2. Modifying your powertrain to optimize performance

3. the beginning of the story... not much use to us yet……..

4. add a powertrain… not much use to us yet…

5. add a cab and controls… Still not much use to us…

6. Finally, a fully vocationalized truck

7. We get there by…

8. This talk today, then, is … Customize to Optimize

9. Today’s Rules of the Road… 1.Automated and automatic transmissions 2. We will talk in generalities 3. Some powertrain features as examples 4. Some reference material is given 5. Use your dealer to do your customization

10. ”I’ll pause for a moment so you can let this information sink in”

11. This is how we used to customize..

12. Customization today… is digital

13. What can we digitally customize on a vocational vehicle? Speed Permissions PTO operation Interlocks Auto Neutrals Shift sequence Performance

14. Speed control Low speed control is often required in some applications…

15. Where do we need low speed control ? Low speed control

16. Rate of speed increase Most engine manufacturers offer speed increase capability when operating under low speed governor control : stepped or ramped Usually the ramp rate can be changed.

17. Ford – Engine speed control PTO mode using Stationary Elevated Idle Control (Park or Neutral only) Minimum engine speed =900 rpm Maximum engine speed =3,000 rpm SEIC initiated by applying battery voltage to Wire Tag : PTO REQUEST 1 Fixed or Variable Target Speed obtained by adding resistor or 5000 Ohm potentiometer to Wire Tag : PTO RPM

18. Mack…PTO Speed Control Engine Speed Ramp Rate Step or Bump Adjustments Hold to Nearest (set speed rounding)

19. International ® – Speed Control for PTO (MaxxForce ® 7,DT,9,10) Stationary PTO applications Preset: 6 speed settings:Low idle > gov. RPM Ramp rate:1 > 1500 rpm/sec. Variable: With CRUISE “ON” switch set, engine speed is increased via the accelerator pedal or the cruise control switches using programmed Ramp Rate Mobile Variable Engine Speed Control Programmable:0 – 20 mph

20. Speed Permissions PTO operation Interlocks Auto Neutrals Shift sequence Performance

21. PTO Operation Power Take Offs Hydraulics Mechanical drives Generators Split shaft units Water pumps

22. Transmission Hydraulic pump Split shaft unit Drive shaft and universal joint Generator / Other equipment Drive shaft Split shaft drive system

23. PTO Operation may need… Engagement Speed control Torque control Remote Control

24. PTO Control PTO’s need to... Engage at: xxx RPM engine speed xxx RPM driveline speed Disengage at: xxx RPM engine speed xxx RPM driveline speed

25. International ® PTO Controls (electric over hydraulic) Programmable Engagement Parameters Status of Service Brake Status of clutch Park brake Engine running Engine speed over set value (must be > 600 rpm) Engine speed engagement limit (< 900 rpm) Status of transmission in Neutral/Park Vehicle speed Air pressure Vehicle master switch

26. Allison PTO Speed Control 1000/2000/3000/4000 families

27. Cummins – PTO Functions - ISL

28. What types of vehicles especially need good PTO speed control ? Snow plows need speed controlled PTO’s

29. PTO torque control Used to manage input torque to a pump or generator powered by the PTO Settings: Engine torque Speed ratio (engine : PTO output)

30. PTO remote control

31. Cummins – Remote PTO (ISB / ISL / ISX) Enable/DisableDefault = OFF Speed setting 11200 rpm Speed setting 2-5 ISB950 rpm ISL / ISX800 – 1100 rpm

32. Speed Permissions PTO operation Interlocks Auto Neutrals Shift sequence Performance

33. Permissions A controller looks at one or more inputs, and if conditions are met, a circuit is closed. For example: PTO enable Drive enable Neutral enable Reverse enable

