H200 TBL2 Carraro Power Shift

TEREX CENTRE OF EXCELLENCE
Basic Service
TEREX Training
Equipment Limited TEREX Compact Equipment Limited
ProLogis Park
Coventry CV6 4BX
TLB2Level
Carraro Power
1 Training Shift
- Hydraulic Cleanliness United Kingdom
Coventry 07
TLB2 Carraro Power Shift
Torque Converter Alignment
Torque Converter
Transmission
Torque Converter Seal Ring

Drive Tangs
Transmission Identification
Rear View
Transmission Carraro S/No.
Type
Oil Type Oil Capacity

Customer Ref.
Right Side Front View
Left Side Top View Rear View

1 Spin on filter Norm. 10µ

2 Oil pump assembly
4 SAE 3 torque converter housing Location of Parts
5 Breather plug
7 Oil inlet port from cooler
8 Oil outlet port to cooler
9(a) Torque converter inlet press. Check port 3.0÷9.0 Bar
10(a) FWD clutch pressure check point 13.5÷16.5 Bar
Max pressure NEUTRAL 0.3 Bar
11(a) REV clutch pressure check point 13.5÷16.5 Bar
Max pressure NEUTRAL 0.3 Bar
12 Suction filter Norm. 250µ
13 Magnetic drain plug
15 Holes eyebbolt threads for lifting
16(a) Lub pressure check point on Neutral clutch pos.1÷5 Bar
on FWD/REV clutch position 1÷5 Bar
21a Differential lock oil pressure port 14÷17 Bar
22 Pipe oil fill/dipstick interface
23 Gear pressure check port
24 Control valve supply pressure check port 14.0÷17.0 Bar
25 On/Off solenoid valve 12V DC 19.8W
26 FWD/REV proportional pressure reducing valves 12V DC 7Ohm
Notes
(a) Measure at 900±2200 engine rpm with oil temperature 80°C
Pump acceptance criteria on bench test:
19Lt.min. total pump flow at 900 rpm measure before spin on filter
Lubrication Oils to ATF-DEXRON II D or ATF-DEXRON III
TOTAL FINA ® HY-Tran

TOTAL FINA ® HY-Tran ULTRA
TOTAL FINA ® HY-Tran PLUS
PAKELO ® Special Transmission Fluid
MOBIL ® Mobil Fluid 424
CHEVRON TEXACO ® Textran 7045
PETROL OFISI ® (Turkish) PO ATF 2
Lubrication Oil Used On First Factory Fill

Oil Level Checking Procedure
Run machine to heat up the oil to operating temperature –
Stop the engine – check the transmission oil level within ONE
MINUTE of stopping the engine.
Sealing Componds
A1 = Loctite 510
B1 = Loctite 542
C3 = Loctite 542
Bolt Retaining Torques

Forward 1st Gear

Oil Flow
Forward 2nd Gear

Oil Flow
Forward 3rd Gear

Oil Flow
Forward 4th Gear

Oil Flow
Reverse 1st Gear

Oil Flow
Reverse Pressure Test Point Fwd Rev 4WD
Forward Pressure Test Point
Clutch Pressure 10(a) 11(a) Hydraulic Diff. Lock

Hydraulic Circuit
14.0÷17.0 Bar (PS1) 30a 14.0÷17.0 Bar (HDL)
12 13 14 21
Trax Software Activated
31 Ramp Valve Gear Clutch

Modulation NOT ADJUSTABLE
31(a) 13.5÷16.5 Bar (TP)
25 23 22 24
Pressure Activated
Main Relief Cartridge (not Adj)

1st 2nd 3rd 4th
30
Pressure Torque Converter
Filter 15µ 1
Drive
Pump Oil Cooler
x16(a) Lube Press. 1.0÷5.0 Bar
Cold Start Valve
x 9(a) 3.0÷9.0 Bar

