APC200 ECM/ECI

Transmission
Control System
Description

SPICER OFF-HIGHWAY APC200 Control System

Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 1/65
 Contents
1. Functional specification ___________________________________________________ 5
1.1 General ________________________________________________________________________ 5
1.2 External interfaces_______________________________________________________________ 6
1.3 Man Machine interface ___________________________________________________________ 9
1.3.1 Shift lever _________________________________________________________________________ 9
1.3.2 Display ___________________________________________________________________________ 9
1.3.3 Other ____________________________________________________________________________ 10
1.4 Operating modes _______________________________________________________________ 11
1.4.1 Normal driving ____________________________________________________________________ 11
1.4.2 Self test mode _____________________________________________________________________ 11
1.4.3 Limp Home mode __________________________________________________________________ 11
1.4.4 Shutdown mode ___________________________________________________________________ 11
1.4.5 Mode identification_________________________________________________________________ 12
1.5 Operating Characteristics________________________________________________________ 12
1.5.1 System___________________________________________________________________________ 12
1.5.2 On/Off inputs _____________________________________________________________________ 13
1.5.3 Analogue inputs ___________________________________________________________________ 13
1.5.4 Speed sensor inputs_________________________________________________________________ 13
1.5.5 On/Off outputs ____________________________________________________________________ 14
1.5.6 Analogue outputs __________________________________________________________________ 14
1.5.7 Speedometer output (combined with RS232 transmit) ______________________________________ 14
1.5.8 Communication interfaces ___________________________________________________________ 14
1.6 Functional description of an automatic control on a forklift ___________________________ 15
1.6.1 External inputs ____________________________________________________________________ 15
1.6.2 General __________________________________________________________________________ 17
1.6.3 Transmission gear changing. _________________________________________________________ 17
1.6.4 Direction reversal protections_________________________________________________________ 19
1.6.5 Behaviour in neutral ________________________________________________________________ 20
1.6.6 Output functions. __________________________________________________________________ 20
1.7 The APC200 Inching System _____________________________________________________ 21
1.7.1 Operation ________________________________________________________________________ 21
1.7.2 Activation of the inching system ______________________________________________________ 21
1.7.3 Leaving Inching mode ______________________________________________________________ 22
1.7.4 Protections preventing Inching mode ___________________________________________________ 22
1.7.5 Function of the brake pedal in relation with inching _______________________________________ 22
1.7.6 Function of the brake pedal without inching _____________________________________________ 23
1.7.7 Tips for effectively using the inching system _____________________________________________ 23
1.8 The APC200 Hydrostatic simulation system_________________________________________ 24
2. Safety related requirements __________________________________________________ 25
2.1 Applicable safety guidelines ______________________________________________________ 25
2.2 Safety concept _________________________________________________________________ 25
2.2.1 General __________________________________________________________________________ 25
2.2.2 ECM/APC200 implementation ________________________________________________________ 26
2.3 Considered faults _______________________________________________________________ 26
SPICER OFF-HIGHWAY APC200 Control System
Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 2/65
 2.4 Behaviour in case of faults _______________________________________________________ 27
2.4.1 General __________________________________________________________________________ 27
2.4.2 Reset Condition ___________________________________________________________________ 27
2.4.3 Over voltage ______________________________________________________________________ 27
2.4.4 Under voltage _____________________________________________________________________ 27
2.4.5 Internal faults _____________________________________________________________________ 27
2.4.6 Redundant Shutdown Path Error ______________________________________________________ 28
2.4.7 Program out of control ______________________________________________________________ 29
