tran FULL IDLE forward neutral REMARK During this warm up procedure it is possible that the converter out temperature of the transmission exceeds the maximum limit This is a consequence of heating up the transmission using this quick procedure When this occurs the engine speed will be limiting to half throttle when the APC200 has engine control or forcing neutral when the APC200 has no engine control To solve this simply leave the transmission in neutral for a minute and throttle the engine to around 1300 rpm This will allow the heat in the converter to be evacuated After one or two minutes you can resume the heating up procedure if the transmission temperature has not reached 60 C yet T27 32 4 SD 03 2010 4 24 Maintenance 4 4 5 CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS This chapter gives an overview of the most common calibration condition messages Normally you will be able to repair the cause of a calibration condition message yourself However you will have to contact the OEM of the machine when a calibration error appears 4 4 5 1 Calibration condition messages
34. manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjustments it is urged that the mechanic studies the instructions in this manual carefully and uses it as a refer ence when performing maintenance and repair operations Whenever repair or replacement of component parts is required only SPICER OFF HIGHWAY PRODUCTS ap proved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment SPICER OFF HIGHWAY PRODUCTS does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied or ap proved by SPICER OFF HIGHWAY PRODUCTS IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS TE27 32 4 SD 03 2010 6 1 SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine if replacement parts are required the
35. of transmission operation When an overhaul of the transmission is done When the transmission is repaired When the APC200 is replaced 4 4 2 running the automatic calibration 4 4 2 1 How to enter the calibration mode io 10 The automatic calibration mode is entered by pressing the S button on the APC200 lt display for 15 seconds dur ing POWER UP of the APC200 See above figure 27 32 4 SD 03 2010 4 21 Maintenance 4 4 3 PERFORMING AN AUTOMATIC CALIBRATION Before the automatic calibration can be started a number of conditions need to be fulfi lled The parking brake on the vehicle has to be activated The transmission temperature needs to be above 60 C See the next paragraph how to use the HEAT mode to do this in a time effective way The engine speed has to be kept at around 800 rpm 200 rpm during the complete calibration If the APC200 has control over the engine the engine speed will be adapted automatically If all the conditions mentioned above are met the actual automatic calibration can be performed starting from the following display on the APC200 To trigger the automatic calibration procedure push the S button once You will get this APC200 display readout ho F The APC200 asks you to put the shift lever in FORWARD The automatic transmission calibration procedure starts This is indicated on the APC200 display cil celi a the fisrt 2 characters indi
36. problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain components Proper operation of the transmission depends on the condition and correct functioning of the other components of the group Therfore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmission fluid charging pump torque converter transmission assembly oil cooler filter connecting lines and controls including the engine as a complete system By analysing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction which may occur in the system 7 1 THE TRANSMISSION TE27 32 powershift transmission with torque converter troubles fall into four general categories 1 Mechanical problems 2 Hydraulical problems 3 Electrical problems 4 Controller problems In addition to the mechanical and electrical components all of which must be in proper condition and functioning correctly the correct functioning of the hydraulic circuit is most important Transmission fluid is the life blood of the transmission It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components 7 2 THE INPUT SHAFT AND DIRECTIONAL CLUTCHES 7 2 1 PERFORMING A ST
37. 010 TE27 32 4 SD OUTPUT SHAFT GROUP Item Description Qty 1 T kenne 1 2 aa 1 3 inicia A cd nein 1 4 1 5 Irene 1 6 SAP MING pL 1 7 HER 1 8 6 tina ERE 1 9 Cap Benin 1 10 M M 1 11 1 12 O 4 13 Lockwasher a 4 14 Nnm 4 15 1 16 1 17 UEM 1 18 Washer Flange 1 19 Borde 1 20 lem T DET 1 TE27 32 4 SD 03 2010 8 102 REGULATOR VALVE GROUP 8 103 03 2010 TE27 32 4 SD REGULATOR VALVE GROUP Item Description Qty 1 ASSY Valve regulator 1 2 Gasket Valve to converter housing Irc ntt Ht Henn 1 3 1 4 PUMP ae enel endo
38. 12 9 COARSE THREAD TORQUE Lbs ft Nm TORQUE Lbs ft Nm TORQUE Lbs ft Nm 5 9 7 4 8 10 8 9 11 1 12 15 9 6 11 8 13 16 M8 x 1 25 14 8 18 4 20 25 22 1 25 8 30 35 25 8 29 5 35 40 M10x 1 5 29 5 36 9 40 50 44 3 47 9 60 65 47 9 55 3 65 75 12 1 75 50 55 68 75 74 81 100 110 85 96 115 130 14 2 81 92 110 125 111 129 150 175 133 155 180 210 M16x 2 125 140 170 190 177 203 240 275 207 236 280 320 M20 x 2 5 236 266 320 360 332 369 450 500 387 443 525 600 M24 x3 420 479 570 650 590 664 800 900 664 774 900 1050 M30 x 3 5 848 959 1150 1300 1180 1328 1600 1800 1364 1549 1850 2100 M36 x 4 1475 1660 2000 2250 2028 2323 2749 3149 2397 2729 3249 3699 Partnumber prefix 1CM 1GM 7CM 10CM 4GM 36 NOM THD SIZE GRADE 8 8 GRADE 10 9 GRADE 12 9 FINE THREAD TORQUE Lbs ft Nm TORQUE Lbs ft Nm TORQUE Lbs ft Nm M8 x1 17 20 23 28 10 1 35 42 47 57 25 28 34 39 30 34 41 46 52 60 71 81 62 69 84 94 M10x 1 25 32 40 44 54 49 57 67 77 58 66 79 89 M12x 1 25 60 68 82 92 89 96 120 130 105 116 143 158 12 1 5 58 65 78 88 86 94 117 127 101 112 138 153 M16x 1 5 159 169 215 228 216 227 293 308 258 273 350 370 M18x2 207 221 280 300 304 315 413 428 347 376 470 510 M20 x 1 5 302 332 410 450 439 476 595 645 503 559 683 758 M22 x 1 5 413 443 560 600 586 623 795 845 681 736 923 998 M24 x 1 5 531 590 720 800 767 841 1040 1140 882 992 11
