Instruction manual SH TROMC Programmable Automatic Shift System Morse Controls AB Box 153 SE-195 24 Marsta Tel +46 8 59178900 Fax +46 8 59114540©1098 Morse Controls INTRODUCTION Legend The new SHIFTRONIC version 2.00 {part number 880900) consist of the following: ECU Electronic Control Unit - 880901 & 880905-waterproof version cbu Cab Display Unit - 880170 Dck Display Cable Kit - 880-180 2m, -181 3m, -182 4m, -183 5m ssk Speed Sensor Kit - 880116 Other components involved in a SHIFTRONIC application; PPU Portable Programming Unit - 880910 PCK Programmer Conversion Kit - 880915 ccu Cab control Unit(Shifter) - 675000-, 2-3-400000-series. Printer 880105 Features ‘SHIFTRONIC is a programable electronic device mainly developed for automatic shifting and for protection of powershitt-transmission but can also be adapted for special applications. # Analogue input for sensing the throtile position, to activate various functions. # Simple to programme before and during operation, # Stabilized and accurate R.P.M monitoring, # Various types of shift controls (CCU) can be accomodated. # Both transmission/vehicle- and-engine speed can be monitored. # Vehicle- and/or acessories malfunction can be detected and displayed. # Two diffrent ranges (High/Low) with 9 forward and 9 reverse gears.SPECIFICATIONS Power supply: Enviromental temperature: Shittpositions: Outputs: Inputs: Material: Weight Size: ‘Shiftranie Instruction manual V2A1 rev 12VDC/24VDC (10-30VDC). ~40°C-72°C (-40°F--162°F) 9 forward and 9 reverse + high/low range. All inputs/outputs are protected against short- circuit. Max load 1 per outlet, total max load 5A9 outlets for gear selection. One outlet for engine control.Lock-up.Indication of malfunction. 6 iniets for the cab control unit (CCU).One inlet for moritering vohiclo(tranemission) speed,One inlet for manual shift mode.One inlet for sensing the position of the throttle pedal.Lock-up. InchingKick- down.2 inlets for indication of ‘malfunction(AUX1;AUX2).One inlet (AUX1) can be used for engine speed monitoring. Extruded aluminum, 880901 - 1.7kg (4.55bs), 880905 - 2.15kg (475Ibs), | D ee Deg. po a}© 1098 Morse Contals FUNCTION Automatic shifting SHIFTRONIC constantly monitor the revolution of the propeller- and engine-shaft (if the optional mode is selected) and will select appropriate gear according to programmed data. In order to prevent continued up- and down-shifiing at equal revolutions of the propeller sheft and of programmed data a hystereses is programmable. When the inlet for kick down is activated all speed limit values are increased by a ‘common percentage. ‘SHIFTRONIC will not upshift beyond selected gear once chosen by the cab control it (CCU). If'a gear is selected by the CCU at a moment when the vehicle speed is higher than programmed value, no shifting will take place until vehicle speed is decreased. Manual shifting If the manual mode is selected SHIFTRONIC will follow solected gears from the CCU regardless of programmed data, except at direction changes. Security functions The following functions are always active in both manual and automatic mode: Interlock protection: SHIFTRONIC will prevent direction changes or shifting from neutral into gear if speed of the vehicle exceeds programmed data. The display shows REV. Malfunction: ‘The malfunction inlets (AUX 1; AUX 2) can be programmed in various ways. Always detected or only when a geer is engaged. They cen optionally activate the engine control and/or the malfunction outlets. The display shows a programmable text, e.g. ERROR. Engine R.P.M. If engine revolutions are to be monitored one of the malfunction inlets (AUX 1) is used. Two different R.P.M. limits are compared. The maximum permitted R.P.M. of the engine is always monitored by SHIFTRONIC. When the programmed mit is exceeded the transmission will automatically shift into neutral and both engine control- and maifunction-outlet will be activated according to selected programmed functions. The display shows RPM. The maximum permitted start engine R.P.M. is only monitored when a gear is ‘engaged after being in neutral. Resulting effect is as described above. The display shows RPM.Shiftronic Instruction manval 2.41 revs Speed sensor: When the propeller shaft R.P.M exceeds a preset limit the pulses are monitored by the ECU to ensure that they are reguler. If the pulses for any reason, should be irregular or non existant the ECU will interpret it as a sensor failure. The