2.4.8 Intermittent power loss ______________________________________________________________ 29
2.4.9 Single faults on analogue outputs ______________________________________________________ 29
2.4.10 Single faults on on/off outputs ________________________________________________________ 31
2.4.11 Incorrect input patterns ______________________________________________________________ 32
2.4.12 Speed sensor faults _________________________________________________________________ 32
2.4.13 Analogue sensor failure _____________________________________________________________ 33
2.4.14 Transmission ratio faults_____________________________________________________________ 34
2.4.15 Converter Temperature problem_______________________________________________________ 34
2.4.16 Service requests ___________________________________________________________________ 35
2.4.17 Indication of faults _________________________________________________________________ 35
2.4.18 Indication of faults that have previously occurred _________________________________________ 38
2.5 Behaviour when faults are removed _______________________________________________ 38
2.5.1 Over voltage ______________________________________________________________________ 38
2.5.2 Under voltage _____________________________________________________________________ 38
2.5.3 Internal faults _____________________________________________________________________ 38
2.5.4 Redundant Shutdown Path Error ______________________________________________________ 39
2.5.5 Program out of control ______________________________________________________________ 39
2.5.6 Intermittent power loss ______________________________________________________________ 39
2.5.7 Single faults on outputs _____________________________________________________________ 39
2.5.8 Multiple faults on outputs ____________________________________________________________ 39
2.5.9 Incorrect input patterns ______________________________________________________________ 39
2.5.10 Speed sensor failure ________________________________________________________________ 39
2.5.11 Analogue sensor failure _____________________________________________________________ 39
2.6 Specific measures to guarantee Fault tolerance ______________________________________ 39
2.7 Organisational measures to protect from external factors _____________________________ 40
2.7.1 Identification______________________________________________________________________ 40
2.7.2 Traceability and configuration control __________________________________________________ 40
2.7.3 Sourcing _________________________________________________________________________ 41
2.7.4 Software _________________________________________________________________________ 41
3. Environmental conditions____________________________________________________ 41
3.1 Nature of environmental conditions _______________________________________________ 41
3.2 Behaviour of the system under certain conditions ____________________________________ 41
3.3 Environmental standards and limits _______________________________________________ 42
3.4 Interference immunity standards and limits_________________________________________ 42
4. Design and development tools ________________________________________________ 42
5. Diagnostics and Guidelines __________________________________________________ 44
5.1 Diagnostics and maintenance _____________________________________________________ 44
5.1.1 General __________________________________________________________________________ 44
5.1.2 Self test Functions__________________________________________________________________ 44
SPICER OFF-HIGHWAY APC200 Control System
Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 3/65
 5.2 Technical guidelines for installation _______________________________________________ 50
5.2.1 Power supply _____________________________________________________________________ 51
5.2.2 Input signals ______________________________________________________________________ 52
5.2.3 Output signals _____________________________________________________________________ 53
5.2.4 Communication interfaces ___________________________________________________________ 54
5.3 Control system calibration _______________________________________________________ 56
5.3.1 Calibration of the accelerator pedal sensor_______________________________________________ 57
5.3.2 Calibration of the brake pedal sensor ___________________________________________________ 58
5.3.3 Calibration of the hydro lever sensor ___________________________________________________ 59
5.3.4 Calibration of the servo motor sensor___________________________________________________ 60
5.3.5 Calibration of clutch control parameters_________________________________________________ 61
6. Statistics__________________________________________________________________ 63
7. Revision record ____________________________________________________________ 64
8. Configuration Record _______________________________________________________ 64

