Product Training: Articulated Dump Truck TA250: TA300 ZF Transmission Controls

Product Training
Articulated Dump Truck

TA250 : TA300
ZF Transmission Controls
110610
Terex Centre of Excellence

Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
United Kingdom
Technical Online Assistance: http://constructionsupport.terex.com
ZF TRANSMISSION CONTROLS
2
Electrical Schematics and Generic Components

3
Making Weld Repairs
Before welding on vehicle:

• Turn key switch OFF.
• Turn master switch OFF.
Disconnect:
• Battery supply and earth cables.
• Alternator supply and earth cables.
• Transmission ECU and Gearshifter
• Engine ECM
• Hydraulic ECU
• Dash panel and ECU
• Body control joystick
• Any other electronic options; rear view camera, etc.
4
Wire / Cable Colours
N - BROWN
U - BLUE
R - RED
P - PURPLE
EXAMPLE:
R/W - RED/WHITE G - GREEN
•MAIN COLOUR RED
•WITH WHITE TRACER L - LIGHT GREEN
W - WHITE
Y - YELLOW
B - BLACK
S - SLATE (GREY)
O - ORANGE
K - PINK
5
ZF Transmission Definitions
6WG260 – TA25
6WG260 – TA27
6WG310 – TA30
No. of Forward Gears kW Input Capability of

Transmission
6
ZF Transmission Definitions
Retarder
(Optional) Control Valve
Lock-Up Solenoid
Central Gear Train
Converter
Differential Lock
7
ZF EST Circuit
Transmission Control Unit

(T.C.U.) Gearshift Lever
Liquid Crystal Display

(L.C.D.)
Control Harnesses
Electro-Hydraulic
Shift Unit
Speed Sensors x 4
8
ZF EST Schematic
-
p o w e r
+ s u p p ly
s p e e d s e n s o r e n g in e
lo c k -u p
s p e e d s e n s o r tu r b in e
re ta rd e r
s p e e d s e n s o r in te r n a l w a r n in g la m p
s p e e d s e n s o r o u tp u t b a c k u p a la r m
F
N
Inputs  g e a r
s e le c to r
R
B 1 / T +
d is p la y Outputs 
B 2 / T - s p e e d o m e te r
B 3 (O p tio n ) E S T -3 7 d ia g n o s tic in te r fa c e
Y 1
Y 2
s ig n a l d e c lu tc h Y 3 tra n s -
b in -u p Y 4 m is s io n
Y 5
re ta rd e r re q u e s t Y 6
d iff.lo c k r e q u e s t
T e m p .
k ic k d o w n
S u m p
-
- Inputs
T e m p .
lo a d s e n s o r R e ta rd e r / C o n v .O u t
C A N -
In te r fa c e
9
ZF EST Generic Schematic
K2 (K17)REVERSE RELAY
F1 BATTERY FUSE - CONSTANT (F10)
S32 BODY PROXY SW.

S5 ENGINE BRK SW.
H3 WARNING LAMP
S28 DIFF-LOCK SW.
S4 KICKDOWN SW.
S1 RETARDER SW.
F2 IGNITION FUSE (F11)
DIAGNOSTIC
OUTPUT SPEED 22 INTERFACE
SENSOR
GEAR SHIFT
CONTROLLER
DISPLAY
A9 SPEEDO OUTPUT
LOAD SENSOR ADM4 SOUNDPOWER OUTPUT

*
A3 HYDRAULIC CONTROL UNIT
T.C.U.
K1 (K14) START
INTERLOCK
B1 ENGINE SPEED SENSOR B9 RET. TEMP

B2 TURBINE SPEED SENSOR SENSOR
B3 CENTRAL GEAR SPEED SENSOR S10 FILTER
DIFFERENTIAL SW.
KEY; Y7 LOCK-UP SOLENOID

Y8 RETARDER SOLENOID
E? INPUT Y9 DIFF-LOCK SOLENOID
A? OUTPUT
VP VOLTAGE(+)
VM VOLTAGE(-) CAN INTERFACE
10
ZF EST Generic Schematic – Useful Key
VP1 Ignition Voltage F11
VPE1/2 Battery Voltage (Constant) F10
VPS1 Voltage supply to clutch activation solenoids

VPS1 - Wire #434 Output to X8:13 - X1:56
VPS2 Voltage supply to auxiliary functions

VPS2 to Lock-Up - Wire #534 Output to X9:8 – X1:8 / 53
VPS2 to Retarder - Wire #544 Output to X9:10 – X1:8 / 53
VPS2 to Diff-Lock - Wire #554 Output to X9:12 – X1:8 / 53
ADM1 to ADM8 Output signals to auxiliary functions (-) ground apply

