CAL-1 Power System

Presented by Port Machinery Business Unit
Power Driving System
Power system is composed of engine, transmission case, transmission shaft and drive axle, etc.
1. Engine 2. Clutch 3.Transmission case 4 . Transmission Shaft 5. Drive axle 6. Tyre

Transmission

Transmission
The basic functions of transmission
1. To increase / Decrease Output shaft Speed / Torque.
2. To disconnect engine from the wheels so that machine can be stopped without
switching off the Engine, this is called as Neutral position of Transmission.
3. To change the direction of travel, i.e. travel in forward or reverse direction as per
operator need.

Transmission
To increase / Decrease Output shaft Speed / Torque.

1. Transmission uses sets of gears normally 4 to 6 sets.
2. By selecting Lower gear ratio , output shaft speed will be increased but torque will be decreased
By selecting Higher gear ratio, Output shaft speed will be decreased but torque will be increased.
Example of Gear ratio shown in Picture
If Small gear is connected to input shaft & gear is having 10 nos. teeth & rotating at 300 rpm
& Big gear is connected to Output shaft & gear is having 30 nos. teeth & it rotates at what rpm ( will be more or less than input
shaft rpm & how much
Driver Gear Driven Gear
10 30
300 Rpm ?
Gear Ratio=30/10=3
RPM of Driven Gear =300/3=100rpm

Transmission
Gear Ratio A gear ratio is the ratio of the no of rotations of a drive gear to the no of rotation of driven gear

Transmission
It is constituted by hydraulic torque converter and gearbox.
US DANA torque gearbox

(4 forward and 4 backward gears )
Germany ZF transmission case

(5 forward and 4 backward gears.)
They both have :

1.automatic and manual gear-transferring way.
2.The gears can be easily electrically controlled.
3.two power take-off mouths to provide power for hydraulic system.

Transmission
Transmission of reach stacker is composed of torque converter, transmission, control valve, etc. as is shown in below picture.
Torque-converter
Engine
Transmission case control valve
Transmission Drive axle

Torque Convertor
Torque converter, structure
The torque converter is mainly constituted by impeller, turbine and guide wheel/stator , etc. as is shown in below picture.
wind
Fan 2 Fan 1
Impeller
Turbine

Torque Convertor
There are four components inside the very strong Fluid

housing of the torque converter:
 Pump
 Turbine
 Stator
 Transmission fluid
The housing of the torque converter is bolted to the flywheel of

the engine, so it turns at whatever speed the engine is running
Stator
at. The pump inside a torque converter is a type of centrifugal
Pump wheel Turbine
pump. As it spins, fluid is flung to the outside. As fluid is flung to
the outside, a vacuum is created that draws more fluid in at the
center.
The fluid then enters the blades of the turbine, which is
connected to the transmission. The turbine causes the
transmission to spin, which basically moves reach stacker.
The blades of the turbine are curved. This means that the fluid,
which enters the turbine from the outside, has to change
direction before it exits the center of
the turbine. It is this directional change that causes the turbine
to spin.

Torque Convertor
So as the turbine causes the fluid to change direction, the fluid causes
the turbine to spin. The fluid exits the turbine at the center, moving in a
different direction than when it entered. The fluid exits the turbine
moving opposite the direction that the pump (and engine) are
running. If the fluid were allowed to hit the pump, it would slow the
engine down, wasting power. This is why a torque converter has a
stator.
The stator resides in the very center of the torque converter. Its job
is to redirect the fluid returning from the turbine before it hits the
pump again. This increases the efficiency of the torque converter.
The stator has a very aggressive blade design that almost completely
reverses the direction of the fluid.
A one-way clutch (inside the stator) connects the stator to a fixed
shaft in the transmission (the direction that the clutch allows the
stator to spin is noted in the figure above). Because of this
arrangement, the stator cannot spin with the fluid -- it can spin only
in the opposite direction, forcing the fluid to change direction as it
hits the stator blades.
Transmission
Manual transmission （ MT ）
Shifting fork
From engine
To Drive axle
Idler
clutch Counter Shaft

Transmission Dana TE 32
4 speed Fwd/Rev

Model Designation
15.7 T E 32 4 1 8 - XX
Specific ratio Specific dash no
Drop
Even No : Long Drop
No of gears
Odd No : Short Drop
Transmission Input Rating X100 Nm
Electronically Controlled
Mounting Type
T=Engine Mounting
RT= Remote Mount
MT= Mid Mount
Convertor Model Wheel Group

Gearbox and clutch layout
3rd shaft
Forward
shaft 1st shaft
Input
shaft
Reverse and 2nd

shaft Output
shaft
4th shaft

The converter, pump drive section and pressure regulating valve.
The input shaft and directional clutches.
The range clutches.
The output section.
The transmission control valve.

