11
CONTROLES TRANSMISIN ZF (2)TA25/27/30 (A825/828/847/850)TA25/27/30 (A825/828/847/850)
300804
22
120 120
END
USER
Can L
Can H
Plug X4
1 - Can H 2 - Can L
Codes 56-58, 65, 66, 69, 6A, 6B, 6E
E.C.UE.C.U
COMUNICACIN ENTRE MOTOR / TRANSMISIN CAN-BUS
120
12060Engine ECU Trans. EST37
33
USING DIGITAL MULTI-METER - RESISTANCE ()IGNITION OFF. ALL CONTROLS HAVE TO BE CONNECTED
MEDIDAS EN EL CAN-BUS
MEASUREMENT BETWEEN
CAN H (X4 PIN 1)
RED PROBE
AND
CAN L (X4 PIN 2)
BLACK PROBE
SPECIFIED VALUE
40
40
40
ACTUAL VALUE
0
60 or 120
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
44
USING DIGITAL MULTI-METER - VOLTAGE(V)
IGNITION ON. ALL CONTROLS HAVE TO BE CONNECTEDMEASUREMENT BETWEEN
CAN H (X4 PIN 1)
RED PROBE
AND
GROUND - BLACK PROBE
CAN L (X4 PIN 2)
RED PROBE
AND
GROUND - BLACK PROBE
SPECIFIED VALUE
2.4 V - 2.9 V
2.2 V - 2.7 V
ACTUAL VALUE
24 V
0 V
0 V - 2.3 V3.0 V - 24 V
24 V
0 V
0 V - 2.1 V2.8V - 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.
MEDIDAS EN EL CAN-BUS
55
POSICIN DEL ACELERADORTerex I.D. B19
KICK-DOWN MECHANICAL FEEL
REFER. TO ENGINE & COOLING TRAINING FOR DETAILED OPERATION.
66
PEDAL ACELERADOR
THROTTLE POTENTIOMETER - B19
IDLE VALIDATION SWITCH - S69
KICKDOWN MICROSWITCH - S74
77
FUNCTION;
KICK-DOWN CAN ONLY BE EXECUTED IN AUTOMATIC MODE.
KICK-DOWN ALLOWS THE OPERATOR TO DOWNSHIFT, PROVIDING THAT THEVEHICLE 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 LEFT2. USE KICK-DOWN
OPERATION;
S74 MAKES CONTACT POWER VIA F11 SIGNALS PLUG X7 PIN
16 (WIRE #422)
ACTIVATES ECU PLUG X1 PIN 22
FUNCIN GOLPEAR ABAJO
88
MLTIPLE RETARDADOR & TRABA DIFERENCIAL
Y3
Y7
CT3
Definitions;
Y3 Retarder Solenoid
Y7 Diff. Lock Solenoid (Axle)
CT3 Pressure Reducing Valve
Located Top Side Transmission
99
RETARDADOR & TRABA DIFERENCIAL
PRESSURE RELIEF SETTING (RETARDER)
CT3 VALVE
TA27(opt) 5.5 bar (80 psi)
TA30 5.5 bar (80 psi)
TRANSMISSION PILOT PRESSURE16 bar+2 bar (232 psi)
1010
TRABA DIFERENCIAL TRANSMISIN
Y7
1111
D R
D - Diff. Lock Request Switch (S60)
R - Retarder Request Switch (S81)
Differential Lock Indicator Lamps
INTERRUPTORES TRABA DIFERENCIAL & RETARDADOR
2
1
1 - Diff. Lock Indicator Lamp
2 - Not UsedRef. Next Slide
1212
OPERACIN TRABA DIFERENCIAL
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.
SYSTEM IS DESIGNED FOR POWERSHIFT DIFFERENTIAL LOCK IN BOTH TRANSMISSION AND AXLE.
DIFFERENTIAL LOCK CAN BE MANUALLY ACTIVATED UP TO 3RD GEAR - ALL SPEEDS.