ADM1 to Warning Lamp - Wire #844 Output to X7:12 – X1:52
ADM2 to Reverse Warning - Wire#808 Output to X7:3 – X1:7
ADM3 to Automatic Park Brake – Wire#812 Output to X7:4 (2010 Build)
ADM4 to Sound Power 1st Gear Restriction - Wire#848 Output to X7:13 – X1:5
ADM5 to Retarder - Wire#540 Output to X9:9 – X1:57
ADM6 to Diff-Lock - Wire#550 Output to X9:11 – X1:11
ADM7 to Lock-Up - Wire#530 Output to X9:7 – X1:34
E?? Inputs
A?? Outputs from TCU to Main Control Valve
VM?? Ground (-)

11
Interface Harness Connections
X4
CAN (Communication)
Connection
X2 X7
Gear Lever Interface
Connection
X8
Interface
X9
Interface
X1 16-Pin
T.C.U. Hydraulic
Connection Control Valve
Connection X25
Diagnostic Connection
VIEW
12
Cab Bulkhead Connectors A / B
B
A
13
Connector E – Chassis Side

Transmission/Chassis Bulkhead
Sockets
Trans. Side Pins
Tractor / Trailer Chassis Bulkhead Connector H – Tractor Side Sockets

Trailer Side Pins
14
ZF Interface - 6WG260/310
Internal Splicing to
ZF Harness
15
ZF Interface
 X7 Plug
X7  828 Wire
 8 Pin
 Connects with X1 Plug
 30 Pin
X1
16
X2/X6/X7 Connection - Schematic
17
X8/9 Connection - 6WG260/310
18
TCU and Connection Locations
X1
Mounted Under Instructor Seat

Fuse/Relay Box 19
Relays:
A E I M Q A. Not Used.
B. Not Used.
C. Sound Power – Body Up (K58)
D. Sound Power – 1st – R gr (K57)
E. Air Con / Heater Ignition (K23)
F. Wiper / Ignition (K23)
G. Horns (K34)
H. Headlights (K15)
I. Reverse Alarm / Lights (K17)
J. Neutral Start (K14)
K. Not Used
L. Not Used
M. Brake Lights (K50)
N. Engine ECU Ignition (K23)
O. A/C Run Relay (K5)
P. Indicator Flasher Unit (K4)
Q. Engine Brake (K32)
R. Body Proximity (K52)
F1. Ignition Sensed Equipment 20A F16. Park / Emergency Brake 3A S. Diff-lock (K27)
F2. Keyswitch 15A F17. Instrument cluster / CPU Ign. 7.5A T. Radio / Auxiliary Function (K23)
F3. Hazard Warning Lights 7.5A F18. Heated Mirrors 15A
F4. Rear Wash / Wipe 10A F19. Ignition Sensed Relays 3A
F5. Horn Front Wash / Wipe 10A F20. 24V Work Socket Battery 15A
F6. Air Seat Compressor 10A F21. Neutral Start 3A F31. Engine ECM Ignition 5A
F7. Dipped Beam Lights 10A F22. Front Washer Pump 3A F32. Engine ECM Battery 10A
F8. Main Beam Lights 10A F23. Rear Washer Pump 3A F33. Proximity Switch 10A
F9. Front Wiper Motor Park 7.5A F24. Horns 10A F34. Sound Power 3A
F10. Transmission TCU Battery 7.5A F25. Ignition Sensed Equipment 30A F35. Brake Pedal Switch 5A
F11. Transmission TCU Ignition 10A F26. Air Con / Heater 15A F36. 12V Work Socket Battery 15A
F12. Reverse Alarm / Lights 15A F27. Reverse Camera / Monitor 10A F’A’ Auxiliary Body Down 5A
F13. TOC8 Controller Ignition 30A F28. Front Working Lights 15A F’K’ Voltage Converter 20A
F14. Cab Interior Light 5A F29. Rear Working Lights 15A F’L’ Engine ECM Battery 10A
F15. Direction Indicators 5A F30. Rotating / Flash beacon 5A F’M’ Instrument Panel CPU Bat (+) 15A
20
F61 / F62 Power Fuses
Inside Battery Box

21
Power Circuit
N
22
Power Circuit
23
Power Circuit
24
ZF Control Software - EST37(A)
Electronic Control For Automatic Transmissions
EST Software;
EST 37 6009 065 XXX - Historical
EST 37A 6009 092 XXX - Current Build
SOFTWARE PROGRAMS ARE NOT COMPATIBLE
EST Hardware;
EST 37 6009 365 005 - Historical
EST 37A 6009 365 007 - Current Build
*NEVER USE 6009 365 001
Serial Data Plates Mounted on TCU

25
Non - RPC Control
PRESSURE APPLY - SPRING RELEASE

26
RPC Clutch Control
• Rotational pressure now assists clutch

application.
• Constant standby pressure of 0.6-1.0 bar
reduces reaction times.
• Cup spring and flow through discs removes
disc application.
• Improves shift quality and torque control.
LUBE +
STANDBY
PRESSURE
LUBE
PRESSURE
27
Transmission Diagnostic VDU

