DOWNLOAD PDF ZF Transmission AS-Tronic 2 Diagnostics Manual

AS-Tronic 2 Diagnostics Here, we are dealing with a collection of well-known complaints as well as remedial action. This documentation is to be used as a supplement to the failure tree documentation.

In all cases, the following applies: Î Î Î Î

Î

All disturbing, impacting factors must be checked prior to replacing components.

Prior to replacing the components, it is mandatory to work off the checklist.

If replacing or exchanging the components does not solve the problem, then the new part must be replaced again by the original part.

In the case of new, unknown complaints, the checklist must be worked off and afterwards (if possible) feedback must be requested from the technical expert department in Friedrichshafen / Germany.

The “general clutch actuator replacement < 42000” campaign has been closed.

BKS-I/BKS-R As of:December 07 , 2005

AS-Tronic 2 Diagnostics

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Table of Contents Short circuit/Interruption TA* 3 Short circuit ADVP* Driveline retarder torque (CAN) Measurement on diagnostic code 28 Input shaft speed defective Speed error ZF-CAN Timeout Harsh engagement Measurement on diagnostic code 114 Clutch self learning error Measurement on diagnostic code 117 Clutch self learning error Air leakages Clutch does not engage Signal error clutch travel Measurement on diagnostic code 124 Clutch travel error, noise Oil temperature sensor Self adjustment error of shift sensor GV (splitter group) does not disengage

2, 3, 4, 5, 6, 7, 8,9,10,17, 34, 35, 36, 37, 38, 39, 40, 41, 42, 49, 66, 67,68, 69, 70, 71, 72, 74, 81 22 28 28 98 99, 100, 101, 28 110 partially 114 partially 114 117 117 117 in connection with 155 118, 145, 151, 154 119 in connection with 124 124 124 124 in connection with 102 128 132 in connection with 154 148

Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 21 Page 22 Page 23 Page 24 Page 25

* TA = Transmission Actuator; *ADVP = Output Digital Power Supply to High Source (+)

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AS-Tronic 2 Diagnostics

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Table of Contents GV (splitter group) does not change Measurement on diagnostic code 149 Wabco transmission actuator < 15000 Selector cylinder jammed Main transmission not engaging No starting gear N-D/R Leaving of engaged position (GE,GV,GP) Gear leaves engaged position Gear leaves engaged position GV (splitter) leaves engaged position Datalogger measurement to FC 160 / 101 Evo- Baureihe CC400 Signal error ignition lock CAN Bus off EvoBus, after SW Pak 7 Update EEProm error while traveling EEProm error after programming EEProm error after engine start CAN Error

BKS-I/BKS-R As of:December 07 , 2005

149 149 145, 146, 147, 149, 154, 156, 158 151, 153 155 155 158, 159, 160 158 158 in connection with 101 160 in connection with 101 160 in connection with 101 163 175 178 188 190, 191, 192 190, 191, 192 192 various

AS-Tronic 2 Diagnostics

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Table of Contents Complaints without diagnostics entry: Engine start not possible Engine start not possible Transmission does not shift Clutch judder TC-Tronic; Juddering while starting movement Defective clutch actuator Limited positions outside of tolerance High level of clutch wear / burned clutch Too high tilt clearance at the DMF (dual mass flywheel) Strong noise during Intarder operation Over speeding of engine Gear-hunting Gear-hunting; no full throttle possible EvoBus model range 300 Long Check Phase (CH)

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AS-Tronic 2 Diagnostics

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Short Circuit/Interruption Shift Valves Diagnostic code:

2, 3, 4, 5, 6, 7, 8, 9, 10, 17, 34, 35, 36, 37, 38, 39, 40, 41, 42, 49, 66, 67, 68, 69, 70, 71, 72, 74, 81

Actions & Measures: Î Check the system’s air with reference to dirt / oil / water Î Replace the transmission actuator!

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Short circuit ADVP* (Output of Supply Power ) Diagnostic code:

22

Actions & Measures: Î

A short circuit may occur at the following components: - Output speed sensor - Clutch actuator - Transmission actuator - Display - Warning buzzer - E-module

Î

The short circuit at the output speed sensor is among the most commonly known defects.