39. 2 WEIGHT DIMENSIONS OIL 12 3 3 TIGHTENING TORQUES rii ener vedanta 13 3 3 1 Torque specifications for lubricated or plated screw threads 13 3 3 2 Elastic stop nut torque reet etre an ASA ERRE 15 3 3 3 Torque tables for plugs 15 3 3 4 Torque tables for pipe plugs eite rtu sanadna naanin annsna siiin aasa 15 3 3 5 Permanent metric plug torque chart 15 3 4 PRESSURE amp TEMPERATURE 85 4 4 44444 nenn 16 3 5 ELECTRICAL SPECIFICATION S 5 reina na enger 17 3 6 HYDRAULIC COOLER LINES 5 17 A MAINTENANCE sive 18 41 OIL SPECIFICATION Pe 19 4 1 1 Recommended lubricants 19 4 1 2 Normal oil change interval ana tr 19 4 2 MAINTENANCE 5 244444 sensns nennen nenne nnn 19 4 2 Nel 19 4 2 2Clutch calibrationi itte ren 1 Denn nnd IF ERE E YN PER 19 4 3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL
40. 39 2 40 rovc 3 41 3 42 EE 12 43 Motril A 12 44 Iure 1 45 RR MAG 1 TE27 32 4 SD 03 2010 TRANSMISSION CASE amp REAR COVER GROUP 8 73 03 2010 TE27 32 4 SD TRANSMISSION CASE amp REAR COVER GROUP Item Description Qty 1 Transmission 83246 1 2 1st speed clutch pressure 1 3 Tube Low shaft rear bearing lube ran enne nn 1 4 Tube 3rd speed clutch pressure vecinita eerte eno tua a in nike 1 5 Sleeve Pressure amp lubr 1 6 edu 6 7 IR 1 8 Plug EXPANSION pU A 1 9 DOW EE 2 10 AA 37 11 EL UU M 7 12 UII le 44 13 Gasket Rear cover to transmission 2 1 1 14 E 2 15 Pugs Magnetit drain RT 1 16 5 5 nut ee des Dedi ond dx
41. 87 FORWARD CLUTCH SHAFT GROUP Item Description Qty 1 an 1 2 T 1 3 Seah me LE 1 4 Screen not sold 1 5 Disc Cl tch ico ae 11 6 Disce Clutch OUter Fev nuu OUR REN FARA Va 11 7 Plate End 1 8 CLE 1 9 1 10 Washer 1 15 11 Ring 1 12 Spacer GIULEN PISTON 1 13 Bearing Clutehidriven gear en 1 14 1 15 NN 1 16 Ringa RETAINING 1 17 Ring 2 18 Ring Ret iningi u 2 000 2 19 1 20 xc 1 21 1 22 Ret alner Oll A 1 23 MA iii nee nee 1 TE27 32 4 SD 03 2010 3RD SPEED CLUCTH SHAFT GROUP TE27 32 4 SD 03 2010 8 89 3RD SPEED CLUCTH SHAFT GROUP
42. 95 1345 M24 x 2 509 568 690 770 730 804 990 1090 845 955 1145 1295 M27 x 1 5 789 848 1070 1150 1129 1202 1530 1630 1308 1420 1175 1925 TE27 32 4 SD 03 2010 3 14 Technical specifications 3 3 2 Elastic stop nut torque THREAD SIZE TORQUE M10 1 6 7 8 10 M14 x 1 5 7 9 10 12 M18 x 1 5 25 30 34 41 M22 x 1 5 35 44 48 60 M33x2 83 103 112 140 3 3 3 Torque tables for plugs o ring ports THREAD SIZE TORQUE Lbs ft Nm Partnumber prefix 5 16 24 3 5 4 7 3 8 24 5 8 7 11 7 16 20 7 10 9 14 1 2 20 10 13 14 18 9 16 18 12 15 16 20 3 4 16 20 25 27 34 7 8 14 30 35 41 47 11 16 12 45 50 61 68 15 16 12 65 75 88 102 15 8 12 75 85 102 115 17 8 12 75 85 102 115 124K 47K 3 3 4 Torque tables for pipe plugs THREAD SIZE TORQUE Lbs ft Nm Partnumber prefix 1 16 27 5 7 7 9 16F 40K 41K 1 1 8 27 7 10 9 14 10F 16F 40K 41K 2 3 8 18 25 30 34 41 11F 16F 40K 41K 6 1 2 14 30 35 41 47 11F 16F 40K 41K 8 3 4 10 or 14 40 45 54 61 11F 16F 40K 41K 12 1 11 1 2 50 55 68 75 11F 16F 40K 41K 16 11 4 11 1 2 60 65 81 88 11F 16F 40K 41K 20 3 3 5 Permanent metric plug torque chart Plugs Permanent plugs Nominal Size Torque Nm Lbs ft M18 x 1 5 6H 34 41 25 30 M26 x 1 5 6H 61 68 45 50 TE27 32 4 SD 03 2010 3 15 Technical specifications 3 4 PRESS
43. ALL TEST A stall test identifies transmission converter or engine problems Use the following procedure With a stall test it is possible to test clutch packslippage or test the converter engine stall speed in each gear How to perform the stall test 1 Putthe vehicle against a solid barrier such as a wall and or apply the parking brake block the wheels 2 Activate calibration mode during power up end holding the S button for 15 seconds 3 Select STAL using the M buttom Full Idle forward neutral TE27 32 4 SD 03 2010 7 60 Maintenance 5 Y ENGINE SPEED t SE 5 ENGINE SPEED Fret Hg ENGINE SPEED Ikah BEE ENGINE SPEED Select FWD or REV in the selected range gear Once the oil temperature reaches 70 C 158 F check max stall speed at full throttle in all gears The figure obtained should be within 50 RPM as mentioned in the vehicle handbook and should be equal in all gears Between gears allow the converter outlet temperature to cool down to 70 C 158 F by selecting neutral Leave the stall mode with the M button or switch off the ignition NO Oi 8 If max stall speed measured is below specifications it could indicate an engine or converter problem If max stall speed measured is above specifications it could indicate slipping clutches CAUTION Do NOT OPERATE THE CONVERTER
44. AT STALL CONDITION LONGER THAN 30 SECONDS AT ONE TIME SHIFT TO NEUTRAL FOR 15 SECONDS AND REPEAT THE PROCEDURE UNTIL DESIRED TEMPERATURE IS REACHED EXCESSIVE TEMPERATURE 120 C 250 F MAXIMUM WILL CAUSE DAMAGE TO TRANSMISSION CLUTCHES FLUID CONVERTER AND SEALS TE27 32 4 SD 03 2010 7 61 Transmission Operation 7 2 2 Transmission pressure checks Transmission problems can be isolated by the use of pressure tests When the stall test indicates slipping clutches then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure In addition converter charging pressure and transmission lubrication pressure can also be measured 7 2 3 Mechanical and electrical checks Prior to checking any part of the system for hydraulic function pressure testing the following mechanical and electrical checks should be made Check the parking brake and inching pedal for correct adjustment Be sure all lever linkage is properly connected and adjusted in each segment and at all connect ing points The controls are actuated electrically Check the wiring and electrical components Be sure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain proper cooling and operating temperatures for the engine and transmission Air clean the radiator if necessary 7 2 4 Hydraulic checks Also before checking th