Display During Operation
1 Bar Manual mode 1st gear
2 Bars Manual mode 2nd gear
3 Bars Manual mode 3rd gear
4 Bars Manual mode 4th, 5th & 6th gears
4 Bars & 2 Arrows Automatic mode
Bars Flashing Converter lock-up clutch open
Spanner At least 1 fault code active - select
neutral gear to view fault.
Left & right character

Normal operation - Will display actual gear and direction
Example;1F, 1R, 2F, 2R, 3F, 3R, 4F, 5F, 6F
LF or LR limp home gear
NN Not in Neutral, waiting for neutral after severe fault or
power up.
** Oil temp too low, no gear available
*N oil temp low, only 1 gear available
Fault mode will display all 2 figure active fault codes.
The truck should be stopped when a fault code is displayed. Fault

code should be investigated and rectified. ZF DISPLAY
28
VDU Display – Main Dash Screen
No fault codes will

be displayed on the
main dash VDU.
Gear Selected
29
ZF Operating Codes
Symbol Fault Description

LR Limp Home - Reverse
LF Limp Home - Forward
WS Sump Temperature Warning
WR Retarder Temperature Warning
WT Torque Converter Temperature Warning
WV Velocity Warning on Output Speed in 6th gr @2600RPM
WE High Engine Speed Warning @ 2500RPM
WL Warning Load - Input Torque Too High
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)
30
ZF Failure Operating Levels
• 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.
31
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
•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.
32
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
•VPS2 Voltage supply to auxiliary functions
VPS2 to Lock-Up - Wire #534 Output to X9:8 – X1:8 / 53
VPS2 to Retarder - Wire #544 Output to X9:10 – X1:8 / 53
VPS2 to Diff-Lock - Wire #554 Output to X9:12 – X1:8 / 53
•ADM1 to ADM8 Output signals to auxiliary functions
ADM1 to Warning Lamp - Wire #844 Output to X7:12 – X1:52
ADM2 to Reverse Warning - Wire#808 Output to X7:3 – X1:7
ADM4 to Sound Power 1st Gear Restriction - Wire#848 Output to X7:13 – X1:5
ADM5 to Retarder - Wire#540 Output to X9:9 – X1:57
ADM6 to Diff-Lock - Wire#550 Output to X9:11 – X1:11
ADM7 to Lock-Up - Wire#530 Output to X9:7 – X1:34
33
Checking Fault Codes
Fault Meaning of Code TCU Reaction Checks
Code Possible Reasons For Faults
B1 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral ·check pressure at clutch K1
TCU calculates a differential speed at closed clutch K1. OP-Mode: limp home ·check main press. in system
If this calculated value is out of range, TCU interprets if failure at another ·check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
·low pressure at clutch K1 TCU shifts to neutral ·check sensor gap at output
·low main pressure OP-Mode: TCU shutdown speed sensor
·wrong signal at internal speed sensor ·check signal at internal
·wrong signal at output speed sensor speed sensor
·wrong size of the sensor gap ·check signal at output
·clutch is defective speed sensor
·replace clutch
D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 •check cables and connectors
TCU measures more than 6V at the pin AU1 to sensors, supplied from
(5V sensor supply) AU1
•check power supply at pin
AU1 (should be approx. 5V)
D5 ERROR AT SWITCH 1 FOR VALVE SUPPLY VPS1 Shift to Neutral ·Check Fuse
TCU switched on VPS1 and measured VPS1 is off or OP-Mode: TCU Shutdown ·check cables from gearbox
TCU switched off VPS1 and measured VPS1 is on to TCU
*Cable or connectors are defect and are contacted to ·check connectors
battery voltage ·replace TCU
*Cable or connectors are defect and are contacted to
vehicle ground
*Permanent power supply at KL30 missing
*TCU defect
34
Sensors
35
6WG260/310 Sensors
9 10 2
4
4 K2 KR KV K4
5 K3 K1
6 Y
8
7
1 DETAIL Y
3
1. Retarder Oil Temp. Sensor 2. Main Control Valve 3. Diff. Lock Solenoid 4. Lock Up Solenoid
5. Engine Speed Sensor 6. Output Speed Sensor 7. Central Gear Train Sensor 8. Turbine Speed Sensor
9. Oil Temp. Sensor (Gauge) 10.Breather KV, KR, K1 etc. Supply Ports to Multi-Disc Clutches
36
6WG260/310 Speed Sensors
8 - Turbine Speed Sensor

