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CONTROLES TRANSMISIN ZF (2)

TA25/27/30 (A825/828/847/850)

300804

11

COMUNICACIN ENTRE MOTOR / TRANSMISIN CAN-BUS


120
Engine ECU
END
USER

Trans. EST37

60

E.C.U

E.C.U

120

120

120

Can L

Can H

1 - Can H

2 - Can L

Codes 56-58, 65,


66, 69, 6A, 6B, 6E

Plug X4
22

MEDIDAS EN EL CAN-BUS
USING DIGITAL MULTI-METER - RESISTANCE ()
IGNITION OFF. ALL CONTROLS HAVE TO BE CONNECTED
MEASUREMENT BETWEEN

SPECIFIED VALUE

ACTUAL VALUE

CAN H (X4 PIN 1)

40

40

60 or 120

RED PROBE
AND
CAN L (X4 PIN 2)
BLACK PROBE
40

33

POSSIBLE CAUSE
S.C. FROM CAN H TO
CAN L
CONNECTION TO 1 or 2
END RESISTOR IS CUT
OFF OR RESISTOR HAS
FAILED
END RESISTOR CUT
OFF, DAMAGED OR CAN
WIRE INTERRUPTED

MEDIDAS EN EL CAN-BUS
USING DIGITAL MULTI-METER - VOLTAGE(V)
IGNITION ON. ALL CONTROLS HAVE TO BE CONNECTED
MEASUREMENT BETWEEN

SPECIFIED VALUE

ACTUAL VALUE
24 V

CAN H (X4 PIN 1)


RED PROBE

2.4 V - 2.9 V

AND

0 V - 2.3 V
3.0 V - 24 V

GROUND - BLACK PROBE

24 V

CAN L (X4 PIN 2)


RED PROBE
AND
GROUND - BLACK PROBE

44

0V

2.2 V - 2.7 V

0V
0 V - 2.1 V
2.8V - 24 V

POSSIBLE CAUSE
S.C. FROM CAN H TO
BATTERY
S.C. FROM CAN H TO
GROUND
S.C. FROM CAN H TO AN
AUXILIARY COMPONENT.
S.C. FROM CAN L TO
BATTERY
S.C. FROM CAN L TO
GROUND
S.C. FROM CAN L TO AN
AUXILIARY COMPONENT.

POSICIN DEL ACELERADOR


Terex I.D. B19

REFER. TO ENGINE & COOLING


TRAINING FOR DETAILED
OPERATION.

KICK-DOWN
MECHANICAL FEEL
55

PEDAL ACELERADOR

THROTTLE
POTENTIOMETER - B19

KICKDOWN
MICROSWITCH - S74
IDLE VALIDATION
SWITCH - S69

66

FUNCIN GOLPEAR ABAJO


FUNCTION;
KICK-DOWN CAN ONLY BE EXECUTED
IN AUTOMATIC MODE.
KICK-DOWN ALLOWS THE OPERATOR
TO DOWNSHIFT, PROVIDING THAT THE
VEHICLE SPEED IS WITHIN A SAFE
OPERATING RANGE.
WHEN IN 2nd GEAR AUTOMATIC,THERE
ARE 2 OPTIONS TO OBTAIN 1st GEAR;
1. MANUALLY SHIFT GEAR LEVER TO LEFT
2. USE KICK-DOWN
OPERATION;
S74 MAKES CONTACT
POWER VIA F11 SIGNALS PLUG X7 PIN
16 (WIRE #422)
ACTIVATES ECU PLUG X1 PIN 22

77

MLTIPLE RETARDADOR & TRABA DIFERENCIAL


Definitions;
Y3 Retarder Solenoid
Y7 Diff. Lock Solenoid (Axle)
CT3 Pressure Reducing Valve

Y3

Y7
CT3

Located Top Side Transmission

88

RETARDADOR & TRABA DIFERENCIAL

PRESSURE RELIEF SETTING


(RETARDER)

CT3 VALVE
TA27(opt) 5.5 bar (80 psi)
TA30

5.5 bar (80 psi)

