Twin Disc TA-90-8501 User manual

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Components:
TA-90-8501 Transmission
8-FLW-2302-0 Torque Converter
TDEC-400 Electronic Control
Document Number: 1020510
TWIN DISCTWIN DISC
TWIN DISCTWIN DISC
TWIN DISC
INCORPORAINCORPORA
INCORPORAINCORPORA
INCORPORATEDTED
TEDTED
TED

NOTICE
Twin Disc, Incorporated makes no warranty or guaranty of any
kind, expressed, implied or otherwise, with regard to the
information contained within this manual. Twin Disc,
Incorporated has developed this manual through research and
testing of the information contained therein. Twin Disc,
Incorporated assumes no responsibility for any errors that may
appear in this manual and shall not be liable under any
circumstances for incidental, consequential or punitive damages
in connection with, or arising out of, the use of this manual. The
information contained within this manual is subject to change
without notice.

Document Number
1020510
Revison 1
May, 2002
Power Shift Transmission
System Operator’s Manual

TWIN DISC, INCORPORATED
EXCLUSIVE LIMITED WARRANTY
GENERAL UNITS
A. Twin Disc, Incorporated warrants all assembled products and parts, (except component products or parts on which written warranties
issued by the respective manufacturers thereof are furnished to the original customer, as to which Twin Disc, Incorporated makes no
warrantyandassumesnoliability)againstdefectivematerialsorworkmanshipforaperiodoftwenty-four(24)monthsfromthedateoforiginal
shipment by Twin Disc, Incorporated to the original customer, but not to exceed twelve (12) months of service, whichever occurs first. This is the
onlywarrantymade by TwinDisc,Incorporated and isinlieu of anyandall other warranties,expressor implied, includingthewarranties
of merchantability or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc,
Incorporated.
The original customer does not rely upon any tests or inspections by Twin Disc, Incorporated or on Twin Disc, Incorporated*s
application engineering.
B. The exclusive remedy provided by Twin Disc, Incorporated whether arising out of warranty within the applicable warranty period as
specified, or otherwise (including tort liability), shall at the sole option of Twin Disc, Incorporated be either the repair or replacement
of any Twin Disc, Incorporated part or product found by Twin Disc, Incorporated to be defective and the labor to perform that work
and to remove and reinstall (or equivalent credit). In this context, labor is defined as the flat rate labor hours established by Twin Disc,
Incorporated in the published Twin Disc Flat Rate Schedule, required to remove, disassemble, inspect, repair, reassemble, reinstall and
test the Twin Disc, Incorporated product only. Under no circumstances, including a failure of the exclusive remedy, shall Twin Disc,
Incorporated be liable for economic loss, consequential, incidental or punitive damages. The above warranty and remedy are subject
to the following terms and conditions:
1. CompletepartsorproductsuponrequestmustbereturnedtransportationprepaidandalsotheclaimssubmittedtoTwinDisc,
Incorporated within sixty (60) days after completion of the in-warranty repair.
2. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted from abuse,
neglect, improper maintenance or accident.
3. The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc,
Incorporated.
4. The warranty is void unless the product or part is properly transported, stored and cared for from the date of shipment to
the date placed in service.
5. The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product
or part with installations properly engineered and in accordance with the practices, methods and instructions approved or
provided by Twin Disc, Incorporated.
6. Thewarrantyisvoidunlessall required replacement partsorproductsareofTwinDiscoriginorequal,andotherwiseidentical
withcomponentsoftheoriginalequipment. ReplacementpartsorproductsnotofTwinDiscoriginarenotwarrantedbyTwin
Disc, Incorporated.
C. Asconsiderationforthiswarranty,theoriginalcustomerandsubsequentpurchaseragreetoindemnifyandhold TwinDisc,Incorporated
harmless from and against all and any loss, liability, damages or expenses for injury to persons or properly, including without limitation,
the original customer*sand subsequent purchaser*semployees and property, due to their acts or omissions or the acts or omissions of
their agents, and employees in the installation, transportation, maintenance, use and operation of said equipment.
D. OnlyaTwinDisc,Incorporatedauthorizedfactoryrepresentativeshallhaveauthoritytoassumeanycostorexpenseintheservice,repair
orreplacement ofany part or product withinthe warranty period,except whensuch cost orexpense is authorized in advancein writing
by Twin Disc, Incorporated.
E. Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials without being obligated to
incorporate such changes in products of prior manufacture. The original customer and subsequent purchasers will not use any such
changes as evidence of insufficiency or inadequacy of prior designs or materials.
F. If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts will be furnished on a
no-charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete
unit.
December 14, 2001 TDWP0002