Note: If the ZF-end output speed sensor is unplugged, then the vehicle can still be operated in the manual mode. (Then, diagnostic code 99 is active.)

*ADVP = Output Digital Power Supply to High Source (+)

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Current Driveline Retarder Torque in Percentage Diagnostic code:

AS-Tronic: 28 (consequential error) Intarder: 3115 (defective speedometer signal)

Actions & Measures: Î Speedometer sensor/wiring must be checked. Î Datalogger measurement (Intarder) must be performed with vehicle stationary: If – during the engine start phase – a short-term rise in the output speed is noticed (despite the stationary vehicle), then the speedometer and/or speed pulse distributor must be checked.

Known: With Neoplan vehicles, there must be a 2nd speed signal amplifier installed. (Output speedometer: B7 / C3) Signal chain (1 speed pulse distributor): Speedsensor

(also refer to measurements on next page)

BKS-I/BKS-R As of:December 07 , 2005

AS-Tronic 2 Diagnostics

Tachograph

speed signal amplifier

EST 42

speed signal amplifier

EST 42

Further ECUs

Page 7

Measurement on Diagnostic Code 28 Engine speed

Output speed (peak)

Control parameters (measured at Intarder ECU): engine speed (unfiltered) = Motordrehzahl output shaft speed (filtered) = Abtriebsdrehzahl

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Input Shaft Speed is Missing or Defective Diagnostic code:

98

(in connection with loud grating noise during gear engagement at standstill)

Actions & Measures: Î The diagnostic code is set e.g. when starting the engine Î driving error. Î The counting disc must be checked.

Torsional clearance of up to 3 mm is normal. If the counting disc can be loosely turned, then the seat of the counting disc must be checked. Î Transmission Î If there are no noticeable problems to be found at the counting disc, then the transmission actuator’s lower part must be replaced.

Important: The input speed is replaced by the engine speed and thus is displayed by the TestmanPro despite the active error 98.

Note: If the diagnostic code 98 occurs at the transmission actuator Wabco no. > 57000, then, the BKS-I, BKS-R, or LKS-T depts. must be contacted immediately!

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AS-Tronic 2 Diagnostics

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Speed Error (EvoBus) Diagnostic code:

99, 100, 101, 28 (EvoBus)

Actions & Measures:

Î

Check software status and update to latest software edition.

Note: Replacing the output speed sensor does not solve the problem.

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ZF-CAN Timeout Diagnostic code:

110

Actions & Measures: Î Î Î Î Î

For EvoBus vehicles, check the speed range selector in line with the ServiceLine instructions.

Check wiring of transmission actuator – E-module. In the case of IVECO, DAF, and EvoBus (new vehicle generation), the E-module is replaced by the speed range selector.

Check the speed range selector and/or E-module.

Measure ZF-CAN (terminal tester; ignition off Î R = 60 Ohm).

Check transmission actuator.

Note: In few cases only, the transmission actuator is the cause for the error and thus, the very last action to be taken is to replace the transmission actuator.

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Harsh Engagement Diagnostic code:

partially 114

Actions & Measures: Î Grease clutch release (can be done with the transmission installed in the vehicle). Î SI 16/04c Î Check the lubrication of input shaft. Î Check the release bearing. Î Check the clutch parts (pressure plate, disc, flywheel). Î

Grease to be used: Optimol Olista Longtime 3EP

100 gr.

1 KG:

0671 190 165 0671 190 050

Note: In only few cases, replacing the clutch actuator will solve the problem. Prior to replacing the clutch parts however, it is recommended to first – temporarily - install a new clutch actuator. If this action does not solve the problem, then the old part must be exchanged!

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Measurement to Harsh Engagement

Toth on toth situation inside the main transmission (sensor[0].messwert)

input speed (n_sek) increases to 345 rev/min Îharsh engagement Îjudder of cabine

clutch (s_kup) leaps up to 40 %

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Clutch Self Learning Error Diagnostic code:

117

Actions & Measures: Î Clutch does not separate (also refer to datalogger measurement).

