•Terex

• Equipment Limited:
Terex Equipment Limited:

TA25, TA27, TA30

Level 1 Product Training - Minor Troubleshooting

TEREX Equipment Limited

Newhouse Industrial Estate

TA25, TA27, TA30 - LEVEL 1 TRAINING

• Level 1 Training Schedule

• Safe Working Practice
• Operator Controls
• Routine Service and Maintenance
• Pressure Checks and Setting
• Minor Troubleshooting
• Cummins Q-Series
• ZF EST System
• Hydraulic Controller (TOC8)
• Level 1 - Basic Electrical Testing
• Level 1 - Hydraulic Cleanliness
• Level 1 - Tyre Maintenance
MINOR TROUBLESHOOTING

General Safety Precautions

Proper service and repair is important to the safe, reliable
operation of all motor vehicles. Detailed service procedures
are recommended and described in various TEREX
publications i.e.;
 Maintenance Manuals
 Operators Handbook
 Parts Book
These publications offer effective methods for performing
service operations. Some of these service operations require
the use of tools specially designed for the purpose. The
special tools should be used when, and as recommended.
It is important to note that these publications contain various
WARNINGS and NOTES which should be carefully read in
order to minimise the risk of personal injury, or the possibility
that improper service methods will be followed which may
damage the vehicle or render it unsafe.
All trucks are installed with warning and instruction decals.
These decals also offer guidance towards the safe service,
maintenance and operation of the TEREX truck.
 MINOR TROUBLESHOOTING

Engine Management
QUANTUM ELECTRONIC CONTROL
ISSUED ON QSC, QSL & QSM

Onboard Diagnostics
 Extensive Fault Detection Fault Capability
 Flash Out Fault Codes
 Fault Lamps Located on Dash
 Engine Protection De-Rate System
 Maintenance Lamp Located on Dash

Offboard Diagnostics
 INSITE - Windows based PC
Service/Diagnostic Tool
 QUICKCHECK - Palmtop Service/Diagnostic
Tool
 MINOR TROUBLESHOOTING

Engine Operator Warning

EW ENGINE WARNING LAMP
ES ENGINE STOP LAMP
EW ES EM ENGINE MAINTENANCE LAMP
WL ENGINE WATER LEVEL WARNING
WT ENGINE WATER TEMPERATURE

WT WL EM

1 2
1. DIAGNOSTIC REQUEST SWITCH 
2. DIAGNOSTIC SCROLL SWITCH
 MINOR TROUBLESHOOTING

Retrieving Engine Fault Codes

 ECM WILL DETECT FAULT ON ENGINE

 EITHER ENGINE WARNING OR STOP LAMP WILL ILLUMINATE DEPENDING ON
SEVERITY OF FAULT
 SELECT DIAGNOSTIC REQUEST SWITCH
 THE AMBER WARNING LAMP WILL FLASH ONCE(1) FOLLOWED BY THE FAULT CODE
FLASHED OUT ON THE RED STOP LAMP. THE AMBER WARNING LIGHT WILL THEN
FLASH ONCE(1) WHEN FAULT CODE IS COMPLETE.
 THIS SEQUENCE WILL CONTINUE UNTIL THE DIAGNOSTIC SCROLL SWITCH IS
SELECTED. PUSHING THE TOP OF THE SWITCH WILL ADVANCE TO THE NEXT FAULT
CODE. PUSHING THE BOTTOM OF THE SWITCH WILL RETURN TO THE PREVIOUS
FAULT CODE.
 IF ONLY 1 FAULT CODE IS ACTIVE, THE SYSTEM WILL CONTINUOUSLY DISPLAY
THE SAME FAULT CODE.
 PRESS DIAGNOSTIC REQUEST SWITCH TO EXIT DIAGNOSTIC MODE.
 MINOR TROUBLESHOOTING

Flash Out Engine Fault Codes

RESULT = CODE 235

Fault Code List

Click Here
 MINOR TROUBLESHOOTING

Engine Protection De-Rate

5 PRE-SET PARAMETERS FOR ENGINE DE-RATE

 COOLANT TEMPERATURE  INLET MANIFOLD TEMPERATURE

 OIL TEMPERATURE(QSM ONLY)  OIL PRESSURE
 ENGINE WATER LEVEL

DE-RATE PROGRAMMING WILL DE-RATE; ENGINE SPEED TO 1600 RPM MAX

TORQUE BY 30%
(TORQUE DE-RATE MEANS ENGINE WILL HAVE 70% OF ITS AVAILABLE TORQUE)

ENGINE WILL DE-RATE SPEED & TORQUE FOR OIL PRESSURE ONLY.
ALL OTHER FAULTS ARE TORQUE ONLY. SO TRUCK WILL LOSE POWER NOT
SPEED.
 MINOR TROUBLESHOOTING

Engine Protection De-Rate

DE-RATE PROCEDURE;
THE TRUCK IS EQUIPPED WITH AN ENGINE PROTECTION DE-RATE SYSTEM, WHICH
RECORDS FAULT CODES AND ILLUMINATES APPROPRIATE WARNING LIGHTS WHEN AN
OUT-OF-RANGE CONDITION ASSOCIATED WITH ANY OF THE ABOVE IS DETECTED.

THE OPERATOR WILL BE ALERTED BY THE ENGINE CHECK LAMP WHEN A DE-RATE
CONDITION HAS BEEN INCURRED. THE ENGINE CHECK LAMP WILL FLASH
CONTINUOUSLY WHEN AN OUT OF RANGE CONDITION HAS BE DETECTED. THE ENGINE
STOP LAMP WILL ILLUMINATE WHEN THE OUT OF RANGE CONDITION BECOMES
SEVERE.