TRANSMISSION PILOT PRESSURE


16 bar+2 bar (232 psi)

99

TRABA DIFERENCIAL TRANSMISIN

Y7

10
10

INTERRUPTORES TRABA DIFERENCIAL & RETARDADOR


D - Diff. Lock Request Switch (S60)
R - Retarder Request Switch (S81)

1 - Diff. Lock Indicator Lamp


Ref. Next
Slide

2 - Not Used

2
Differential Lock Indicator Lamps

11
11

OPERACIN TRABA DIFERENCIAL


OPERATOR
WARNING

SYSTEM IS DESIGNED FOR POWERSHIFT DIFFERENTIAL


LOCK IN BOTH TRANSMISSION AND AXLE.
DIFFERENTIAL LOCK CAN BE MANUALLY ACTIVATED UP
TO 3RD GEAR - ALL SPEEDS.
WARNING! - CRITERIA FOR 4TH TO 6TH GEAR IS THAT TORQUE THROUGH
TRANSMISSION MUST BE BELOW 400Nm.
4TH TO 6TH GEAR CRITERIA IS CONTROLLED VIA THE EST(TRANSMISSION ECU)
SYSTEM
TRANSMISSION ECU WILL NOT ACTIVATE SIGNAL TO DIFFERENTIAL LOCK IF
TORQUE IS GREATER THAN 400Nm.

12
12

OPERACIN TRABA DIFERENCIAL


DIFFERENTIAL LOCK REQUEST SWITCH (S60)

S60

OPERATION;
S60 SENDS REQUEST SIGNAL TO
PLUG X7 PIN 8
TRANS. ECU RECEIVES REQUEST
SIGNAL AT PLUG X1 PIN 30 (WIRE#430)
TRANS. ECU DETERMINES DIFF. LOCK
OPERATING PARAMETERS ARE OKAY.
ACTUATION SIGNAL TO DIFF. LOCK
SOLENOID IS SENT VIA PLUG X9 PINS
11 & 12

13
13

DIAGRAMA TRABA DIFERENCIAL


X9

OPERATION;
POWER SUPPLIED VIA K27 RELAY CHECK ACROSS PLUG X9 PINS 11 & 12
Y7 TRANSMISSION DIFF-LOCK SOLENOID
ENERGISED - DISENGAGE
DE-ENERGISED - ENGAGED
Y7 AXLE DIFF-LOCK
DE-ENERGISED - DISENGAGE
ENERGISED - ENGAGED

14
14

IDENTIFICACIN RELEVOS

12

24

36

48

K17

K23

K34
K15

15
15

13

25

37

K5
K51

K27

K52

K23

K14

K23

K32

K50

K33
K4

K27
K23

VALORES BOBINAS SOLENOIDES

Y7

Diff-Lock Solenoid (Axle) 14 watt

41

0.6amp

Y3

Retarder Solenoid

14 watt

41

0.6amp

Y7

Transmission Diff-Lock

19watt

30

0.8amp

(Approx. figures rated for 24 Volts)

Electrical Formula
(Click Here)

16
16

POWERSHIFT DIFF-LOCK
Torque Split 1:3
(Dis-Engaged)
Torque Split 1:1
(Spring Engaged)

Definitions;
VA Output Front Axle
HA Output Rear Axle
1

Output Shaft to VA

Powershift Diff.
Hydraulic Disengage

K3 Spur Gear Input

Planetary Gear (Outer


Hole Circle)

Ring Gear

Output Shaft to HA

Planetary Carrier

Screening Plate

Sun Gear

10 Powershift Diff. Spring


Engaged
11 Planetary Gear (Inner
Hole Circle)
17
17

DIFFERENTIAL LOCK - TORQUE SPLITTING

TORQUE SPLIT 1:3


DIFF. LOCK DIS-ENGAGED

18
18

TORQUE SPLIT 1:1


DIFF. LOCK ENGAGED

INTERRUPTOR RETARDADOR
R - Retarder Request Switch (S81)

MANUAL RETARDER OPERATION(SWITCH ON);


SELECT RETARDER REQUEST SWITCH (S81)
PROVIDING THAT THE TRANSMISSION STOP LAMP IS OUT,
TRANSMISSION IS IN LOCK-UP, FOOT IS OFF GAS AND THE
TRANSMISSION OIL TEMP. IS WITHIN OPERATING RANGE - A
RETARDER APPLY WILL BE MADE.