Note: Follow-up damage at the transmission’s brake cannot be excluded in such a case. Î Release bearing broken and/or unhooked? Î Release fork broken? Î Air supply OK? Î Pilot bearing scored? Î EvoBus: Defect at adjustable clutch

Note: In only few cases, components such as the transmission or clutch actuator are the cause for the problem i.e. the diagnostic code!

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Measurement on Diagnostic Code 117

Note: In this case, s_kup_abs (mm) must be measured as a variable. s_kup (%) only shows plausible values after successful teach-in process.

Measurement: Ignition on Î Clutch opens (here: approx. 6mm) Engine start: Engine speed must increase; The transmission input speed must only increase with closing clutch (value increasing).

Here: Transmission input speed increases immediately with engine start and cannot be decreased despite actuation of transmission brake.

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Clutch self learning Error Diagnostic code:

117 in connection with 155

Actions & Measures: Î Check transmission braking gradient (e.g. oil leakage at the transmission ventilation unit). Î Check the clutch’s parts. Î If the clutch’s parts are OK, then replace the transmission actuator’s lower part. (Only known with transmission actuator GS3 Wabco no. < 15000)

Note: Replacing the transmission actuator with the Wabco no. < 15000 in general (without a complaint) is not acceptable!

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Air Leakage Diagnostic code:

118, 145, 151, 154

Actions & Measures: Î Check software status (floating valves) and update correspondingly Î Check pressure relief valve (PRV); in case of leakage, replace.

Note: In the case of EvoBus vehicle applications until production year 05/04, problems have been reported in the compressor range. Here, it may happen that strongly soiled air enters into the air circuit.

Consequence: Damage to the clutch actuator, transmission actuator, pressure relief valve, as well as the accumulator charge valve.

Responsibility: EvoBus

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Clutch Does Not Engage Diagnostic code:

119 in connection with 124

Actions & Measures:

Î Check clutch parts Î In connection with diagnostic code 124, it must be assumed that this issue is due to a sensor problem.

Inspection possibility: Apply lite hits (e.g. with screwdriver) on clutch actuator with ignition on. Sensor value (clutch travel in mm) may not change thereby! Î Exchange or replacement of clutch actuator is justified.

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Signal Error “Clutch Travel” Diagnostic code:

124

Actions & Measures: Î Water / Oil in the air system Responsibility: OEM Î Counting disc loose in transmission Responsibility: ZF (basic transmission) Î Length of the clutch rod correct?

In the past, it happened several times that the wrong clutch rod was installed. Here, the entire operating range of the cylinder is shifted.

- Continue on the next page -

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AS-Tronic 2 Diagnostics

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Signal Error “Clutch Travel” Diagnostic code:

124

Actions & Measures: Î In connection with the self-adjusting clutch (Setra, EvoBus), unwanted resetting also took place several times while traveling. Î Here, replacing the clutch becomes necessary. Î In connection with CR engines (MAN).

If the starting process of the engine is rather sluggish, then this may trigger error detection of the diagnostic code 124. Î Responsibility of the OEM.

Note: In only few cases, components such as the transmission or clutch actuator are the cause for this diagnostic code!

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Measurement on Diagnostic Code 124 Starting procedure of a CR-Motor

n_mot = 400 rev/min Î clutch adjusting starts

n_sek increase though n_mot < 400 rev/min Î adjusting procedure failed

diagnostic code 124 is active proposal of measurement parameters: n_mot (engine speed) n_sek (input speed) s_kup (clutch travel value %) s_kup_abs (clutch travel value mm) z_Sys_Status_2_UFB Bit 2 = Cluch adjusting activ Bit 3 = Clutch adjusting finished

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Clutch Travel Error, Noise Diagnostic code:

124 in connection with 102

Actions & Measures: Î Securing rings incorrectly mounted. Î Also refer to 2004 Annual Technical Seminar, Chapter 05a, Slide 15.

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Temperature Sensor (Oil) Diagnostic code:

128

Actions & Measures: Î Oil temperature must be checked by means of TestmanPro (interruption = - 9°C).

