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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
BKS-I/BKS-RAs of:December 07 , 2005
AS-Tronic 2 Diagnostics Page 2
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
BKS-I/BKS-RAs of:December 07 , 2005
AS-Tronic 2 Diagnostics Page 3
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
BKS-I/BKS-RAs of:December 07 , 2005
AS-Tronic 2 Diagnostics Page 4
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
BKS-I/BKS-RAs of:December 07 , 2005
AS-Tronic 2 Diagnostics Page 5
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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AS-Tronic 2 Diagnostics Page 6
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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AS-Tronic 2 Diagnostics Page 7
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
BKS-I/BKS-RAs of:December 07 , 2005
AS-Tronic 2 Diagnostics Page 8
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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AS-Tronic 2 Diagnostics Page 9
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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AS-Tronic 2 Diagnostics Page 10
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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AS-Tronic 2 Diagnostics Page 11
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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AS-Tronic 2 Diagnostics Page 12
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!
BKS-I/BKS-RAs of:December 07 , 2005
AS-Tronic 2 Diagnostics Page 13
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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AS-Tronic 2 Diagnostics Page 14
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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AS-Tronic 2 Diagnostics Page 17
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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AS-Tronic 2 Diagnostics Page 18
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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AS-Tronic 2 Diagnostics Page 19
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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AS-Tronic 2 Diagnostics Page 20
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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AS-Tronic 2 Diagnostics Page 22
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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AS-Tronic 2 Diagnostics Page 24
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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AS-Tronic 2 Diagnostics Page 25
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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AS-Tronic 2 Diagnostics Page 26
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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AS-Tronic 2 Diagnostics Page 27
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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AS-Tronic 2 Diagnostics Page 28
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!
BKS-I/BKS-RAs of:December 07 , 2005
AS-Tronic 2 Diagnostics Page 29
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.
BKS-I/BKS-RAs of:December 07 , 2005
AS-Tronic 2 Diagnostics Page 30
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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AS-Tronic 2 Diagnostics Page 31
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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AS-Tronic 2 Diagnostics Page 32
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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AS-Tronic 2 Diagnostics Page 34
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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AS-Tronic 2 Diagnostics Page 36
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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AS-Tronic 2 Diagnostics Page 38
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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AS-Tronic 2 Diagnostics Page 39
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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AS-Tronic 2 Diagnostics Page 41
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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AS-Tronic 2 Diagnostics Page 42
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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AS-Tronic 2 Diagnostics Page 44
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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AS-Tronic 2 Diagnostics Page 47
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.
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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!
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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 Klaus.Graf@zf.com
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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:
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.
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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.