transmission will automatically shift into neutral and the malfunction outlet will be activated, The display shows SENS. Short circuit: The ECU is protected against short circuits at all outlets. if a short circuit should occur or if each outlet is loaded with more than 1A (totally 4A), all outlets will be deactivated to prevent false gearshifting etc. The dispiay shows AMP. Other functions Malfunction mode: If any of above security functions have been activated and a normal circuit activation is subsequently switched on, the ECU should either be shifted into neutral or could remain in previous position depending cn programmed function before starting again. (ERROR KEEP GEAR) Rev. prot. mode: Itis possible to select the following mode: If the CCU is shifted from an engaged gear into neutral when the vehicle is in progress, it can be possible to return to previous gear but only if the vehicle is in the permitted speed range according to programmed value. (REENTER IF REV) Lock-up: The inlet signal for lock-up corresponds directly to the lock-up outlet, except immediately before and after the lockup is engaged. The time delay is, programmable. Inching: When the inching input is activated, Shiftronic selects neutral-position. When deactivated Shiftronic astivates the engine start rpm, to prevent any gear to be engaged at too hich engine speed. The inching cirquit can be normally closed or open. Engine control: The engine control outlet is activated immediately before and after a gear is engaged to provide smooth gear shifting. The time delay is programmable. It is possible to have a common or a separate value for each gear shift It is also possible to program the engine control not to be activated when down-shitting, andior down- shifting when the kick down inlet is activated.Furthermore it is possible to have the engine control activated when diffrent malfunctions occur Although the different time1998 Morse Conlros intervals described above are not necessary to control gear shifting and lock-up ‘engagement. the time is monitored anyway. Consequently there has to be a minimum time before gear- and lock-up-engagement can take place. Special appl.: To control various other vehicle functions as 4-wheel crive etc., which should not be activated before the transmission is in it's neutral position and/or before the vehicle has come to a complete stop, itis possible to receive a signal from the ECU when the transmission is in neutral and when the propeller shaft R.P.M is below programmed value of the interlock protection (REV PROT). Tachometer To simplify programming of the different speed values the ECU is prepared to display the present R.P.M of the transmission- and engine-shafts. This function is activated by pressing one of the reset buttons situated on the ECU's front panel or on the CDU front cover. The display will initially show TRANS for a moment, and then automatically follow with the present R.P.M of the transmission shaft. By pressing one of the reset buttons a second time the display will return to it's default mode. To receive information of the engine shaft R.P.M, one of the reset buttons has to be pressed a third time. The display will show MOTOR for a moment before the engine R.P.M is displayed‘Shiftronie instroction manual V2.A7 rev CONNECTIONS / ADJUSTEMENTS Connector - P41 P1 is @.25-pin female d-sub connector. Corresponding male d-sub connector is supplied together with the ECU. Function and programming values are as described below: [Pin _|In/Out | Description Value 07 _[ Output_| Vollage supply for the speed sensor. = 02_|- Ground supply, for speed Sensor. = (03 _ | Output_| Signal GO for gear engaging/solenoids etc. 007 (04 | Output [Signal G1 for gear engaging/solenoids etc. (002 (05 | Output_| Signal G2 for gear engaging/solenoids etc. 004 (06 | Output_| Signal G3 for gear engaging/solenoids ete. 010 O7 | Output | Signal G4 for gear engaging/solenoids etc. 020 08 Output | Signal G5 for gear engaging/solenoids etc. 040 (09 | Output _| Signal G6 for gear engaging/solenoids etc. 700 40 | Output_| Signal G7 for gear engaging/solenoids etc. 200 47 | Output | Signal G8 for gear engaging/solenoids etc. or outlet signal 200 when transmission is in neutral and transmission R.P.M is below REV PROT (ID No 004 and 010). 72_ | Output | Signal for lock-up or inching. 5 43 | Output _| Signal for engine control 2 14 [input | Signal from PNP speed-sensor, monitoring R-P.M of propeller |- shaft. 