Suction Filter
5 250µ T.C.Press. Relief Valve
TLB2 Carraro Power Shift Test & Lubrication Points
Torque Converter lube
Lubrication
2nd speed lube
4th speed lube
1st speed lube
3rd speed lube
FWD clutch pressure
REV clutch pressure

Note; Gasket to be assembled DRY
Pressure Filter – This is

remotely mounted Drive Solenoids
Ramp Modulation
Valve
Suction Filter
Transmission
Pressure Relief
Valve
Transmission Pump Speed Sensor

1st speed piping

3rd speed piping
Pressure sensor
3rd speed solenoid
Temperature sensor
115°C
1st speed solenoid
FWD clutch solenoid
Lube piping
REV clutch solenoid
4th speed solenoid
4 WD piping
4 WD solenoid
2nd speed solenoid
Ramp valve
4th speed piping
2nd speed piping
Pressure setting valve

Transmission Gear Pump

Filter Delivery Cooler Delivery
Torque Converter Delivery Suction Line

RMP
2ND 1ST 3RD 4TH
23 25 22 24 FWD Proportional Pressure Reducing Valve

Valve Assembly REV Proportional Pressure Reducing Valve
14 13 12 21 1ST 2/3 Directional Valve
2ND 2/3 Directional Valve
4WD REV FWD HDL
3RD 2/3 Directional Valve
4TH 2/3 Directional Valve
RMP Ramp Valve
TP Supply Clutch Pressure Port
HDL Hydraulic Diff. Lock engage/
disengage
12
13 14 21
31
25 23 22 24
Valve Locations Forward Pressure Test Point

10a
16a 11a
Reverse Pressure Test Point
Lube Pressure Test Point
Main Transmission
Relief Valve
Speed Sensor
CARRARO TLB2 TRAX

TEREX BHL
CA339216 R2 Software Update
TRAX HW/SW ASSEMBLY CODES – TLB2 TEREX BHL
ASSY
CA339923
Software SW HW Hardware
CA339216 CA339360
CA339216 R2 TRAX Software – TLB2 TEREX BHL
TRAX HW p/n and revision
What is in the
TLB2 Software p/n and revision
TRAX unit
ECU ASSEMBLY p/n and revision

CA339216 R2 TRAX Software – TLB2 TEREX BHL
New Features:
 STANDARD/GERMAN setup configuration
 Startup oil pressure signal check and failure

management
 Startup temperature sensor signal check and failure
management
 Engine speed signal check and failure management
Alternator Pick-up
 New Hall-Effect speed sensor signal management
Output Speed
 Auto kickdown FWD-to-REV disengagement
Standard and German setup configuration
 German Setup: 3rd FWD / 3rd REV max gear

 Standard Setup: 4th FWD /4th REV max gear
Oil pressure switch signal check and failure management

Start-up congruency check of oil pressure switch sensor signal
If something is wrong (i.e. sensor wiring broken, oil pressure not ok):
DTC code 150
“LIMP HOME” mode active (fwd/rev 2nd gear only) until failure removed
Temperature signal check and failure

management
Start-up congruency check of temperature sensor signal
If something is wrong (i.e. sensor wiring broken, oil pressure not ok):
DTC code 130/140
Trans. Status lamp blinks 3 times every 3 seconds
Temperature fixed to 60° (Trax Set – Not transmission)
Engine speed signal check and failure management

Congruency check of engine speed signal
If something is wrong (i.e. sensor wiring broken): Alternator Failures ??
DTC code 160
Trans. Status lamp blinks 5 times every 3 seconds
Rpm fixed to 1600 rpm ( Trax Set – Not engine)
CARRARO TRAX
TLB2 Electronic Module
Specification
Application
TRAX electronic module is designed to drive and control CARRARO
TLB2 transmission in mobile applications
Main TRAX ECU features:
•Remote mounting
•High I/O capability for advanced applications
•Advanced ARM7-TDMI microcontroller
•Coils currents digital closed loop control
•Active shuttle clutches management during up and down shifting
•Real time system diagnosis available via RS232 / CAN BUS
•High insulation degree
•Broad range of supply voltages without degradation in performance
•Reverse polarity protected power supply
•Short circuit proof coil outputs
Note; Data cables twisted to protect against electronic corruption

