CONTROLES TRANSMISIÓN ZF (2)

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

300804

11
 COMUNICACIÓN ENTRE MOTOR / TRANSMISIÓN CAN-BUS

120Ω

Engine ECU 60Ω Trans. EST37

END
E.C.U E.C.U
USER
120Ω 120Ω
120Ω 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 (Ω)

IGNITION OFF. ALL CONTROLS HAVE TO BE CONNECTED

MEASUREMENT BETWEEN SPECIFIED VALUE ACTUAL VALUE POSSIBLE CAUSE

CAN H (X4 PIN 1) 40 Ω 0Ω S.C. FROM CAN H TO
CAN L
RED PROBE
CONNECTION TO 1 or 2
AND 40 Ω 60 Ω or 120 Ω
END RESISTOR IS CUT
CAN L (X4 PIN 2) OFF OR RESISTOR HAS
FAILED
BLACK PROBE
END RESISTOR CUT
40 Ω ☺Ω OFF, DAMAGED OR CAN
WIRE INTERRUPTED

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 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 POSSIBLE CAUSE
24 V S.C. FROM CAN H TO
BATTERY
CAN H (X4 PIN 1)
S.C. FROM CAN H TO
RED PROBE 2.4 V - 2.9 V 0V
GROUND
AND
S.C. FROM CAN H TO AN
0 V - 2.3 V
GROUND - BLACK PROBE AUXILIARY COMPONENT.
3.0 V - 24 V

24 V S.C. FROM CAN L TO

CAN L (X4 PIN 2)
BATTERY
RED PROBE 2.2 V - 2.7 V
S.C. FROM CAN L TO
0V
AND GROUND
GROUND - BLACK PROBE 0 V - 2.1 V S.C. FROM CAN L TO AN
2.8V - 24 V AUXILIARY COMPONENT.

44
 POSICIÓN DEL ACELERADOR
Terex I.D. B19 REFER. TO ENGINE & COOLING
TRAINING FOR DETAILED
OPERATION.

KICK-DOWN
MECHANICAL FEEL

55
 PEDAL ACELERADOR

KICKDOWN
THROTTLE MICROSWITCH - S74
POTENTIOMETER - B19
IDLE VALIDATION
SWITCH - S69

66
 FUNCIÓN 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

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 MÚLTIPLE 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)

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 TRABA DIFERENCIAL TRANSMISIÓN

Y7

10
10
 INTERRUPTORES TRABA DIFERENCIAL & RETARDADOR

D - Diff. Lock Request Switch (S60)

R - Retarder Request Switch (S81)

1
D R

1 - Diff. Lock Indicator Lamp

Ref. Next
2 - Not Used 2
Slide

Differential Lock Indicator Lamps

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11
 OPERACIÓN TRABA DIFERENCIAL
OPERATOR
1
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.

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12
 OPERACIÓN 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

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 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

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 IDENTIFICACIÓN RELEVOS

K32
48 K17
K50
K52
K27
36 K23 K23
24 K14
12 K27
K23 K33
K5 K23
K34 K4
K51
K15

37
25
13
1

15
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 VALORES BOBINAS SOLENOIDES

Y7 Diff-Lock Solenoid (Axle) 14 watt 41Ω 0.6amp

Y3 Retarder Solenoid 14 watt 41Ω 0.6amp
Y7 Transmission Diff-Lock 19watt 30Ω 0.8amp

(Approx. figures rated for 24 Volts)

Electrical Formula
(Click Here)

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16
 POWERSHIFT DIFF-LOCK
Definitions;
Torque Split 1:3
(Dis-Engaged) VA Output Front Axle

Torque Split 1:1 HA Output Rear Axle

(Spring Engaged)
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)

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17
 DIFFERENTIAL LOCK - TORQUE SPLITTING

TORQUE SPLIT 1:3 TORQUE SPLIT 1:1

DIFF. LOCK DIS-ENGAGED DIFF. LOCK ENGAGED

18
18
 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.
AUTOMATIC RETARDER OPERATION(SWITCH OFF);
R 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
WARNING/FAULTS CODES; RPM.
WS SUMP TEMP. WARNING THE RETARDER WILL AUTOMATICALLY DIS-ENGAGE WHEN
TRANSMISSION OIL TEMPERATURE REACHES 150°C (300°F).
WR RETARDER TEMP. WARNING VEHICLE SPEED MUST BE REDUCED USING SERVICE BRAKES.
WE HIGH ENGINE SPEED WARNING WITH THE ACCELERATOR APPLIED (ON GAS), THE RETARDER
WILL AUTOMATICALLY APPLY AT 2600 RPM AND DIS-ENGAGE
B7 HIGH SUMP TEMP. FAULT AT 2450 RPM.
B8 HIGH RETARDER TEMP. FAULT ABNORMAL OPERATION WILL ACTIVATE TRANSMISSION FAULT
CODES THAT WILL BE DISPLAYED AND RECORDED BY THE
ECU.