7 - Central Gear Train Sensor
6
5 - Engine Speed Sensor
6 - Output Speed Sensor
37
Speed Sensor Data Sheet
Inductive Transmitters
(Engine, Turbine & Central Gear Train)
Resistance 1050Ω (±10%) @ 20°C
Temperature Range -40°C to +150°C
Torque Limit 30Nm
Data for ‘Hall-Sensor’ of the Output
(At sensor or with X8 / X9 disconnected)
Temperature Range -40°C to +150°C
Working Range 2hz - 5khz
Supply / Return ∞
Supply / Signal ∞
Signal / Return 460 kΩ
Supply Voltage 24V
38
Speed Sensor Check Locations
All Transmission Range
Engine Speed Sensor (B13) Plug X8 Pins 1 & 2

Turbine Speed Sensor (B13) Plug X8 Pins 3 & 4
Central Gear Train Sensor (B13) Plug X8 Pins 5 & 6
Transmission Output Speed (B13) Return Plug X8 Pin 21

Signal Plug X8 Pin 22
Supply Plug X9 Pin 1
39
Speed Sensor Setting
Inductive Transmitter
Setting Dimension (S)
INDUCTIVE TRANSMITTER
Engine Sensor
0.5+0.3mm
Turbine Speed Sensor

0.5+0.3mm
Central Gear Train Sensor Speed Sensor (Hall Sensor)

0.3±0.1mm
Speed Sensor (Hall)

1.0 - 1.5 mm
40
Retarder Temperature Switch
Temperature
Gauge Sender
Retarder
Temperature
Switch (B32)
(B32)RATING 800Ω - 1500Ω CHECK PLUG X9 PINS 15 & 16

B32 ACTS AS BOTH CONVERTER & RETARDER TEMPERATURE SWITCH
RECORDS RETARDER TEMPERATURE WHEN FUNCTION IS SELECTED
41
Transmission Fan Drive Temperature Switch – Without Retarder Option
Retarder Temp.
Sw. Removed (B32)
Harness Remains
Fan Drive Temp.
Switch (B35)
Temp. Gauge
Sender (B21)
To VDO Panel
No C3 or B8 Fault Codes will be recorded

42
Sump Temperature Sensor
SENSOR DATA
B21
RESISTANCE
1000Ω - 1500Ω
CHECK (B21)
Plug X8 Pins 14 & 15
43
Sensor Electrical Checks - Schematical
44
Temperature Warning Trigger Points
SUMP TEMPERATURE
WARNING ON WARNING OFF FAULT ON FAULT OFF
WS B7
6WG210 102 100 112 110
6WG260 111 108 115 113
6WG310 111 108 115 113
RETARDER TEMPERATURE
WR B8
6WG210 ~ ~ ~ ~
6WG260 145 140 150 145
6WG310 145 140 150 145
CONVERTER TEMPERATURE
WT C3
6WG210 120 115 125 120
6WG260 120 115 125 120
6WG310 120 115 125 120
(°C)
45
Gear Shift Control

46
Hydraulic Control Valve
6WG260/310
47
Proportional Control Valves
CHECK
Plug X8
Pins 7 thru 13
DATA; Resistance Current Pressure Range

19Ω (±10%) @ 20°C 180 - 500mA 0.8 bar - 8.3 bar
Y1-(KR) 100 - 500mA
48
Proportional Control Valve Schematic
DEFINITIONS; FROM TRANSMISSION

HDV MAIN PRESSURE VALVE (16 BAR) PUMP VIA FILTERS
RV-9 PRESSURE REDUCTION VALVE (9 BAR)
NFS FOLLOW ON SLIDE
MAIN PRESSURE
D VIBRATION DAMPER
CONTROLLED MAIN PRESSURE
B ORIFICE
Y1-Y6 PRESSURE REGULATOR PILOT PRESSURE
P1-P6 PROPORTIONAL VALVE CONVERTER INLET PRESSURE
49
6WG260/310 Proportional Valve/Clutch Engagement
Pressure Regulator Under Voltage

Driving Direction Speed Y1 Y2 Y3 Y4 Y5 Y6 Engaged Clutches
Forward 1 X X K1 KV
2 X X K4 K1
3 X X KV K2
4 X X K4 K2
5 X X K3 KV
6 X X K4 K3
Reverse 1 X X KR K1
2 X X KR K2
3 X X KR K3
Engaged Clutch KR K4 K1 K3 KV K2
Valve Block ID F E D C B A
Measurement Point 55 60 56 58 53 57
50
6WG260/310 Proportional Valve Schematic
PLUG X8:
PIN 13 COMMON
VREF
PIN7 Y1 GND
PIN8 Y2 GND
PIN9 Y3 GND
PIN10 Y4 GND
PIN11 Y5 GND
PIN12 Y6 GND
51
6WG260/310 Hydraulic Pressure Measurement
Measuring Points for Hydraulic Oil Pressure (Z.F. I.D.)