OPERATOR WARNING 1
1313
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
OPERACIN TRABA DIFERENCIAL
1414
DIAGRAMA TRABA DIFERENCIAL
OPERATION;
POWER SUPPLIED VIA K27 RELAY -CHECK ACROSS PLUG X9 PINS 11 & 12
Y7 TRANSMISSION DIFF-LOCK SOLENOIDENERGISED - DISENGAGE
DE-ENERGISED - ENGAGED
Y7 AXLE DIFF-LOCKDE-ENERGISED - DISENGAGE
ENERGISED - ENGAGED
X9
1515
IDENTIFICACIN RELEVOS
K27K23
K23
K34
K15K51
K5
K14
K17
K4
K33
K23
K50K32
K27
K23
K52
113
2412
48
3725
36
1616
VALORES BOBINAS SOLENOIDES
Y7 Diff-Lock Solenoid (Axle) 14 watt 41 0.6ampY3 Retarder Solenoid 14 watt 41 0.6ampY7 Transmission Diff-Lock 19watt 30 0.8amp
(Approx. figures rated for 24 Volts)
Electrical Formula(Click Here)
1717
POWERSHIFT DIFF-LOCKDefinitions;
VA Output Front Axle
HA Output Rear Axle
1 Output Shaft to VA
2 Powershift Diff. Hydraulic Disengage
3 K3 Spur Gear Input
4 Planetary Gear (Outer Hole Circle)
5 Ring Gear
6 Output Shaft to HA
7 Planetary Carrier
8 Screening Plate
9 Sun Gear
10 Powershift Diff. Spring Engaged
11 Planetary Gear (Inner Hole Circle)
Torque Split 1:3 (Dis-Engaged)
Torque Split 1:1 (Spring Engaged)
1818
DIFFERENTIAL LOCK - TORQUE SPLITTING
TORQUE SPLIT 1:3DIFF. LOCK DIS-ENGAGED
TORQUE SPLIT 1:1DIFF. LOCK ENGAGED
1919
R
R - Retarder Request Switch (S81)INTERRUPTOR RETARDADOR
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.
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.
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
2020
REARDADOR / PEDAL FRENO Brake Pedal Potentiometer (B36)
Brake Pedal Interface Module (N5)
2121
PEDAL INTERFACE BOXPEDAL INTERFACE BOXBRAKE LIGHT OUTPUT SIGNAL
RETARDER 0V
RETARDER OUTPUT SIGNAL
(+)BATTERY
(-)BATTERY
BRAKE LIGHT 0V
(WHITE)
(BROWN)
(GREEN)
(ORANGE)
(RED)
(BLACK)
(VIOLET)
(BLUE)
(GREY)
SIG
0V
+5V
PEDA
L INT
ERFA
CE B
OX
PEDA
L
POTE
NTIO
METE
R
1
2
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 BUS-
BAR TO ACTIVATE APPROPRIATE SOLENOIDS AND LAMPS.RELAYS ARE DE-ACTIVATED WHEN PEDAL POTENTIOMETER
2222
IDENTIFICACIN RELEVOS
K51
K50
K23
K23
K34
K15K51
K5
K14
K17
K4
K33
K23
K50K32
K27
K23
K52
113
2412
48
3725
36
K50 STOP LAMPS K51 RETARDER SELECT
113
3725
2323
DIAGRAMA ELCTRICO RETARDADOR
B36 BRAKE PEDAL POTENTIOMETER N5 BRAKE PEDAL INTERFACE MODULEK51 RETARDER RELAY S81RETARDER REQUEST SWITCH
2424
DIAGRAMA SOLENOIDE RETARDADORY3 RETARDER SOLENOIDCHECK PLUG X9 PINS 9/10RATINGS;14 Watts410.6 Amp
X9X8
2525
REVISIN SOLENOIDE RETARDADOR
Retarder Solenoid
Terex I.D. Y3
Z.F. I.D. Y8
Y3 Retarder Solenoid 14 watt 41 0.6amp
Check;
Plug X9 - Pins 9 & 10
2626
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 GAUGERETARDER PRESSURE WILL RISE. COULD TAKE UP TO 30-40 SECS TO STABILISE.