15 | Input ‘AUX1. Either maifunction input or signal from PNP speed- - sensor monitoring rpm of engine shat. 16 [Input AUX2. Pure maifunction input. = 77__[ Input _ | Transmission speed-pickup input. : 18 [input — | Transmission speed-pickup input, Fanon-grounded pickup is |- used. 75__[input [Engine speed-pichup input. : 20 [input _| Engine speed-pickup input, if a non-grounded pickup is used. |- 21 [Input | Optional input for programming unit, “Svdc" = 22 [input — | Optional input for programming unit, "26vde™ = 23 [Input Optional input for programming unit, "TDAT". a 24 [input __| Optional input for programming unit, "PROG MOD". : 25 | Input __| Optional input for programming unit, "RDAT™. E1908 Morse Controle Connector - P2 P2 is a 15-pin male d-sub connector, Corresponding female d-sub connector is. supplied together with the ECU. Function and programming values ere described below. Pin [In/Out |Description Value O1 [input | Voltage supply for the ECU, 12/24vde. = oz_|- ‘Ground supply for the ECU. = 03 [Input | Signal UGO from the CCU, shifter. of 04 [Input | Signal UGT from the CCU, shitter. 2 06 [Input | Signal UG2 from the CCU, shifter. 04 06 [Input | Signal UGS from the CCU, shifter. 70 07 [input | Signat UG4 trom the CCU, shifter. Activates the lowregister | 20 |_| ifpin 3 on dipswitch 1 is on. 08 [Input | Signal UGS from the CCU, shifter. Activates the quick first | 40 function, if programmed. Activates the lowregister if pin 2 on dipswitch 4 is on. 09 [Input _|Lock-up or inching signal in from switch or pedal. = 710 [Input | Kick down signal in from pedal or switch. = 771_|Input |Manual shit mode signal in from switch. = 12 | Output |Malunction outlet. Signal for external devices such as |- buzzers ete. Signal will be provided if inlet signal is actioved at P1/15 {if used as malfunction inlet)and/or P1/16. Signal is also provided when a sensor failure is. registered. 73 [Output | Voltage supply to potentiometer in throttle pedal, = 14__[Input __| Signal in from potentiometer in throttle pedal. = 15 [Output [Ground supply to potentiometer in throttie pedal = ee 2.)‘Shiftronic Instruction manual W247 rex Connector - P3 ‘The P3-connector is an eight pin moduler connector. The connector is used to connect the cab display unit, part number 880170. The display unit is delivered without a connecting cable. The connecting cables for the CDU are avaliable in four different lengths; 2m - 880180, 3m - 880181, 4m - 880182, 5m - 880183. 880170 Cad Display Unit, size; 65 (2) x 4%1008 Morse Controle Connector - P4 ‘The P4-connector is a six pin modular connector. The connector is used to connect the portable programming unit, part number 880910. For customers who have both version of Shiftronic (V1.xx, V2.xx) and only one type of programmer, a conversion kit is sold, The conversion kit enables the user to connect any type programming unit to both versions of Shiftronic. The Programmer Conversion Kit - PCK is sold uder part number 880915. 40‘Shitronic Instruction manual V2.41 rovS Adjusting the interface When the Shiftronic is used together with magnetic pickups to monitor engine or transmission speed, the interface needs to be adjusted in order to get correct rpm values into Shiftronc. To locate the two dip switches, the Shiftronic must be taken apart. Once this has been done the to dip swiches (dip-2 & dip-3) ere found on the P2-, P3-, P4-circuit board. See the picture below; The switch marked DIP-2 adjusts the transmission input, and DIP-3 the engine input. To adjust the switches a small instrument of some kind is needed, a pencil is usually adequate. A switch is active when itis putin it's off-position. The switches add up to a desired value, if you want to divide with 16 you simply put switch 16 in it’s off Position. See the example below; 424 816.3264 128 ON 1©1938 Morse Controls Damping the signal from a magnetic pickup The signal from the magnetic-pickup could easilly be disturbed, when the pickup is used to monitor transmission or engine speed. If that is the case, Shiftronic has a damping feature that could take care of the problem. The general idea is when you damp the signal coming in, you also damp the disturbances coming in. The damping is separate between the transmission and engine. To activate follow the function you have ‘o disassemble the Shiftronic box, when this is done you find a dip switch on the P1 circuit board. The switch has two channels, ngine 2=Transmision, To