Tamrock T&K 1 (4)
1.6.2006AMF
T007 LOGIG CONTROLLED GEARSHIFTING: TESTING
Instructions to test logic controlled gearshifting in repairs and maintenance
1. Tests before connecting power:
-Correct polarity on the supply voltage?
-Correct power and earth links?
-No short circuits on outputs?
2. Tests with power on:
When you are connecting power to a readily programmed logic controller, the signal led-lamps can at
first flash a couple of times and the yellow STOP led will be on. After 3-5 seconds the green RUN led
will be on. SF and STOP leds should not be on or flash. I/O leds will be on according to input and
output functions, some of them can be flashing almost all the time.
STATUS-LEDS:
LED STATE CAUSE
SF red on System Fault, inside logic controller
RUN green on Program is running, OK
STOP yellow on Program is stopped
Restoring program and factory settings
If you have to restore program or factory settings you can do that by using a separate memory module.
When the power is off place the module to it’s place under a lid in the upper right corner of the logic
controller. Switch the power on and wait about ten seconds until the amber STOP led turns off and
green RUN light turns on. After that turn power off and remove the memory module. The program and
factory settings are now restored.
Place for a memory
module. Can be
covered with tape in
STOP / a new controller.
CPU216-2
TERM /RUN
switch. Must
be in run
position.
Tamrock T&K 2 (4)
1.6.2006AMF
I/O-LEDS:
- I indicates an input state, i.e +24V.
- Q indicates an output state, control on.
LED STATE CAUSE
I00 on + button steering lever
I01 on - button steering lever, not used in open canopy model
I02 on shift mode selector, not used in closed cabin model
I03 on shift mode selector
I04 on shift mode selector
I05 on service brake on
I06 on speed pulses, 500Hz - 2500Hz
I07 on neutral button steering lever
I10 on R (reverse) button steering lever, reverse on RC
I11 on F (forward) button steering lever, forward on RC
I12 on engine rpm pulses, 12 pulses/1 engine revolution
I13 on remote control selected gears are working only with RRC
I14 on parking brake released gears can be selected
I15 on door open gears can not be selected
I16 on engine running gears can be selected
I17 on central lubrication grease end
I20 on
I21 on display select button
I22 on
I23 on
F.ex. to select gears from cabin:
I13 has to be OFF (remote control not selected)
I14 has to be ON (parking brake released)
I15 has to be OFF (door is closed)
I16 has to be ON (engine is running)
Q00 on gear reverse
Q01 on gear forward
Q02 on gear 2.
Q03 on gear 3.
Q04 on gear 4.
Q05 on torque limit
Q06 on extra throttle
Q07 on display
Q10 on display
Q11 on display
Q12 on display
Q13 on display
Q14 on display
Q15 on display
Q16 on start inhibit, engine already running
Q17 on central lubrication control, motor has to be running
Tamrock T&K 3 (4)
1.6.2006AMF
Troubleshooting
A. No function at all
First check the system status led:s according to page 1. The green RUN led should be on.
-If no led:s at all are on, check fuses because you might have lost the supply voltage. Also check the
ground links.
-If yellow STOP led is on, check that the STOP / RUN switch is at RUN position, try if it goes any further
right. If it was in wrong position, turn power off and on, and check again. If that doesn’t help, try to
reload the program according to the instructions on page 1. If that doesn’t help, you have to change the
controller.
-If red SF light is on, try to reload the program according to the instructions on page 1. If that doesn’t
help, you have to change the controller.
-If the green RUN led is on, and there is still no function at all, check all the wire links in controller. Also
check the fuses.
Note! There is no fuses or repairable components inside PLC.
B. Some function is missing
-First check from instructions that all the required conditions are fullfilled. For example, central
lubrication is not working if the motor is not running, gears are not working if the door is open, and so
on.
-Check from the output led-lamps of the controller that output is working. If it is ok, and there is still no
function, check the output relay. If the output is not working, and you are absolutely sure that all the
required conditions are fullfilled, you have to change the controller.
-All the functions, except display, have an output relay. These relays are of terminal type and they each
have a led-lamp that indicates that there is power in the coil of the relay. Check if the relay is working. If
it is not, check the wiring. If the wiring is ok, change the relay.
-If output and its relay are working, check all the wiring and fuses affecting the circuit after them.
C. Automatic gear shifting doesn’t work at all.
-At first check that the manual gear selecting is working with all gears. That way you can ensure that
the inputs from push-buttons and outputs to the terminal relays and from there to gear selecting
solenoids are ok.
-If the manual gear selecting is ok check that speed- and engine rpm measurements are working.
SPEED:
-Drive with the manual mode and press the “display select” button. You should see the
speed of the machine in km’s/hour x 10 in the number display, meaning that 5km/h shows
as 050, 15.4 km/h shows as 154, and so on. Note that you have to drive with gear on, if
the machine is running freely with neutral gear the speed indicates zero (000).
-If there is no speed indication, check that green led in speed measurements optocoupler
(inside dashboard) is illuminated when you are driving. If it is not, check the wiring. You
can also check with an oskilloscope that there are some pulses coming in when you are
driving. If the wiring and the pulses are ok, change the optocoupler.
-If the optocoupler is working, check that the input led is working. If it is not, try to
interchange the wires coming to speed input (I0.6) and rpm input (I1.2). Now when you
are driving, you should see at least some speed measurement when you are pressing the
Tamrock T&K 4 (4)
1.6.2006AMF
“display select” button. If it is still constantly zero, try to reload the program according to
the instructions on page 1. If that doesn’t help, you have to change the controller.
-If you see some speed, logic controller is ok and you have to re-check the speed
measurements optocoupler. Also check the wiring and the cabel that are going to the
speed sensor. If they are ok, change the speed sensor.
ENGINE RPM:
-First check that the rpm meter in the dashboard is working ok. The rpm meter and logic
controller are using the same rpm pulse that is coming from a Detroit Diesel DDEC and if
the pulse is missing, check first the VIH cable and the wiring that are coming from DDEC
to cabin. If they are ok, and you don’t get any reading, refer to Detroit Diesel manuals.
-With the engine running, turn the “gear mode” selector to “S” (setting) or “P”
(programming) position. You should see the engine rpm in the number display. Note that
readings over 2000 are shown with +(plus), for example rpm 2100 is +1100.
-If there is no rpm indication, check that the green led in rpm measurements optocoupler
(inside dashboard) is illuminated when the engine is running. If not, check the wiring. You
can also check with an oskilloscope that there are some pulses coming in. If the wiring
and the pulses coming in are ok, change the optocoupler.
-If the optocoupler is working, check that the input led is working. If not, try to interchange
the wires coming to speed input (I0.6) and rpm input (I1.2). Now when you are driving, you
should see at least some rpm measurement when you are turning the “gear mode”
selector to “S” (setting) or “P” (programming) position. If it is still constantly zero, try to
reload the program according to the instructions on page 1. If that doesn’t help, you have
to change the controller.
-If you see rpm, logic controller is ok and you have to re-check the rpm measurements
optocoupler.
-If the speed and rpm measurements are ok, re-check the wiring coming from “gear mode” selector
switch and from push-buttons. If they are ok, try to reload the program according to the instructions on
page 1. If that doesn’t help, you have to change the controller.
D. Automatic gear shifting doesn’t work properly
-You can adjust the shifting points and -delays by changing their parameters according to the separate
instructions. If the changing is too rough, check also that the torque limit- and the extra throttle relays
are working ok.