Trax will operate at 10.5 ÷ 16 V
Connector: Framaton 56 pins P/N 211PL562L0011

Mates with : Framaton 56 pins P/N 211PC562S0009
BASIC SOFTWARE PACKAGE
Forward – Reverse Management

Manual gear selection
Declutch Feature
TRAX Status Signal available for Vehicle Dashboard
RS232 Communication for service and diagnostics
OPTIONAL FEATURES
•Automatic gear-shifting
•Kick-down
•Signal exchange between TRAX and vehicle dashboard
•Signal exchange between TRAX and 4WS steering ECU
•4WD Management
•HDL Management
•CAN bus communication
TRAX PIN TRAX PIN Description Configuration Connection

1 Logic Supply +12V +12v battery Direct to battery
17,29 Logic ground Battery GND Direct to battery
2,30,5,32,8,35,36,34 Power Supply +12V +12v battery under key Battery under key
18 Digital input 01 Forward input command
46 Digital input 02 Reverse input command
Pull-down
19 Digital input 03 GearCmd01 input command
47 Digital input 04 GearCmd02 input command
20 Digital input 05 Crab signal (optional)
48 Digital input 06 Circle signal (optional)
Pull-up
21 Digital input 07 Declutch input command
49 Digital input 08 Kickdown input command (optional)
22 Digital input 09 4WD Switch (optional)
Pull-down
50 Digital input 10 STOP Switch (optional)
43 Temperature input NTC Temperature sensor
44 Analog Input 01 Pull-up Main Ring Pressure Switch
25 Frequency Input 01 Inductive Transmission output speed sensor
53 Frequency Input 02 Inductive Engine alternator “W” signal
28 Rs232 TX Serial/CAN interface
56 Rs232 RX Serial/CAN interface
27 CAN: CAN_H Serial/CAN interface
55 CAN: CAN_L Serial/CAN interface
26 CAN: SHIELD Serial/CAN interface
3 PWM 01 Output PWM Forward valve command
12 PWM 01 Current Current input Forward valve current feedback
7 PWM 04 Output PWM Reverse valve command
41 PWM 04 Current Current input Reverse valve current feedback
9 Digital output 01 Source digital out st
Valve s1 (1 Gear)
37 Digital output 02 Source digital out Valve s2 (2 nd Gear)
10 Digital output 03 Source digital out Valve s3 (3 rd Gear)
38 Digital output 04 Source digital out Valve s4 (4 th Gear)
11 Digital output 05 Source digital out HDL Valve (optional)
39 Digital output 06 Source digital out 4WD Valve (optional)
42 Digital output 07 Switch to ground digital out dashboard "Automatic" Lamp
(optional)
14 Digital output 08 Switch to ground digital out Buzzer / danger lamp
4 PWM02 Output as digital output, source 4WD Lamp
TRAX PINOUT OVERVIEW
Logic Supply
Sensor supply output
Power Supply A
Logic Ground
PWM Output 1-2
Digital Inputs
Power Supply B
Serial Line RS232
PWM Output 3-4
Digital Outputs (src) CAN
01 14 15 28
29 42 43 56
Power Supply C Frequency Inputs
PWM Feedback 1-4 Analogue Input
Digital Outputs (src) Temperature Input
Power ground
TRAX General
Operating Temperature -40 … +85 °C

Storage Temperature -40 … +85 °C
Insulation degree IP 67
TRAX Material
Material Thermoplastic
Weight 0.25Kg
Installation block diagram
“AUTO” Lamp
Laptop RS232 / CAN TRAX status signals

DASHBOARD
4WD Lamp
RPM
Cab Kick-down
Levers / Declutch
Switches 4WD
HDL
4th
Shifter
FWD
RVS
TRAX 3rd
2nd
Selector GearCmd01
ECU 1st
GearCmd02 RPM TLB2