activate the damping function you simply slide the switch from it's off position to on. ‘The factory preset is both channels- damping off. Using the throttle-position feature The Shiftronic V2.40 is equipped with an analogue input for sensing the position of the throttle pedal. The input is used to activate the Shiftronics lowregister for engine braking, and/or kickdown feature. Shifironic constantly monitors the inout, and activates the lowregister/xickdown at the adjusted positions. To adjust the activating position there are two trim- potentiometers, one for lowregister- & one for kickdowr-position. The function is selected with a dip switch. To activate and adjust the function, follow the instruction below; To activate the function the Shiftronic box has to be disassembled. Once this has been done, a switch can be found on the P2., P3- & P4-circuit board. The dip switch adjusts the function of the analogue input. The switch has three channels 4=Activate the kickcown function with the analogue input 2=Activate the lowregister (P2/8) with the analogue input. 3=Activate the lowregister (P2/7) with the analogue input. The two trim potentiometers adjusts the throttie-position where the function is to be activated. The potentiometers are marked P1 & P2, and are found on the P1 circuit board. P1 adjusts the kickdown feature. If the potentiometer is turned clockwise, the activation point is moved towards the end of the throttle-pedals travel. P2 adjusts the lowregister feature. If the potentiometer is tumed anti-clockwise, the activation point is moved towards the beginning of the throttie pedals travel 12“Shifironie Instruction manual V2.AT reve PROGRAMMING Instruction of portable programming unit PPU. The programmer is connected to connector P4. itis also possible to connect a printer to the PPU and print the present program in the Shiftronic. The ECU should be switched off before the PPU is connected. When supply is switched on again after connecting the PPU, the display will show SHIFTRONIC V1.XX, XX represents the version of the program that is in the Shiftronic. Note! If the version number of your Shiftronic is different from the one at the top of every page in the manual, your manual may be old. Contact your dealer to recieve a new copy. Review and adjustment of parameters. By pressing the following push buttons on PPU the following functions will be achieved! * The parameters will appeer on the display of the PPU in sequence until the end (END) of the programme is reached. By pressing the button again the program wil restart from the beginning. ‘As above but the parameters will appear in reverse order. R Each parameters has its own identification number, which will be shown on the display of the PPU as soon as the Ris pressed. RXXR By pressing the buttons in this sequence it is possible to jump directly to required parameter.XX = Parameter identification number. s After finding required perameter to be modified and after the new value is entered the push bulton $ has to be pressed, to Save the new value. ce If an incorrect value is entered, simply press the CE button and the previous value will reappear on the display of the PPU. Text the text paremeters are entered by special number sequences as the legend is showing on the PPU. The text TEMP is entered by the number sequence : 64, 45, 55, 60. 13©1998 Morse Controls Printer The printer which can be connected to the PPU consists of the following: Printer Paper roll (thermal) Cable with connectors. ACIDC Battery cherger. Operating manual. Print Printing is started by pressing the following push buttons on the PPU; R.1 Printer technical data. Interface connector:All signals according to V24. Pin2 TD - Data outlet to printer, 1200 baud. Pin CTS - "Ready" signal from printer. Pin 7 SG - Ground signal. Dip switches. Dip switches are situated at the rear of the printer and should all be in their OFF position, exceot for switch number 5, which should be ON. 14Shifironie Instruction manual v2.47 rev3 Parameters Programmable parameters. 001 PULSES/REV (Pulses per revolution). Specifies the number of lugs mounted on the transmission and engine outputshafis. The same value is valid for both transmission and engine shaft. 002 SPEED FILTER Specifies how rapidly Shiftronic should adapt to changes in revolution. 64 and 65 are the two recommended values. 