SPICER OFF-HIGHWAY APC200 Control System

Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 4/65
 APC200 for ECM / ECI

1. Functional specification

1.1 General

The APC200 (Transmission Controller for ECM) is a device used to control the shifting of the
Spicer Off Highway Products ECM powershift transmissions.
ECM means Electronic Controlled Modulation and refers to a transmission control technology that
is available on a range of transmission models.
ECI means Electronic Controlled Inching. This refers to the capability of ECM transmissions with
APC200 to run at very low controlled speed at virtually any engine speed. This function is desirable
in a/o. forklift truck applications.
To date, within these models, three transmission types are supported: TE13, TE17 and TE32
transmissions with 4/4, 4/3 and 3/3 gear sets.

POWER T ra n sm is sio n

Sh ift Le ve r C o nt ro l
V a lve

T h ro t t le Pe da l Engine Speed
APC2 0 0 Turbine Speed
Drum Speed
Output Speed
Bra k e Pe da l
Temperature

M od e Se le c t ion
E ng ine

T h ro t t l e
Se rvo
C on t ro l
CAN GND

SPICER OFF-HIGHWAY APC200 Control System

Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 5/65
 The APC200 takes care of all transmission related functions in order to achieve superior shift
quality and high reliability. Additionally it can control the engine speed either through use of a
suitable servo motor on the injection pump or via the standardized SAE J1939 CAN protocol..
The built in self-test and trouble shooting features allow fast problem resolution.
The integration in the vehicle wiring system is straightforward and mainly involves connections
between the APC200, the shift selector, the speed sensors, and the transmission control valve.

DIG OUT

DIG INP
FB

ANA INP ANA I/O

FB
PWM
SPEED INP I+

I-
I/V
STAT

Red.ShutDown
FB

Additionally the APC200 requires some connections for supplying power and for selection of
different operating modes. For more detail, check the application specific wiring diagrams.
Refer to section 5.2 for details about the installation.

1.2 External interfaces

The APC200 is connected to the vehicle wiring system using a 48 pole Packard Metripack
Connector.
The two mating connectors (18 pole and 30 pole) have following components and Packard part
numbers.

Part Packard Part number

Receptacle 30 pin 1203 4398
Receptacle 18 pin 1204 0921
Contact 12089290 (0.35-0.5 mm²)
12103881 (0.8 - 1.0 mm²)

SPICER OFF-HIGHWAY APC200 Control System

Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 6/65
 The different connector pin functions for the APC200 are listed below.

Following type designations are considered:

Ptg pull to ground Input internally pulled high, must be connected to Ground
to activate. Alternately senses resistance 0 - 5 kOhm
Ptp pull to plus input internally pulled low, must be connected to Plus to
activate
Stg switch to ground Output switches internally to Ground. Other side of Load
must be connected with Plus
Stp switch to plus Output switches internally to Battery plus. Other side of
Load must be connected with Ground
Pwr power supply line connected to battery
Gnd ground ground reference line or supply line
Sns sense sensor input for frequency, voltage or current
Pwm pulse width Output uses PWM to control the output current. When
modulated combined with the proper sns input, closed loop current
control is possible.
Comm communication control line used for communicating information with other
controllers and / or PC’s
Hbrg bi-directional motor Output can control the speed of a DC motor in both
control directions

In below table all references to terminals have prefix TC meaning they refer to the APC200
connector pins

WIRE PIN FUNC TYPE DESCRIPTION 4/3 SPEED DESCRIPTION 3/3 & 4/4 SPEED
A01 01 A1 PPWR Pwr Permanent Battery Plus Permanent Battery Plus
A02 02 B1 VFS0+ Pwm Fwd VFS Hi Side Out Fwd VFS Hi Side Out
A03 03 C1 VFS0- Sns Fwd VFS Lo Side In Fwd VFS Lo Side In
A04 04 D1 VFS1+ Pwm Rev/Hi VFS Hi Side Out 2nd/4th VFS Hi Side Out
A05 05 E1 VFS1- Sns Rev/Hi VFS Lo Side In 2nd/4th VFS Lo Side In
A06 06 F1 VFS2+ Pwm 2nd VFS Hi Side Out Rev VFS Hi Side Out
A07 07 G1 VFS2- Sns 2nd VFS Lo Side In Rev VFS Lo Side In
A08 08 H1 VFS3+ Pwm 1th/3th VFS Hi Side Out 1th/3th VFS Hi Side Out
A09 09 J1 VFS3- Sns 1th/3th VFS Lo Side In 1th/3th VFS Lo Side In
A10 10 K1 DO0 Stp RSP Drive Solenoid + RSP Drive Solenoid +
A11 11 A2 ANI0 Ptg Pressure feedback Pressure feedback
A12 12 B2 DIGIN0 Ptp Shiftlever 1-2 Shiftlever 1-2
A13 13 C2 DIGIN1 Ptp Shiftlever 2-3 Shiftlever 2-3
A14 14 D2 DIGIN2 Ptp Free Shiftlever input Shiftlever 3-4
A15 15 E2 DO1 Stp Alarm output (option) 2/4 VFS selector
A16 16 F2 DO2 Stp 1/3 VFS selector 1/3 VFS selector
A17 17 G2 DIGIN3 Ptp Shiftlever NEU Shiftlever NEU