Temperature
+12V under key
FWD
+12V direct to battery
RVS
4WD
GND
HDL
Vehicle
electrics
Shift Lever Assembly

Kick Down Button In manual – the gearbox will not change
from 3rd to 4th until over 18 kph
FWD
1
2 1 F
2
N
3
4 R
3
4
Auto - select 4th For/Rev unit will automatically select 2nd
REV then change up gears after 4 kph
- CONNECTOR V1 -
Receptacle: DEUTSCH DT 04-8PA-CE02
Mates with:
Plug: DEUTSCH DT 06-8S
TLB2 transmission hydraulic connectors
- CONNECTORS: 1st, 2nd, 3rd, 4th, FWD, RVS, 4WD,HDL

Receptacle: DEUTSCH DT 04-2P
Mates with:
Plug: DEUTSCH DT 06-2S
TLB2 transmission NEW HALL-EFFECT speed sensor
Output of gearbox speed

TLB2 transmission Pressure Sensor Switch – 10.5 Bar

TLB2 transmission temperature sensor with alarm switch
Pre set @ 115° C

Installation wiring spreadsheet

4WD
SWITCH
+15 39 4WD VALVE
22
4WD SWITCH
LAMP DIFFLOCK
+15 SWITCH
SPEED 11
25 HDL VALVE
SENSOR
DIFFLOCK
LAMP
PRESSURE
44
SWITCH
3
Overtemperature
Lamp
+15 12 FWD VALVE
switch TEMPERATURE
signal 43
GND SENSOR 7
41 RVS VALVE
“W” Engine Alternator Signal (engine speed)

53
STOP
9 S1 VALVE
SWITCHES
+15 GEAR1
50 DASHBOARD LAMP
SX Brake DX Brake
37 S2 VALVE
FWD 18 GEAR2
RVS 46 TRAX DASHBOARD LAMP
Shifter Lever GearCmd01 19
GearCmd02 47
ECU
10 S3 VALVE
GEAR3
VEHICLE DASHBOARD LAMP
CRAB 20
CIRCLE 48 38 S4 VALVE
GEAR4
DECLUTCH 21 DASHBOARD LAMP
KICKDOWN 49
DASHBOARD “AUTO” LAMP

42 +15
+30 (DIRECT TO BATTERY) BUZZER / DANGER

1
+15 (UNDER KEY) STATUS LAMP +15
DIAGNOSTIC
34 14
2 INTERFACE
30 4WD LAMP (optional)
5 04
32
8 3 RS232
35 26 1 5
DB9 FEMALE
36 28 5 6 2 CONNECTOR
56 6 4 5
17 27 2 SERIAL/CAN
29 55 3 INTERFACE
4 (6-WAY CONNECTOR) 3 2 CAN
2 7 DB9 FEMALE
CONNECTOR
1
Declutch feature
Instantaneous interruption in power transmission, irrespective of shifter

position (FWD, RVS), piloted by the driver through a monostable switch.
Note; Nearest button to the operator on the gear stick
TRAX status signal available for Vehicle Dashboard
TRAX is capable to provide a single electric signal to allow a visualization

of its current operating status. Typical application: failure blinking codes,
indication of incongruence between selected and engaged gear , etc.
RS232/CAN Communication
Via RS232 serial port or CAN port, TRAX allows typical functions related to
the communication as real time visualization of system variables, system
parameterisation, advanced diagnostic, history error log.
Automatic gear shifting
• Shifter selector positions:

• Position 1: 1st gear engaged
• Position 2: 2nd gear engaged
• Position 3: 3rd gear engaged
• Position 4: 2nd to 4th automatic gear shifting depending on vehicle speed
• 2nd gear engaged in automatic mode when starting
• AUTO to Manual mode switching always available
Kick-down
Principle of functioning
• Sequential Up & Down shifting (i.e 2nd to 1st, then 1st to 2nd, …)
• Kick Down can be armed only when 2nd gear is engaged
• Kick Down function is always available, irrespective of shifter position (F, N, R)
• Kick Down is cancelled shifting the gear selector (1st, 2nd, 3rd, Auto)
• Kick Down is maintained ? moving the shifter position (F to N, F to R, …)
During manual gear selection