003 SENS CHK (Sensor check value).Specifies from wich minimum trans. rpm velue, the pulses should be checked for sensor error. Ifthe rpm value is higher than the programmed value, Shiftronic will not allow the pulses to disappear rapidly. This is to prevent unwanted downshifts. If the pulses should dissappear the display will read SENS and the transmission will go to neutral. 004 REV PROT (FWD--REV protection value). Specifies the maximum allowed rpm value of the transmisson cutpuishaft, when a gear is selected from neutral 005 SHIFT DOWN TYPE. Specifies how the Shiftronic engine control should work during downshifting.0 = Engine control is activated with all types of downshifting.1 Engine control is not activated with kickdown.2 = Engine control is not activated with any downshifting.3 = Give throttle with downshifting, activates G7(P1/10) according to the pre and post values of parameter No 117--132 and 151-166 (006 NO NEUT ACK (No neutral acknowledgement). Specifies if the shifter (CCU) has to be shifted into neutral position to confirm an error message.0 = Confirmation required.1 = Confirmation not required. 007 REENTER IF REV. Specifies if it should be possible to return to the previoulsly selected gear when the REV PROT rpm has been exceeded, or i the shifter has to remain in neutral position untill the vehicle speed has been decreased under the REV PROT-value.0 = Itis not possible to return to previous gear.1 = It is possible to retum to previous gear as long as the vehicle is in approperiate speed, according to the programmed value. 008 DIRECT REVERSE (preselection)Gives the possibility to go directly from forward to reverse withiout passing neutral. Shiftronic only permits this to happen if you are below the REVPROT-value.0 = No direct reverse.1 = Direct reverse is activated, itis also possible to go to neutral with a unique neutral-signal.2 = Direct reverse is activated, the only way to engage neutral is by putting the shifter in neutral under the REVPROT-value. 009 REVPROT OUTPUT (Revprotection output). Specifies if G8(P1/11) is used as an ordinary outlet signal for gear engaging, or if mentioned outlet is used to provide a signal whenever the transmission rpm is below the value of the REV PROT 1S‘©1998 Morse Controls parameter. This signal could be used to activate warning lamps when the vehicle is driving slow and working.0 = Output is used as an outlet for gear engaging.1 = Output is activated whenever the transmission rpm is below the REV PROT value. 010 SELECTIVE MTCL (Selective engine control) Specifies if separate time delays are used for engirie contrcl at each gear shift.0 = Standard PRE and POST values {ID No 015 and 017) are used for engine control.1 = Separate PRE and POST values are used (activates ID No 099--116 and 133--150). 011 NO AUTO FIRST (Non automatic activation of first gear). Specifies if Shifironic should exclude first gear. Whenever it engages gear from neutral it selects second gear.0 = First goar remains. 1 = Exlude first gear. 012 QUICK FIRST (Quick selection of first gear)Specifles if it should be possible to activate first gear with a button, preferable placed in the top of the RMH shifter. Whenever the button is pressed first gear will be preselected and activated when the proper rpm value is reached. The button should be momentary and connected to UG5(P2/8). Shiftronic will be locked in first gear. To deactivate first gear you have to bring the shifter to neutral, or twist the twistgrip of the shifter.0 = UGS5(P2/8) is used as anormal iniet.1 = UG5(P2/8) will activate first gear as desribed above, 013 ERROR KEEP GEAR Specifies if Shiftronic should stay in the presently activated gear when an error ocours.0 = Activate neutral when error occurs. = Stay in gear when error occurs. 014 DUMMY RANGEGives the possibility to switch between the hi- and lo-register without stopping in neutral, this could be used to get the engine to "brake" the vohicle.0 = No dummy range. 1 = Dummy range is activated. 015 SPEED PICKUPSpecifies if the pickup used for monitoring the transmission rpm, is a pnp- or a magnetic-pickup.0 = PNP-transmitter.1 = Magnetic pickup. 016 MOTOR PICKUPSpecifies if the pickup used for monitoring the engine rpm, is a pnp- or a magnetic-pickup.0 = PNP-transmitter.1 = Magnetic pickup. 017 INCHING INPUTSpecifies the signal from the inching-pedal to Shiftronic.0 = No inching function.1 = Inching activated when power to P2/9.2 = Inching activated when no power to P2/9, 018PRE LCKUP (Pre lockup value) Specifies, in seconds, how long before each gear shift Shifironic should release the lockup signal, P1/12,Possble interval 0.03-8 8. 