In the case of unrealistic values, the transmission actuator’s lower part must only be replaced if the diagnostic code 128 has been saved to the error memory.

Note: If the diagnostic code 128 occurs with the transmission actuator Wabco no. > 57000, then immediately get in contact with the BKS-I, BKS-R, or LKS-T departments!

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AS-Tronic 2 Diagnostics

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Self Adjustment Error of Shift Sensor Diagnosecode:

DC 132 in connection with 154

Actions & Measures: Î Neutral will not be recognized.

Check the sensor increment value in neutral.

Nominal value: 300 – 350 inc Î Refer to chapter „Engine Start Not Possible“

Note: Engine start is possible for vehicles which are using the neutral switch for the starter interlock. But while self adjustment or shifting neutral will not be reconized.

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GV (Splitter Group) does not disengage Diagnostic code:

148

Actions & Measures: Î Lack of grease at the input shaft + hub (clutch disc).

Thus, a residual torque occurs with GV (splitter group) shifts (e.g. 11-12). The GV cannot be turned off.

The transmission must be disassembled and the input shaft must be greased with Optimol Olista Longtime 3EP after cleaning.

100 gr.

1 KG:

0671 190 165 0671 190 050

Note: Remove excess grease! Also refer to SI 16/04c.

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GV (Splitter Group) Does Not Change Diagnostic code:

149

Actions & Measures: Î Check clutch separating behavior. Î Build-up of torque to be checked (1st gear in maneuvering mode: Drive at approx. 30 % of clutch travel) Î Defective GV (splitter group) synchronization (unlocking edge worn / damaged).

The diagnostic code can be reproduced as follows:: - Starting the engine.

- Engaging the hand/parking brake.

- Shifting with vehicle stationary 1-2-1 (approx. 40 times) (with 10-speed transmissions 2-3).

Note: Replacing the components (clutch actuator, transmission actuator) does not solve the problem!

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AS-Tronic 2 Diagnostics

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Measurement on Diagnostic Code 149

Splitter blocked at 457 inc.

Diagnostic code 149 is set Clutch does engage to disengage the blocking

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Transmission Actuator Wabco No. < 15000 Diagnostic code:

145, 146, 147, 149, 154, 156, 158, 159, 160

Actions & Measures: Î Check limited positions of the transmission. Î If the limited positions are Ok, then replace the transmission actuator’s lower part (defective crimping). Î If the limited positions are not Ok, then check the neutral signal and the shift forks. (also refer to “Stop limits outside of tolerance”)

Note: Replacing the transmission actuator with the Wabco no. < 15000 in general (without a complaint) is not acceptable!

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Selector Cylinder Jammed Diagnostic code:

151, 153

Actions & Measures: Î Disassemble transmission actuator and check gate cylinder with reference to possible sluggishness, stiffness of movement.

The transmission actuator’s lower part must be replaced.

Note: The matter has only been reported for transmission actuator Wabco no. < 17153. In the case of noticeable problems with transmission actuator GS3 > 17513 please contact the technical expert departments in Friedrichshafen, Germany.

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AS-Tronic 2 Diagnostics

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Main Transmission Not Engaging Diagnostic code:

155

Actions & Measures: Î Check the transmission braking gradient (datalogger measurement) (e.g. oil leakages at the transmission ventilation unit).

In the case of a defective transmission brake, it becomes mandatory to check the oil for possible water ingress. (also refer to ZF-ServiceLine: Final sheet of UFB (fault finding and trouble shooting) L03/04: Transmission brake defective) See Annual Technical Seminar 2005 chapter 04 site 23 Î The clutch parts must be checked.

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AS-Tronic 2 Diagnostics

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No starting gear N-D/R (Neoplan) Diagnostic code: 155 (31_55 MAN) Complaints:

No starting gear N – D/R most in warm condidtion

Affected variants:

SW 6009 374 483 (V33_4d) for MAN D2876LOH20CR in Neoplan Starliner 2 and MAN R0x / P21 / 22 busses

Cause of complain: Î ZF Software; parameter too small (= difference of layshaft to mainshaft rpm) during the shifting Î stationary: additional wrong parameter by selecting the starting gear Remedy: Î SW Update to SW Paket 7 Stand 6009 374 635AS in case of complain Î serial production change of the software Note: Î Update of the chassis side datafile through MAN necessary Î technical infomation from MAN will follow See also Annual Technical Seminar 2005 chapter 15a site 21

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Leaving of Engaged Position (GE, GV, GP) Diagnostic code:

158, 159, 160

Actions & Measures: Î Check earth continuity connector (bonding) of the transmission.