WARNING/FAULTS CODES;
WS SUMP TEMP. WARNING
WR RETARDER TEMP. WARNING
WE HIGH ENGINE SPEED WARNING
B7

HIGH SUMP TEMP. FAULT

B8

HIGH RETARDER TEMP. FAULT

19
19

AUTOMATIC RETARDER OPERATION(SWITCH OFF);


APPROACHING AN OVER-SPEED CONDITION, THE
TRANSMISSION WILL AUTOMATICALLY UP-SHIFT TO
DECREASE ENGINE RPM.
WITH THE ACCELERATOR PEDAL RELEASED (OFF GAS), THE
RETARDER WILL AUTOMATICALLY APPLY WHEN VEHICLE
SPEED REACHES 2000 RPM AND WILL DIS-ENGAGE AT 1850
RPM.
THE RETARDER WILL AUTOMATICALLY DIS-ENGAGE WHEN
TRANSMISSION OIL TEMPERATURE REACHES 150C (300F).
VEHICLE SPEED MUST BE REDUCED USING SERVICE BRAKES.
WITH THE ACCELERATOR APPLIED (ON GAS), THE RETARDER
WILL AUTOMATICALLY APPLY AT 2600 RPM AND DIS-ENGAGE
AT 2450 RPM.
ABNORMAL OPERATION WILL ACTIVATE TRANSMISSION FAULT
CODES THAT WILL BE DISPLAYED AND RECORDED BY THE
ECU.

REARDADOR / PEDAL FRENO


Brake Pedal Potentiometer (B36)

Brake Pedal Interface Module (N5)


20
20

PEDAL INTERFACE BOX

RETARDER OUTPUT SIGNAL

(ORANGE)

(BLACK)

(-)BATTERY

(BLUE)

0V

(GREY)

+5V

DA

(RED)

SIG

PE

(+)BATTERY

(VIOLET)

PO
TE PE
NT DA
IO L
M
ET
ER

(GREEN)

BO
X

RETARDER 0V

AC
E

(BROWN)

RF

BRAKE LIGHT 0V

IN

(WHITE)

TE

BRAKE LIGHT OUTPUT SIGNAL

1 - K50 RELAY (STOP LAMPS)


2 - K51 RELAY (RETARDER SELECT)

OPERATION;
PEDAL POTENTIOMETER WORKS ON 0 TO 5 V SCALE.
RELAYS ARE ACTIVATED WHEN PEDAL POTENTIOMETER >1V. THIS ALLOWS 24V (FUSED) FROM BUSBAR TO ACTIVATE APPROPRIATE SOLENOIDS AND LAMPS.
RELAYS ARE DE-ACTIVATED WHEN PEDAL POTENTIOMETER <1V.
FIRST 4-5 MOVEMENT ACTIVATES ELECTRICAL SIGNAL FOR LIGHTS & RETARDER.
AFTER INITIAL 4-5 MOVEMENT - SERVICE BRAKE PRESSURE STARTS TO APPLY (+RETARDER).
RETARDER WILL REMAIN ON UNTIL ANY ONE OF THE OPERATING PARAMETERS DETAILED ON PARA.2
SLIDE 18 ARE OUT OF RANGE.
(TOTAL PEDAL DEFLECTION 20)

