HPTO12D THEORY OF OPERATION SECTION 1 OF 3

HPTO UNIVERSITY 2014/15

Instructor: Sam Harbin

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 HPTO12D THEORY OF OPERATION SECTION 1 OF 3
HPTO UNIVERSITY 2014/15

HPTO12D UNIVERSITY TRAINING COMPLETION:

•TRAINING MODUAL 1 OF 3: THEORY OF OPERATION

•TRAINING MODUAL 2 OF 3: REBUILD TRAINING

•TRAINING MODUAL 3 OF 3: FAILURE ANALISIS

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 HPTO12D CUTAWAY

FRICTION PLATES
DRIVE RING SEPARATOR PLATES

RELEASE SPRINGS

PISTON OIL INLET

LUBE OIL

OIL TO CLUTCH PISTON

OUTPUT SHAFT

OVERSIZE SPHERICAL BEARING

END PLATE
CYLINDRICAL BEARING

INPUT SPEED PICK-UP

 HYDRAULIC SECTION

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 HYDRAULIC SECTION COMPONENTS DEFINED

CHYPV-002 PWM VALVE

• The CHYPV-002 is a proportional valve

• PWM valve ramps pressure during startup
• PWM valve maintains pressure in the circuit
• CHYPV-002 (PWM Valve) feeds flow to our
CHYSV-001 (On/Off valve) (when the coil is
CHYPV-002 energized by a currant from the Master Unit)
PWM VALVE

CHYSV-001 ON/OFF VALVE

• CHYSV-001 ON/OFF valve is used to engage

clutch piston by allowing flow from the CHYPV-
002 PWM valve to pass through the ON/OFF
valve. (when coil is energized)
CHYSV-001
ON/OFF VALVE

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 HYDRAULIC SECTION COMPONENTS DEFINED

CHYPT-003-D
PRESSURE TRANSDUCER

CECCL-002-D
24Vdc COIL

CECCL-002-D
24Vdc COIL

CHYSV-001 CHYPV-002
ON/OFF VALVE (COMES WITH COIL) PWM VALVE (COMES WITH COIL)

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 HYDRAULIC SECTION THEROY OF OPERATION

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 HYDRAULIC SECTION THEROY OF OPERATION

CHYPT-003-D
PRESSURE TRANSDUCER

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 HYDRAULIC SECTION THEROY OF OPERATION

PRESSURE / FLOW INLET 400 psi MINIMUM / 2 gpm

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 HYDRAULIC SECTION THEROY OF OPERATION

CHYPV-002
PWM VALVE (COMES WITH COIL)

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 HYDRAULIC SECTION THEROY OF OPERATION

TEST PORT (LABELLED “G” ON MANIFOLD

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 HYDRAULIC SECTION THEROY OF OPERATION

CHYSV-001
ON/OFF VALVE (COMES WITH COIL)

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 HYDRAULIC SECTION THEROY OF OPERATION

TANK DRAIN LINE (5 psi MAXIMUM)

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 G = 0‐225 Psi
HYDRAULIC SECTION TESTING

G PORT: We will see 225 psi with the engine running, and during engagement
the pressure will drop to 0 psi and bump from 65 psi to 225 psi until engaged

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 DP 0‐4.0 Psi
HYDRAULIC SECTION TESTING

D PORT: A maximum of 5.0 psi is allowable at the Drain Port back to tank

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 HYDRAULIC SECTION TESTING

Checking flow from the tank (DP) drain port: Insert a 0.0 to 10 gpm flow meter into the clutch
engagement port on the end cover as indicated above, with the machine running, clutch engaged you
should NOT see more then 1.5 gpm. You will see from 0.0 to 1.2 gpm which is normal.

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 ELECTRICAL SECTION

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 ELECTRICAL SECTION

• The system runs on a positive negative concept, as well we incorporate Can Bus
• When testing the power/ground circuit, insure you use PIN 7 on the Master Unit Gray
Plug. (DO NOT USE CHASSIS for a ground)
• DO NOT USE CHASSIS for a ground
• Reasoning for the above two points: If you use the chassis for testing our circuit you will
not be testing the complete circuit (wire harness), EXAMPLE:
• Testing the Temp Switch CHYTS-200-001-D a technician use chassis for ground and
finds he has 24vDC at PIN 1 and knowing it’s a NC switch he has 24vDC at PIN 2 on
same switch, yet he still has a 521506 Clutch Oil Temperature Fault. If the issue was in
the ground circuit between chassis ground and our CMCMU-008-DC Master Unit and or
from Switch to PIN 7 the field tech will miss this because he used chassis for his test
procedures
• CONTROL AREA NETWORK or CAN
• Can Bus is a industry standard to move a lot of information at the same time along a two
wire circuit as apposed to mutable wires