No. Position Description Pressure Valve Mark
51 In Front of Converter 8.5 bar H
52 Behind Converter 5 bar
53 ‘KV’ Forward Clutch 16+2 bar B
55 ‘KR’ Reverse Clutch 16+2 bar F
56 ‘K1’ Clutch 16+2 bar D
57 ‘K2’ Clutch 16+2 bar A
58 ‘K3’ Clutch 16+2 bar C
60 ‘K4’ Clutch 16+2 bar E
65 System Pressure 16+2 bar K
67 Lock-Up Pressure 14±1 bar
52
6WG260/310 Hydraulic Pressure Check Points
(K1) (K3)
(K4)
(KV)
(KR) (K2)
(F/CONV.) (L/U) (SYS.)

53
Hydraulic Pressure Check Points
CHECKING CLUTCH SOLENOID PRESSURES 
Utilise connections provided for converter & system pressures.
Move connector to appropriate check point on control valve & attach
pressure gauge to either point ‘C’ or ‘S’ inside the battery box to
monitor pressures.
R Diagnostic Check Points:

R = Retarder Pressure
C C = Converter Pressure
S = Transmission System Press.
S
Gear shift Control – Selecting Gear
Function
Button
To select gear the procedure is as follows:
1. Press the function button from neutral and Forward

move the gear lever forward to select  Upshift
automatic mode forward.
2. Press the function button from neutral and
move gear lever back to select automatic
mode reverse.
Reverse
3. Pressing the function button when in drive  Downshift
mode will change between automatic and
manual mode operation.
4. In manual mode an upshift or downshift can
be made by pushing the lever to the right or
left.
NOTE: When in manual mode, if the engine RPM drops below lock
up disengaging rpm the transmission will automatically downshift
to the next lowest gear. A manual up shift will only be accepted if
the transmission is in lock up.
Gear shift Control – Stall / Clutch Test Function
Button
When performing a stall test the following
procedure has to carried out to allow manual
Forward
selection of individual gears with the truck at
 Upshift
standstill.
1. Press the function button from neutral and

move the gear lever forward to select
automatic mode.
2. Press function button 5 times within 4 Reverse
 Downshift
seconds.
3. Manually select gear by pushing the lever
to the right or left.
Gearshift Control - Diagnostic Check 56
Codes 11,12 & 15
Continuity Check
N - Pins 2 & 5
F - Pins 2 & 4
R - Pins 2 & 6
Up - Pins 2 & 7
Down - Pins 2 & 8
Button - Pins 2 & 10
Continuity should be seen only

between 2 pins at any time
57
Gearshift Control - Diagnostic Check
2
3 Plug X2
1
Z.F. Harness
4
7
3, 2, 1
10 6, 5, 4
9, 8, 7
N - Pins 2 & 5 12, 11, 10
F - Pins 2 & 4
R - Pins 2 & 6
Up - Pins 2 & 7
Down - Pins 2 & 8
Button - Pins 2 & 10
58
Clutch Calibration
X25
TEL No. 15273664
When to conduct calibration:

 Initial start up at factory
 After first 500 hours of service
 If rough gear shifts become evident
 F6 code becomes active
 When a TCU, control valve or gear box/clutch pack is replaced
Clutch Calibration Procedure 59
Step Display Message Remark

1. Warm up transmission oil Normal operating messages
2. Turn off ignition
3. Insert AEB starter to X25 connection
4. Ensure gear lever is in Neutral (N)
Ensure Park/Emergency Brake is applied
5. Start Engine PL TCU must recognise PL
for at least 2 seconds prior
to pressing the AEB
starter button.
6. Set engine RPM to low idle PL
7. Press and hold button on AEB starter ST Do not release the AEB
button until the TCU has
started the calibration
8. Hold AEB button until calibration has started K1 TCU has started the
calibration and begins to
adjust K1, K2….KR. AEB
starter button can be
released.
9. Wait until calibration is complete OK
10. Turn off ignition and disconnect AEB starter
Display During AEB Mode 60
61
Lock Up Solenoid Check
6WG260/310
EXAMPLE
SOLENOID DATA
RESISTANCE
60Ω - 80Ω
CURRENT
0.25 amp - 0.35 amp
VOLTAGE
24 V
PRESSURE CHECK 67
(67) 13 - 14 BAR
(K22) PLUG X9 - PINS 7 & 8

LOCK-UP AUTOMATICALLY ENGAGES WHEN ENGINE RPM >1300 (TRAVELLING)
Sound Power Circuit 62
Sound Power function

limits engine speed to
1800rpm in 1st gear
manual (K57) and when
tipping the body (K58)
for territories where
noise legislation is in
place.
X7: Pin 13 to X1: Pin 5

