We have a 2003 Terex TA27 that just started acting up. It worked fine all summer then sat for a month. In the fall we took it to a field 8 miles away. Once it got there we went to put it in reverse and it just beeps. Investigated it in the field couldn't figure anything out so we brought it to the shop. Once at the shop it started only going in reverse. Once we started looking at it and testing things it wouldn't go in either. We have codes A5, 3A, 3E, and 9B. We have changed the speed sensor, checked solenoids, and got a different shifter and TCU. Changed out those and didn't gain much. We are going to unplug the transmission and see if that helps anything. We think we need to delete codes and would like to do a calibration. Wondering what software is best used. We have a couple computers. One John Deere, and the other has most Truck apps. Hard to find the right tool hoping someone has a easy answer. Thank you
I had an old TA27 a few years back. I found the transmission calibration tool on Ebay. Don't remember the exact price, but it was very reasonable. If I can think of the tool name I will post here for you. Im sure others will chime in too.
Nodak, the TA 27 was built with 6WG210 for a while, with a 6WG260 for a while. At the end it doesn't matter in your case. Possibly share a picture of type plate or tranny. Code A5 is minor thing, code 3A short or open circuit at output speed sensor, 3E: Speeds do not fit, means clutches are engaged, sensor turbine or intermediate gears have speed, but no speed at output. 9B: solenoid for lockup clutch not connected, cable or plug broken or solenoid internal failure, lockup will not engage. Will unit try to pull away? And suddenly drop out of gear? Calibration of clutches will NOT help in this situation, you need to cure the fault codes. Later calibration will work and improve shifts. ZF called it "AEB-starter", same part for Deere, Moxy, CNH, Hyundai etc. It is a small box with few buttons plugged into diagnostic connector in wiring harness.
Thanks for the reply. For full disclosure. When we bought this 4 years ago the transmission was in pieces in a box in the back. It was the 6wg-260 with retarder. We ended up buying another front end and pulled the tranny and a reputable guy (but not a ZF guy) rebuilt one out of the two and ended up being a 260 without retarder. in the machine. It worked fine for three seasons until this problem. It has been weird how it acted for awhile it wouldn't go in forward or reverse. Where we are now it goes in reverse fine and yes rolls forward slightly but doesn't catch. We have been going through the whole harness again yesterday and today. Looking at getting the AEB as well.
Oil looks clear? No smell? Filter clean? Possible test to check proper condition of KR: block KR hose from control valve with plug, leave clutch port at shaft open. (Little oil coming out). Will truck still move reverse? Or stay in neutral? (As it should)
Oil looked fine we went ahead and changed the filters and drained the tranny and filled back up. There were some fines but minimal. With that and the wiring that we patched up we ran it and still the same. Reverse is fine. Forward just rocks a little. A5 is the only code still on now so getting somewhere. We removed the clutch solenoid to look for one. Would you know what voltage is supposed to be there. It was between 1.5 to 2.5v both forward and reverse. We are going to try the KR test now Thanks
The last part on voltages mispoke. They were around 20v on each pole not running. Put the ground to the frame and get 24 so going to chase that ground now.
I had a TA40 that had a similar problem. We ended up rebuilding two of the clutch packs. Palmer Johnson carries the AEB starters for 300 I think Might find one on E-bay. I still have one in the garage I think. The forum really helped with ours. I believe we found a PDF manual on line.
Repair of KR (if necessary) is definitely tricky stuff. Follow strictly ZF recommendations. Needs the exact part number of discs.
Parts Manual was also available free online. I ended up ordering the parts from the UK to save about half. Had to make a tool for the press to compress the clutch pack. Kinda like a slipper gear on the newer skidoo snowmobiles. There are parts available here in the US.