Currently: MAN mass node in the cable duct is loose above of the engine Î OEM Î In the case of the transmission actuator < 15000, the transmission actuator’s lower part must be replaced.

Note: Replacing the transmission actuator with the Wabco no. < 15000 in general (without a complaint) is not acceptable!

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Gear Leaves Engaged Position Diagnostic code:

158 (without any other diagnostic entries )

Actions & Measures: Î Check limited positions (outside of tolerance Î Shift forks and/or neutral signal to be checked; also refer to “Limited positions outside of tolerance“) Î In the case of new vehicles and/or after transmission replacement, then the countershaft’s position must be checked. (error in coasting-traction changes can be reproduced). Î Countershaft production error Î Assembly error Markings on the countershaft must be aligned (also refer to repair stage 3) If there is no marking, then the laterally positioned bores must be positioned at 180° offset (countershafts between R gear and 1st gear).

(Also refer to 2004 Annual Technical Seminar, chapter 05a, Slide 14.)

Note: Replacing the transmission actuator does not solve the problem!

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AS-Tronic 2 Diagnostics

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Gear Leaves Engaged Position Diagnostic code:

158 in connection with 101

Actions & Measures: Î Check limited positions (Outside of tolerance Î Check shift forks)

Note: Replacing the components (transmission actuator / clutch actuator / output speed sensor) does not solve the problem!

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AS-Tronic 2 Diagnostics

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GV (Splitter Group) Leaves Engaged Position Diagnostic code:

160 in connection with 101

Actions & Measures: Î The error can be reproduced as follows (datalogger recordings): Carry out shifts: 1-2-1 If the GV (splitter group) does not shift through, then actuate the accelerator pedal after 4-5 seconds. Î Diagnostic code 160 is set since the GV (splitter group) signal is drifting away. Î Diagnostic code 101 is set since the software detects “gear engaged” although mechanically, the GV (splitter group) does not shift through. If the accelerator pedal is actuated now, then the clutch closes and the status of setting off is detected.

However, if the vehicle remains stationary, then the software detects an output speed sensor failure. Î GV (splitter group) must be checked.

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AS-Tronic 2 Diagnostics

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Datalogger Measurement to DC 160 / 101 Accelerator pedal is actuated; input speed is on the increase.

GV (splitter group) does not engage; remains stopped at 244inc.

Error is set.

Clutch closes

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EvoBus model CC400 with SW 33_4a (MB Nr.A0012604600)

Diagnostic code:

163 (EvoBus:91_40)

Complaints:

no increase of engine rev. inspite of tourque request

Cause of complain: Î During a downshift 7-6 in throttle, AS Tronic is changing the signal „limit of engine rpm“ between on and off. Signal does toggle. Î Because of toggling, the engine does not accept the transmission request Remedy: Î SW Update SW Paket 7 Stand V33_4g (MB Nr.A0014462109) in case of complain Î no generell field action

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AS-Tronic 2 Diagnostics

Page 37

Signal Error Ignition Lock Diagnostic code:

175

Actions & Measures: Î Power supply to transmission actuator (Terminal 15) must be checked. Case well known: Î IVECO: Defective body computer.

Note: Replacing the transmission actuator does not solve the problem.

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AS-Tronic 2 Diagnostics

Page 38

CAN Bus Off Diagnostic code:

178

Actions & Measures: Î Control units that are connected to the vehicle CAN must be checked. Î The CAN plug connections from the vehicle CAN must be checked.

Currently known: MAN The CAN connections (vehicle end) are to be checked in line with MAN SI 101902a. In those cases known, it was respectively the plug connection in the cable duct above the engine that was defective.