019 PRE MOTOR (Pre engine control value). Specifies, in seconds, how long before each gear shift Shiftronic should activate the engine control signal, P1/13. Possible interval 0.03--6 s. 16Shifronis Instruction manual VAT rev 020POST LCKUP (Post lockup value). Specifies, in seconds, how long after each ear shift Shiftronic should activate the lockup signal, P1/12.Possiole interval 0.03-8 s 021 POST MOTOR (Post engine control value). Specifies, in seconds, how long aftor each gear shift Shiftronic should activate the engine control signal, P1/13, Possible interval 0.03--8 s, 022 KICK DOWNSpecifies with how many percent the soeed values (ID No 067-- 088) should be increased when the kick down inlet is activated (P2/10). 023 AUX1 MODE (Auxillary inlet 1 mode)Specifies how the AUX1 inlet (P1/15) is used;if the inlet is NOT used for monitoring the engine rpm, but is used as a pure maffunction inlet, the function will be a sum of the following values;1 = Activate matfunction outle (2/12) when inlet is activated 2 = Activate engine control outlet (P2/13) when inlet is activated.4 = check the inlet only when a gear is activated from neutral. IF the inlet is used for monitoring the engine rpm the function will be a sum of the following values;01 = Activate the malfunction outlet (P2/12) when the engine rpm exceeds the At MAX RPM value (ID No 020).02 = Activate the engine control outlet (P2/13) when the engine rpm exceeds the A1 MAX RPM value (ID No 020).04 = Activate the malfunction outlet (P2/12) when the engine rpm exceeds the Al START RPM (ID No 021),10 = Activate the engine control outlet (2/13) when the engine rpm exceeds the A1 START RPM value (ID No 027)20 = Specifies that the AUX1 inlet is used for engine rpm monitoring E.g. ff itis required to monitor the engine rpm and if the engine control should be activated only when the A1 MAX RPM is exceeded, the value 20 + 2 = 22 should be entered. 024 A1 MAX RPM (Auxillary inlet 1 maximum rpm value).Specifies the maximum accepted rpm of the engine outputshaft. This parameter only exist if the AUX1 inlet Js used for engine rpm monitoring according to parameter ID No 019. 025 A1 START RPM (Auxillary inlet 1 start rpm value). Specifies the maximum. accepted rpm of the engine outputshaft in the start procedure (every time a gear is engaged from neutral). This parameter only exist if the AUX1 inlet is used for engine fpm monitoring according to parameter ID No 019. 026 AUX1 TEXT (Auxillary inlet 1 display text).Specifies the text to be shown on the cab display unit when the infet Is activated (P 1/15). The text is programmed as described under paragraph 5.2. This paramater only exist when the AUX1 inlet is not used for engine rpm monitoring according to parameter ID No 019. 027 AUX2 MODE (Auxillary inlet 2 mode), Specifies how the AUX2 inlet (P1/16) is used, The function will be a sum cf the following values;1 = Activate malfunction outlet (P2/12 ) when the inlot is activated.2 = Activate engine control outlet (P2/‘3) when the inlet is activated.4 = Check the inlet only when a gear is activated from neutral. 7‘©1898 Morse Contros 028 AUX2 TEXT (Auxillary inlet 2 display text). Specifies the text to be shown on the cab display unit when the inlet is activated (P1/16), The text is programmed as described under paragraph 5.2. 029 STEP CONTROL Specifies if a step control shifter is used.0 = No, an ordinary multi-signal shifter is used,(Most common)t = Step control shifter is used. 030 MASK N (Coding the neutral signal). Specifies wich of the pins P2/3-8 that are used for forward and reverse signals. This is to help Shiftronic to define neutral. 031 GEARS FH (Number of gears in forward high register) Specifies the number of gears in forward high register direction 032 GEARS RH (Number of geers in reverse high register), Spetifies the number of Qeers in reverse high register direction, 033 IN NH (Inlet signals in neutral high register). Specities wich of the pins P2/3-8 should be activated in neutral (if a neutral signal is requirec}. The function wil be a sum of the following values|01 = UGO (P2/3)02 = UG1 (P2/4)04 = UG2 (P2/5)10 = UG3 (P2/6)20 = UG4 (P2/7)40 = UGS (P2/8)E.9. If pins Nos 3 and 4 of the P2 connector should be activated in neutral, the value 1 +2 = 3 should be entered 034 IN FH1 (Activated inlets of gear 1 in forward high register)Specifies wich of the pins P2/3--8 should be activated in forward and first gear of high register. The function will be a sum of the values described in iD No 029, 035--042 IN FH2--FHS See ID No 034 043-051 IN RH1--RH9Same as ID No 030-038 but specifies the reverse mode instead. 