SPICER OFF-HIGHWAY APC200 Control System

Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 7/65
WIRE PIN FUNC TYPE DESCRIPTION 4/3 SPEED DESCRIPTION 3/3 & 4/4 SPEED
A18 18 H2 DIGIN4 Ptp Shiftlever FWD Shiftlever FWD
A19 19 J2 DIGIN5 Ptp Shiftlever REV Shiftlever REV
A20 20 K2 DO3 Stg RSP Drive Solenoid - RSP Drive Solenoid -
A21 21 A3 GND Gnd Supply Ground Supply Ground
A22 22 B3 SS0 Sns Drum speed sensor+ Drum speed sensor+
A23 23 C3 SS0 Gnd Drum speed sensor - Drum speed sensor -
A24 24 D3 SS1 Sns Output speed sensor+ Output speed sensor+
A25 25 E3 SS1 Gnd Output speed sensor - Output speed sensor -
A26 26 F3 SS2 Sns Engine speed sensor+ Engine speed sensor+
A27 27 G3 SS2 Gnd Engine speed sensor - Engine speed sensor -
A28 28 H3 ANI1 Ptg TransmTemperature TransmTemperature
A29 29 J3 ANI2 Ptg Cooler input temperature Cooler input temperature
A30 30 K3 SGND Gnd Signal Ground Signal Ground

WIRE PIN FUNC TYPE DESCRIPTION 4/3 SPEED DESCRIPTION 3/3 & 4/4 SPEED
B01 31 L1 VFS4+ HbrgA Engine control motor A Engine control motor A
B02 32 M1 ANI4 Sns 5V Reference voltage out 5V Reference voltage out
B03 33 N1 VFS5+ HbrgB Engine servol motor B Engine servo motor B
B04 34 P1 ANI5 Sns Engine servo pos. input 0-5V Engine servo pos. input 0-5V
B05 35 R1 VFS6+ Pwm Ana.brake valve Analog brake valve
B06 36 S1 ANI6 Sns Accelerator pedal analog input Accelerator pedal analog input 0-5V
0-5V
B07 37 L2 CANL Comm CAN Lo CAN Lo
B08 38 M2 CANH Comm CAN Hi CAN Hi
B09 39 N2 RXD Comm RS232 RXD RS232 RXD
B10 40 P2 TXD Comm RS232 TXD / SPEEDO OUT RS232 TXD / SPEEDO OUT
B11 41 R2 SS3 Sns Turbine speed sensor+ Turbine speed sensor+
B12 42 S2 SPWR Pwr Switched Battery Plus Switched Battery Plus
B13 43 L3 DIGIN6 Ptp Inching Enable switch Inching Enable switch
B14 44 M3 DIGIN7 Ptp manual / automatic selection manual / automatic selection
B15 45 N3 DIGIN8 Ptp Parking Brake OFF/ON Parking Brake OFF/ON
B16 46 P3 DIGIN9 Ptp
B17 47 R3 ANI3 Ptg Brake pedal analog input 0-5V Brake pedal analog input 0-5V
B18 48 S3 GND Gnd VFS Ground VFS Ground

Note that different configurations are supported. The Input / Output mix can be varied through the
use of parameter sets which determine the exact I/O allocation. Further, most non-transmission
related functions can be routed through the CAN bus instead.

