ZF Intarder EST-42 Troubleshooting 68-Pole

1

2

3

4

5

6

7

8 9 0

2 0 0 6 0 0 8 0 0 6

003 105

Electrical troub troubleshooting leshooting Testing with 68-pole terminal tester 6038 756 111b

Subject to alterations in design

Copyright by ZF These repair instructions are protected by copyright. Any reproduction and dissemination in whatever form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law. Printed in Germany

Edition: 01.97

6038 756 111b

ZF Intarder Electrical troubleshooting

Contents

Page Preface ....................................................................................................................................................................

3

Work safety, brief description..................................................................................................................................

4

Items in tester set .....................................................................................................................................................

5

Test set-up................................................................................................................................................................

6

Example measurements...........................................................................................................................................

7

Circuit diagram........................................................................................................................................................

8

Checklist, vehicle circuit .........................................................................................................................................

9

Checklist, ABS signal..............................................................................................................................................

9

Checklist, proportional solenoid valve ....................................................................................................................

9

Checklist, solenoid valve.........................................................................................................................................

9

Checklist, display lamp .......................................................................................................................................... 10 Checklist, relay........................................................................................................................................................ 10 Checklist, temperature sensor ................................................................................................................................. 10 Checklist, braking level selector ............................................................................................................................. 11 Checklist, flashing code button ............................................................................................................................... 13 Checklist, solenoid valve, relay valve, display lamps ............................................................................................ 14 Notes ....................................................................................................................................................................... 15


Preface

This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF product in accordance with the state of development on the date of issue.

However, due to continuing development of the product, repair work might require work practices and test or adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our after-sales service training courses. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Well-trained personnel 2. Specified equipment, e.g. specialized tools 3. Genuine ZF spares, to our latest specifications

All work performed in these service points is carried out conscientiously and with care. Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual conditions.

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together with follow-on costs caused by such work, is excluded from the contractual guarantee agreement. This also applies where genuine ZF spares have not been used.

ZF FRIEDRICHSHAFEN AG

Friedrichshafen Division After-Sales Service

3

General


Important work safety notice:

Companies who repair ZF units are responsible for their own work safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations.

Personnel required to carry out repairs on these products must receive apprpriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.

The following safety instructions appear in this manual: NOTE:

Refers to special processes, techniques, data, use of auxiliary equipment, etc..

CAUTION

This is used when incorrect, unprofessional working practices could damage the product.

!

DANGER

This is used when lack of care could lead to personal injury or death.

NOTE: Read this manual carefully before starting any tests or repair work.

After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly.

BRIEF DESCRIPTION The terminal tester can be used to test the resistance (ohms) and the function of transmission components such as selector control, load sensor, solenoid valves, sensors etc., with the components still installed. CAUTION The test must only be carried out with the vehicle stationary, parking brake applied and engine "OFF". Otherwise the vehicle may roll away, causing injury or damage.

4


Items in tester set

1

2

1

2

3

4

5

6

7

8 9 0

2 0 0 6 0 0 8 0 0 6

3

4

003 106

5

6

7

8

001691

001692 001689

001689

001690

001690

001691

001692

Terminal Tester Set 6008 199 001

1 2 3 4

= Terminal tester = Jumpers (68) = 68-, 55-, 25-pole plug for connection to ECU = 68-, 55-, 25-pole adapter for connection to vehicle cable harness

5 = 68/55-pol plug adapter included in scope of supply 6 = 68/55-pol socket adapter included in scope of supply 7 = 55/25-pol plug adapter 6008 004 027 8 = 55/25-pol socket adapter 6008 004 026

5

Test set-up


Connecting the terminal tester

1. Secure vehicle to prevent it rolling away unintentionally (parking brake).

4. Disconnect Electronic Control unit. 5. Connect terminal tester between ECU and vehicle cable harness.

2. Switch off engine and ignition. 3. Check whether ZF system is protected by correct fuse (5-8 amperes).

Connections:

Terminal box 68-pole

Terminal Tester Set 6008 199 001

Terminal box 55-pole

1P01 137 834 6008 006 002 discontinued

Adapter cable 68 55-pole

-

Soc. 6008 004 024 Plug 6008 004 025

Adapter cable 55 25-pole

-

Soc. 6008 004 026 Plug 6008 004 027

Electronic control unit 25-pole EST 32 Intarder

6


Voltage measurement

1

+ V –

2

Measuring range min. 24 V DC. In this example, voltage is mea sured between Terminals 1 and 2, with the positive lead of the voltmeter connected to Terminal 1 and the negative lead connected to Terminal 2.