34. REQUEST ACTION PTO engagement Is engine speed below the set limit? Is road speed below the set limit? Have transmission conditions been met (e.g. is oil feed pressure high enough to safely operate the PTO clutch) ? Air pressure (if air engagement is used) PTO speed overrides A programmable condition which allows the operator to momentarily override a programmed PTO speed using the accelerator Split shaft engagement Is park brake enabled? Is the transmission locked in the correct gear? Engine speed operation and high idle Service brakes or park brakes set, if programmed? Programmable alarms? Systems to enable the vehicle to slowly move without throttle application at constant engine speed (e.g. Eaton’s Creep or Urge-to- Move systems) Forward gear / Reverse gear Are engine speeds correct for engagement? Are all switches for auxiliary equipment in their correct state? Is service brake enabled (if so required by programming) DECISION CONDTIONS

35. Speed Permissions PTO operation Interlocks Auto Neutrals Shift sequence Performance

36. Interlocks Auxiliary function Dump bed Doors Lift gate Bucket lift Outriggers Range selection Drive Reverse

37. How mistakes are made... COSTLY FATAL

38. Speed Permissions PTO operation Interlocks Auto Neutrals Shift sequence Performance

39. Auto neutrals are essential in some applications, like Refuse Packers. Auto Neutrals Initiated by: Park Brake Work Brake Service Brake Drive re-attained by Range reselection (with or without override) Release of brake + switch

40. Eaton … Auto Neutral UltraShift PLUS & Fuller Advantage Automated Neutral attained when Parking Brake is applied. Auxiliary devices must provide an electrical interface with the transmission. Auto Neutral integrated via: Normally-closed pressure switch. J1939 Park Brake status message (on later models)

41. Allison Auto Neutrals Requiring reselection of range Park Brake ON NEUTRAL DRIVE Park Brake OFF Reselect Function L

42. Park Brake ON NEUTRAL DRIVE Park Brake OFF Reselect Function CD Override Park Brake Allison Auto Neutrals Requiring reselection of range

43. Allison Auto Neutrals Automatic reselection of range Park Brake ON NEUTRAL DRIVE Park Brake OFF Function AG Switch OPEN Switch CLOSED

44. Allison Auto Neutrals Automatic reselection of range Park Brake ON NEUTRAL DRIVE Park Brake OFF Function AK Arms RETRACTED Arms EXTENDED

45. Allison Auto Neutrals Automatic reselection of range Park Brake ON NEUTRAL DRIVE Park Brake OFF Function CN Service Brakes ON

46. Allison Auto Neutrals Automatic reselection of range J1939 Service Brake Status ON NEUTRAL DRIVE Service Brake Status OFF OR Switch OPEN OR Range RESELECTED OR Output SPEED > cal Function CA Switch CLOSED

47. Speed Permissions PTO operation Interlocks Auto Neutrals Shift sequence Performance

48. Automated transmissions may skip shift. Allison automatics can start in 1 st or 2 nd and be limited in the number of gears which can be attained. Stand up position with different shift mask Shift pattern (mask)

49. Speed Permissions PTO operation Interlocks Auto Neutrals Shift sequence Performance

50. Examples of acceleration control: Rate Speed threshold

51. Setting shift points for levels of performance: Shifts for economyShifts for performance Computer algorithms measure “road load” …

52. Settings are available for LEVELS of performance… High ECONOMY High PERFORMANCE

53. Customize to Optimize Engine, transmission and truck OEM’s have a great variety of electronic features which can be used to greatly enhance the vocational capability of your truck.

54. Customize to Optimize Users and Fleet Owners Identify the features you need Make sure default values are what you expect Work with your dealer to customize the values to satisfy your needs

55. Customize to Optimize Bodybuilders Work with your customer to identify the features they need, as well as the values Work with your OEM so that the chassis is delivered to you with as many settings as possible “baked into” the calibration via VEPS (Vehicle Engineering Programming Stations)

56. Johansson & Associates 317-657-9619 joe@josephjohansson.com www.josephjohansson.com Details given are taken off publicly available websites. The author has no vested interest in any of the products or companies mentioned. Not all products or features by all OEM’s have been covered, but mainly those engaged in powertrain components for Class 7 and 8 vocational trucks. Not all features are available from all OEM’s. The intent has been to provide a thought-starter, and then to encourage the reader to take further questions to the OEM or the dealer network.