45. Maintenance amp Service Manual TE27 TE32 Powershift Transmission 4 Speed Short Drop SPICER OF F HIGHWAY COMPONENTS CD ROM 8100101 MANUAL 8100102 03 2010 Table of Contents 1 TOWING OR PUSHING uro ans 5 FOREWORD 2 een RT 6 1 SAFETY PREGCAUTIONS 5 conr ects rrr Dna nea 7 2 CLEANING INSPECTION AND LEGEND SYMBOLS 9 2 ReH ilcc M 9 2 1 1 7 4 41 9 2 12 HOUSING S eee Bananen 9 2 2 INSPECTION 9 221 5 9 2 2 2 OIL SEALS GASKETS seen 10 2 2 3 GEARS amp SHAFTS ies ea 10 2 2 4 HOUSINGS COVERS BdC cional 10 2 3 LEGEND oras 10 3 TECHNICAL SPECIFICATIONS ae 11 3 1 IDENTIFICATION OF THE 12 3
46. SING BY ENGINE MANUFACTURER 7 Install drive plate attaching screw and washer Snug screw but do not tighten Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of cork the drive plate screws Rotate the engine flywheel install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten DRIVE PLATES After all eight 8 screws are installed E FLYWHEEL 1 Torque each one according to torque specifications This will require tightening each screw and rotating the engine flywheel until the full amount of eight 8 screws have been tightened to specified torque FIG 3 FIG 4 20 PLATES TO INSTALLED 8 Measure engine crankshaft end play after transmission 15 WITH CONCAVE SIDE has been completely installed on engine flywheel This value must be within 0 025 mm 0 001 of the end play 08 recorded in step No 2 Does not apply to units having 3 intermediate drive plates See Fig 4 TE27 32 4 SD 03 2010 5 29 Installation details 5 3 EXTERNAL PLUMBING
47. TIVLSNI 5991090 081 paads auibu3 SUld 516077 2 1031 05 35 03395 557 T3dOW V NOILISOd X YOLDANNOD ASSY NOISSINSNVHL vif 8 NOILVLOY 4Y39 220 N 114130 4 a 1 335 ke SE UN 61 21 437841 11 6 M34IS INOYOL lt 2 1317104 081 YO LNAWSAOW 1331 30 NOI19384 0 3H1 NI 9 11 104 915 NOILISOd HLIM HOSN3S 5 4 SPEED SENSOR INSTALLATION Installation details e TE27 32 4 SD Installation details 5 4 SPEED SENSOR INSTALLATION CONTINUED Pin 2 Pin 1 A The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 mA and 14 mA The sensor has an integrated AMP superseal 2 pin connector The two pins are numbered 1 and 2 Following table shows the relation between wire colour pin number and connection PIN NUMBER FUNCTION CONNECTION BLUE 2 Current output Ground wire Note THE SENSOR WIRES HAVE A POLARITY A BE SURE TO CORRECTLY OBSERVE SENSOR POLARITIES AS WRONG CONNECTIONS WILL DEACTIVATE THE SENSOR 5 5 TEMPERATURE SENSOR INSTALLATION 3 i 2 STAINLESS STEEL HOUSING qui 855303 equiv DIN 1 4305 2 46 5 0 NPTF 1 8 X 27 SPADE TERMINALS A2 8 X 0 8 DIN 46244 WITHOUT HOLE TE27 32 4 SD 03 2010 5 32 6 TRANSMISSION OPERATION
48. The APC200 expects the shift lever Put the shift jever back in NEUTRAL to be in NEUTRAL but finds it in another position FORWARD or REVERSE THE 200 expects the partking Put the parking brake ON brake to be ON while it is OFF The APC200 has detected output Verify that the parkiing brake is ON and working prop speed erly If this is already the case you will be obliged to keep the machine at standstill by using the footbrake Once the machine has been stopped the APC200 will ask the driver to shift to FORWARD before con tinuing the calibration Engine RPM is to low according If the vehicle is equiped with throttle by wire the to the limit that is necessary for engine RPM will be automatically adapted In the calibration other case the driver has to change the throttle pedal position until the display looks as follows Engine RPM is to high according to the limit that is necessary for calibration After being to low or to high the engine RPM is coming back into the correct bounderies for calibra tion When during the automatic trans Use the M button on the APC200 to go back to the mission calibration the temperature HEAT mode and the S button to trigger this mode becomes to low the APC200 dis Now you have to warm up the transmission again un play indicates the actual transmis til the temperature is above 60 140 F Then go sion temperature back to the automatic tuning mode by t
49. URE amp TEMPERATURE SPECIFICATIONS Normal operating temperature 70 120 C 158 2482 measured at temperature check port to cooler port 71 or port 32 Maximum allowed transmission temperature 120 C 248 F Transmission regulator pressure neutral port 31 at 600 RPM 22 5 bar 326 3 PSI minimum at 2650 RPM 25 5 bar 369 8 PSI maximum Pump flow 7 System pump flow 100 7 I min minimum 26 60 GPM at 2170 RPM Lube pump flow 52 4 I min 13 84 GPM minimum at 2170 RPM selective lube 84 6 I min 22 35 GPM maximum at 2910 RPM Clutch pressures 1st clutch port 41 2nd clutch port 42 3rd clutch port 43 4th clutch port 44 forward clutch port 45 reverse clutch port 46 at 2200 RPM 20 5bar 297 3PSI minimum with 1st clutch activated Filter bypass valve set at 4 1 to 4 5 bar 59 4 to 65 2 PSI Lube pressure port 34 4 0 5 5 bar 58 80 PSI at 2200RPM Internal total leakage at 1000 engine RPM Fwd Rev 4l min 1 GPM maximum 1st 9 21 2 43 GPM maximum 2nd 3rd 4th Al min 1 GPM maximum Converter 5 12 I min 1 3 3 2 GPM at 1000RPM Safety valve cracking pressure 7 8 8 9 6 bar 127 6 139 2 PSI To cooler converter out pressure 33 5 bar 72 5PSI min at 2000RPM engine speed and a max of 8 5 bar 123 3 PSI pressure at no load governed speed All pressur
50. Y BOLT CIRCLE DIA BOLT CIRCLE DIA BACKING RING 2 INTERMEDIATE DRIVE PLATES BACKING RING 3 INTERMEDIATE DRIVE PLATES A Dimension Bolt circle diameter A Dimension Bolt circle diameter 15 381 0 mm diameter 15 381 0 mm diameter 16 406 4 mm diameter 16 406 4 mm diameter 17 431 8 mm diameter 17 431 8 mm diameter Each kit will include the following parts Each kit will include the following parts 2 Intermediate drive plates 3 Intermediate drive plates 1 Drive plate and weld nut assembly 1 Backing ring 1 Backing ring 6 Mounting screws 6 Mounting screws Lock washers 6 Lock washers 1 Instruction sheet 1 Instruction sheet Position drive plate and weld nut assembly on torque converter assembly with welded nuts toward converter Align intermediate drive plates and backing ring with holes in torque converter assembly Note A Two DIMPLES 180 APART IN BACKING RING MUST BE OUT TOWARD THE ENGINE FLYWHEEL Install cap screws and washers Tighten 40 50 Nm 30 to 37 Ibft torque TE27 32 4 SD 03 2010 5 28 Installation details 5 2 TRANSMISSION TO ENGINE INSTALLATION FLYWHEELHOUSING MOUNT PROCEDURE DIAL INDICATOR HERE 1 Remove all burrs from flywheel mounting face and nose pilot bore Clean drive plate surface with solvent 2 Check engine flywheel amp housing for conformance to standard SAE No 3 per SAE J927 and J1033