Note: In only few cases, replacing the transmission actuator will solve the problem.

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AS-Tronic 2 Diagnostics

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EvoBus Software update package 7 Diagnostic code:

188 (EvoBus:66_10)

Complaint:

fault code 188 after software update to package 7 (ECU problem - faulty interrupt or GS3 and software incompatible)

Cause :

prevention of components; F188 appears with the old GS3: 6009 274 055 (new: 6009 274 070, serial since the 21. ofJune 2002)

Transmisson serial no.:

200825.

All transmission, which were produced before that serial no., are equipped with the old version of GS3 and are incompatible with the new software package 7.

affected spec.lists (old GS3): 1337 044 001 1337 042 006 1337 044 002 1337 044 003 1337 044 004 1337 044 005 1337 044 007

BKS-I/BKS-R As of:December 07 , 2005

A001 260 30 00 A001 260 29 00 A001 260 35 00 A001 260 33 00 A001 260 31 00 A001 260 37 00 A001 260 39 00

amount of transmission: TC400 OM457 LA 310kW 26 TC400 OM502 LA 350kW 104 TC400 OM502 LA 320kW 4 300 GT-HD OM457 LA 310kW 6 300 UL OM457 hLA 260kW 8 300 UL OM457 hLA 300kW 5 300 GT-HD OM502 LA 320kW 4

AS-Tronic 2 Diagnostics

Page 40

EE-Prom Error Diagnostic code:

190, 191, 192 (while traveling)

Actions & Measures: Î For the ZF transmission actuator GS-3 no. < 372733, the transmission actuator’s upper part must be replaced.

Note: Replacing the transmission actuator’s upper part is only justified if the error occurs while traveling. The vehicle will be ready for operation after a renewed configuration release / approval.

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AS-Tronic 2 Diagnostics

Page 41

EE-Prom Error Diagnostic code: process

190, 191, 192 after the programming

Actions & Measures: Î The parameterization must be checked. Î Check cabling of Terminal 15/Terminal 30.

Note: For the current SW status of TestmanPro, the following icon must be activated: “Configuration“ “Additional brakes“ Software status is V31 13f or new

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AS-Tronic 2 Diagnostics

Page 42

EE-Prom Error Diagnostic code:

192 after engine start (transmission + PTO)

Actions & Measures: Î If, with ignition on, the signal “Nebenabtrieb PTO1 aktiv“ (=power take-off PTO1 active) is set, then the transmission actuator’s (GS-3) electronics do not switch off correctly. Î After ignition ON, (sometimes) the diagnostic code 192 is displayed. Î MAN: The following input at the vehicle control unit (VCU controller) must be checked: X4 /15 (mass triggered) With ignition OFF, no signal should be displayed here!! Î OEM / Body builder Î IVECO: Various body builders control the PTO via a remote control unit. Thus, because of a wiring error, it may happen that Terminal 15 of the transmission is switched off by the transmission but not by the body control computer.

With ignition OFF, no signal from the PTO should be present at the range selector lever Î OEM / Body builder.

Note: Simple opportunities for inspection: With ignition OFF, the GP has to shift to GPS. If that is not the case, then check Terminal 15!

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AS-Tronic 2 Diagnostics

Page 43

CAN Error Diagnostic code:

Various

Actions & Measures: Î The respectively sending control unit is responsible for the corresponding signal! Î Vehicle CAN and control unit must be checked Î OEM.

Note: Replacing the transmission actuator does not solve the problem!

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AS-Tronic 2 Diagnostics

Page 44

Engine Start Not Possible Diagnostic code:

None (MAN: FFR 3197)

Actions & Measures: Î Î Î Î

Check air supply.

Ensure that mechanically, no gear is engaged.

Vehicle equipped with a neutral switch: (DAF, partially Neoplan) Check neutral switch.

Check vehicle equipped with a neutral switch via CAN (MAN, EvoBus, IVECO, Neoman) with reference to measurement value from main transmission sensor in neutral position. Î

Important: Possible higher limited positions are also due to the transmission actuator’s GS-3 lower part.