2727
VLVULA RETARDADOR
To Lubrication
After Converter
From Retarder
To Lubricant
To Retarder
Breather
From Heat Exchanger
To Heat Exchanger
Activation Pressure Retarder Valve Not Switched
2828
1st 500 Hr.1000 Hr.
>50C &
2929
FILTROS TRANSMISIN
NO SE ACEPTAN SUBSTITUTOS
3030
Plug X9 - Pins 17 & 18Switch Connected 5 VSwitch Disconnected 14 VSwitch Connected 500
Transmission FilterTerex I.D. S90Z.F. I.D. S10
Oil @ Operating Temp
INTERRUPTOR BY PASS FILTRO
3131
BOMBA EMERGENCIA DIRECCIN
3232
1st Digit Fault Description Actual Error Source
1 Digital Input Signal Inputs From Shift Lever2 Analog Input signal Engine Load Sensors, Temp. Sensors3 Speed signal Signal Inputs From Speed Sensors4 CAN Signal Error(Not Used) Not Used By Terex5 CAN Signal Error CAN-Bus Fault6 CAN Signal error CAN-Bus Fault7 Analog Current Output Signal Gear Selection Signal - ECU to Control Valve8 Analog Current Output Signal Gear Selection Signal - ECU to Control Valve9 Digital Output Signal Outputs From Solenoid ValvesA Digital Output Signal Outputs From Solenoid ValvesB Trans. Error, Clutch Error Clutch Slippage, Overheat, PressuresC Logical Error Converter Temperature Warning, CAN FaultD Power supply High or Low Voltages to ECU or SensorsE High Speed Signal Signal Between ECU & Display(LCD)F General Error ECU Failure, Calibration Required
CDIGOS DE FALLA
3333
Symbol Fault DescriptionWS Sump Temperature WarningWR Retarder Temperature Warning WT Torque Converter Temperature WarningWE High Engine Speed WarningF or R Flash Gear Selected While Turbine Speed Too High
(CAUTION Gear Will Engage When Turbine Speed Drops)
EE No Communication At Display(LCD)
CDIGOS OPERATIVOS
3434
5 OPERATING LEVELS1. 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 ControlCase: 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.
NIVELES OPERACIN CDIGOS DE FALLA
3535
3. Limp HomeCase: 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 afault code is displayed.The vehicle must be stopped and the operator must shift the gear selector into neutral position. The operator can then shiftinto either forward or reverse, the TCU will then select an appropriate limp home gear. The vehicle will move without up-or downshift.
4. Transmission ShutdownCase: 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 failureVPS1 - 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.
MANEJANDO LOS NIVELES DE CDIGOS DE FALLA
3636
5. TCU ShutdownCase: 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 solenoidsVPS1 - Wire #908 Output to X8:13
VPS2 Voltage supply to auxiliary functionsVPS2 to Lock-Up - Wire #946 Output to X9:8VPS2 to Retarder - Wire #946 Output to X9:10VPS2 to Diff-Lock - Wire #946 Output to X9:12
ADM1 to ADM8 Output signals to auxiliary functionsADM1 to Warning Lamp - Wire #452 Output to X7:12ADM2 to Reverse Warning - Wire#407 Output to X7:3ADM5 to Retarder - Wire#457 Output to X9:9ADM6 to Diff-Lock - Wire#411 Output to X9:11ADM7 to Lock-Up - Wire#434 Output to X9:7
MANEJANDO LOS NIVELES DE CDIGOS DE FALLA
3737
CALIBRACIN VELOCMETRO (P1)Con llantas estandares
TA25 333650TA27 232100TA30 232100
PULSE/Adjust
0
2
1
CALIBRACIN VELOCMETRO
N4
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
3838
TIPOS ACEITE TRANSMISIN
TIPO ACEITE: 15W40, CH4
INTERVALOS DE SERVICIO:
1ST 500 Hrs DRENE / RELLENE Y CAMBIE FILTROS
1000 Hrs DRENE RELLENE Y CAMBIE FILTROS
3939
DEPARTAMENTO SOPORTE AL PRODUCTO
Para futura informacin contacte a www.terex.com
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.