Diagnose AStronic Eng

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BKS-I/BKS-R As of:December 07 , 2005 AS-Tronic 2 Diagnostics Page 1 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: 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. AS-Tronic 2 Diagnostics

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Transcript of Diagnose AStronic Eng

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 1

    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:

    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.

    AS-Tronic 2 Diagnostics

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    Short circuit/Interruption TA* 3 2, 3, 4, 5, 6, 7, 8,9,10,17, 34, 35, 36, Page 537, 38, 39, 40, 41, 42, 49, 66, 67,68, 69, 70, 71, 72, 74, 81

    Short circuit ADVP* 22 Page 6Driveline retarder torque (CAN) 28 Page 7Measurement on diagnostic code 28 28 Page 8Input shaft speed defective 98 Page 9Speed error 99, 100, 101, 28 Page 10ZF-CAN Timeout 110 Page 11Harsh engagement partially 114 Page 12Measurement on diagnostic code 114 partially 114 Page 13Clutch self learning error 117 Page 14Measurement on diagnostic code 117 117 Page 15Clutch self learning error 117 in connection with 155 Page 16Air leakages 118, 145, 151, 154 Page 17Clutch does not engage 119 in connection with 124 Page 18Signal error clutch travel 124 Page 19Measurement on diagnostic code 124 124 Page 21Clutch travel error, noise 124 in connection with 102 Page 22Oil temperature sensor 128 Page 23Self adjustment error of shift sensor 132 in connection with 154 Page 24GV (splitter group) does not disengage 148 Page 25

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

    Table of Contents

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    GV (splitter group) does not change 149 Page 26Measurement on diagnostic code 149 149 Page 27Wabco transmission actuator < 15000 145, 146, 147, 149, 154, 156, 158 Page 28Selector cylinder jammed 151, 153 Page 29Main transmission not engaging 155 Page 30No starting gear N-D/R 155 Page 31Leaving of engaged position (GE,GV,GP) 158, 159, 160 Page 32Gear leaves engaged position 158 Page 33Gear leaves engaged position 158 in connection with 101 Page 34GV (splitter) leaves engaged position 160 in connection with 101 Page 35Datalogger measurement to FC 160 / 101 160 in connection with 101 Page 36Evo- Baureihe CC400 163 Page 37Signal error ignition lock 175 Page 38CAN Bus off 178 Page 39EvoBus, after SW Pak 7 Update 188 Page 40EEProm error while traveling 190, 191, 192 Page 41EEProm error after programming 190, 191, 192 Page 42EEProm error after engine start 192 Page 43CAN Error various Page 44

    Table of Contents

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    Complaints without diagnostics entry:

    Engine start not possible Page 45Engine start not possible Page 46Transmission does not shift Page 47Clutch judder Page 48TC-Tronic; Juddering while starting movement Page 49Defective clutch actuator Page 50Limited positions outside of tolerance Page 51High level of clutch wear / burned clutch Page 52Too high tilt clearance at the DMF (dual mass flywheel) Page 53Strong noise during Intarder operation Page 54Over speeding of engine Page 55Gear-hunting Page 56Gear-hunting; no full throttle possible Page 57EvoBus model range 300 Page 58Long Check Phase (CH) Page 59

    Table of Contents

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    Short Circuit/InterruptionShift 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:

    Check the systems air with reference to dirt / oil / water Replace the transmission actuator!

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    Short circuit ADVP* (Output of Supply Power )

    Diagnostic code: 22

    Actions & Measures:

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

    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:

    Speedometer sensor/wiring must be checked. 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):

    (also refer to measurements on next page)

    Tachograph EST 42speed signal amplifier

    Further ECUs

    Speedsensor

    EST 42speed signal amplifier

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    Measurement on Diagnostic Code 28

    Engine speed

    Output speed (peak)

    Control parameters (measured at Intarder ECU):

    engine speed (unfiltered) = Motordrehzahloutput 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:

    The diagnostic code is set e.g. when starting the engine driving error. 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. Transmission

    If there are no noticeable problems to be found at the counting disc, then thetransmission actuators 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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    Speed Error (EvoBus)

    Diagnostic code: 99, 100, 101, 28 (EvoBus)

    Actions & Measures:

    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:

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

    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 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:

    Grease clutch release (can be done with the transmission installed in the vehicle). SI 16/04c

    Check the lubrication of input shaft. Check the release bearing. Check the clutch parts (pressure plate, disc, flywheel).