052 OUT NH (Output signals in neutrat high register). Specifies wich of the pins P1/3- -14 should be activated in neutral. (If a neutral signal is required) The function will be 2 sum of the following values;001 = GO (P1/3)002 = G1 (P'1/4)004 = G2 (P'1/5)010 = G3 (P1/6)020 = G4 (P1/7)040 = G5 (P1/8)100 = G6 (P1/9)200 = G7 (P1/10}400 = GB Panty 053--061 OUT FH1--FH9.Specifios wich of the output signals should be activated in forward high register gears 1-9.The function will be a sum of the values described in ID No 048, 062--070 OUT RH--RH9. Same as ID No 049-057 but specifies the reverse made instead. ODD PARAMETERSO71--085 SP FH1.-FH9 (Speed forward high register first to ninth gear). Specifies, for each gear forward, ai wich rpm of the transmission outputsiait the shifting should occur. 18‘Shiftroni¢ Instruction manual V2.41 rev3 EVEN PARAMETERSO72--085 HY FH1--FH9 (Hystereses forward high register first. toninth gear) Specifies the hystereses for the previous parameters.E.g, Ifthe speed for FH1--FH2 is set to 600 rpm and the hystereses for FH1-FH2 to 100 rpm, upshifting will occur at 650 rpm and downshifting at $50 rom. 087-102 SP RH1--RH9 AND HY RH1--RH9.Same as ID No 067--082 but specifies the reverse mode instead. 103--120 PRE AND POST FHt--FH9.Specifies the engine control time described in {0 No 015 and 017 separately for each gear. This parameter is only activated if 1D No 010 is set to the value 1 121--134 PRE AND POST FH9--FH1 Specifies the pre and post values for giving thrattie with downshifting. This parameter is only activated if ID No 005 is set to the value 3. 137--14 PRE AND POST RH1-RH9.Same as ID No 089--116 only specifies the reverse mode instead. 455-170 PRE AND POST RH9--RH1 Same ads ID No 117-132 only specifies the reverse mode instead. 171 GEARS FL (Number of gears in forward low register).Specifies the number of gears in the forward low register. 172 GEARS RL (Number of gears in reverse low register).Specifies the number of gears in the reverse low register, IF THE THE HIGH/LOW REGISTER IS NOT WANTED, [D No 171 AND 172 SHOULD BE SET TO OHF THE ID No 171 AND 172 ARE PROGRAMMED TO ANYTHING BUT 0, THE SAME PARAMETERS THAT OCCURED AFTER ID No 031 AND 032 WILL APPEAR. So we will have;473 IN. NL 474-182 IN FL1--FL9 483--191 IN RL1-RL9 492 OUT NL 193-201 OUT FL1--FL9 202--210 QUT RL1--RL9 0DD211--225 SP FL1--FL9 227-243 SP RL1--RL9 EVENZ12--226 HY FL1-FL9 228--244 HY RL1—RLO If ID No 010 is set to 1, the pre and post values will appear in parameter No 245--310 317 END(©1998 Morse Contros INSTALLATION Installation of speed sensor kit-SSK. ‘The speed sensor kit consists of the following: Speed sensor -1 peSensor lugs - 8 pes Brackets as shown on drawing 880115. ~16. Itis important that the brakets and the sensor lugs ere firmly attached at an appropriate place, The enclosed drawing show a suggested installation and how many sensor lugs are needed depending on flange diameter. The same drawing also shows the critical measurements which have to be observed. ‘The are two diffrent types of sensors which can be incorporated in a Shiftronic application were the PNP type (3-wires) is supplied as standard, ‘The connections for both types are as follows PNP-transmitter. Brown Supply voltage, connect to P1, pin 1 (P1/1) Blue Ground supply, connect to P1, pin 2 (P1/2) Black Signal from sensor, connect {o P41, pin 14 ((P1/14)(transmission shaft sensor) and/or P1,pin 15 ((P1/15)(engine shaft sensor). Magnetic engine pickup Connection is made to the P1 connector of ‘the Shiftronic. Paz Transmission speed input. pris Transmission speed input, if a non-grounded pickup is used. P19 Engine speed input, 1/20 Engine speed input, if a non-grounded pickup is used. Installation of electronic control unit-ECU. Mechanical installation: The box of the ECU should be installed inside @ cab provicing an acceptable environment for the electronic circuitary. If the ECU has to operate in humid environment the 880905 waterproof series should be used, The ECU panel should be mounted verically with the cables downwards. Ifit is mounted in a high position, the heavy cables should be supported by cable clamps ete. Electrial installation: It is