51. cates which clutch is calibrated clutch 1 to clutch 6 the last 2 characters indicates the calibration phase inwhich this clutch is mode 1 or mode2 When all clutches have been calibrated the APC200 displays dont At this point the automatic calibration has completed successfully The normal duration of a complete transmission calibration is around 15 minutes To exit the automatic calibration mode you should need to switch off the ignition key the vehicle Make sure that the 200 has powered down wait for 2 seconds Now restart the vehicle and the new tuning results will be activated automatically REMARK 1 If you get any different information on the APC200 display as described above there can be two possible reasons e the calibration conditions are not fulfi lled temperature is too low parking brake switched off the vehicle is moving engine rpm is too high or too low e a calibration error has occurred during the calibration message starting with an E For possible messages see chapter 4 4 5 T27 32 4 SD 03 2010 4 22 Maintenance REMARK 2 By selecting REVERSE on the shift lever while the automatic calibration is performing the procedure will abort the automatic calibration immediately and restart the APC200 You can use this as an emergency procedure when something goes wrong during the calibration procedure Note by aborting the automatic calibration the calibration is not finalized and needs to be
52. done from the beginning 4 4 4 HEATING UP THE TRANSMISSION BY USING THE HEAT MODE The HEAT mode allows to select forward reverse while the parking brake is activated without forcing neutral and will disable the inching and declutch function During the heat mode the highest gear is forced even when the shift lever is in a lower gear This combination allows the driver to heat up the transmission by going into stall The paragraph how to enter the calibration mode see 1st paragraph also displays how the HEAT mode can be activated Once you see on the display tran you can press the M button once to go into the heat mode APC200 will display To trigger the HEAT mode push the S button The APC200 will display the sump temperature 6920 This means the actual sump temperature of the transmission is 20 C 27 32 4 SD 03 2010 4 23 Maintenance Perform the following steps in order to heat up the transmission 1 Make sure the parking brake is active and works properly 2 Put the transmission in forward by selecting forward with the shift lever and then accelerates the engine to full throttle 3 Keep the engine at full throttle for about 15 seconds and then put the gearbox in neutral by selecting neutral with the shift lever Keep the engine at full throttle 4 Keep the gearbox in neutral at full engine throttle for about 15 seconds again 5 Release the throttle pedal and decelerate the
53. e transmission clutches torque converter charging pump and hydraulic circuit for pressure and rate of flow it is imporatant to make the following transmission fluid check Check oil level in the transmission The transmission fluid must be at the correct full level All clutches and the converter and its fluid circuit lines must be fully charged filled at all times Note THE TRANSMISSION FLUID MUST BE AT OPERATING TEMPERATURE OF 82 93 C 180 200 F To YA OBTAIN CORRECT FLUID LEVEL AND PRESSURE READINGS Do NOT ATTEMPT TO MAKE THESE CHECKS WITH COLD OIL To raise the oil temperature to this specification it is necessary to either operate work the vehicle or run the engine with converter at stall refer to 6 2 1 stall test Caution A BE CAREFULL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGINE AND CONVERTER AT STALL RPM 7 2 5 Controller APC200 Please refer to functional description TE27 32 4 SD 03 2010 7 62 Transmission Operation 7 3 TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles 7 3 1 Low clutch pressure Cause Remedy 1 Low oil level 1 Fill to proper level 2 Clutch pressure regulating valve stuck open 2 Clean valve spool and housing 3 Faulty charging pump 3 Replace pump 4 Broken or worn clutch shaft or piston sealing rings 4 Replace sealing rings 7 3 2 Low charging pump outpu
54. es and flows to be measured with oil temperature of 82 93 C 180 200F Refer to section troubleshooting for check port identification TE27 32 4 SD 03 2010 3 16 Technical specifications 3 5 ELECTRICAL SPECIFICATIONS Proportional valves FWD REV 1st 3rd 2nd 4th coil resistance 7 250 at 20 C 68 F Selection valves FWD N REV 1st 3rd 2nd 4th coil resistance 12V 7 1 Q at 20 C 68 F coil resistance 24V 28 5 O at 20 C 68 F Speed sensor type magneto resistive sensor sensing distance 0 1 8 mm 0 0 077 Sensor signal generates a square current with a fixed amplitude changing between 7 14 mA Temp sensor Material silicon Resistance at 25 C 77 F 2000 O x 1 Pressure sensor Supply voltage 4 5 5 5V Maximum current 10mA Pressure range 1 to 31 bar 14 5 450PSI 1 2 full scale 31bar 450PSI range 1 to 25 bar 14 5 363 PSI 2 5 full scale 31bar 450PSI range 25 to 31 bar 363 450PSI 3 6 HYDRAULIC COOLER LINES SPECIFICATIONS Minimum 25 4mm 1 internal diameter for lines and fittings Suitable for operation from ambient to 120 C 248 F continuous operating temperature Must withstand 28 bar 406PSI continuous pressure and with 41 bar 595PSI intermittent surges Conform SAE J1019 and SAE J517 100RI TE27 32 4 SD 03 2010 3 17 4 MAINTENANCE T27 32 4 SD 03 2010 Maintenance 4 1 OIL SPECIFICATION 4 1