Example measurement

Connections

1

2

In this example, a connection must be created between Terminals 1 and 2.

1

2

In this example, a connection between Terminals 1 and 2 must be removed. Resistance measurement in temperature range 20 °C to 105°C

1

+ Ω –

2

Measuring range min. 400 Ohms for solenoid valve or relay. In this example, the ohmmeter is connected between Terminals 1 and 2.

7

Circuit diagram

+ VEH. CIR. + BN

ZF Intarder electrical trouble-shooting

1

2

1

2

S1

F1

1

H2 2

11

1 10 22 9 8 7 6 19

1 2 3 4 5 6 +KEY +TASTER

A2

ED1 ED2 ED3 ED4 ED5 ED6 ED9

ADM

VP

SDDI

A1

21 ED7 20 5 4

1

ABS

A31

A30

A7

ED8

AD1 AIP

3 14

EF1 ER VMG1

VM1

12

13

VM2 25

AD2

1

2

ED7

RAIP

2 86

H1

A11

AD3

15

B2 T

1 (+) 2 K 3 (-)

18

87

23

86

87

85

30

1

Y1

1

Y2 2

2

S2 K1 2

85

30

(-) STECKERANSICHT

ITEM

CONNECTOR DIAGRAM SHOWN

PIN PATTERN X1

PIN PATTERN X2

PIN PATTERN X3

PIN PATTERN X4

PIN PATTERN X5

PIN PATTERN X8

PIN PATTERN X9

PIN PATTERN X6, X7

001 522

AMP AMP 25-POLE 8-POLE CONTACT JACK CONTACT JACK

AMP JUN POW TIMER 18-POLE CONTACT JACK

AMP MATE-N-LOK 9-POLE CONTACT JACK CONNECTOR HOUSING

ROUND PLUG 2-POLE, K24

CANNON 6-POLE CA PIN

AMP MATE-N-LOK 3-POLE PIN ADAPTER HOUSING

ROUND PLUG 2-POLE, K27

TITLE

A1

EST 32 ELECTRONIC CONTROL UNIT

A2

BREMSOMAT BRAKING LEVEL SELECTOR

A7

DIAGNOSIS (ISO 9141 TESTER)

A11

OUTPUT SPEED SIGNAL

A30

FLASHING CODE BUTTON

A31

ABS

B2

COOLING WATER TEMPERATURE SENSOR

F1

3A FUSE

H1

INTARDER DISPLAY LAMP ON

H2

DIS PL AY LAM P FLA SHI NG CO DE

K1

BRAKE LAMP RELAY

S1

INTARDER SWITCH ON

S2

ABS OFF SWITCH

Y1

INTARDER PROPORT. SOLENOID VALVE

Y2

INTARDER ACCUMULATOR SOLENOID VALVE


No.

Name

Pre-set position

Checklist

Measure. dev. test connection

Rated value

Cause if not at rated value

Vehicle circuit 1

Veh. circuit

ECU unplugged, veh. circuit 'ON', Intarder switch 'ON'

1

+ V –

13

24 V

Fuse defective, line interrupted, Intarder switch 'ON' defective

2

Veh. circuit


1

+ V –

25

24 V

Fuse defective, line interrupted, Intarder switch 'ON' defective

3

Intarder switch 'ON'

ECU unplugged, veh. circuit 'ON', Intarder switch 'OFF'

1

+ V –

25

0V

Intarder switch 'ON' defective


1

+ V –

21

0V

Intarder switch 'ON' defective, ABS signal present, ABS relay defective

–

23

23-33 Ω

Cable harness line interrupted/short-circuit, plug loose, proportional solenoid valve Y1 defective

–

13

51-73 Ω

Cable harness line interrupted/short-circuit, plug loose, solenoid valve Y2 defective

ABS signal 4

ABS signal

Proportional solenoid valve 5

Proportional solenoid valve Y1

ECU unplugged, veh. circuit 'OFF'

14

+

Ω


3

+

Ω

Solenoid valve

6

Solenoid valve Y2

New valves: 120-130 Ω

9


Checklist

No.