Note: The neutral signal is the only transmission-end signal which inhibits an engine start.

For MAN vehicles, there may be an additional diagnostic code displayed: FFR 3197 (neutral signal missing).

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AS-Tronic 2 Diagnostics

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Engine Start Not Possible Cause of failure Î

excessive wear inside the main piston of the GS3 because of unusual incoming frequency

Remedy Î

Î

serial introduction steel shim week 14 / 2005 serial no. GS3 - 20pin plug Standard: 131495 - 18pin plug variant: 5284 in case of complain or any diagnostic procedure, please verify the sensor increment value in Neutral: (if the value is >345 IC, the repair kit 0501 322 388 for the complete main transmission piston must be exchanged)

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AS-Tronic 2 Diagnostics

Page 46

Transmission Does Not Shift Diagnostic code: Complaint:

None - Transmission does not shift.

- Remains caught in 1st …16th gear.

- Confuse shifting.

Actions & Measures: Î Check software status. Î Work off checklist; accelerator pedal + brake signal must also be checked while traveling. Î Customer is not satisfied with the driving strategy. ¾

Detailed and exact complaint directly to be noted with the driver present and, if possible, insist upon demonstration. (registration by means of datalogger) ¾ Upon request, carry out driver training (Sales Promotion) Note:

Replacing the transmission actuator and/or clutch actuator and/or transmission does not solve the problem.

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AS-Tronic 2 Diagnostics

Page 47

Clutch Stick-Slip Problems (Clutch Judder / Shudder) Diagnostic code:

None

Actions & Measures: ÎGround flywheel: Tendency for juddering is reinforced. ÎWrong clutch installed (also refer to ZF-ServiceLine / Checklist). ) ÎRelease mechanism is sluggish (release unit's parts must be checked).

Î OEM Î OEM Î ZF

Note: In only few cases, replacing the transmission actuator will solve the problem. Prior to replacing the clutch parts however, it is recommended to first – temporarily - install a new clutch actuator. If this action does not solve the problem, then the genuine part must be reinserted!

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AS-Tronic 2 Diagnostics

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TC-Tronic (H95) Juddering while starting movement Diagnostic code:

None

Complaints: Î

Juddering while starting movement

Cause: Î

With software pak 7 (6009 374 584) comparing to pak 5 (6009 374 514) the clutch closes faster to reduce the clutch wear.

Actions: Î Î

Work off the checklist Measurement with Datalogger. Set: n_mot s_kup n_ab

n_sek alpha_fp sollgang

Activate handtrigger while the complaint occurs. Î

Records and checklist have to be send to Klaus.Graf@zf.com

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AS-Tronic 2 Diagnostics

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Diagnosis via Davie (DAF) Diagnostic code:

Clutch actuator defective (is only detected via the DAF diagnostic system called DAVIE)

Actions & Measures: Î The DAVIE diagnostic system controls the clutch actuator without transmission actuator control as such. Thus, it may happen that the clutch actuator – despite that control mode – does not travel.

Note: In this case, we are dealing with a wrong diagnosis. The clutch actuator is OK and thus, there is no need for replacement.

BKS-I/BKS-R As of:December 07 , 2005

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Limited Positions Outside of Tolerance Diagnostic code:

None

Actions & Measures: Î Shift fork wear due to non-hardened shift forks has only been reported up to the following transmission serial numbers: 10 AS 2301: 12 AS 2301: 16 AS 2601: Tolerance:

200249 203953 200603

and/or without IT: and/or without IT:

Upper range: max. 590 inc.

Lower range: min. 80 inc.

1518 394

(also refer to checklist)

Note: In the case of higher limited positions > also refer to the above stated transmission serial numbers, then -prior to removing the transmission- contact must be made with the respective technical expert departments in Friedrichshafen/ Germany.