    Grease to be used: Optimol Olista Longtime 3EP 100 gr. 0671 190 1651 KG: 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

    input speed (n_sek) increases to 345 rev/min harsh engagementjudder of cabine

    clutch (s_kup)leaps up to 40 %

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

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    Clutch Self Learning Error

    Diagnostic code: 117

    Actions & Measures:

    Clutch does not separate (also refer to datalogger measurement).Note: Follow-up damage at the transmissions brake cannot be excluded in such a case.

    Release bearing broken and/or unhooked? Release fork broken? Air supply OK? Pilot bearing scored? 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

    Measurement:

    Ignition on 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.

    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.

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    Clutch self learning Error

    Diagnostic code: 117 in connection with 155

    Actions & Measures:

    Check transmission braking gradient (e.g. oil leakage at the transmission ventilation unit).

    Check the clutchs parts. If the clutchs parts are OK, then replace the transmission actuators 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:

    Check software status (floating valves) and update correspondingly 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:

    Check clutch parts 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!

    Exchange or replacement of clutch actuator is justified.

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    Signal Error Clutch Travel

    Diagnostic code: 124

    Actions & Measures:

    Water / Oil in the air system Responsibility: OEM Counting disc loose in transmission Responsibility: ZF (basic transmission) 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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    Signal Error Clutch Travel

    Diagnostic code: 124

    Actions & Measures:

    In connection with the self-adjusting clutch (Setra, EvoBus), unwanted resetting also took place several times while traveling. Here, replacing the clutch becomes necessary.

    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. 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 clutch adjusting starts

    diagnostic code 124 is active

    n_sek increase thoughn_mot < 400 rev/min

    adjusting procedure failed

    proposal of measurementparameters:

    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 activBit 3 = Clutch adjusting finished

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    Clutch Travel Error, Noise

    Diagnostic code: 124 in connection with 102

    Actions & Measures:

    Securing rings incorrectly mounted. Also refer to 2004 Annual Technical Seminar,

    Chapter 05a, Slide 15.

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    Temperature Sensor (Oil)

    Diagnostic code: 128

    Actions & Measures:

    Oil temperature must be checked by means of TestmanPro(interruption = - 9C).

    In the case of unrealistic values, the transmission actuators 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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    Self Adjustment Error of Shift Sensor

    Diagnosecode: DC 132 in connection with 154

    Actions & Measures:

    Neutral will not be recognized.Check the sensor increment value in neutral.

    Nominal value: 300 350 inc

    Refer to chapter Engine Start Not Possible

    Note: Engine start is possible for vehicles which are using the neutral switch for the starterinterlock. 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:

    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. 0671 190 1651 KG: 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:

    Check clutch separating behavior. Build-up of torque to be checked (1st gear in maneuvering mode: Drive at approx. 30

    % of clutch travel) 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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    Measurement on Diagnostic Code 149

    Splitter blocked at 457 inc.

    Clutch does engageto disengage the blocking

    Diagnostic code 149 is set

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    Transmission Actuator Wabco No. < 15000

    Diagnostic code: 145, 146, 147, 149, 154, 156, 158, 159, 160

    Actions & Measures:

    Check limited positions of the transmission. If the limited positions are Ok, then replace the transmission actuators lower part

    (defective crimping). 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:

    Disassemble transmission actuator and check gate cylinder with reference to possible sluggishness, stiffness of movement.

    The transmission actuators 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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    Main Transmission Not Engaging

    Diagnostic code: 155

    Actions & Measures:

    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

    The clutch parts must be checked.

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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:

    ZF Software; parameter too small (= difference of layshaft to mainshaft rpm) during the shifting stationary: additional wrong parameter by selecting the starting gearRemedy: SW Update to SW Paket 7 Stand 6009 374 635AS in case of complain serial production change of the software

    Note: Update of the chassis side datafile through MAN necessary 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:

    Check earth continuity connector (bonding) of the transmission.Currently: MAN mass node in the cable duct is loose above of the engine

    OEM In the case of the transmission actuator < 15000, the transmission actuators 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:

    Check limited positions (outside of tolerance Shift forks and/or neutral signal to be checked; also refer to Limited positions outside of tolerance)

    In the case of new vehicles and/or after transmission replacement, then the countershafts position must be checked. (error in coasting-traction changes can be reproduced).