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19
 REARDADOR / PEDAL FRENO
Brake Pedal Potentiometer (B36)

Brake Pedal Interface Module (N5)

20
20
 PEDAL INTERFACE BOX
1 - K50 RELAY (STOP LAMPS)
2 - K51 RELAY (RETARDER SELECT)
BRAKE LIGHT OUTPUT SIGNAL (WHITE)

1 (BROWN)
BRAKE LIGHT 0V

X
(VIOLET) SIG

BO

ER
E
RETARDER 0V (GREEN)

ET
IO L
AC

NT DA
(BLUE) 0V

M
RF
2

TE PE
RETARDER OUTPUT SIGNAL (ORANGE)

TE
IN
(GREY) +5V

L
(+)BATTERY (RED)

PO
DA
(-)BATTERY (BLACK)
PE
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 <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°)

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 IDENTIFICACIÓN RELEVOS

K50

K32
K50
48 K17 K52
36 K23 K23
24
12 K14 K27
K23 K33
K5 K23
K34 K4
K51
K15

37
25
13 37
1 25
13 K51
1

K50 STOP LAMPS K51 RETARDER SELECT

22
22
 DIAGRAMA ELÉCTRICO RETARDADOR

B36 BRAKE PEDAL POTENTIOMETER N5 BRAKE PEDAL INTERFACE MODULE

K51 RETARDER RELAY S81RETARDER REQUEST SWITCH

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23
 DIAGRAMA SOLENOIDE RETARDADOR
X8 X9
Y3 RETARDER SOLENOID
CHECK PLUG X9 PINS 9/10
RATINGS;
14 Watts
41Ω
0.6 Amp

24
24
 REVISIÓN SOLENOIDE RETARDADOR

Check;
Plug X9 - Pins 9 & 10

Y3 Retarder Solenoid 14 watt 41Ω 0.6amp

Retarder Solenoid
Terex I.D. Y3
Z.F. I.D. Y8

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25
REVISIÓN 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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 VÁLVULA RETARDADOR
Activation Pressure Retarder Valve Not Switched

To Lubricant
From Heat Exchanger

To Retarder

Breather
From Retarder

To Heat Exchanger
After Converter

To Lubrication

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27
 FILTROS TRANSMISIÓN
>50°C & <2000RPM
T.E.L. No.
15274198

Code BA

TA25 SWITCH

1st 500 Hr.

1000 Hr.

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28
 FILTROS TRANSMISIÓN

NO SE ACEPTAN SUBSTITUTOS

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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 5V
Switch Disconnected 14 V
Switch Connected 500 Ω

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30
 BOMBA EMERGENCIA DIRECCIÓN

31
31
 CÓDIGOS DE FALLA
1st Digit Fault Description
1 Digital Input Signal
2 Analog Input signal
3 Speed signal
4 CAN Signal Error(Not Used)
5 CAN Signal Error
6 CAN Signal error
7 Analog Current Output Signal
8 Analog Current Output Signal
9 Digital Output Signal
A Digital Output Signal
B Trans. Error, Clutch Error
C Logical Error
D Power supply
E High Speed Signal
F General Error
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32
Actual Error Source
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
 CÓDIGOS OPERATIVOS

Symbol Fault Description

WS Sump Temperature Warning
WR Retarder Temperature Warning
WT Torque Converter Temperature Warning
WE High Engine Speed Warning
F or R Flash Gear Selected While Turbine Speed Too High
(CAUTION Gear Will Engage When Turbine Speed Drops)

EE No Communication At Display(LCD)

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NIVELES OPERACIÓN – CÓDIGOS 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 CÓDIGOS 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 up-
or 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.

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35
 MANEJANDO LOS NIVELES DE CÓDIGOS 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

36
36
 CALIBRACIÓN VELOCÍMETRO
CALIBRACIÓN VELOCÍMETRO (P1)
Con llantas estandares
TA25 333650
TA27 232100
TA30 232100
0

PULSE/Adjust
Señal del velocímetro
Desde la transmisión a través del ECU via divisor de
frecuencia (N4)
N4
ECU X1 Pin 36 cable 436
Tapón X7 Pines 19 a N4
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37
 TIPOS ACEITE TRANSMISIÓN

TIPO ACEITE: 15W40, CH4

INTERVALOS DE SERVICIO:
1ST 500 Hrs DRENE / RELLENE Y CAMBIE FILTROS
1000 Hrs DRENE RELLENE Y CAMBIE FILTROS

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 Para futura información contacte a www.terex.com

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

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