recommended that the ECU is protected with a 8A fuse. Supply connection P2ipin 1. The ECU and all other electrial components which are intergated in a Shiftronic system should have @ common ground,Ground connection P4/pin 2 and P2/pin 2. The sensor of PNP type should source its voltage supply from the ECU as described in chapter 4 20TROUBLE SHOOTING Malfunctions indicated by the CDU. ‘Shiftronie Instruction manval V241 revs Display |Description Remedy REV The driver has tried to change direction of the vehicle in a nonpermitted speed range according to programmed value. The transmission will automatically shift into neuiral Decrease the spead of the the vehicle. Depending of programme the driver has to Shift into neutral, remain in present position or select another direction, ID No 006. The ECU will not allow gear engeging until permitted speed of the vehicle is reached. RPM | Only exist if engine monitoring made is selected, ID No 019,1)The driver has tried to shift into a gear at a nonpermitted engine speed.2)The engine speed has exceeded the maximum permitted rpm. Decrease the engine speed. Ifengine control is selected this will be made automatically ID No 019. “The ECU is either shoricircuited or the load of one of the outlet pins is exceeding 1A. All outlets will be disconnected automatically at described error indication. T)Check ifthe connections aré made correctly and not causing a shortcircuit in the system, 2)Chock the load of the consumer which should not exceed 24 fer 24V OC system of 12W for 12V system per outlet. If the load exceeds these specified values, relays have to be installed which will reduce the load, If this is nescessary please install diodes over the relays. This to avoid jurbing Shifironic. The described condition is reset by the reset button on the ECU or the CDU. SENS |The ECU has failed, partially or {otally, to receive signals from the sensor kit monitoring speed on the propeller shaft. Check if the sensor bracket is firmly fastened. 2)Gheck the lugs providing the sensor with inductive signals. 3)Check the sensor itself by placing a piece of metal in front of the sensor. The sensors red led should light. See enclosed drawing.The described condition is reset by the reset button on the ECU or on the CDU. No. automatic shift occurs T)Check by pressing the reset bution if revolutions are shown on the display. 2) Check the sensor itself according to SENS, above. 21{ SHIFTRONIC 880000/900- A- 7175 KUNDICUSTOMER Kalmar Industries OY AB PROGRAM Program 80 DATUM ‘SIGN sAV MASKINIMACHINE MODELL TRANSMISSION 50/25 MOTORIENGINE VERSION 2.42 ~~ KORTNRIGARD NO MOTORIENGIN 418159 INTERFACE, TRANS-INTERFACE ‘ANM/NOTE. E.2416148| (TESTPROGRAM 0080) | SHIFTRONIC V1.42 1 [Pulsesirev z 76 [HyFHSFHa [150 | 205 [Out RL4 2 [Speed titer ics) “ar_[SpRHi-RH2 (250 | 211 [Sp FLI-FL2 3_/Sens chk ‘soorpm | 88 [Hy RH7-RH2 [80 [212 |My FLI-FL2 4 [Rev prot ‘zoorpm | 69 |SpRHZ-RH3 [700 213: (Sp FL2-FL3, 3 | 2 90 [Hy RH2-RH3|100 214 [Hy Fi 5 6 1 91 |SpRHG-RH4 [1200 | 215 |SpFLaFLa r 7 92 RHE-RHA [160 215 Ay FLL a 1 1 Pernt | joo0s | 227 |SpRLt 9 _[Revprot output 1 ~| 104 /Post FHT joo0s ‘228 [Hy RLI-RL2 40 _|Selective met 1 | 105 [Pre FH2 jO1es 229 |Sp RL2-RL3 41 |No auto first o | 106 |Post FH2 jooss 230 _|Hy RL2-RL3 12 [Quick first oO 407 [Pre FH3 [ates 231 |SpRLS-RL4 13 |Err keep gear 0 108 [009s 232_|Hy RL3-RL4 44 [Dummy range 0 109 (009s re F 15 _|Speed pickup 1 110 [Post FH4 O08 16 _|Motor pickup 1 121 Pre FH2-FI i 17 Inching input 2 122_|Post Ickup | 0.00: 123 |Pre FH3-FH2 _|0.00s 19 [Pre motor | 000s | 124 |PostFH3-FH2 [0.00 _ | 20 [Post ickup ©. 125_|Pre FH4-FH3 21. [Post motor 000s [Post FH4-FH3 Post FL4 22 |Kickdown| 0.0% | Pre RH Pre FL2-FL1 23. |AUX1 mode 32 Post RH1 | Post FL2-FL4 24 |At max | (2900 rom Pre RH2_| Pre FL3-FL2_ 25 Alert | 4000 rpm Post RH2 Post FL3-FL2 26 (AUX? mode 4 Pre RH Pie FLAFLS. 27 _AUX2 text | BRAKE - |PostRH3 | Post FL4-FL3 28 _|Step control 0 Pre RH4 Pre RL1 29 [Mask N 3 _ Post RH4 PostRL1 30 [Gears FH 4 Pre RHD.RFE Pre RL2 3 [Gea RH) Post RH2-RH Post RL2 32 lin NH | 0 Pre RLS Sine Post RHS.RH2 Post RLS 34 [In FH2 | 34 Pre RH4-RH3__|0.00s Pre RL14 38 In FH3 | 21 760 |[PostRH4.RH3 [000s Post RL4 36 [in FH 1 171 a Pre 43 In RH1 36 472 4 [Post RL2-RL1 44 [in REZ ~is2 473 0 Pre RLZ-RL2 ~45 in -RHS 2 4174 75 208 [Post RL3-RL2 45 in RHA 2 476 |InFl2_—(7t 200 [Pro RL4-RL3 52 OutNH o 476 [inFis et 300 53. 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