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.