    Countershaft production error 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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    Gear Leaves Engaged Position

    Diagnostic code: 158 in connection with 101

    Actions & Measures:

    Check limited positions (Outside of tolerance Check shift forks)

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

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    GV (Splitter Group) Leaves Engaged Position

    Diagnostic code: 160 in connection with 101

    Actions & Measures:

    The error can be reproduced as follows (datalogger recordings):

    Carry out shifts: 1-2-1If the GV (splitter group) does not shift through, then actuate the accelerator pedal after 4-5 seconds. Diagnostic code 160 is set since the GV (splitter group) signal is drifting away. 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.

    GV (splitter group) must be checked.

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    Datalogger Measurement to DC 160 / 101

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

    Accelerator pedal is actuated; input speed is on the increase.

    Clutch closes

    Error is set.

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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:

    During a downshift 7-6 in throttle, AS Tronic is changing the signal limit of enginerpm between on and off. Signal does toggle.

    Because of toggling, the engine does not accept the transmission requestRemedy:

    SW Update SW Paket 7 Stand V33_4g (MB Nr.A0014462109) in case of complain no generell field action

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    Signal Error Ignition Lock

    Diagnostic code: 175

    Actions & Measures:

    Power supply to transmission actuator (Terminal 15) must be checked. Case well known:

    IVECO: Defective body computer.

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

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    CAN Bus Off

    Diagnostic code: 178

    Actions & Measures:

    Control units that are connected to the vehicle CAN must be checked. The CAN plug connections from the vehicle CAN must be checked.

    Currently known: MANThe 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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    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 areincompatible with the new software package 7.

    affected spec.lists (old GS3):amount of transmission:

    1337 044 001 A001 260 30 00 TC400 OM457 LA 310kW 261337 042 006 A001 260 29 00 TC400 OM502 LA 350kW 104 1337 044 002 A001 260 35 00 TC400 OM502 LA 320kW 4 1337 044 003 A001 260 33 00 300 GT-HD OM457 LA 310kW 61337 044 004 A001 260 31 00 300 UL OM457 hLA 260kW 81337 044 005 A001 260 37 00 300 UL OM457 hLA 300kW 5 1337 044 007 A001 260 39 00 300 GT-HD OM502 LA 320kW 4

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    EE-Prom Error

    Diagnostic code: 190, 191, 192 (while traveling)

    Actions & Measures:

    For the ZF transmission actuator GS-3 no. < 372733, the transmission actuators upper part must be replaced.

    Note:Replacing the transmission actuators 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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    EE-Prom Error

    Diagnostic code: 190, 191, 192 after the programming process

    Actions & Measures:

    The parameterization must be checked. Check cabling of Terminal 15/Terminal 30.

    Note: For the current SW status of TestmanPro, the following icon must be activated: ConfigurationAdditional brakes

    Software status is V31 13f or new

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    EE-Prom Error

    Diagnostic code: 192 after engine start (transmission + PTO)

    Actions & Measures:

    If, with ignition on, the signal Nebenabtrieb PTO1 aktiv (=power take-off PTO1 active) is set, then the transmission actuators (GS-3) electronics do not switch off correctly. After ignition ON, (sometimes) the diagnostic code 192 is displayed.

    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!! OEM / Body builder

    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 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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    CAN Error

    Diagnostic code: Various

    Actions & Measures:

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

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

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    Engine Start Not Possible

    Diagnostic code: None (MAN: FFR 3197)

    Actions & Measures:

    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.

    Important: Possible higher limited positions are also due to thetransmission actuators 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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    Engine Start Not Possible

    Cause of failure excessive wear inside the

    main piston of the GS3 because ofunusual incoming frequency

    Remedy

    serial introduction steel shim week 14 / 2005serial no. GS3 - 20pin plug Standard: 131495- 18pin plug variant: 5284

    in case of complain or any diagnostic procedure, please verify the sensor increment valuein Neutral:(if the value is >345 IC, the repair kit 0501 322 388 for the complete main transmissionpiston must be exchanged)

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    Transmission Does Not Shift

    Diagnostic code: None

    Complaint: - Transmission does not shift. - Remains caught in 1st 16th gear.- Confuse shifting.