TWIN DISC, INCORPORATED
Flat Rate Hours Allowance
(Hourly Labor Rate Must Be Acceptable to Twin Disc, Incorporated)
* Travel and related expenses are not included as a part of Twin Disc General Unit Warranty.
GENERAL UNITS
Model Series R&R Repair & Test
Powershift Transmissions
1000, 1100, 1300, 1400 14.0 24.0
1600, 2000, 2600, 3100 14.0 30.0
2800 14.0 18.0
3600 14.0 36.0
8500 14.0 72.0
Matching Torque Converters
6-1300, 6-1500 6.0 6.0
8-1400, 8-1450, 8-1600 6.0 8.0
8-1700, 8-1800, 8-1750, 8-1850 8.0 12.0
4-2000 6.0 12.0
8-2300 8.0 20.0
Industrial Torque Converters
6-1300 & 6-1500 6.0 8.0
4-1600 & 4-2000 6.0 12.0
4-2200 w/cooler 12.0 30.0
4-2600 & 4-3400 w/cooler 20.0 40.0
10,000 & 11,500 6.0 12.0
11,500 HD & 13,800
w/Radiator 10.0 24.0
w/o Radiator 10.0 20.0
16,000 w/Radiator 14.0 32.0
w/o Radiator 14.0 28.0
Fluid Couplings
14.5 HC, HM, HU & HUC 2.0 4.0
17.5 HC, HM, HU & HUC 2.0 4.0
21 HC, HM, HU & HUC 2.0 6.0
27 HC & HM 4.0 8.0
27 HUD w/Radiator 8.0 32.0
w/o Radiator 8.0 28.0
Power Take Off's Clutches Only
C106 6" 1.0 2.0 1.0
C107 7" 1.0 2.0 1.0
C108 8" 1.0 2.5 1.0
C110 10" 1.0 3.0 1.5
SP-X11 11" 2.0 4.0 2.0
SL-X11 11" 2.0 5.5 2.0
TC-X13 13" 2.0 2.0 1.0
SP-X14 14" 3.0 6.0 3.0
SL-X14 14" 3.0 6.0 3.0
IBF-X14 14" 3.0 8.0 3.0
B-X18 18" 4.0 10.0 4.0
SP-X18 18" 4.0 10.0 4.0
IBF-X 18 18" 4.0 10.0 4.0
SP-X21 21" 6.0 14.0 6.0
December 14, 2001 TDWP0002A

7
Twin Disc, Incorporated Table of Contents
Power Shift Transmission System Operator’s Manual #1020510
Table of Contents
Introduction ...........................................................9
General Information ............................................................................ 9
Replacement Parts ............................................................................ 10
Preventative Maintenance/Troubleshooting ................................. 11
Safety .................................................................................................. 12
Sources of Service Information ...................................................... 13
Warranty.............................................................................................. 14
Description and Specifications.........................15
General................................................................................................ 15
Description ......................................................................................... 16
Sump ................................................................................................... 16
Pump ................................................................................................... 16
Regulator Valve Assembly ............................................................... 17
Range Selector Valve........................................................................ 17
Special Features................................................................................ 18
Specifications .................................................................................... 19
Operation..............................................................21
Checking Oil Level ............................................................................ 22
Basic System Description................................................................ 23
Transmission Component Summary ............................................ 29
Transmission Hydraulic System ..................................................... 30
Power Flow Through Transmission System................................. 33
D.C. Power Supply............................................................................. 35
Electronic Control System Overview ............................................. 36
TDEC-400 Electronic Control System Components..................... 40
System Operation.............................................................................. 45
Fracturing rig Operating Modes ..................................................... 46
Operational Problems....................................................................... 50

