CONTROLES TRANSMISIÓN ZF (2) TA25/27/30 (A825/828/847/850)
300804
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COMUNICACIÓN ENTRE MOTOR / TRANSMISIÓN CAN-BUS 120Ω Engine ECU END USER
Trans. EST37
60Ω
E.C.U
E.C.U 120Ω 120Ω
120Ω 120Ω 120Ω 120Ω
Can L
Can H
1 - Ca Can H
2 - Ca Can L
Codes 56-58, 65, 66, 69, 6A, 6B, 6E
Plug X4 2 2
COMUNICACIÓN ENTRE MOTOR / TRANSMISIÓN CAN-BUS 120Ω Engine ECU END USER
Trans. EST37
60Ω
E.C.U
E.C.U 120Ω 120Ω
120Ω 120Ω 120Ω 120Ω
Can L
Can H
1 - Ca Can H
2 - Ca Can L
Codes 56-58, 65, 66, 69, 6A, 6B, 6E
Plug X4 2 2
MEDIDAS EN EL CAN-BUS USING USING DIGITAL DIGITAL MULTIMULTI-MET METER ER - RESIST RESISTANCE ANCE ( ) IGNITION OFF. ALL CONTROLS HAVE TO BE CONNECTED MEASUREMENT BETWEEN CAN H (X4 PIN 1) RED PROBE AND CAN L (X4 PIN 2) BLACK PROBE
SPECIFIED VALUE ACTUAL VALUE 40 Ω 0Ω 40 Ω
40 Ω
3 3
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
MEDIDAS EN EL CAN-BUS 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 GROUND - BLACK PROBE
4 4
SPECIFIED VALUE ACTUAL VALUE 24 V 2.4 V - 2.9 V
0V 0 V - 2.3 V 3.0 V - 24 V 24 V
2.2 V - 2.7 V
0V 0 V - 2.1 V 2.8V - 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.
POSICIÓN DEL ACELERADOR Terex I.D. B19
REFER. TO ENGINE & COOLING
TRAINING FOR DETAILED OPERATION.
KICK-DOWN MECHANICAL FEEL 5 5
PEDAL ACELERADOR
THROTTLE POTENTIOMETER - B19
KICKDOWN MICROSWITCH - S74 IDLE VALIDATION SWITCH - S69
6 6
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 8 8
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)
9 9
TRABA DIFERENCIAL TRANSMISIÓN
Y7
10 10
INTERRUPTORES TRABA DIFERENCIAL & RETARDADOR D - Diff. Lock Request Switch (S60) R - Retarder Request Switch (S81)
D
R
1
1 - Diff. Lock Indicator Lamp Ref. Next Slide
2 - Not Used
2 Differential Lock Indicator Lamps
11 11
OPERACIÓN TRABA DIFERENCIAL OPERATOR WARNING
1
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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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
13 13
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
14 14
IDENTIFICACIÓN RELEVOS
1 2
2 4
3 6
4 8
K 1 7
K 2 3 K 2 3
K 1 5
1
15 15
1 3
2 5
3 7
K 5 K 5 1
K27
K 5 2
K 2 3
K 1 4
K 3 4
K 3 2
K 5 0
K 3 3 K 4
K 2 7 K 2 3
VALORES BOBINAS SOLENOIDES
Y7 Diff-Lock Solenoid (Axle) 14 watt Y3 Retarder Solenoid 14 watt Y7 Transmission Diff-Lock 19watt
41Ω 41Ω 30Ω
0.6amp 0.6amp 0.8amp
(Approx. figures rated for 24 Volts)
Electrical Formula (Click Here)
16 16
POWERSHIFT DIFF-LOCK Torque Split 1:3 (Dis-Engaged) Torque Split 1:1 (Spring Engaged)
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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)
DIFFERENTIAL LOCK - TORQUE SPLITTING
TORQUE SPLIT 1:3 DIFF. LOCK DIS-ENGAGED
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TORQUE SPLIT 1:1 DIFF. LOCK ENGAGED
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); 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.