55. he M button and trigger this one again to continue calibration 4 4 5 2 Calibration errors Calibration errors have the form E1 xx or E2 xx example E1 25 Please contact the OEM of the machine if an error of this form appears on the display 27 32 4 SD 03 2010 4 25 4 4 6 PERFORMING A STALL TEST ith a stall test it is possible to test clutch pack slippage or test the converter engine stall speed in each gear How to Preform a stall test 1 Activate parking brake 2 Activate calibration mode during power up and holding the S button for 15 seconds 3 select STAL using the M button A 4 Select the requested range gear with the 5 button ENGINE SPEED ENGINE SPEED ENGINE SPEED ENGINE SPEED 5 Select FWD or REV in the selected range gear 6 request full throttle and read the engine speed at the APC display 7 All speeds should reach approximately the same value when the transmission in ok 8 Leave the stall mode with the M button or switch off the ignition 27 32 4 SD 03 2010 4 26 5 INSTALLATION DETAILS TE27 32 4 SD 03 2010 5 27 5 INSTALLATION DETAILS 5 1 CONVERTER DRIVE COUPLING Measure the A dimension bolt circle diameter and order drive plate kit listed below Note three 3 kits have two 2 intermediate drive plates and one 1 drive plate and weld nut assembly Three 3 kits with three intermediate drive plates 1 DRIVE PLATE AND WELD NUT ASSEMBL
56. he turbine shaft driven from the turbine transmits power to the directional clutches fwd rev These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston The piston is oil tight by the use of sealing rings The steel discs with internal splines and friction discs with external splines are alternated until the required total is achieved A back up plate is then inserted and secured with a retainer ring A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch To engage the clutch the solenoid will direct oil under pressure through tubes and passages to the selected clutch shafts Oil sealing rings are located on the clutch shafts These rings direct the oil through a drilled passage in the shaft to the desired clutch Pressure of the oil forces the piston and discs against the back up plate The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit When the clutch is released a return spring will push the piston back and oil will drain back via the shift spool the bleed hole or holes in the clutch piston into the transmission sump These bleed holes will only allow quick escape of o
57. i deq 07 0 019 0 8885 31 38055384 2290019 IATVANOLLVINGOW 03710810 INOWLII13 9 ft N 105135 38155384 HIND AM o o LIT 088151 600 03123135 WLAN ueq ubi ainssaid uoneoniqn1 WYYOWIG IMAVICAH JAVA MOM TIN NOISSINSNYYL 905 lt lt 410510 XA uv udi oz 001 Zand 350H 1015919 557448 Laid SIMIM 3S0H 1 1002 lt ISOH MOS 3NOYOL 1N3WDINdWOD 80108840 ISOH Cur aw 30H ISOH 6 40 03 2010 TE27 32 4 SD Transmission Operation 6 4 1 Neutral 1 Continued TE27 32 4 SD 03 2010 6 41 Transmission Operation MIND MIND Hip LJ 600 600 800 ja 6 4 2 Forward 1st speed HOLA 0 dst LJ 600 600 OS N N 105185 34155384 HLP ONZ Sosan auns 8 129 0019 NOLYINGOW 311081502 2INOULDTH av HOLM MIND amd 9 ZN UE LSL WYYDVIC 3A vA MOTH NOISSIWSNVL 181 LJ 600 600
58. il when the pressure to the piston is released The engagement of all range and directional clutches is modulated and electronically controlled This means that clutch pressure is built up gradually This will enable the unit to make forward reverse shifts while the vehicle is still moving and will allow smooth engagement of drive INPUT SECTION TE27 32 4 SD 03 2010 6 36 Transmission Operation 8 1 3 The range clutches 77777 7 7 7 Once directional clutch is engaged power is transmitted to the range clutches Operation and actuation of the directional clutches is similar to the range clutches The engagement of the directional clutches is modulated For the 1st clutch assembly there is an extra bleed hole to allow full drain when the pressure to the piston is released 6 1 4The output section RANGE CLUTCH With a range clutch engaged power is finally transmitted to the output shaft Output rotation is the opposite to input rotation when the forward clutch is engaged OUTPUT SECTION TE27 32 4 SD 03 2010 6 37 Transmission Operation 6 2 THE TRANSMISSION CONTROLS REFER TO HYDRAULIC DIAGRAM The transmission is controlled by a TCON ECU This unit has a microprocessor that receives certain inputs gear selector position speed senors which are processed and will give output signals to the control va
59. ing nenne 1 18 rro 1 19 M 1 20 Covel Impeller ERA ERR ER RA 1 21 Bearing Turbine NUD eoe 1 22 1 23 1 24 MEA UNA 1 25 Hub Impeller Cover 2 en an kenn YER 1 TE27 32 4 SD 03 2010 FLEX PLATE GROUP 8 83 03 2010 TE27 32 4 SD DRIVE PLATE GROUP Item Description Qty 1 Assembly Drive plate and when used welded 5 1 2 Plate 5 3 FRING BACKING cs aaa id 1 4 14 TE27 32 4 SD 03 2010 8 84 FWD amp REV 2ND AND 3TH OR 4TH CLUTCH SHAFT ASSY TE27 32 4 SD 03 2010 FWD amp REV 2ND AND 3TH OR 4TH CLUTCH SHAFT ASSY Item Description Qty 1 Fwd shaft drum 1 2 Rev 2nd 8 2 ee esse 1 3 3rd shaft drum assy on 1 3 Ath shaft drum shaft assy 4 1 TE27 32 4 SD 03 2010 8 86 FORWARD CLUTCH SHAFT GROUP TE27 32 4 SD 03 2010 8
60. ion important notice Mark before disassembly observe marks when reasembl Carricare riempire olio lubrificante Filling topping up refilling e g oil cooling water etc T Attrezzature speciali P Pagina Scarricare olio lubrificante T Special tool P Drain off oil lubricant Rispettare direzione di montaggio Tendere Note direction of installation Montaggio di particollari ingombranti Evitare danni ai materiali danni ai pezzi Reinstall remount parts which had obstructed disassembly Guard against material damage damage to parts y gt l Tighten clamp tightening a clamping device Controllare esaminare controllo visuale Insere pressione nel circuito idraulico Visual inspection Apply pressure into hydraulic circuit Controllare regolare p e coppie misure pressione etc Check adjust e g torque dimensions pressures etc 1 G Eventualimente riutilizzable sostituire se necessario Pulire D Possibly still serviceable renew if necessary To clean TE27 32 4 SD 03 2010 2 10 3 TECHNICAL SPECIFICATIONS TE27 32 4 SD 03 2010 Technical specifications SPICER OFF HIGHWAY 5 TEN BRIELE 3 B 8200 BELGIUM O O MODEL ERIAL P 3 1 IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2