Connector layout :

SPICER OFF-HIGHWAY APC200 Control System

Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 8/65
1.3 Man Machine interface

1.3.1 Shift lever

The main interface with the driver is the shift lever. It allows selecting the driving direction and the
different ranges. The shift lever output signals serve as inputs for the APC200.
The APC200 is designed to interface with a variety of shift levers. Refer to the application specific
wiring diagram for detailed information about shift patterns.
Note that the APC200 supports remote control via the CAN bus as documented in the CAN EDI.

1.3.2 Display

The display is located on the APC200

front panel and consists of:
SPICER OFF-HIGHWAY D
M
E
F
S
APC200

• 4 red 7-segment LED digits APC200 front panel display

• 3 status LED lamps
("D","E","F")
• 2 push buttons 'M' and 'S' for
display mode selection.

The LED lamp labelled 'D' is yellow and is used to indicate test modes.
The LED lamp labelled 'E' is yellow and is used to indicate faults.
The LED lamp labelled 'F' is red and is switched on when the APC200 is in the reset condition.
Refer to SOHPD drawing IAPC200A for installation dimensions.
After power up, the display defaults to the last display mode selected when the controller was last
powered down.
Typically, this will be the gear position mode. In this mode, the centre left digit shows the actually
engaged direction and the centre right digit shows the currently engaged range (gear).
Pressing the 'M' switch changes the displayed information group, while pressing the 'S' button
selects the item within the group.
While pushing the switch (and about 0.5 seconds after it is released) the display shows which
information is about to be displayed.
There are 3 display groups : the most commonly used one allows to switch between gear
display and vehicle speed display.

SPICER OFF-HIGHWAY APC200 Control System

Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 9/65
 The second group shows the shift lever position and some other less used but nevertheless quite
relevant values (see list below).
The third display accessed with the M-button isn’t actually a group of screens but is used to inform
you about any current or previously active faults. The display normally shows ‘ — — ‘ to indicate
there are no faults, but if one or more faults are (or have been) detected, themost severe one is
shown until you press the ‘S’ - button. Doing so reveils the next fault until no more faults are
present, at which time again the ‘ — — ‘ sign is shown.

Display mode Comment

GPOS Reflects the actually engaged transmission direction and range.

Shows vehicle speed in km/h or MPH (parameter setting). Speeds are shown
VSPD with a 0.1km/h or 0.1 MPH resolution.

Shows the distance travelled in km or in miles (parameter setting). Distance is

DIST shown with a 0.1 km or 0.1 mile resolution. To reset this display, the “S” –
button has to be pressed and keep it pressed during 3 seconds, when this
display is selected.

CPOS Reflects the current shift lever direction and position.

TSPD Shows measured turbine speed (RPM)

ESPD Shows measured engine speed (RPM)

OSPD Shows measured output speed (RPM)

Reflects the current speed ratio (calculated as TSPD/ESPD [turbine speed /

SRAT engine speed]) and is an important factor in automatic shifting.

TQ I Measured torque at transmission input side (Nm)

TTMP Shows transmission temperature in °C or °F (parameter setting)

CTMP Shows cooler input temperature in °C or °F (parameter setting)

ERR The fault display

When the controller detects an error, the 'E' led blinks slowly to indicate this. You can always
select the fault display mode (ERR) to view the nature of the problem. Error codes are described
in section 2.4 Behaviour in case of faults.

1.3.3 Other
Additionally several on/off switches and position sensors with function described in section 1.6.1
can be used to control the different operating functions. The control system can receive state
information of these inputs either directly through its own inputs or via the CAN-bus using
standardised messages.

SPICER OFF-HIGHWAY APC200 Control System

Description for ECM / ECI

Ten Briele 3, 8200 Brugge, Belgium Controls 08 march 2002

Tel: +32/50/402459 CONTROLS@DANA.COM Doc P/N : 4207049 Rev 1.1 10/65