THE ENGINE POWER AND/OR SPEED WILL BE GRADUALLY REDUCED DEPENDING ON

THE LEVEL OF SEVERITY OF THE OUT-OF-RANGE CONDITION. THE OPERATOR MUST
SHUT DOWN THE ENGINE TO AVOID SERIOUS DAMAGE.

AFTER ACTIVATION OF THE ENGINE PROTECTION DE-RATE SYSTEM,THE ENGINE

SHOULD NOT BE RESTARTED AFTER IT HAS BEEN SHUT DOWN, UNLESS THE PROBLEM
HAS BEEN DIAGNOSED AND CORRECTED.
 MINOR TROUBLESHOOTING

Engine Maintenance Lamp

 THE MAINTENANCE MONITOR USES DATA RECEIVED
FROM THE ENGINE ECM TO DETERMINE WHEN IT IS TIME
TO CHANGE THE OIL.
 THE ENGINE MAINTENANCE LAMP WILL FLASH FOR
APPROXIMATELY 12 SECONDS AFTER IGNITION KEY ON.
THE FLASHING SEQUENCE WILL BE 3 QUICK FLASHES
FOLLOWED BY A PAUSE. THIS FLASH SEQUENCE WILL GO
THROUGH 5 CYCLES IN THE 12 SECOND PERIOD.
 THIS SEQUENCE WILL OCCUR AT EVERY IGNITION KEY
ON UNTIL THE MAINTENANCE MONITOR HAS BEEN RE-
SET.

MAINTENANCE MONITOR IS DESIGNED TO ALERT THE

OPERATOR OF THE NEED FOR A ROUTINE MAINTENANCE STOP.
MAINTENANCE RECORDS MUST STILL BE MAINTAINED FOR
HISTORICAL PURPOSES.

THE DIAGNOSTIC REQUEST SWITCH WHENEVER AN ELECTRICAL FAULT HAS

MUST BE OFF FOR THE FLASHING OCCURRED, THE MAINTENANCE
SEQUENCE TO OCCUR MONITOR DATA CAN BE INACCURATE
 MINOR TROUBLESHOOTING

Transmission Fault Display

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. MOVE GEAR LEVER TO NEUTRAL(N) AND APPLY
EMERGENCY BRAKE FAULT CODE SHOULD BE INVESTIGATED AND
Transmission Stop Lamp RECTIFIED.
 MINOR TROUBLESHOOTING

Failure Handling 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.
 MINOR TROUBLESHOOTING

Failure Handling Operating Levels

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.
 MINOR TROUBLESHOOTING

Failure Handling Operating Levels

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
• ADM1 to ADM8 Output signals to auxiliary functions
 MINOR TROUBLESHOOTING

Checking Transmission 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
 MINOR TROUBLESHOOTING

Transmission Operator Warnings

Symbol Fault Description

WS Sump Temperature Warning
WR Retarder Temperature Warning
WT Torque Converter Temperature Warning
WE High Engine Speed Warning
WV Warning Velocity at 2600 RPM engine
WL Warning High Load Thru Transmission
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)

ZF Fault Codes
Click Here
 MINOR TROUBLESHOOTING

Clutch Calibration (A.E.B.)

X25

T.E.L. No. 15273664 Step 3 - Calibration Procedure

WHEN TO CONDUCT CALIBRATION

 INITIAL START UP @ FACTORY
 AFTER FIRST 500 Hours OF SERVICE
 IF ROUGH GEAR SHIFTS BECOME EVIDENT
 F6 CODE BECOMES ACTIVE
 WHEN A T.C.U., GEARSHIFT CONTROLLER, CONTROL VALVE OR GEAR
BOX/CLUTCH PACK IS REPLACED
 MINOR TROUBLESHOOTING

Clutch Calibration Procedure

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
AEB Codes
Click Here
10. Turn off ignition and disconnect AEB starter
 MINOR TROUBLESHOOTING

TOC8 Status Indicators

Normal Status Error Status

Green LED - Power On
Yellow LED (Flashing) - Normal Status
Red LED (Flashing) - Error Status
 MINOR TROUBLESHOOTING

TOC8 System Diagnostics

LED Indicators Flashing Sequence

Normal Status (No Errors) Yellow LED (Flashing)

Error Code Red LED (Flashing)

Code 1 - Output Error
Code 2 - Input Error
Code 3 - VREF Error
Code 4 - Supply Voltage Error
Code 5 - Temp. Critical or
Checksum Error
Code 6 - Fatal Software Error

STOP TRUCK
 MINOR TROUBLESHOOTING

Quiz
1. How many engine warning lamps are there on the dashboard?.

A. 5 B. 6

C. 4 D. 3

2. What is the purpose of the engine diagnostic scroll switch?.

A. To read codes faster B. To pause the code sequence

C. To switch between engine and trans. codes D. To advance to next code - to return to previous code

3. How many digits are there in each engine code?.

A. 2 B. 3

C. 4 D. 1

4. How does each engine flash out code begin?

A. Engine stop lamp flashes once B. Engine stop lamp illuminates for 3 seconds

C. Single flash from the engine check lamp D. Engine check lamp flashes continuously for 12 seconds
 MINOR TROUBLESHOOTING

Quiz
7. How many operating fault levels can be activated on the transmission

A. 2 B. 3

C. 4 D. 5

8. What is a ‘WS’ transmission operator warning?.

A. Warning - Stop B. High transmission sump temperature

C. Wait to start D. High speed

9. What is meant by ‘LF’ when displayed on the transmission display?.

A. Low Fuel B. Limited Oil Flow

C. Limp Home - Forward Gear D. Stop Light Failure

10. What transmission fault code is displayed when the transmission and TCU become out of calibration?

A. F7 B. B6

C. F6 D. B7