61. lve Operation of the valve Regulated pressure 22 26 bar 319 377 PSI is directed to the proportional valve and selector valves to acti vate the clutches required When activated the proportional valve will give an output pressure curve from 0 to 26 bar 0 87PSI proportional to a current from 0 mA to 1000mA Dampers are used to dampen any hydraulic vibration Directional selection When a direction forward or reverse is selected the required selector valve is activated for forward or reverse and the proportional valve will provide a pressure rise from 0 to 26 bar feeding the directional clutch with modulated pressure Range selection When 1st clutch is selected the 1st 3rd selector valve is actevated and the 1st 3rd proportional valve will provide a pressure rise from 0 to 26 bar feeding the 1st clutch with modulated pressure When 2nd clutch is selected the 2nd 4th selector valve is activated the 1st 3rd proportional valve will decrease pressure from 26 to 0 bar thus releasing the 1st clutch in a controlled manner At the same time the 2nd 4th pro portional valve is activated and will provide a pressure curve from 0 to 26 bar which will provide clutch overlap When the shift is finalized the 1st 3rd selector valve is deactivated When 3rd clutch is selected the 3rd 1st selector valve is not activated The 2nd 4th proportional valve will decrease pressure from 26 to 0 bar thus releasing the 2nd clutch in a controlled manner A
62. n 6 4 5 Forward 4TH speed MID Hu HDI LJ 600 OS OS 600 a MIND 0 151 HDI 9 Ld 600 OD OD HIP ONZ La 600 600 v a fi 046131 N 109185 600 Gr Y 103145 GUV MYO WYYOWIG MOTA TIN NOISSINSNYYL aunssaid ainssaid MOT uone gt niqn NIDS uv 410510 001 LdWnd JAWA 5884 18 i 350H SIG 19 lt gt aw 350H 10111193 34055344 196 SNDDWD INYA ALYS ts 3ANASSVd AB HD JON 1 2005 1 lt gt NOD 310801 S am LNIWLUYdWOD 40144340 350H SIG 6 48 03 2010 TE27 32 4 SD Transmission Operation 6 4 5 Forward 4th speed continued TE27 32 4 SD 03 2010 6 49 ion Operat ission Transm ainssaid MO MM MIND HOLM Hl Que ISl uone niqn 4 Y N 4 gt lt
63. n 3 1mm 0 12in Max 3 5mm 0 14in 11 seperator plates with inner splines 10 friction plates friction material on both sides with outer splines 2 1 sided friction plates friction material on one 1 side with outer splines Clearance Min 3 1mm 0 12in Max 3 5mm 0 14in Choose an end plate with suitable thickness to obtain this clearance TE27 32 4 SD 03 2010 9 112 ASSEMBLY INSTRUCTIONS Be sure that shielded and sealed bearings are mounted as shown Seals must be pressed in perpendicular upon shaft axis from bearing side Tighten air breather to 31 41 Nm 25 30 Lbs ft Tighten nut to 145 160 Nm 107 118 Lbs ft Tighten nut to 339 407 Nm 250 300 Lbs ft Tighten 2 coil nuts to 6 8 9 5 Nm 250 300 Lbs ft Tighten 1 valve to 53 73 Nm 39 54 Lbs ft Tighten 6 screws to 5 6 Nm 3 7 4 4 Lbs ft Tighten 2 coil nuts to 6 8 9 5 Nm 5 7 Lbs ft Tighten 2 pressure sensors to 7 11 Nm 5 8 Lbs ft Tighten 2 valves to 34 36 Nm 25 27 Lbs ft VVVVVVVVVVV
64. parts must be replaced by spare parts which have the same part number or with equivalent parts DO NOT USE A SPARE PART OF LESSER QUALITY The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use a spare part service procedure or tool which is not recommended by SPICER OFF HIGHWAY PRODUCTS must first determine that neither his safety nor the safe operation of the machine will be jeopardised by the spare part service procedure or tool selected IMPORTANT IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS CAUTIONS AND NOTICES THAT MUST BE CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL INJURY DURING SERVICE OR REPAIR OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE CAUTIONS AND NOTICES ARE EXHAUS TIVE BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT FROM FAILURE TO FOLLOW THESE INSTRUCTIONS TE27 32 4 SD 03 2010 1 7 2 CLEANING AND INSPECTION TE27 32 4 SD 03 2010 2 8 2 CLEANING INSPECTION AND LEGEND SYMBOLS 2 1 CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in clean ing fluid and moved up and down slowly until
65. ping rags free of abrasive materials such as metal fillings contaminated oil or lapping compound 2 2 INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date 2 2 1 BEARINGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for fur ther use DO NOT REPLACE A BEARING CONE OR CUP INDIVIDUALLY without replacing the mating cup or cone at the same time After inspection dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed TE27 32 4 SD 03 2010 2 9 Cleaning and Inspection amp Legend symbols 2 2 2 OIL SEALS GASKETS etc Replacement of spring load oils seals O rings metal sealing rings gaskets and snap rings is more economical when the unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particularly when being installed Cutting scratching or curling under of lips of seals seriously impairs its efficiency When assembling new metal type sealing rings these should be lubricated with a coat of chassis grease to stabilise rings in their grooves for ease of as