8
Twin Disc, Incorporated
Table of Contents
Power Shift Transmission System Operator’s Manual #1020510
Preventative Maintenance ..................................51
General................................................................................................ 51
Hydraulic System .............................................................................. 52
Periodic Visual Inspection ............................................................... 56
Hydraulic System Pressure Checks............................................... 59
Troubleshooting..................................................61
General................................................................................................ 61
Pressure and Flow Test Kit.............................................................. 62
Troubleshooting Discussion ........................................................... 63
Problems that Show No Fault Messages in the Display .............. 64
Problems that Show Fault Messages in the Display.................... 85
Display Faults..................................................................................... 87
Diagnostic Test................................................................................101
Engineering Drawings......................................131
List of Engineering Drawings ........................................................131
1019142 (System, Elect. Control) .................................................133
238008A (Schematic, Hydraulic)...................................................134
229578E (Diagram, Piping) ............................................................135
1019876 (page 1 of 6) (Transmission Parts) ...............................136
1019876 (page 2 of 6) (Transmission Parts) ...............................137
1019876 (page 3 of 6) (Transmission Parts) ...............................138
1019876 (page 4 of 6) (Transmission Parts) ...............................139
1019876 (page 5 of 6) (Transmission Installation) ..................... 140
1019876 (page 6 of 6) (Transmission Installation) ..................... 141
X237074A (Clutch Assembly, 1, 4, 7) ............................................142
X237073A (Clutch Assembly, 3, 6, 9) ............................................143
X229489F (Clutch Assembly, 2, 5, 8) ............................................144
1018460 (Range Selector Valve Assembly).................................145
X229460P (Valve Assembly, Main Regulator) .............................146
X229823B (page 1 of 3) (Torque Converter Installation) ........... 147
X229823B (page 2 of 3) (Torque Converter Parts) .....................148
X229823B (page 3 of 3) (Torque Converter Parts) .....................149
1018360 (partial) (Valve Assembly, solenoid) .............................150

9
Twin Disc, Incorporated
Power Shift Transmission System Operator’s Manual #1020510
Introduction
Introduction
General Information
This publication provides the information necessary for the operation and
maintenanceoftheTwinDisc,Incorporated equipment specified onthecover
of this manual. Specific engineering details and performance characteristics
can be obtained from the Product Service Department of Twin Disc,
Incorporated, Racine, Wisconsin, USA.
Operationandmaintenancepersonnelresponsibleforthisequipmentshould
have this manual at their disposal and be familiar with its contents. Applying
the information in the manual will result in consistent performance from the
unit and help reduce downtime.
Special Tools
Engineering drawings are available for the fabrication of special tools that
should be used during disassembly and assembly of a unit. Repair of this
equipment should not be attempted without special tools. Twin Disc does
not manufacture these tools for general use.