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 ELECTRICAL SECTION COMPONENTS DEFINED

CHYPT-003-D PRESSURE TRANSDUCER DEFINED:

• The CHYPT-003-D has a max psi value of 300 psi

• Bellow 205 psi we will indicate a 521504 Clutch Oil
Pressure Fault
• The CHYPT-003-D is a three wire sensor
• Red wire is supply voltage from Master Unit = 12Vdc
• Black wire is earth/ground from Master Unit
• White wire is signal voltage from Pressure Transducer to
Master Unit, that data is used by the Master Unit to
CHYPT-003-D insure we control the pressure at the PWM valve
PRESSURE TRANSDUCER • The pressure transducer scale is 1 to 5 volts = 0 - 225
psi (1v = 75Psi)

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 ELECTRICAL SECTION COMPONENTS DEFINED
CMCMU-008 MASTER UNIT

• The Master Unit is seeing inputs from the

following:
• Engine – Input Speed Sensor – Pressure
Transducer – Filter Switch – Temp Switch
• The Master Unit is sending outputs to the
following:
• Pressure Transducer – PWM Coil –
On/Off Coil – Temp Switch – Filter Switch

CMCMU-008-DA CECCL-002-D 24 VOLT DC COIL

MASTER UNIT
• Coil has a resistance value of 28.5 ohms
+/- 1 ohms at 68 degrees Fahrenheit
• Pin 2 on both PWM and ON/OFF coils is
ground.
• ON/OFF coil is seeing system voltage at
pin 1 to engage clutch
• PWM coil see’s a currant or 0 – system
voltage depending on what the master unit
CECCL-002-D is asking it to do
24Vdc COIL

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 ELECTRICAL SECTION COMPONENTS DEFINED

CECES-001-D FILTER SWITCH

• CECES-001 is a NC (normally closed)

switch
• If switch (or circuit) goes open we will
indicate a 521508 Clutch Oil Filter Clog
• System voltage is supplied from the
CMCMU-008-DA Master Unit PIN1
Orange Wire from Gray 12 PIN Plug
• If switch is working correctly system
voltage will return from CECES-001
Brown Wire through PIN 3 Gray 12 PIN
Plug at the CMCMU-008-DA Master
Unit

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 ELECTRICAL SECTION COMPONENTS DEFINED

CMCDU-008 DISPLAY UNIT

• The Display Unit is used to read inputs

from the CMCMU-008-DA Master Unit
• CMCDU-008-DA is used to engage the
clutch by sending a command through our
Can Bus (black and white wires) network
to the CMCMU-008-DA Master Unit to
both PWM and ON/OFF coils

CMCDU-008
DT04-3P-P007 PLUG and DT06-3S-P006
DISPLAY UNIT
TERMINATING PLUG

• The DT06-3S-P006 has a 120 ohm

resistor to be one end of the terminator in
the Can Bus circuit (black white wires)
• The DT04-3P-P007 plug is used to plug in
the CMCDU-008 Display unit to the
CMCMU-008-DA Master Unit
DT04-3P-P007 DT06-3S-P006
PLUG TERMINATING PLUG

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 ELECTRICAL SECTION COMPONENTS DEFINED

CECSP-003-D SPEED PICKUP

• The Speed Pickup uses a supply DC

voltage to create a return AC signal
that our Master Unit can read into a
RPM range
• The Speed Pickup is a magnetic
sensor

Hertz Calculation is based on Flywheel Ring

Gear Size
HPTO 8 & 10's = 72 Teeth HPTO 12 = 59
Teeth
72 Teeth 960 Hz 800
72 Teeth 1080Hz 900
72 Teeth 1200Hz 1000
CECSP-003-D
59 Teeth 786Hz 800
SPEED PICKUP
59 Teeth 885Hz 900
59 Teeth 983Hz 1000