TE 32 Full Flow Valve
Torque coil nut : 6.8 – 9.5 Nm

Fwd / N / Rev selector
Rev Fwd
Prop Fwd/Rev
Prop 2nd/4th
Prop 1st/3rd
1st/3rd selector
2nd/4th selector
Pressure Pressure
sensor 2nd/4th sensor 1st/3rd Prop = proportional pressure reducing valve
TE 32 Full Flow Valve
Accumulator 1st/3rd
Prop 1st/3rd
1st/3rd selector

Solenoid Valve Logic Control

Neutral
A ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar

B PRESSURE INTENSIFIER 0-6 TO 0-20 bar
FWD/REV 1st/3rd 2nd/4th
FWD/N/REV 1st/3rd 2nd/4th
Rev Clutch FDW Clutch 1st Clutch 3rdt Clutch 2nd Clutch Clutch
07/09/2024
Forward 1st Gear
07/09/2024 Presented by Port Machinery Business Unit

Forward 2nd Gear
07/09/2024
Forward 3rd Gear
07/09/2024
Forward 4th Gear
1st/3rd 2nd/4th
FWD/REV
FWD/N/REV 2nd/4th
1st/3rd
07/09/2024
Reverse 1st Gear
07/09/2024
Reverse 2nd Gear
07/09/2024
Reverse 3rd Gear
07/09/2024
Reverse 4th Gear
07/09/2024
Transmission Dana TE 32-Right View

Speed Sensors
Type Magneto resistive sensor.

Sensing distance up to 1.8 mm
Sensor signal generates a square current with a fixed amplitude changing between 7 and 14 mA.
Drum speed sensor Turbine and output (x2) speed sensor Combined engine speed sensor and temperature

Transmission Dana TE 32-Front & Rear View

Technical Specifications
Pump flow
System pump flow : 108-128 l/min at 2200 RPM.

Lube pump flow : 80-95 l/min at 2200 RPM.
Converter out pressure (to cooler)

5 bar min. at 2000 RPM and max. 8.5 bar at no load governed speed.
Safty valve
cracking pressure 8.8-9.6 bar

Ratio TE32418
TE32418 F1 F2 F3 F4 R1 R2 R3 R4
RATIO 5.065 2.422 1.379 0.784 5.065 2.422 1.379 0.784
SPREAD 2.091 1.757 1.760 2.091 1.757 1.760
TOT SPD 6.464 6.464
F/R ratio 1.00
Speed pick-up :
1. Engine speed combined with temperature located on pump drive gear
2. Turbine speed located on input gear
3. Drum speed located on forward drum
4. Output speed located on output shaft gear

Proportional Valves FWD/REV - 1st/3rd - 2nd/4th

Coil Resistance: 7.25 Ω at 68°F / 20°C
Solenoid Valves FWD/N/REV - 1st/3rd
Coil Resistance: 12V - 7.1Ω at 68°F / 20°C
Coil Resistance: 24V - 28.5Ω at 68°F / 20°C
Temperature Sensor Material: Silicon
Resistance: 77°F / 25°C = 2000+ 1%
Pressure Sensor Supply Voltage: 4.5-5.5V
Maximum Current: 10mA
Pressure Range: 14.5-450 PSI / 1-31 bar
+ 1.2% full scale (450 PSI / 31 bar) range 14.5-363 PSI / 1-25 bar
+ 2.5% full scale (450 PSI / 31 bar) range 363-450 PSI / 25-31 bar

Converter/Transmission Oil System
Oil Level inspection: (Approximate: measured at 600 RPM input speed and oil temp between 60 and 70°C, neutral)
Oil Type  ONLY ATF Dexron III approved

viscosity at 40°C: 33  38 cSt
viscosity at 100°C: 7  8 cSt
flash point: min 160°C
pour point: max –42°C
Oil change  1000 hours
Filtration  2 x Spin On
change every 1000 hours
first change: 100 hrs or after rebuild
Normal operating temperature 70 - 120°C at temperature check port converter out