    Actions & Measures: Check software status. Work off checklist; accelerator pedal + brake signal must also be checked while

    traveling. Customer is not satisfied with the driving strategy. Detailed and exact complaint directly to be noted with the driver present and, if

    possible, insist upon demonstration. (registration by means of datalogger) 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.

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 48

    Clutch Stick-Slip Problems (Clutch Judder / Shudder)

    Diagnostic code: None

    Actions & Measures:

    Ground flywheel: Tendency for juddering is reinforced. OEMWrong clutch installed (also refer to ZF-ServiceLine / Checklist). ) OEMRelease mechanism is sluggish (release unit's parts must be checked). 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 re-inserted!

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 49

    TC-Tronic (H95)Juddering while starting movement

    Diagnostic code: None

    Complaints: Juddering while starting movement

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

    wear.

    Actions: Work off the checklist Measurement with Datalogger. Set:

    n_mot n_seks_kup alpha_fpn_ab sollgang

    Activate handtrigger while the complaint occurs.

    Records and checklist have to be send to [email protected]

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 50

    Diagnosis via Davie (DAF)

    Diagnostic code: Clutch actuator defective

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

    Actions & Measures:

    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-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 51

    Limited Positions Outside of Tolerance

    Diagnostic code: None

    Actions & Measures: Shift fork wear due to non-hardened shift forks has only been reported up to the following

    transmission serial numbers:10 AS 2301: 20024912 AS 2301: 203953 and/or without IT: 151816 AS 2601: 200603 and/or without IT: 394

    Tolerance: Upper range: max. 590 inc.Lower range: min. 80 inc. (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 actuators lower part must be replaced. (alternative: repair kit 0501 322 388)

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 52

    High Level of Clutch WearBurned Clutch

    Diagnostic code: None

    Actions & Measures: Read out statistics memory and save data. Under the following menu item, the loads exerted on the clutch can be read out:

    - Clutch data - Clutch overload protection / System energy

    Check software status:Latest software must be loaded.

    Instructions for the driver:Because of incorrect operation, the clutch can be destroyed in short time.

    EvoBus (model range 400 ; Travego)Model ranges before October 2003 did not have the CL on the display. Remedy:SW- update from the vehicles computer Responsibility of the OEM

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 53

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

    Diagnostic code: None

    Actions & Measures: OEMs affected: EvoBus; Neoplan Measure when installed in the vehicle:

    Tilting clearance up to 4 mm is admissible.

    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-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 54

    Loud Noise During Intarder Operation

    Diagnostic code: None

    Actions & Measures: 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-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 55

    Over speeding of Engine

    Diagnostic code: None

    Actions & Measures: Because of tolerances in the driveline, it may happen that the engines overrevs/overspeeds directly

    after or during the shift process.

    Remedy:

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

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 56

    Gear-Hunting

    Diagnostic code: None

    Actions & Measures: Check the kick-down signal.

    Important: For MAN vehicles: Kick-down is only deactivated again after Contact the BKS-R dept.

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 57

    No Full Throttle Possible;Gear-Hunting

    Diagnostic code: None

    Actions & Measures: Vehicles from the EvoBus model range 300 are affected by this. If, with ignition ON, the engine is started immediately, then the engines electronics are taught the

    wrong engine torque. In the case of a 100% accelerator pedal position, only 80% injection volume is output.

    Remedy:After ignition ON, wait for approx. 1-2 seconds before starting the engine.

    Responsibility: EvoBus

    Note:Control parameters with the datalogger:

    alpha_fp (position of accelerator pedal)m_mot_akt (current injection volume)

  • BKS-I/BKS-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 58

    EvoBus Model Range 300

    Diagnostic code: None

    Complaints: 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-RAs of:December 07 , 2005

    AS-Tronic 2 Diagnostics Page 59

    Long Check Phase (CH)

    complaint: Long CH check phase, long shifting times, delay in the clutch learningprocess, bad shift quality

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

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

    new: contaminated:

    remedy action: EvoBus did recognize this behavior mainly at the six cylinder engine withstraight 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 chargedtowards EvoBus.