10
Twin Disc, Incorporated
Power Shift Transmission System Operator’s Manual #1020510
Introduction
Replacement Parts
Parts Lists
Engineering assembly drawings are provided in appropriate sections of this
manual to facilitate ordering spare or replacement parts. Current bill of
materials are available from Twin Disc or the nearest Authorized Twin Disc
Distributor.
Ordering Parts
All replacement parts or products (including hoses and fittings) must
beofTwin Disc originorequal,and otherwise identicalwithcomponents
of the original equipment. Use of any other parts or products will void
the warranty and may result in malfunction or accident, causing injury
to personnel and /or serious damage to the equipment.
Renewal parts and service parts kits may be obtained from any authorized
Twin Disc distributor or service dealer.
Parts Shipment
Furnish the complete shipping information and postal address. All parts
shipments made from the factory will be FOB factory location, USA. State
specifically whether the parts are to be shipped by freight, express, etc. If
shipping instructions are not specified, the equipment will be shipped the
best way, considering time and expense. Twin Disc, Incorporated will not
be responsible for any charges incurred by this procedure.
Twin Disc, Incorporated having stipulated the bill of material number on the
unit’s nameplate absolves itself of any responsibility resulting from any
external,internalorinstallationchangesmadeinthefieldwithouttheexpress
written approval of Twin Disc. All returned parts, new or old, emanating
from any of the above-stated changes will not be accepted for credit.
Furthermore, any equipment which has been subjected to such changes will
not be covered by a Twin Disc warranty.

11
Twin Disc, Incorporated
Power Shift Transmission System Operator’s Manual #1020510
Introduction
Preventative Maintenance/Troubleshooting
Frequentreferencetotheinformationprovided in this manual regarding daily
operation and limitations of this equipment will assist in obtaining trouble-
free operation. Schedules are provided for the recommended maintenance
oftheequipmentand,ifobserved,minimumrepairs(asidefromnormalwear)
will result.
In the event a malfunction does occur, a troubleshooting table is provided to
help identify the problem area and lists information that will help determine
the extent of the repairs necessary to get a unit back into operation.
Lifting Bolt Holes
Most Twin Disc products have provisions for attaching lifting bolts. The
holes provided are always of adequate size and number to safely lift the
Twin Disc product.
These lifting points must not be used to lift the complete power unit.
Lifting excessive loads at these points could cause failure at the lift
point (or points) and result in damage or personal injury.
Select lifting eyebolts to obtain maximum thread engagement with bolt
shoulder tight against housing. Bolts should be near but should not
contact bottom of bolt hole.

12
Twin Disc, Incorporated
Power Shift Transmission System Operator’s Manual #1020510
Introduction
Safety
General
Safe practices must be employed by all personnel operating and servicing
this unit. Twin Disc, Incorporated will not be responsible for personal injury
resulting from careless use of hand tools, lifting equipment, power tools, or
unaccepted maintenance/operating practices.
Important Safety Notice
Becauseofthepossibledangerto person(s) orpropertyfromaccidentswhich
mayresult from the use ofmanufacturedproducts, it is important thatcorrect
procedures be followed. Products must be used in accordance with the
engineering information specified. Proper installation, maintenance, and
operation procedures must be observed. Inspection should be made as
necessary to assure safe operations under prevailing conditions. Proper
guards and other suitable safety codes should be provided. These devices
areneitherprovidedbyTwinDisc, Incorporated nor aretheytheresponsibility
of Twin Disc, Incorporated.

13
Twin Disc, Incorporated
Power Shift Transmission System Operator’s Manual #1020510
Introduction
Sources of Service Information
Each series of manuals issued by Twin Disc, Incorporated is current at the
time of printing. When required, changes are made to reflect advancing
technology and improvements in state-of-the-art.
Individual product service bulletins are issued to provide the field with
immediate notice of new service information.
For the latest service information on Twin Disc products, contact any Twin
Disc distributor, or contact the Product Service Department, Twin Disc,
Incorporated, Racine, Wisconsin 53405-3698, USA, or by e-mail at
[email protected].

14
Twin Disc, Incorporated
Power Shift Transmission System Operator’s Manual #1020510
Introduction
Warranty
Equipment for which this manual was written has a limited warranty. For
details of the warranty, refer to the warranty statement at the front of this
manual.