Mmaximum allowed transmission temperature 120° C

Clutch pressures Transmission regulator pressure :

• 600 RPM 22.5-24.5 bar
At 1800 RPM 20.5 - 24.5 bar
• 2200 RPM 23.5-25.5 bar
Filter bypass
valve set at 4.1 to 4.5 bar
Lube pressure
0.9 – 1.4 bar at 100 l/min. lube flow.(+/-1000RPM)
Internal leakage @ 1800 RPM

Fwd/Rev max 4 l/min
1st max 9.2 l/min
2nd/3rd/4th max 4 l/min

APC 200
The APC200 (Transmission Controller for ECM) is a device used to control the shifting of the Spicer Off
Highway Products ECM power shift transmissions.
ECM means Electronic Controlled Modulation and refers to a transmission control technology that is available
on a range of transmission models
07/09/2024
APC 200
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 via the 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.
07/09/2024
Display
Controller
4 red 7-segment LED digits

3 status LED lamps
• D -> Yellow, Diagnostic modes
• E -> Yellow, Error
• F -> Red, Failure or APC 200 in reset conditions
2 push buttons
• M -> which information group
• S -> item within group

Display Modes
M M
S S S

Display Modes
Controller
“GPOS” display Reflects the actually

engaged transmission direction and range
“VSPD” display
Shows the vehicle speed in km/h or MPH, with a
resolution of0.1 km/h or 0.1 MPH

Display Modes
Controller
“DIST” display
Shows the distance travelled in km or
miles, with a resolution of 0.1 km or
0.1 miles
Note : the distance can be reset by pushing the “s” button during 3 seconds when being in this display mode.
“oper” display
Shows the operating time (engine running time) in
hours
Note : The numbers of “.” gives the number of 10000 hours to add to the displayed value
– example : 12.5.1. = 30000 + 1251 = 31251 hrs.

Display Modes
Controller
CPOS”display
Reflects the actually shiftlever position
ESPD” display
Shows the measured engine speed in RPM
TSPD” display
Shows the measured turbine speed in RPM

Display Modes
Controller
“OSPD” display
Shows the measured output speed in RPM
“SRAT” display
Reflects the current speed ration ( Tspd / Espd ), which is
an important factor in automatic shifting
TQ I” display Reflects the measured torque

(turbine torque) at the transmission input side in Nm

Display Modes
“TTMP” display
Shows the transmission sump temperature in °C
 CTMP” display
Shows the Converter out temperature in °C
Note : due that the converter out temperature is measured by a temperature switch :
1. 50 on the display means below 120° C
2. 150 on the display means above 120° C

Display Modes
Controller
APC200
“ERR” display
Shows all existing error codes (none blinking

error code) and error codes detected in the past
(blinking error code).
(none blinking)
(blinking)
S
(end of faults)
S
Note : when an error is active, the error led will be blinking

Transmission Dana 36000
Dana 36000
• 4 speed Fwd/Rev

Transmission Dana 36000
Transmission case of reach stacker is composed of torque converter, power shifting gearbox, control valve, etc. as is shown in below picture.
Hydraulic
pump
Respirator
Flexible
plate
Valve Oil checking screw -

block high
Hydraulic torque
converter Oil checking screw - low
Oil drainage
Solenoid plug
valve group

Hydraulic Diagram 36000 -4 Speed
07/09/2024
Hydraulic Diagram 36000 -4 Speed
07/09/2024
Electric Solenoid Logic Controls
Transmission Gear Activated Solenoid Activated Clutch
F1 Forward,1st,2nd,3rd Forward,1st
F2 Forward 2nd,3rd Forward, 2nd
F3 Forward 3rd Forward, 3rd
F4 Forward Forward, 4th
Neutral No solenoid Activated No Clutch Engaged
R1 Reverse,1st,2nd,3rd Reverse, 1st
R2 Reverse,2nd,3rd Reverse, 2nd
R3 Reverse,3rd Reverse,3rd
R4 Reverse Reverse,4th

07/09/2024
Transmission case
Pressure test ports:

