Zf Controles (4)

CONTROLES TRANSMISIÓN ZF (2)

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

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

120Ω 120Ω END USER Can L Can H

1 - Can H

2 - Can L

Codes 56-58, 65,

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

E.C.U

E.C.U

COMUNICACIÓN ENTRE MOTOR / TRANSMISIÓN CAN-BUS

120Ω

120Ω

60Ω

USING DIGITAL MULTI-METER - RESISTANCE (

Ω)

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 Ω

40 Ω

40 Ω

ACTUAL VALUE

0 Ω

60 Ω or 120 Ω

☺

Ω

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

USING DIGITAL MULTI-METER - VOLTAGE(V)

IGNITION ON. ALL CONTROLS HAVE TO BE CONNECTED

MEASUREMENT BETWEEN

CAN H (X4 PIN 1)

RED PROBE

AND

GROUND - BLACK PROBE

CAN L (X4 PIN 2)

RED PROBE

AND

SPECIFIED VALUE

2.4 V - 2.9 V

2.2 V - 2.7 V

ACTUAL VALUE

24 V

0 V

0 V - 2.3 V

3.0 V - 24 V

24 V

0 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

MEDIDAS EN EL CAN-BUS

POSICIÓN DEL ACELERADOR

Terex I.D. B19

KICK-DOWN

MECHANICAL FEEL

REFER. TO ENGINE & COOLING

TRAINING FOR DETAILED

PEDAL ACELERADOR

THROTTLE

POTENTIOMETER - B19

IDLE VALIDATION

SWITCH - S69

KICKDOWN

MICROSWITCH - S74

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

MÚLTIPLE RETARDADOR & TRABA DIFERENCIAL

Y3

Y7

CT3

Definitions;

Y3

Retarder Solenoid

Y7

Diff. Lock Solenoid (Axle)

RETARDADOR & TRABA DIFERENCIAL

PRESSURE RELIEF SETTING

(RETARDER)

CT3 VALVE

TA27

5.5 bar (80 psi)

TA30

5.5 bar (80 psi)

TRANSMISSION PILOT PRESSURE

TRABA DIFERENCIAL TRANSMISIÓN

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 Used

Ref. Next Slide

OPERACIÓN TRABA DIFERENCIAL

WARNING! - CRITERIA FOR 4

_{TO 6}

_{GEAR IS THAT TORQUE THROUGH}

TRANSMISSION MUST BE BELOW 400Nm.

4

_{TO 6}

_{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 3

_{GEAR - ALL SPEEDS.}

OPERATOR

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

DIAGRAMA TRABA DIFERENCIAL

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

IDENTIFICACIÓN RELEVOS

K27

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

POWERSHIFT DIFF-LOCK

Definitions;

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)

DIFFERENTIAL LOCK -

TORQUE SPLITTING

TORQUE SPLIT 1:3

DIFF. LOCK DIS-ENGAGED

TORQUE SPLIT 1:1

DIFF. LOCK ENGAGED

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 150°C (300°F). 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

REARDADOR / PEDAL FRENO

PEDAL INTERFACE BOX

PEDAL INTERFACE BOX

BRAKE 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

PEDAL INTERFA

CE BOX

PEDAL

POTENTIOMETE

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 <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.

IDENTIFICACIÓN RELEVOS

K51

K50

DIAGRAMA ELÉCTRICO RETARDADOR

B36 BRAKE PEDAL POTENTIOMETER N5 BRAKE PEDAL INTERFACE MODULE K51 RETARDER RELAY S81 RETARDER REQUEST SWITCH

DIAGRAMA SOLENOIDE RETARDADOR

Y3 RETARDER SOLENOID

CHECK PLUG X9 PINS 9/10 RATINGS; 14 Watts 41Ω 0.6 Amp X9 X8

REVISIÓN SOLENOIDE RETARDADOR

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

Y3

Retarder Solenoid 14 watt

41Ω

0.6amp

Check;

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

VÁLVULA RETARDADOR

To Heat Exchanger

>50°C & <2000RPM

T.E.L. No.

15274198

Code

BA

FILTROS TRANSMISIÓN

TA25 SWITCH

FILTROS TRANSMISIÓN

Plug X9 - Pins 17 & 18

Switch Connected

5 V

Transmission Filter

Terex I.D.

S90

Z.F. I.D.

S10

Oil @ Operating Temp

1

_Digit

_{Fault Description}

_{Actual Error Source}

1

Digital Input Signal

Inputs From Shift Lever

2

Analog Input signal

Engine Load Sensors, Temp. Sensors

3

Speed signal

Signal Inputs From Speed Sensors

4

CAN Signal Error(Not Used)

Not Used By Terex

5

CAN Signal Error

CAN-Bus Fault

6

CAN Signal error

CAN-Bus Fault

7

Analog Current Output Signal Gear Selection Signal - ECU to Control Valve

8

Analog Current Output Signal Gear Selection Signal - ECU to Control Valve

9

Digital Output Signal

Outputs From Solenoid Valves

A

Digital Output Signal

Outputs From Solenoid Valves

B

Trans. Error, Clutch Error

Clutch Slippage, Overheat, Pressures

C

Logical Error

Converter Temperature Warning, CAN Fault

D

Power supply

High or Low Voltages to ECU or Sensors

E

High Speed Signal

Signal Between ECU & Display(LCD)

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)

• 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.

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.

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

CALIBRACIÓN VELOCÍMETRO (P1)

Con llantas estandares

TA25

333650

TA27

232100

TA30

232100

PULSE/Adjust

CALIBRACIÓN VELOCÍMETRO

N4

Señal del velocímetro

Desde la transmisión a través del ECU via divisor de

frecuencia (N4)

TIPOS ACEITE TRANSMISIÓN

TIPO ACEITE:

15W40, CH4

INTERVALOS DE SERVICIO:

1

ST

_{500 Hrs}

_{DRENE / RELLENE Y CAMBIE FILTROS}

DEPARTAMENTO SOPORTE AL

PRODUCTO

Para futura información contacte a www.terex.com

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.