66. que converter is located between and at the centre of the inner diameters of the impeller and turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element This recirculation will make the converter to multiply torque The torque multiplication is function of the blading impeller turbine and reaction member and the converter out put speed turbine speed The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM stall Therefore we can say that as the turbine shaft is decreasing in speed the torque multiplication is increasing The hydraulic pump is connected with the pump drive gear This pump drive gear is driven by the impeller hub gear Since the impeller hub gear is connected with the impeller cover the pump speed is in direct relation with the engine speed N f KUCHEN 1111 Ae pum 11111 CONVERTER SECTION CONTROL VALVE TE27 32 4 SD 03 2010 6 35 Transmission Operation 6 1 2 The input shaft and directional clutches T
67. reading should be either 1 2V from the 7mA 1mA current level or 2 6 3 0V for the 14mA 1mA current level If the teeth can be moved slowly distinct toggling between the two levels should be noticed sensor 200 Ohm 1 Watt TE27 32 4 SD 03 2010 7 68 Transmission Operation 7 6 FULL FLOW VALVE COMPONENTS 241 VALVE FWD REV SELECTOR FWD REV PROPORTIONAL VALVE N 3RD 1ST PRESSURE SENSOR SENSOR gt gt 4 PROPORTIONAL PROPORTIONAL VALVE 2ND 4TH VALVE 3RD 1ST 4TH 2ND SELECTOR 4TH 2ND PRESSURE 7 69 03 2010 TE27 32 4 SD 8 SECTIONAL VIEWS amp PARTS IDENTIFICATION TE27 32 4SD 03 2010 8 70 TORQUE CONVERTER GROUP TE27 32 4 SD 03 2010 8 71 TORQUE CONVERTER GROUP Item Description Qty 1 Torque en 1 2 Not MUS 1 3 59 01 11 3 4 I 1 5 gum M M M n 1 6 A 1 7 1 8 1 9 ie E 2 10 OC EID
68. ri ere e een 1 17 Disc Clutch 11 18 Disc Cl tch ufer cia EA 11 19 Plate ana an 1 20 1 21 1 22 Washer 15 23 Spacer Glutch PISTON e rettet duet a EY RET 1 24 iro EE 1 25 Bearing 1 26 Ring BLEU 1 27 Ring 1 28 Beain 1 29 Ring reso 2 ls unus 1 30 hieme 1 31 Washer Bearing thirst ee race eden aaa 1 32 Aub 2nd Clutch 0 1 33 Silence 1 34 Retainer 1 35 SNAPIING 1 36 FRING aA 3 TE27 32 4 SD 03 2010 8 94 1ST SPEED CLUTCH SHAFT GROUP 8 95 03 2010 TE27 32 4 SD 1ST SPEED CLUTCH SHAFT GROUP Item Description Qty 1 a a a 1 2 Seal PISO OU m 1 3 Seal PISTON IM aiii een 1 4 screen not Sold Seperate cuni
69. s analysis can provide useful inforamtion but a transmission should not be removed from service based solely on this analysis FILTERS Service oil filter element intervals 100hrs first time Then every 1000 hrs under normal envirronmental and duty cycle conditions 4 2 MAINTENANCE INTERVALS 4 2 1 Daily Check oil level daily with engine running at idle 600 RPM and oil at 82 93 C 180 200 F Maintain oil level at full mark 4 2 2Clutch calibration Every 2000hrs perform automatic clutch calibration DEXRON is a registered trademark of GENERAL MOTORS CORPORATION T27 32 4 SD 03 2010 4 19 Maintenance 4 3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL The transmission torque converter and its allied hydraulic system are important links in the driveline between the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other Therefore whenever repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered complete After the overhauled or repaired transmission has been installed in the machine the oil cooler and connecting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and a degree of judgement must be exercised as to the method employed The following are considered the minimum steps to be taken 1 2 Drain entire system thoroughly Disconnect and clean all h
70. sembly of mating members Lubricate all O rings and seals with recommended type Automatic Transmission Fluid before assembly 2 2 3 GEARS amp SHAFTS If Magna Flux process is available use process to check parts Examine teeth on all gears carefully for wear pitting chipping nicks cracks or scores If gear teeth show spots where case hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or spline twisted and that shafts are true 2 2 4 HOUSINGS COVERS etc Inspect housings covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures 2 3 LEGEND SYMBOLS 7 Smontaggio di sottogruppi Sostituire con ogni montaggio y Disassembly of assembly groups Renew at each reassembly 1 Montaggio di sottogruppi Togliere mettere la sicura 1 Reassemble to assembly group Unlock lock e g split pin locking plate etc rt Smontaggio di particollari ingombranti Mettere la sicura incollare mastice liquido Ly Remove obstruction parts Lock adhere liquid sealant ria Attenzione indicazione importante Marchiari prima dello smontaggio per il montaggio Attent
71. some grease to piston rings before assembly Apply a thin coating of grease between seal lips on lip type seals prior to assembly Use only precoated pipe plugs On uncoated pipe plugs apply a light coat of Loctite 592 Pump must be filled up with oil prior to assembly After assembly of parts using Loctite there must not be any free or excess material which might enter the oil circuit gt Apply a light coat of Loctite 262 or 270 to all thru hole stud holes gt Teflon seals must be sized prior to assembly Add some grease to seal diameter of clutch hub before assembly gt Fwd and Rev Clutch TE32 11 seperator plates with outer splines 11 friction plates friction material on both sides with inner splines Clearance Min 6 0mm 0 23in Max 6 4mm 0 25in TE27 8 seperator plates with outer splines 8 friction plates friction material on both sides with inner splines Clearance Min 6 0mm 0 23in Max 6 4mm 0 25in Choose an end plate with suitable thickness to obtain this clearance ZN CAUTION The seperator plates for Fwd and Rev and 1st and 2nd are not the same DO NOT MIX PLATES WITH PLATES FROM OTHER CLUTCHES gt 1st Clutch TE32 11 seperator plates with outer splines 11 friction plates friction material on both sides with inner splines Clearance Min 4 35mm 0 17in 4 75 0 19 27 10 seperator plates with outer splines 10 friction plates friction material on both sides with inner