Name

Pre-set position


Rated value


Display lamp –

13

approx. 46 Ω

Cable harness line interrupted/short-circuit lamp H1 defective, lamp H1 loose

1

+ Ω –

11

approx. 46 Ω

Cable harness line interrupted/short-circuit lamp H2 defective, lamp H2 loose


2

+ Ω –

13

278-330 Ω

Cable harness line interrupted/short-circuit relay K1 loose, relay K1 defective, not fitted


4

+ Ω –

12

at 20 °C approx. 50 k Ω at 80 °C approx. 3.5 k Ω at 120 °C approx. 1 k Ω

7

Intarder 'ON' display lamp H1


15

8

Flashing code H2 display


Brake lamp relay K1

+

Ω

Relais 9

Temperature sensor 10

10

Water temperature sensor B2

Cable harness line interrupted/short-circuit plug loose, water temperature sensor defective


No.

Name

Checklist

Pre-set position


Rated value

ECU unplugged, veh. circuit 'ON Level '0'

10

+ V –

13

0V

22

+ V –

13

0V

9

+ V –

13

0V

8

+ V –

13

0V

7

+ V –

13

0V

6

+ V –

13

0V

19

+ V –

13

0V

10

+ V –

13

24 V

22

+ V –

13

0V

9

+ V –

13

0V

8

+ V –

13

0V

7

+ V –

13

0V

6

+ V –

13

0V

19

+ V –

13

0V

10

+ V –

13

24 V

22

+ V –

13

24 V

9

+ V –

13

0V

8

+ V –

13

0V

7

+ V –

13

0V

6

+ V –

13

0V

19

+ V –

13

0V


Braking level selector 11

12

13

Braking level selector A2 Level '0'



ECU unplugged, veh. circuit 'ON Intarder switch 'ON' Level '1'

ECU unplugged, veh. circuit 'ON Intarder switch 'ON' Level '2'

Braking level selector A2 defective Short-circuit in 24 V line

Cable harness line interrupted/short-circuit to 24 V / earth (ground), plug loose, braking level selector A2 defective


11


Checklist

No.

Name

Pre-set position


Rated value

ECU unplugged, veh. circuit 'ON' Intarder switch 'ON' Level '3'

10

+ V –

13

24 V

22

+ V –

13

24 V

9

+ V –

13

24 V

8

+ V –

13

0V

7

+ V –

13

0V

6

+ V –

13

0V

19

+ V –

13

0V

10

+ V –

13

24 V

22

+ V –

13

24 V

9

+ V –

13

24 V

8

+ V –

13

24 V

7

+ V –

13

0V

6

+ V –

13

0V

19

+ V –

13

0V

10

+ V –

13

24 V

22

+ V –

13

24 V

9

+ V –

13

24 V

8

+ V –

13

24 V

7

+ V –

13

24 V

6

+ V –

13

0V

19

+ V –

13

0V



15

16

12










No.

Name

Checklist

Pre-set position


Rated value


10

+ V –

13

24 V

22

+ V –

13

24 V

9

+ V –

13

24 V

8

+ V –

13

24 V

7

+ V –

13

24 V

6

+ V –

13

24 V

19

+ V –

13

0V

10

+ V –

13

0V

22

+ V –

13

0V

9

+ V –

13

0V

8

+ V –

13

0V

7

+ V –

13

0V

6

+ V –

13

0V

19

+ V –

13

24 V



18


Braking level selector A2 Level '0', Bremsomat 'actuated'

ECU unplugged, veh. circuit 'ON' Intarder switch 'ON' Bremsomat 'ON'



Flashing code button 19

Flashing code button A30 'OFF'

ECU unplugged, veh. circuit 'ON', flashing code button 'OFF'

1

+ V –

20

0V

Short-circuit, cable harness A30 defective

20

Flashing code button A30 'ON'

ECU unplugged, veh. circuit 'ON', flashing code button 'ON'

1

+ V –

20

24 V

Cable harness line interrupted/short-circuit to earth (ground), plug loose, not fitted

13


Checklist

No.

Name

Pre-set position


Rated value


Solenoid valve, relay valve, display lamps 21

Solenoid valve Y2

ECU unplugged, veh. circuit 'ON'

1

3

Accumul. pressurized

Solenoid valve Y2 defective, no air pressure, piston sticking

22

Relay K1


1

2

Brake lamp lit

Relay K1 defective, brake lamp defective, not connected

23

Display lamp Intarder 'ON'


1

15

Intarder display lamp 'ON' lit

Display lamp H1 defective, not connected

24

Display lamp flashing code H2


11

Flashing code display lamp lit

Display lamp H2 defective, not connected

13

NOTE: Do not test proportional solenoid valve Y1 with voltage or it will be damaged.

14

ZF Intarder Electrical trouble-shooting

Notes

ZF Intarder EST-42 Troubleshooting 68-Pole

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