Y
Y
Sound Power Circuit Fault Codes 63
Fault Meaning of Code TCU Reaction Checks

Code Possible Reasons For Faults
18 S.C. TO BATTERY VOLTAGE AT ADM4 No reaction ·check cables from TCU to
TCU detected a wrong voltage at output pin, relay.
that looks like a s.c. to the battery voltage ·check connectors from TCU
·cable is defective and is contacted to battery voltage to relay.
·relay has an internal defect ·check the resistance of
·connector pin is contacted to battery voltage relay
19 O.C. AT ADM4 No reaction ·check cables from TCU to

TCU detected a wrong voltage at output pin, relay.
that looks like a s.c. to the battery voltage ·check connectors from TCU
·cable is defective and has no connection to TCU to relay.
·relay has an internal defect ·check the resistance of
·connector has no connection to TCU relay
64
Kickdown Function
Kickdown Function
 Kickdown is a tranmission mode that

changes the shift schedule to allow earlier
downshifts and later upshifts.
 Kickdown is activated by pressing the

throttle pedal to the maximum travel
position and holding. This activates the
switch (S74) on the pedal.
 Kickdown can only be utilised in

automatic mode and will deactivate when
the throttle is released.
S74
S69
Kickdown 66
Kickdown
function is
activated by
switch S74.
X7: Pin 16
to
X1: Pin 22
67
Differential Lock
68
Transmission Differential Lock

Operation of the transmission differential lock
request switch sends a signal to the
transmission ECU requesting activation of the
transmission differential lock.
• Engaging operating parameters

• Vehicle speed less than 5 km/hr
• The differential lock warning lamp will be

Transmission
Diff Lock
illuminated when the differential lock is Request (S60)
activated.
• With the transmission differential lock

applied the front and rear drive shafts will
be rotating in a 1:1 power ratio
Main Dashboard LED Cluster

Transmission Differential Lock Solenoid 69
Y7
Cross Axle Differential Lock Solenoid 70
Definitions:
Y7 Diff. Lock Solenoid (X-Axle)
40 bar from port DL on Main
Valve. Generated by Pressure
Reducing Valve (9).
S107
Y7
Cross axle diff-lock switch is inactive unless the

transmission diff-lock switch (S60) is activated.
Powershift Differential Lock 71
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)
Powershift Differential Lock 72
TORQUE SPLIT 1:3 TORQUE SPLIT 1:1

DIFF. LOCK DIS-ENGAGED DIFF. LOCK ENGAGED
Differential Lock Operation - Input 73
Differential lock
is requested
through switch
S60.
X7: Pin 8
to
X1: Pin 30
Vehicle speed
must be below
5kph before the
TCU will engage
the diff-lock.
Differential Lock - Output 74
 Relay K27 controls the differential lock.
 The TCU energises K27 by grounding

X9: pin 11 (X1:11).
from F11
Supply
 Pin 12 is 24V VPS2. (X1:8/53)
 Transmission diff-lock solenoid Y7:

 Energised = Diff-lock released
 De-energised = Diff-lock engaged
 Cross axle diff-lock solenoid Y7 can

only be operated by switch S107 when
the transmission diff-lock is applied
S107
Differential Lock Coil Ratings 75
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)

76
Transmission Retarder (Option)

Transmission Retarder - Option 77
Definitions:
Y3 Retarder Solenoid
Y7 Diff. Lock Solenoid (X-Axle)
CT3 Pressure Reducing Valve
5.5 bar MAX
Y3
S107
Y7
CT3
Transmission Retarder (Option)
Operation of the retarder request switch
sends a signal to the transmission ECU
requesting activation of the transmission
retarder. Retarder
Request
• Operating parameters S81
• Foot off the gas

• Transmission lock up clutch engaged
• Transmission check lamp is OFF
• Activation of the retarder request switch

disables the engine brake function.
• The retarder will apply automatically if the

engine enters an overspeed condition.
• Off throttle;
ON = 2150 rpm, OFF = 1650 rpm
• On throttle;
ON = 2600 rpm, OFF = 2450 rpm
79
Down Hill (Grade) Descent

Trans. Retarder: Before the machine starts down the grade, request the transmission retarder and release the
accelerator. For maximum retardation, oil circulation and cooling, the machine downgrade speed (retarder applied)
gear is recommended to be preselected manually. The manually preselected gear should be high enough to keep the
engine operating at governed speed. Generally the gear used to ascend a grade, fully laden, is also correct for its
descent.
Retarder Schematic 80
X8 X9
Y3 RETARDER SOLENOID
CHECK PLUG X9 PINS 9/10
RATINGS;
14 Watts
41
0.6 Amp
81
• Transmission Retarder (Option)

• Retarder Pressure Check
Retarder Pressure Check - Typical 82
 RETARDER CHECK HARNESS