15
Twin Disc, Incorporated Description and Specifications
Power Shift Transmission System Operator’s Manual #1020510
Description and Specifications
General
(Reference - Twin DiscApplication #AN4019)
TheTwinDiscTA-90-8501transmissionisahydraulicallyactuated powershift
transmission,providingninespeedsforward. Usedwiththis transmission is a
TwinDisc torqueconvertermodel8-FLW-2302-0. Thetransmissionandtorque
converterareelectronicallycontrolledbyaTwinDisc modelTDEC-400control.
ModelIdentityNumbersandLetters
TA--90-8501, BOM 67425
T=Transmission
A=Nodropbox,outputandinputareaxiallyinline
9 = Nine speeds forward
0= No reverse
85 = Transmission model series
01=Basicmodelnumber(Assignedinconsecutivesequencetoidentifyspecific
modifications or gear ratios)
8-FLW-2302-0, BOM 67288
8=type8TwinDisctorqueconverter
F=Flywheelmountedunit
L=with lockupclutch
W=withstatorfreewheel
230=23.0-inchconvertercircuitsize
2 = specific model for application
0=housingsizetomatchSAEflywheel
TDEC-400electroniccontrol,BOM 41488

16
Twin Disc, IncorporatedDescription and Specifications
Power Shift Transmission System Operator’s Manual #1020510
Description
Therearetwomainsectionsofthe transmission, a countershaft inputsection,
and a planetary output section. The input section consists of three geared-
togetherclutchshaftsandadrivenfrontoutputshaft. A9-inchballdumpclutch
is directly connected to, and driven by the input shaft, and when engaged, is
directly connected to the front output shaft. The outer member of this clutch
pack(geardriver)mesheswiththeinputmembersoftwoshaftmountedclutches.
Theseclutchesare10.5inchandaretheStype. Whenoneoftheinputsection
clutchesisengaged,poweristransmittedtothefrontoutputshafteitherdirectly
orthroughthedrivengears,andtotheinput members of the planetary output
section. Therearethreeclutchpackassembliesintheplanetaryoutputsection.
Thehighrangeclutch isa12.5-inchandisof theLD type. Whenengaged,the
output shaft rotates at the same speed as the front output shaft in the input
sectionofthetransmission. Therearetwo23-inchplanetaryclutch assemblies
(nondumpvalve) thatconnecttotheoutputflangethroughplanetaryreduction
gearsets. Thesearereferredtoasthelowrangeandintermediaterangeclutch
pack assemblies
Thehydraulictorqueconverteris asinglestageType 8 designwithanintegral
lockupclutch,andstatorfreewheel. Thelockupclutchishydraulicallycontrolled
inconjunctionwiththeelectroniccontrol.
Sump
Thebottom of thetransmissionhousing serves asthesump for alloilused in
thetransmission/torqueconvertersystem.Asuctionstrainerisinstalledinthe
sumptopreventdebrisfrombeingdrawnintothepumpinlet.
Pump
Thehydraulicsystemdualpumpassemblyis located on the rearofthetorque
converteronapumpmounttotherightof center as viewed from therear. The
twopumps are of thepositivedisplacementgear-type and are drivendirectly
bytheengine.Thepumpinletsdrawoil throughasuctionstrainer.Theoilfrom
thepumpsisdirectedthroughfiltersandregulatorvalvesandsuppliespressure
forclutchapply, torque converterandlube. Thepumpsrun at engine speed.
Ascavengepumpisontherearofthetorqueconverteron apumpmounttothe
leftofcenterasviewedfromtherear. The scavenge pump draws oil from the
bottomoftheengine flywheelandconverterhousingsand returnstheoiltothe
transmissionsump.