• After Kick Down selection, 1st gear is maintained irrespective of vehicle speed
During automatic gear shifting
• Kick Down is cancelled exceeding a programmable speed threshold
Signal exchange between TRAX and 4 Wheel Steering ECU
4 Wheel Steering ECU knows current engaged gear from relevant

valves wiring
When CRAB steering signal from 4WS ECU is active, 3rd and 4th gear are not
allowed by TRAX while selected by operator
When CIRCLE steering signal from 4WS ECU is active, 4th gear is not
allowed by TRAX while selected by operator
4WD Management
4WD feature works in negative way, that is if the 4WD operator switch is
OFF (4WD disabled), then 4WD valve is ON. 4WD operator switch can
activate 4WD feature in all operating conditions (1st, 2nd, 3rd or 4th gear),
while it is automatically activated if the transmission is in 3rd or 4th gear
and the operator brakes.
HDL management
If 1st or 2nd gear is engaged, then HDL switch is enabled to pilot HDL valve,
which is responsible to activate the differential lock feature
Note; Unit may be towed at NO more then 15 kph

DO NOT WELD ON THE MACHINE WITHOUT THE TRAX DISCONNECTED

H200 TBL2 Carraro Power Shift

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TEREX CENTRE OF EXCELLENCE

Torque Converter Alignment

Torque Converter Seal Ring

Oil Type Oil Capacity

Right Side Front View

Left Side Top View Rear View

1 Spin on filter Norm. 10µ

Lubrication Oils to ATF-DEXRON II D or ATF-DEXRON III

TOTAL FINA ® HY-Tran

Lubrication Oil Used On First Factory Fill

Bolt Retaining Torques

Forward 1st Gear

Forward 2nd Gear

Forward 3rd Gear

Forward 4th Gear

Reverse 1st Gear

Reverse Pressure Test Point Fwd Rev 4WD

Forward Pressure Test Point

Clutch Pressure 10(a) 11(a) Hydraulic Diff. Lock

31 Ramp Valve Gear Clutch

Main Relief Cartridge (not Adj)

x 9(a) 3.0÷9.0 Bar

Torque Converter lube

2nd speed lube

4th speed lube

1st speed lube

3rd speed lube

FWD clutch pressure

REV clutch pressure

Note; Gasket to be assembled DRY

Pressure Filter – This is

Transmission Pump Speed Sensor

1st speed piping

4th speed solenoid

2nd speed solenoid

Pressure setting valve

Transmission Gear Pump

Torque Converter Delivery Suction Line

2ND 1ST 3RD 4TH

23 25 22 24 FWD Proportional Pressure Reducing Valve

Valve Locations Forward Pressure Test Point

Reverse Pressure Test Point

Lube Pressure Test Point

CARRARO TLB2 TRAX

TRAX HW/SW ASSEMBLY CODES – TLB2 TEREX BHL

CA339216 R2 TRAX Software – TLB2 TEREX BHL

TRAX HW p/n and revision

ECU ASSEMBLY p/n and revision

CA339216 R2 TRAX Software – TLB2 TEREX BHL

 Startup oil pressure signal check and failure

Standard and German setup configuration

 German Setup: 3rd FWD / 3rd REV max gear

Oil pressure switch signal check and failure management

Temperature signal check and failure

Engine speed signal check and failure management

Main TRAX ECU features:

Note; Data cables twisted to protect against electronic corruption

Trax will operate at 10.5 ÷ 16 V

Connector: Framaton 56 pins P/N 211PL562L0011

BASIC SOFTWARE PACKAGE

Forward – Reverse Management

TRAX PIN TRAX PIN Description Configuration Connection

TRAX PINOUT OVERVIEW