• Yellow/White connect ground (-) = ADM5 • START ENGINE AND ALLOW TO IDLE
• Blue/Black connect positive (+) = VPS2 • 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)
Transmission Retarder Pressure =

5.5 b (80lb/in2) MAX
R
CONNECT APPROPRIATE PRESSURE GAUGE

RETARDER PRESSURE WILL RISE. COULD
TAKE UP TO 30-40 SECS TO STABILISE.
Retarder Spool 83
Activation Pressure
Retarder Valve Not Switched
To Lubricant
From Heat Exchanger
To Retarder
Breather
From Retarder
To Heat Exchanger
After Converter
To Lubrication
Retarder Layout 84
85
Communication
J1939 CAN_Bus Circuit 86
Plug X4
CAN_Bus Circuit - Transmission Side Check transmission CAN resistance direct @
87
CAN H (+) Pin 25 TCU across Pins 25/27 with X1 connector off.
To Engine
ECM
Target figure = 120Ω
Connection  CAN L (-) Pin 26 With X1 connected - Pins 26/27 are internally
Shield Pin 28 bridged via the WP harness splice.
With X1 connected - the 120 Ω resistance could be
checked at pins 25/26 or 25/27
CAN_Bus Circuit – TCU Resistance Check 88
Transmission TCU
23 1
45 24
68 46
Check transmission CAN resistance direct @ TCU across Pins 25/27 with X1 connector off.
Target figure = 120Ω
With the X1 connected - Pins 26/27 are internally bridged via the WP harness splice.
With the X1 connected - the 120Ω resistance could be checked at pins 25/26 or 25/27
With the X1 connected, the 120Ω TCU resistance can also be checked at the X4 connection Pins 1/2.
Remember to disconnect the engine harness from the X4.
CAN_Bus Fault Codes 89
ZF Fault Codes
56 - Timeout of CAN message Engine CONF from Engine ECM
57 - Timeout of CAN message EEC1 from Engine ECM
58 - Timeout of CAN message EEC3 from Engine ECM
65 - CAN signal for engine torque is defective
66 - CAN signal for engine torque is defective
69 - CAN signal for reference of engine torque is defective
6A - CAN signal for actual engine torque is defective
6B - CAN signal for nominal friction torque is defective
6E - Timeout of CAN message EEC2 from Engine ECM
CA – Engine retard config timeout
CB – ERC1 Timeout
CAN_Bus Fault Codes 90
• Interference on CAN_Bus
56,57,
• Engine controller is defective
58,6E,
CA,CB • CAN wire/connector is broken
• CAN wire/connector defective / has contact to vehicle
ground or battery voltage
65,69, • Engine controller is defective

6A,6B • Interference on CAN_Bus
• If 65 & 6A – Low Engine RPM possible
CODES CAN BE CAUSED BY LOW ENGINE RPM & DIRTY FUEL FILTER
Measurement On CAN_Bus 91
USING DIGITAL MULTIMETER - RESISTANCE ()

IGNITION OFF. ALL CONTROLS HAVE TO BE CONNECTED
MEASUREMENT BETWEEN SPECIFIED VALUE ACTUAL VALUE POSSIBLE CAUSE

CAN_H (X4 PIN 1) 60 Ω 0.1 Ω Short circuit from CAN_H
to CAN_L
Or diagnostic pin C
Resistor failure or open
RED PROBE 60 Ω 120 Ω
circuit
AND
CAN_L (X4 PIN 2)
Or diagnostic pin D 60 Ω ∞Ω
Open circuit
BLACK PROBE
Measurement On CAN_Bus 92
USING DIGITAL MULTIMETER - VOLTAGE(V)

IGNITION ON. ALL CONTROLS HAVE TO BE CONNECTED
MEASUREMENT BETWEEN SPECIFIED VALUE ACTUAL VALUE POSSIBLE CAUSE
CAN_H (X4 PIN 1) 24 V S.C. from CAN_H to
battery
Or diagnostic pin C
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
Or diagnostic pin D 2.2 V - 2.7 V
S.C. from CAN_L to
0V
RED PROBE ground
AND 0 V - 2.1 V S.C. from CAN_L to an
2.8V - 24 V auxiliary component.
GROUND - BLACK PROBE
CAN_Bus Circuit Connection Points 93
QSM
 Engine 50-Pin OEM Connection on QSM engines. 50 PIN OEM
CONNECTION
 Cab bulkhead connections – 48 Pin Bulkhead

CAN-H Pin 32
CAN-L Pin 36
Shield Pin 18
 Transmission X1 and X4 TCU connections. Located below instructor

seat.
X1 - 68 Pin TCU Connection
X1
X4 - 4 Pin Communication Connection
CAN_Bus Circuit - Continuity Checks 94
Based on QSM Circuit