17
Twin Disc, Incorporated Description and Specifications
Power Shift Transmission System Operator’s Manual #1020510
Regulator Valve Assembly
Pressure regulating valves for controlling main pressure, converter circuit
pressure,andlubeoil pressuresarecontainedinthe regulatorvalveassembly
onthetorqueconverter. Theregulatorvalveonthetorqueconverteralsoincludes
acoldoilreliefforprotectionoftheconverter.
Range Selector Valve
Sixproportionalvalves,mountedontheleftofthetransmissionhousing,(viewed
fromtherear)controltheapplicationofthe transmission clutches. The valves
arecontrolledbyelectronicallymodulatedsignals. These valves areidentical,
andareidentifiedas1,2,3,4,5,and6. Thesesolenoidnumbersarereferenced
in the electronic control system drawing to aid technicians in troubleshooting
thesystem.
Thelockupclutchinthetorqueconverteriscontrolledby a proportional valve,
identicaltothesixinthetransmission, located in theregulatorvalveassembly
onthetorqueconverter, andisactuatedbyanelectronically modulatedsignal.
Thecontrolsystemispoweredby24voltsdc.

18
Twin Disc, IncorporatedDescription and Specifications
Power Shift Transmission System Operator’s Manual #1020510
Special Features
Clutches
Hardenedsteelplatesand organicfiberfrictionplatesare usedonallclutches.
The9-inch(inputsection)clutchis a ball-dumptypeclutch. Thetwo10.5-inch
clutches(inputsection)areoftheSdumpvalve configuration. The highrange
(outputsection)12.5-inchclutchisoftheLDdumpvalveconfiguration.Thetwo
23-inch(output section) aremodulatablenondump valve clutches. All ofthe
clutchesarehydraulicallyactuated,spring-released,and oil cooled.
Bearings
The input section clutch shafts and the front output shaft are supported with
taperedrollerbearings. Thesebearings (in conjunction with shims) are used
tocontrol the end playof the shafts. The planetaryshafts are supported with
cagedneedlebearings,and endfloatiscontrolledbythrust washers. Thering
gearfloatiscontrolled with luberingassembliesoneachside. The highrange
clutch is supported on the front output shaft with a ball bearing, and the end
thrust is controlled by this bearing and a ball bearing in the sun gear on the
opposite end. The allowable float is controlled with shims between the sun
gearandthe clutchhub. Theoutputshaft andplanetarycarrieris supportedby
adoubletapered roller bearing set.

19
Twin Disc, Incorporated Description and Specifications
Power Shift Transmission System Operator’s Manual #1020510
Specifications
NormalTemperatureRange:
180°-220° F (82°-104° C)
Low Speed Pressures:
Run at 715 rpm
MainPressure(X):
185 psi (1276 kPa) minimum at regulator.
ClutchApplyPressure(CL):
180 psi (1241 kPa) minimum at end caps and within 5 psi (34 kPa) of each
other.
TransmissionLubePressure:
15psiminimum (103 kPa) at lube regulator (G).
2psi(14kPa) minimum at clutch lube ports.
Converteroutletpressure(W):
30 psi minimum (207 kPa)
HighSpeed Pressures:
Run at 1950 rpm
MainPressure(X):
235-255 psi (1620-1758 kPa) at main regulator.
ClutchApplyPressure(CL):
Within 12 psi (83 kPa) of main at end caps.
Transmission Lube Pressures:
35-60 psi (241-417 kPa) at lube regulator (G).
5-20psi(34-138 kPa) at clutch lube testports.
Converteroutletpressure(W):
45 to 55 psi (310-379 kPa)

20
Twin Disc, IncorporatedDescription and Specifications
Power Shift Transmission System Operator’s Manual #1020510
Enginespeeds(approximate)
(B J Services oil well fracturing rig with MTU/DDC 16V4000 engine, 3000 hp
@ 1950 rpm)
Fullload 1950 rpm
No load 1960 rpm
Converterstallspeed 1953 rpm
TDEC-400CONTROL
FurnishedwiththetransmissionistheTDEC-400electroniccontrol.Thecontrol
provides shifting for the transmission/converter system and is necessary to
coordinatethefunctionofthe fracturing rig,torqueconverterandtransmission
intheoilwellservicingapplication.Thecontroloperateson24voltsdcprovided
bythefracturingrig’sbattery.