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 ELECTRICAL SECTION TESTING

CHYPT-003-D PRESSURE TRANSDUCER

• Test ohm’s of resistance between PIN 2 and PIN 4

• Desired results: 4.8 ohms +/- .5 ohms

CHYPT-003-D
PRESSURE TRANSDUCER

Pin. 1 Pin. 4

Pin. 2 Pin. 3

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 ELECTRICAL SECTION TESTING

Remove speed pickup from clutch housing and disconnect from wiring
harness. Check resistance between red and black wires (pins 1 & 2).
Resistance should measure 900 Ω (+/- 90 Ω)

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 PRO LINK

• Pro Link 2.1.1 Displays in Real Time

• Clutch Information
– Clutch output Speed
– Temperature Switch
– Solenoid Status
– Pressure Sensor Status
• Engine Information
– Coolant Temperature
– Speed
– Percentage Load %
• Fault History for Diagnostic
• Data Viewing, Recording & logging
 ELECTRICAL SECTION THEROY OF OPERATION
KEY ON:

 Power light illuminated

 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)

ENGINE RUNNING – CLUTCH DISENGAGED:

 Power light illuminated

 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated
 Pressure in “G” port of manifold is 225 psi (15.5 bar)

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 ELECTRICAL SECTION THEROY OF OPERATION
ENGINE RUNNING – CLUTCH ENGAGING:  Power light illuminated
 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated

 Pressure in “G” port of manifold drops to 65 psi when engage button is pressed
 Clutch engaged light flashes after button is held for 3 seconds
 Controller “bumps” through a pre determined sequence to engage clutch
 Pressure in “G” port increases (bumps) during clutch engagement process

ENGINE RUNNING – CLUTCH ENGAGED:

 Power light illuminated

 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated
 Output Speed light illuminated
 Clutch engaged light illuminated
 Pressure in “G” port of manifold is 225 psi (15.5 bar)

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 ELECTRICAL SECTION THEROY OF OPERATION

Pin 1. Switched Power Pin 7. Supply ground

Pin 2. Not Used Pin 8. Battery power
Pin 3. Not Used Pin 9. To PWM coil
Pin 4. Not used Pin 10. To on/off coil
Pin 5. Optional start switch Pin 11. To input speed sensor
Pin 6. Not Used Pin 12. From input speed sensor

GRAY 12 PIN

BLACK 12 PIN

Pin 1. Not Used Pin 7. Machine supplied can low

Pin 2. Not Used
Pin 3. Not Used
Pin 4. Bare metal drain wire
Pin 5. Can high from display
Pin 6. Can low from display
Pin 8. Machine supplied can high
Pin 9. Power to display screen
Pin 10. 12Vdc power to PT
Pin 11. Ground to transducer
Pin 12. Return signal from PT
Pin 12. Signal voltage from transducer

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 ELECTRICAL SECTION THEROY OF OPERATION

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 ELECTRICAL SECTION THEROY OF OPERATION

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 HPTO12D
THEORY OF OPERATION

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 GP1 = 0 Psi

OPERATING LOGIC KEY ON

5 AMP

24 Volts

+ 12 Volts 

0.8 to 1.2 volt 
 GP1 = 225 Psi

ENGINE RUNNING
5 AMP

24 Volts

+ 12 Volts  400 PSI 
Minimum

225PSI

4 Volts 

PWM 
Coil

0 PSI 
 GP1 = 0‐225 Psi

ENGAGING
5 AMP

24 Volts

+ 12 Volts  400 PSI 
Minimum

0 ‐ 225PSI

1 ‐ 4 Volts 
5 PSI 
Maximum 
ON/OFF  PWM 
Coil Coil
PRO-LINK START UP
 GP1 = 225 Psi

ENGAGED
5 AMP

24 Volts

+ 12 Volts  400 PSI 
Minimum

225PSI

4 Volts 
5 PSI 
Maximum 
ON/OFF  PWM 
Coil Coil
 GP1 = 225 Psi

DISENGAGED
5 AMP

24 Volts

+ 12 Volts  400 PSI 
Minimum

225PSI

4 Volts 

PWM 
Coil

0 PSI 
OIL TRAVEL
AVALIBLE KITS
OUTER SEAL KIT: HPTO12-66-100

Terex Part number 2451‐9175
FRICTION DISC KIT HPTO12DD-60-101

Terex Part number 2451‐9170
END PLATE KIT: HPTO12DD-62-100

Terex Part number 2451‐9172
COMPLETE REBUILD KIT:
HPTO12TS-63-100

Terex Part number 2451‐9173
 GENRAL INFORMATION:

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 THANK YOU…

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