CAN_H Continuity - Check for continuity between Transmission X1 Pin 25 and Engine OEM
connector Pin 46. Shake wire, check for loose connection
 CAN_L Continuity - Check for continuity between Transmission X1 Pin 26 and Engine OEM
 CAN Shield Continuity - Check for continuity between Transmission X1 Pin 28 and Engine OEM
50 PIN OEM
CONNECTION
Transmission X1 Connection
95
Oil Filtration
6WG260/310 Transmission Filter 96
>50°C & <2000RPM
1000 Hr.
TEL No: 15274198
Code BA
Filter Bypass Switch 97
Oil @ Operating Temp Transmission Filter

Terex ID. S90
ZF ID. S10
Plug X9 - Pins 17 & 18

Connected Open circuit or 500 Ω
Transmission Filters 98
ACCEPT NO SUBSTITUTE
Transmission Oil Levels 99
Notes; Cold Fill

Level Hot Level Cold Level
Cold Level Running Oil Temp 40°C (104°F) Minimum Band Engine
Hot Level Running Oil Temp 80°C (176°F) Engine Engine Running
Oil returns to sump and raises oil up
Off Running Minimum
dipstick tube.
Hot Level Cold Level

Band Engine
Engine Running
Running Minimum
Max Min
100
Transmission Cooler Oil Fill
Bleed
Hose
WARRANTY BLEED
DEFAULT SCREW
FILL
ENSURE TRANSMISSION COOLER IS COMPLETELY FILLED PRIOR TO COLD

START. PARTICULARLY IMPORTANT AFTER COMPLETE SYSTEM DRAIN.
101
Diagnostic Tools
102
ZF Diagnostic Tools
ZF TestMan Part Number:
15501299
6WG210/260/310 Software
Part Number:
15501300
AEB Starter Part Number:
15273664
103
Terex Equipment Limited

Motherwell, ML1 5RY
Scotland
+44 (0)1698 732121
+44 (0)1698 734046
Web
www.terex.com
Technical Online Assistance

http://constructionsupport.terex.com

Product Training: Articulated Dump Truck TA250: TA300 ZF Transmission Controls

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Product Training: Articulated Dump Truck TA250: TA300 ZF Transmission Controls

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Product Training

Articulated Dump Truck

Terex Centre of Excellence

Electrical Schematics and Generic Components

Making Weld Repairs

Before welding on vehicle:

No. of Forward Gears kW Input Capability of

Central Gear Train

Transmission Control Unit

Liquid Crystal Display

S32 BODY PROXY SW.

LOAD SENSOR ADM4 SOUNDPOWER OUTPUT

B1 ENGINE SPEED SENSOR B9 RET. TEMP

KEY; Y7 LOCK-UP SOLENOID

VPE1/2 Battery Voltage (Constant) F10

VPS1 Voltage supply to clutch activation solenoids

VPS2 Voltage supply to auxiliary functions

ADM1 to ADM8 Output signals to auxiliary functions (-) ground apply

A?? Outputs from TCU to Main Control Valve

VM?? Ground (-)

Cab Bulkhead Connectors A / B

Connector E – Chassis Side

Tractor / Trailer Chassis Bulkhead Connector H – Tractor Side Sockets

Mounted Under Instructor Seat

Inside Battery Box

Serial Data Plates Mounted on TCU

PRESSURE APPLY - SPRING RELEASE

• Rotational pressure now assists clutch

Transmission Diagnostic VDU

Left & right character

The truck should be stopped when a fault code is displayed. Fault

VDU Display – Main Dash Screen

No fault codes will

Symbol Fault Description

2. Substitute Clutch Control

•Effect: Normal clutch modulation during shifts is replaced by a simple

•Effect: The TCU can select one gear in each direction.

8 - Turbine Speed Sensor

All Transmission Range

Engine Speed Sensor (B13) Plug X8 Pins 1 & 2

Transmission Output Speed (B13) Return Plug X8 Pin 21

Turbine Speed Sensor

Central Gear Train Sensor Speed Sensor (Hall Sensor)

Speed Sensor (Hall)

(B32)RATING 800Ω - 1500Ω CHECK PLUG X9 PINS 15 & 16

No C3 or B8 Fault Codes will be recorded

Gear Shift Control

DATA; Resistance Current Pressure Range

DEFINITIONS; FROM TRANSMISSION

Pressure Regulator Under Voltage

Measuring Points for Hydraulic Oil Pressure (Z.F. I.D.)

(F/CONV.) (L/U) (SYS.)

R Diagnostic Check Points:

1. Press the function button from neutral and Forward

1. Press the function button from neutral and

Codes 11,12 & 15

Continuity should be seen only

TEL No. 15273664

When to conduct calibration:

Step Display Message Remark

(K22) PLUG X9 - PINS 7 & 8

Sound Power function

X7: Pin 13 to X1: Pin 5