21
21

IDENTIFICACIN RELEVOS
K50

12

24

36

48

K17

K23

K34
K15

1
1

13
13

25
25

K50 STOP LAMPS


22
22

K52

K23

K14

K23

K32

K50

K5

K33
K4

K27
K23

K51

37
37

K51

K51 RETARDER SELECT

DIAGRAMA ELCTRICO RETARDADOR

B36
K51

23
23

BRAKE PEDAL POTENTIOMETER


RETARDER RELAY

N5 BRAKE PEDAL INTERFACE MODULE


S81RETARDER REQUEST SWITCH

DIAGRAMA SOLENOIDE RETARDADOR


X8

Y3 RETARDER SOLENOID
CHECK PLUG X9 PINS 9/10
RATINGS;
14 Watts
41
0.6 Amp

24
24

X9

REVISIN SOLENOIDE RETARDADOR

Check;
Plug X9 - Pins 9 & 10

Y3

Retarder Solenoid

Retarder Solenoid
Terex I.D.

Y3

Z.F. I.D.

Y8

25
25

14 watt

41

0.6amp

REVISIN SOLENOIDE RETARDADOR (2)


RETARDER CHECK HARNESS
START ENGINE AND ALLOW TO IDLE
REMOVE CONNECTION X1 FROM
TRANSMISSION ECU
EE CODE WILL BE DISPLAYED ON LCD
CONNECT APPROPRIATE PRESSURE
GAUGE TO DIAGNOSTIC POINT
APPLY 24V SUPPLY TO HARNESS
(DIRECT FROM BATTERIES)

CONNECT APPROPRIATE PRESSURE GAUGE


RETARDER PRESSURE WILL RISE. COULD
TAKE UP TO 30-40 SECS TO STABILISE.
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26

VLVULA RETARDADOR
Activation Pressure

Retarder Valve Not Switched

To Lubricant
From Heat Exchanger
To Retarder
Breather
From Retarder
To Heat Exchanger
After Converter
To Lubrication

27
27

FILTROS TRANSMISIN
>50C & <2000RPM

T.E.L. No.
15274198
Code BA

TA25 SWITCH

1st 500 Hr.


1000 Hr.
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28

FILTROS TRANSMISIN

NO SE ACEPTAN SUBSTITUTOS

29
29

INTERRUPTOR BY PASS FILTRO


Oil @ Operating Temp

Transmission Filter
Terex I.D.
S90
Z.F. I.D.
S10

Plug X9 - Pins 17 & 18


Switch Connected
Switch Disconnected
Switch Connected
30
30

5V
14 V
500

BOMBA EMERGENCIA DIRECCIN

31
31

CDIGOS DE FALLA
1st Digit
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F

32
32

Fault Description

Actual Error Source

Digital Input Signal


Analog Input signal
Speed signal
CAN Signal Error(Not Used)
CAN Signal Error
CAN Signal error
Analog Current Output Signal
Analog Current Output Signal
Digital Output Signal
Digital Output Signal
Trans. Error, Clutch Error
Logical Error
Power supply
High Speed Signal
General Error

Inputs From Shift Lever


Engine Load Sensors, Temp. Sensors
Signal Inputs From Speed Sensors
Not Used By Terex
CAN-Bus Fault
CAN-Bus Fault
Gear Selection Signal - ECU to Control Valve
Gear Selection Signal - ECU to Control Valve
Outputs From Solenoid Valves
Outputs From Solenoid Valves
Clutch Slippage, Overheat, Pressures
Converter Temperature Warning, CAN Fault
High or Low Voltages to ECU or Sensors
Signal Between ECU & Display(LCD)
ECU Failure, Calibration Required

CDIGOS OPERATIVOS
Symbol
WS
WR
WT
WE
F or R Flash

Fault Description
Sump Temperature Warning
Retarder Temperature Warning
Torque Converter Temperature Warning
High Engine Speed Warning
Gear Selected While Turbine Speed Too High
(CAUTION Gear Will Engage When Turbine Speed Drops)

EE

33
33

No Communication At Display(LCD)

NIVELES OPERACIN CDIGOS DE FALLA


5 OPERATING LEVELS
1. Normal
Case: There is no fault detected by the TCU or the fault has no or slight
effect on the transmission control. Fault could be on a secondary
device, i.e. torque converter lockup clutch defective.
Effect: TCU will work without or with little limitations.
Secondary device cannot be used, truck may have some
performance limitations, ie power, speed and temperature.
i.e. lockup clutch cannot be closed running in converter
continually.