F-------forward clutch solenoid valve ；
R------reverse clutch solenoid valve ；
3------3rd clutch solenoid valve ；
2------2nd clutch solenoid valve ；
1------1st clutch solenoid valve ；
FC----forward clutch pressure test port ；

RC---- reverse clutch pressure test port ；
2C---- 2nd clutch pressure test port ；
RP---reverse pilot pressure test port ；
FP---forward pilot pressure test port ；
1P---1st pilot pressure test port ；
2P---2nd pilot pressure test port ；
3P---3rd pilot pressure test port

Transmission case
pressure temperature test points
Oil from filter

Transmission fluid to filter
Engine rotate speed

Oil
dipstick
Outlet temperature of
torque-converter
Outlet pressure of
torque-converter
1st clutch
pressure Rotate speed of
turbine
3nd clutch pressure

Transmission case
pressure temperature test points
From torque converter to cooler
Forward clutch pressure test port
From cooler to gearbox
Turbine speed sensor

connector

Transmission case
1 － Torque converter outlet temperature:

Put the oil temperature meter in the cab. The specification of the temperature meter is 140°C (300°F). The normal tested
temperature should be between the range of 82.2-121.1°C (180°-260°F).
2 － Torque converter outlet pressure:

Warm the transmission case to the normal working temperature. Keep the oil temperature of torque converter outlet at
82.2°-93.3°C (180°-200°F).
When the engine speed is 2000RPM and the machine is unloaded, the normal tested pressure should be as below: min 1.7
bar (25 PSI), max. 4.9 bar (70 PSI)
3 － Clutch pressure:
It is suggested that test the clutch pressure with the pressure meter of 0-400 PSI (0-2758kPa). Put the pressure meter in the
cab. Normally the clutch pressure should be 17 to 21 bar (240–310 PSI)

Transmission case
Turbine speed sensor.
Turbine speed sensor

Part No.: 4200573
Thread size: M18 x 1,5
Type: inductor type
Installation clearance: 0 - 0.6 mm
Resistance : 1050  ( 100 )
Transmission solenoid valve
Normal resistance is 39.9 .

Transmission Shaft

Drive Axle

Drive Axle
3.1 Drive axle, structure

1. Germany Kessler D102PL341/528NLB8460
Diagram: 101.1349.3a , welded axle
Main reducer and

differential
Hub reducer
Service brake
Parking brake
2. US Meritor (Rockwell) PRC7534 W4H, casted axle

brake counter plate (7), brake plate (8), brake disk carrier (9), brake
counter plates (10) and brake plates (11).

Drive Axle
Main reducer and differential

Main reducer, located at the input end of drive axle, is constituted by a pair of umbrella gears with vertical axis. It is used to input the
power to half axis, to lower down the rotate speed and to increase the driving torque.
Driving
Input flange conic gear Half axis gear
Cross shaft
Conic rolling
bearing
Planet gear
Driven
conic gear

Drive Axle
Main reducer
Main reducer, located at the input end of drive axle, is constituted by a pair of umbrella gears with vertical axis. It is used to input the power
to half axis, to lower down the rotate speed and to increase the driving torque.
Half axis
Driving
conic gear
Driven
Driven conic gear
conic gear

Drive Axle
Differential mechanism
turning a corner or passing on the rough road ,

the rotating speed of inside and outside wheel will be different
Wear tyre
turning a corner passing on the rough road
How to solve the

problem?

Drive Axle
Make a turn
Straight driving

Drive Axle
Straight driving Make a turn
Straight driving

Drive Axle
Differential mechanism, located in the middle of drive axle, is constituted by four differential umbrella gears and two umbrella gears on
the left and right half axis. Differential umbrella gears are installed between the two umbrella gears on half axis. When the differential gear is
rolling on the umbrella gear, the rotate speeds of left and right half axis are different. Thus, the differential movement is beginning. This
mechanism ensures that the torque from gearbox transmits to two half axis, thus making the two drive wheels rotate at different speed and
the movement of drive wheel to the ground act as rolling.
1-Bearing ； 2-Left housing ； 3-Gasket ； 4-Half axis gear ； 5-Washer ；