R
19 19
REARDADOR / PEDAL FRENO
Brake Pedal Interface Module (N5) 20 20
Brake Pedal Potentiometer (B36)
PEDAL INTERFACE BOX 1
2
BRAKE LIGHT OUTPUT SIGNAL
(WHITE)
BRAKE LIGHT 0V
(BROWN)
RETARDER 0V
(GREEN)
RETARDER OUTPUT SIGNAL
(ORANGE)
(+)BATTERY
(RED)
(-)BATTERY
(BLACK)
1 - K50 RELAY (STOP LAMPS) 2 - K51 RELAY (RETARDER SELECT)
X O B E C A F R E T N I L A D E P
(VIOLET)
SIG
(BLUE)
0V
(GREY)
+5V
R E L E T A D M E P T I O N E T O P
OPERATION; PEDAL POTENTIOMETER WORKS ON 0 TO 5 V SCALE. RELAYS ARE ACTIVATED WHEN PEDAL POTENTIOMETER >1V. THIS ALLOWS 24V (FUSED) FROM BUSBAR 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°) 21 21
IDENTIFICACIÓN RELEVOS K50
1 2
2 4
3 6
4 8
K 1 7
K 2 3 K 2 3
K 1 5
1 1
1 3 1 3
2 5 2 5
K50 STOP LAMPS 22 22
K 5 2
K 2 3
K 1 4
K 3 4
K 3 2
K 5 0
K 5
K 3 3 K 4
K 2 7 K 2 3
K 5 1
3 7 3 7
K51
K51 RETARDER SELECT
DIAGRAMA ELÉCTRICO RETARDADOR
B36 K51
23 23
BRAKE PEDAL POTENTIOMETER RETARDER RELAY
N5 BRAKE PEDAL INTERFACE MODULE S81RETARDER REQUEST SWITCH
DIAGRAMA SOLENOIDE RETARDADOR X8
Y3 RETARDER SOLENOID CHECK PLUG X9 PINS 9/10 RATINGS; 14 Watts 41Ω 0.6 Amp
24 24
X9
REVISIÓN SOLENOIDE RETARDADOR
Check; Plug X9 - Pins 9 & 10
Y3
Retarder Solenoid Terex I.D. Y3 Z.F. I.D. Y8 25 25
Retarder Solenoid 14 watt
41Ω
0.6amp
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 . 26 26
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
27 27
FILTROS TRANSMISIÓN >50°C & <2000RPM
T.E.L. No. 15274198 Code BA
TA25 SWITCH
1st 500 Hr. 1000 Hr. 28 28
FILTROS TRANSMISIÓN
NO SE ACEPTAN SUBSTITUTOS
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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 Switch Disconnected Switch Connected 30 30
5V 14 V 500 Ω
BOMBA EMERGENCIA DIRECCIÓN
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CÓDIGOS DE FALLA 1 st Digit
1 2 3 4 5 6 7 8 9 A B C D E F
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Fault Description
Actual Error Source
Digital Input Signal Analog Input signal Speed signal CAN Signal Error(Not Used) CAN Signal Error CAN Signal error Analog Current Output Signal Analog Current Output Signal Digital Output Signal Digital Output Signal Trans. Error, Clutch Error Logical Error Power supply High Speed Signal General Error
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
WS WR WT WE F or R Flash
Fault Description
Sump Temperature Warning Retarder Temperature Warning Torque Converter Temperature Warning High Engine Speed Warning Gear Selected While Turbine Speed Too High (CAUTION Gear Will Engage When Turbine Speed Drops)
EE
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No Communication At Display(LCD)
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 transmissio n cont rol . Fault co uld be on a second ary device, i.e. torque converter lo ckup c lutch defective. •Effect: TCU will work witho ut or with little limitations. Second ary device cannot be used, truck m ay have some performance limitations, ie power, speed and temperature. i.e. lockup clutch cannot be closed running in con verter continually.
2. Substitute Clutch Control •Case:
Significant fault, i.e. speed senso r failu re
•Effect: Normal clutch modulation during shifts is replaced by a simple time dependant modu lation. Results in poor s hift quality.
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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 shif ts to Neutral wh en the fault is firs t detected and a fault code is displayed. The vehicle must be stopp ed and the operator must s hift t he gear selector into n eutral positi on. The operator can then shift into either for ward or reverse, the TCU will th en select an approp riate limp ho me gear. The vehicle will mov e witho ut upor downshift.
4. Transmission Shutdown •Case:
The TCU has detected a safety critical fault. The TCU will shut down all solenoid v alves for clutch activation by disabling th e comm on power supp ly (VPS1). i.e. gear s elector failure VPS1 - Wire #908 Outpu t to X8:13
•Effect: Transmission shif ts to Neutral when the fault is detected first and a fault cod e is displ ayed. The operator mus t slow the vehicle to a stop. The vehicle cannot m ove furt her on as long as fault persis ts.
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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 contr ol of t he EST system. •Effect: Transmission s hifts to Neutral when the fault is detected and a fault code is di splayed. Power supply for all solenoids is switched off and also all co mmon volt age supplies VPS1 and VPS2. All func tion s con trol led by out puts A DM1 to ADM8 are also d isabled. The vehicle cannot mo ve further on. • VPS1 Voltage supp ly to clu tch activation so lenoids •VPS1 - Wire #908 Outpu t to X8:13 •VPS2 Voltage supp ly to auxil iary func tion s •VPS2 to L ock-Up - Wire #946 Outpu t to X9:8 •VPS2 to Retarder - Wire #946 Outpu t to X9:10 •VPS2 to Diff-Loc k - Wire #946 Outpu t to X9:12 • ADM1 to ADM8 Out pu t s ig nal s t o au xi li ary funct ions • ADM1 to Warning Lamp - Wire #452 Outp ut t o X7:12 • ADM2 to Rev erse War ning - Wire#407 Outp ut t o X7: 3 • ADM5 to Ret arder - Wire#457 Outp ut t o X9: 9 • ADM6 to Di ff -Loc k - Wire#411 Outp ut t o X9: 11 • ADM7 to L ock -Up - Wire#434 Outp ut t o X9: 7
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CALIBRACIÓN VELOCÍMETRO
CALIBRACIÓN VELOCÍMETRO (P1) Con llantas estandares
TA25 TA27 TA30
333650 232100 232100 0 1 2
PULSE/Adjust
Señal del velocímetro Desde la transmisión a través del ECU via divisor de frecuencia (N4) ECU X1 Pin 36 cable 436 Tapón X7 Pines 19 a N4 37 37
N4
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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