2. Substitute Clutch Control


Case: Significant fault,
i.e. speed sensor failure
Effect: Normal clutch modulation during shifts is replaced by a simple
time dependant modulation.
Results in poor shift quality.

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34

MANEJANDO LOS NIVELES DE CDIGOS DE FALLA


3. Limp Home
Case: The detected fault in the system has severe limitations to
transmission control. i.e. clutch defective
Effect: The TCU can select one gear in each direction.
The TCU shifts to Neutral when the fault is first detected and a
fault code is displayed.
The vehicle must be stopped and the operator must shift the
gear selector into neutral position. The operator can then shift
into either forward or reverse, the TCU will then select an
appropriate limp home gear. The vehicle will move without upor downshift.

4. Transmission Shutdown
Case: The TCU has detected a safety critical fault. The TCU will shut
down all solenoid valves for clutch activation by disabling the
common power supply (VPS1). i.e. gear selector failure
VPS1 - Wire #908 Output to X8:13
Effect: Transmission shifts to Neutral when the fault is detected first
and a fault code is displayed. The operator must slow the
vehicle to a stop. The vehicle cannot move further on as long
as fault persists.

35
35

MANEJANDO LOS NIVELES DE CDIGOS DE FALLA


5. TCU Shutdown
Case: Safety critical fault, the transmission TCU has detected a severe
fault that can/will disable the control of the EST system.
Effect: Transmission shifts to Neutral when the fault is detected and a
fault code is displayed. Power supply for all solenoids is switched
off and also all common voltage supplies VPS1 and VPS2. All
functions controlled by outputs ADM1 to ADM8 are also disabled.
The vehicle cannot move further on.
VPS1 Voltage supply to clutch activation solenoids
VPS1 - Wire #908 Output to X8:13
VPS2 Voltage supply to auxiliary functions
VPS2 to Lock-Up - Wire #946 Output to X9:8
VPS2 to Retarder - Wire #946 Output to X9:10
VPS2 to Diff-Lock - Wire #946 Output to X9:12
ADM1 to ADM8 Output signals to auxiliary functions
ADM1 to Warning Lamp - Wire #452 Output to X7:12
ADM2 to Reverse Warning - Wire#407 Output to X7:3
ADM5 to Retarder - Wire#457 Output to X9:9
ADM6 to Diff-Lock - Wire#411 Output to X9:11
ADM7 to Lock-Up - Wire#434 Output to X9:7

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36

CALIBRACIN VELOCMETRO

CALIBRACIN VELOCMETRO (P1)


Con llantas estandares

TA25
TA27
TA30

333650
232100
232100
0
1
2

PULSE/Adjust
Seal del velocmetro
Desde la transmisin a travs del ECU via divisor de
frecuencia (N4)
ECU X1 Pin 36 cable 436
Tapn X7 Pines 19 a N4
37
37

N4

TIPOS ACEITE TRANSMISIN


TIPO ACEITE:

15W40, CH4

INTERVALOS DE SERVICIO:

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1ST 500 Hrs

DRENE / RELLENE Y CAMBIE FILTROS

1000 Hrs

DRENE RELLENE Y CAMBIE FILTROS

Para futura informacin contacte a www.terex.com

DEPARTAMENTO SOPORTE AL
PRODUCTO
Las ilustraciones, La informacin Tcnica, los datos y los textos descriptivos de esta presentacin, han sido lo
mejor de nuestro conocimiento, fue corregido al momento de la elaboracin. Terex Equipment Limited, dentro
de su poltica de desarrollo continuo, se reserva el derecho de cambiar: las especificaciones, las instrucciones
del equipo y su mantenimiento sin aviso previo.
Por favor refirase a las hojas de especificaciones o consulte con el Representante de Fbrica para estar
seguro de que la informacin esta actualizada.

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