With those higher limited positions, it is also the shift signal in neutral position which must be checked. If this signal is higher (> 345 inc.), then the transmission actuator’s lower part must be replaced. (alternative: repair kit 0501 322 388) BKS-I/BKS-R As of:December 07 , 2005

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High Level of Clutch Wear Burned Clutch Diagnostic code:

None

Actions & Measures: Î Read out statistics memory and save data. Î Under the following menu item, the loads exerted on the clutch can be read out: - Clutch data - Clutch overload protection / System energy Î Check software status: Latest software must be loaded. Î Instructions for the driver: Because of incorrect operation, the clutch can be destroyed in short time. Î EvoBus (model range 400 ; Travego) Model ranges before October 2003 did not have the CL on the display.

Remedy: SW- update from the vehicle’s computer Î Responsibility of the OEM

BKS-I/BKS-R As of:December 07 , 2005

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Too High Tilting Clearance at the DMF (Dual-Mass Flywheel) Diagnostic code:

None

Actions & Measures: Î OEMs affected: EvoBus; Neoplan Î Measure when installed in the vehicle: Tilting clearance up to 4 mm is admissible. Î If the tilting clearance is > 4mm, then the DMF must be removed and checked according to the test specification (OEM).

Note: Responsibility resides with OEM

BKS-I/BKS-R As of:December 07 , 2005

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Loud Noise During Intarder Operation Diagnostic code:

None

Actions & Measures: Î The output bearing must be checked in the case of loud noise in particular during Intarder operation.

Note: Only install bearings with 11 rollers!

Order no.: 0750 116 394

BKS-I/BKS-R As of:December 07 , 2005

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Over speeding of Engine Diagnostic code:

None

Actions & Measures: Î Because of tolerances in the driveline, it may happen that the engines overrevs/overspeeds directly after or during the shift process.

Remedy: MAN: EvoBus:

BKS-I/BKS-R As of:December 07 , 2005

Consultation with LKS-T dept. (Mr. Jung) bzw. BKS-I (Mr. Vogel, Mr. Pricha) Consultation with BKS-R dept. (Mr. Schelkle)

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Gear-Hunting Diagnostic code:

None

Actions & Measures: Î Check the kick-down signal.

Important: For MAN vehicles: Kick-down is only deactivated again after <80% of the accelerator pedal position. Î Check accelerator pedal. Î EvoBus: For vehicles from the model range 300, it must be checked whether a DMF (Dual Mass Fly) has been installed or not. -> Contact the BKS-R dept.

BKS-I/BKS-R As of:December 07 , 2005

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No Full Throttle Possible; Gear-Hunting Diagnostic code:

None

Actions & Measures: Î Vehicles from the EvoBus model range 300 are affected by this. Î If, with ignition ON, the engine is started immediately, then the engine’s electronics are taught the wrong engine torque. Î In the case of a 100% accelerator pedal position, only 80% injection volume is output. Î Remedy: After ignition ON, wait for approx. 1-2 seconds before starting the engine. Î Responsibility: EvoBus

Note: Control parameters with the datalogger: alpha_fp m_mot_akt

BKS-I/BKS-R As of:December 07 , 2005

(position of accelerator pedal) (current injection volume)

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EvoBus Model Range 300 Diagnostic code:

None

Complaints: Î Î Î Î Î Î

Shifting characteristics “Getting stuck on an uphill gradient.“ Overspeeding of engine.

No adaptation shifts below approx. 20 km/h up to standstill.

Shift noise during GP (range change group) shifting.

Load build-up in R gear operation too slow.

Speed limit for shifting in the lower speeds is not optimal.

Actions & Measures: Contact the BKS-R dept.

Remedial action planned for presumably end of 2005 by means of a software update.

BKS-I/BKS-R As of:December 07 , 2005

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Long Check Phase (CH) complaint:

Long „CH“ check phase, long shifting times, delay in the clutch learning process, bad shift quality

cause:

Air compressor contaminates the air system with hot engine oil with the result of a carbonization of the air hoses and all periphery components.

example:

Air connection (check valve/filter, Kit No.0501 322 365) new:

remedy action:

contaminated:

EvoBus did recognize this behavior mainly at the six cylinder engine with straight head OM 457 LA und HLA. Any remedy action must be organized via EvoBus. In case of complain, all ZF components must be exchanged and charged towards EvoBus.

BKS-I/BKS-R As of:December 07 , 2005

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