6-Planet gear ； 7-Driven gear ； 8-Right housing ； 9-Cross shaft ； 10-Bolt

Drive Axle
Hub reducer
Hub reducer is a secondary planet reducer constituted by secondary middle gear, teeth, gear and planet gears among the teeth. Its function
is to lower the rotating speed and increase the drive torque.
Wheel Bearing
Inner gear hub
Planetary
Grade II central carrier
gear
Planetary
wheel housing
Inner teeth
bracket
Grade I planet
gear
Grade II planet
gear
Drive axle
Half axis housing

Drive Axle
3.3 Travelling brake

Travelling brake, a multi-plate brake, is composed of brake plates and friction plates. Travelling
brake utilize hydraulic oil to control and operate. When there is pressure in the brake oil-way, the
pressure oil would push the piston to compact brake plates and friction plates, thus making the
travelling brake immobilize.
Service brake piston
Brake friction sheet
Mirror surface oil seal
Brake housing
Wheel hub
Grade II planet reducer
07/09/2024
Drive Axle
3.4 Parking brake

Parking brake, located at the input end of drive axle, is a spring brake and hydraulic release
coiled brake. It is constituted by brake disc and brake pliers. When there is no pressure in
brake release oil-way, brake plier would lock the brake disc under the function of brake spring
and mobilize the brake. However, if there is some pressure, brake plier would push the brake
disc under the function of brake spring and immobilize the brake. This brake is used for
parking brake and emergency brake. Oil inlet
port Adjusting bolt
Parking brake bracket Parking brake
Parking brake
sheet
Parking brake
disc Piston Disc spring
07/09/2024
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CAL-1 Power System

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CAL-1 Power System

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Presented by Port Machinery Business Unit

Power Driving System

1. Engine 2. Clutch 3.Transmission case 4 . Transmission Shaft 5. Drive axle 6. Tyre

Presented by Port Machinery Business Unit

Presented by Port Machinery Business Unit

The basic functions of transmission

1. To increase / Decrease Output shaft Speed / Torque.

Presented by Port Machinery Business Unit

To increase / Decrease Output shaft Speed / Torque.

Example of Gear ratio shown in Picture

Presented by Port Machinery Business Unit

Presented by Port Machinery Business Unit

It is constituted by hydraulic torque converter and gearbox.

US DANA torque gearbox

Germany ZF transmission case

They both have :

Presented by Port Machinery Business Unit

Transmission case control valve

Transmission Drive axle

Presented by Port Machinery Business Unit

Torque converter, structure

Presented by Port Machinery Business Unit

There are four components inside the very strong Fluid

The housing of the torque converter is bolted to the flywheel of

Presented by Port Machinery Business Unit

clutch Counter Shaft

Presented by Port Machinery Business Unit

Presented by Port Machinery Business Unit

Specific ratio Specific dash no

Convertor Model Wheel Group

Gearbox and clutch layout

Reverse and 2nd

Presented by Port Machinery Business Unit

The converter, pump drive section and pressure regulating valve.

The input shaft and directional clutches.

The range clutches.

The output section.

The transmission control valve.

Presented by Port Machinery Business Unit

Torque coil nut : 6.8 – 9.5 Nm

Presented by Port Machinery Business Unit

Presented by Port Machinery Business Unit

A ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar

FWD/REV 1st/3rd 2nd/4th

FWD/N/REV 1st/3rd 2nd/4th

FWD/REV 1st/3rd 2nd/4th

FWD/N/REV 1st/3rd 2nd/4th

07/09/2024 Presented by Port Machinery Business Unit

FWD/REV 1st/3rd 2nd/4th

FWD/N/REV 1st/3rd 2nd/4th

FWD/REV 1st/3rd 2nd/4th

FWD/N/REV 1st/3rd 2nd/4th

FWD/REV 1st/3rd 2nd/4th

FWD/N/REV 1st/3rd 2nd/4th

FWD/REV 1st/3rd 2nd/4th

FWD/N/REV 1st/3rd 2nd/4th

FWD/REV 1st/3rd 2nd/4th

FWD/N/REV 1st/3rd 2nd/4th

FWD/REV 1st/3rd 2nd/4th

FWD/N/REV 1st/3rd 2nd/4th

Presented by Port Machinery Business Unit

Type Magneto resistive sensor.

Presented by Port Machinery Business Unit

Presented by Port Machinery Business Unit