72. splines Clearance Min 4 35mm 0 17 in 4 75 0 19 Choose an end plate with suitable thickness to obtain this clearance TE27 32 4 SD 03 2010 9 111 ASSEMBLY INSTRUCTIONS gt 2nd Clutch TE32 TE27 7 seperator plates with outer splines 7 friction plates friction material on both sides with inner splines Clearance Min 2 75mm 0 10in Max 3 15mm 0 12in 6 seperator plates with outer splines 6 friction plates friction material on both sides with inner splines Clearance Min 2 75mm 0 10in Max 3 15mm 0 12 Choose an end plate with suitable thickness to obtain this clearance 3rd Clutch TE32 TE27 12 seperator plates with inner splines 11 friction plates friction material on both sides with outer splines 2 1 sided friction plates friction material on one 1 side with outer splines Clearance Min 3 5mm 0 14in Max 3 9mm 0 16in 9 seperator plates with inner splines 8 friction plates friction material on both sides with outer splines 2 1 sided friction plates friction material on one 1 side with outer splines Clearance Min 3 5mm 0 14in Max 3 9mm 0 16in Choose an end plate with suitable thickness to obtain this clearance 4th Clutch TE32 TE27 11 seperator plates with inner splines 10 friction plates friction material on both sides with outer splines 2 1 sided friction plates friction material on one 1 side with outer splines Clearance Mi
73. t flow Cause Remedy 1 Low oil level 1 Fill to proper oil level 2 Suction screen clogged 2 Clean suction screen 3 Defective charging pump 3 Replace charging pump 7 3 3 Overheating Cause Remedy 1 Worn oil sealing rings 1 Remove disassemble and rebuild converter assy 2 Worn charging pump 2 Replace charging pump 3 Low oil level 3 Fill to proper level 4 Dirty oil cooler 4 Clean cooler 5 Restriction in cooler lines 5 Change cooler lines 7 3 4 Noisy converter Cause Remedy 1 Worn charging pump 1 Replace charging pump 2 Worn or damaged bearings 2 A complete disassembly will be necassary to USlS 7 3 5 Lack of power Cause Remedy 1 Low engine RPM at converter stall 1 Tune engine check governor 2 See Overheating and make same checks 2 Make corrections as explained in Overheating TE27 32 4 SD 03 2010 7 63 Transmission Operation 7 4 CHECK POINTS Port 34 Pressure check port Lube TE27 32 4 SD Port 42 Pressure check port 2nd clutch Port 46 Pressure check port Rev clutch y Port 44 Pressure check port 4th clutch 4 ON FRONT VIEW Plug Magnetic drain M22 x 1
74. t the same time the 1st 3rd proportional valve is activated and will provide a pressure curve from 0 to 26 bar which will provide clutch overlap When the shift is finalized the 2nd 4th selector valve is deactivated When 4th clutch is selected the 2nd 4th selector valve is not activated The 1st 3rd proportional valve will decrease pressure from 26 to 0 bar thus releasing the 3rd clutch in a controlled manner At the same time the 2nd 4th proportional valve is activated and will provide a pressure curve from 0 to 26 bar which will provide clutch overlap Restriction plug The pressure line is connected to the drain line via a restricted hole This ensures the drain line to remain air free at all times and guarantees the reliable functioning of the proportional valves TE27 32 4 SD 03 2010 6 38 Transmission Operation Pressure sensor The control valve also has a pressure sensor installed to monitor overlap on range clutches 6 3 ELECTRIC SOLENOID CONTROLS Selector valve Proportional valve clutches A BEE A Neural Path 148 Neutrals 34 NENNEN TE27 32 4 SD 03 2010 6 39 Transmission Operation 6 4 POWERFLOWS ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT HIND Hip HUM 6 4 1 Neutral 1 Selected 600 Ol mo LIT gt lt HD ASL 600 600 O ay OS av DX LA N 10945 anss
75. tolerance specifications for pilot bore size pilot bore runout and PILoTBoRE mounting face flatness Measure and record engine crankshaft end play Fig 1 FLYWHEEL 3 Install two 63 50 mm 2 50 long transmission to flywheel housing guide studs in the engine flywheel housing as shown Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole Fig 2 FLYWHEEL HOUSING CONVERTER HOUSING 4 Install 101 60 mm 4 00 long drive plate locating stud 3750 24 fine thread in a drive plate nut Align the dm locating stud in the drive plate with the flywheel drive plate ARY TA mounting screw hole positioned in step 3 d V 5 Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate d mounting screw hole positioned in step No 3 Locate 5 2 ALIGNING d transmission on flywheel housing Al 8 Aligning drive plate to flywheel and transmission to FLYWHEEL Com mr flywheel housing guide studs Install transmission to 7 flywheel housing screws Tighten screws to specified torque Remove transmission to engine guide studs an Install remaining screws and tighten to specified torque eT en SELF LOCK NUT FURNISHED 6 Remove drive plate locating stud FLYWHEEL HOU
76. ydraulic lines Where feasible hydraulic lines should be removed from machine for cleaning Replace oil filter element The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow will not adequately clean the cooler If necessary cooler assembly should be removed from machine for cleaning using oil compressed air and steam cleaner for that purpose IMPORTANT DO NOT USE FLUSHING COMPOUNDS FOR CLEANING PURPOSES Reassemble all components and use only type oil recommended from lubrication section Fill transmission through filler opening until fluid comes up to the oil level check port Run engine 2 minutes at 500 600 R P M to prime torque converter and hydraulic lines Recheck level of fluid in transmission with engine running at idle 500 600 R P M Add quantity necessary to bring fluid level to oil level check port Recheck with hot oil 180 200 F 82 93 C Recheck all drain plugs lines connections etc for leaks and tighten where necessary 27 32 4 SD 03 2010 4 20 Maintenance 4 4 PROCEDURE FOR PERFORMING AUTOMATIC CALIBRATION 4 4 1 Introduction The APC200 firmware contains an automatic transmission calibration procedure which is able to optimize the shift quality of the transmission An automatic calibration has to be done When the vehicle is build at the OEM Every 2000 hrs
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