zf intarder est-42 troubleshooting 68-pole
TRANSCRIPT
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6 0 0 8 0 0
6 0 0 2
1 2
3 4
5 6
7 8
9 0
003 105
Electrical troubleshootingTesting with68-pole terminal tester
6038 756 111b
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Subject to alterations in design
Copyright by ZF
These repair instructions are protected by copyright. Any reproduction and dissemination in whateverform – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical orelectronic 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
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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
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This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry outmaintenance 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 oradjustment data which are not contained in this manual. We therefore recommend that work done on your ZFproduct is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated ona 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 contractualconditions.
Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, togetherwith follow-on costs caused by such work, is excluded from the contractual guarantee agreement. This also applieswhere genuine ZF spares have not been used.
ZF FRIEDRICHSHAFEN AG
Friedrichshafen DivisionAfter-Sales Service
ZF Intarder Electrical troubleshooting Preface
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5
ZF Intarder Electrical troubleshooting Items in tester set
Terminal Tester Set 6008 199 001
1 = Terminal tester 2 = Jumpers (68)3 = 68-, 55-, 25-pole plug for connection to ECU4 = 68-, 55-, 25-pole adapter
for connection to vehicle cable harness
5 = 68/55-pol plug adapter included in scope of supply6 = 68/55-pol socket adapter included in scope of
supply7 = 55/25-pol plug adapter 6008 004 027 8 = 55/25-pol socket adapter 6008 004 026
6 0 0 8 0
0 6 0 0 2
2 3
7 8
9 0
3 4
21
6 5
4
1
003 106
001689001690
001691
001692
5 6 7 8
001689 001690 001691 001692
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Test set-up ZF Intarder Electrical troubleshooting
6
Connecting the terminal tester
1. Secure vehicle to prevent it rolling awayunintentionally (parking brake).
2. Switch off engine and ignition.
3. Check whether ZF system is protected by correctfuse (5-8 amperes).
Connections:
4. Disconnect Electronic Control unit.
5. Connect terminal tester between ECU and vehiclecable harness.
Terminal box68-pole
6008 006 002
Terminal box55-pole
1P01 137 834
discontinued
Adapter cable68 - 55-pole
Soc. 6008 004 024Plug 6008 004 025
Adapter cable
55-
25-pole
Soc. 6008 004 026Plug 6008 004 027
Electronic control unit25-pole
EST 32 Intarder
Terminal Tester Set6008 199 001
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ZF Intarder Electrical troubleshooting Example measurement
7
Voltage measurement
Measuring range min. 24 V DC.In this example, voltage is measured between Terminals1 and 2, with the positive lead of the voltmeter connected
to Terminal 1 and the negative lead connected to Termi-nal 2.
Resistance measurement in temperature range20 °C to 105°C
Measuring range min. 400 Ohms for solenoid valve or relay.In this example, the ohmmeter is connected between Ter-minals 1 and 2.
Connections
1 2
In this example, a connection must be created betweenTerminals 1 and 2.
1 2
In this example, a connection between Terminals 1 and 2must be removed.
+ – V1 2
+ – 1 2Ω
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Circuit diagram
A2
+ BN1 2
F1
1 2
S1
123456
+TASTER
1022
9876
19
ED1ED2ED3ED4ED5ED6ED9
1
VP ADM
H2
1
2
11
SDDI18
AD13
AIP14
ED8
EF1
ERVMG1 VM2VM1 AD2 AD3 RAIP
A120
5
4
12 13 25 15 2 23
1 86
2 85
K1
1
2
Y1
A30 A11
B2
H1T
1
2
( - )
A31
ABS
ED721
86
85
87
30
S2
ED7
87
30
001 522
IT
A A A A
A A
BFHHKSSYY
PIN PATTERNX1
PIN PATTERNX2
PIN PATTERNX3
PIN PATTERNX4
PIN PATTERNX5
PIN PATTERNX8
PIN PATTERNX9
AMP8-POLECONTACT JACK
AMP25-POLECONTACT JACK
AMP JUN POW TIMER 18-POLECONTACT JACK
AMP MATE-N-LOK 9-POLECONTACT JACK CONNECTORHOUSING
ROUND PLUG2-POLE, K24
ROUND PLUG2-POLE, K27
CANNON6-POLE CAPIN
AMP MATE-N-LOK 3-POLEPINADAPTER HOUSING
PIN PATTERNX6, X7
+ VEH. CIR.
+ K E Y
STECKERANSICHT
CONNECTOR DIAGRAM SHOWN
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No. Name Pre-set position Measure. dev. Rated Cause if not attest connection value rated value
1
2
3
4
5
6
Veh. circuit
Veh. circuit
Intarder switch'ON'
ABS signal
Proportionalsolenoid valveY1
Solenoid valveY2
ECU unplugged, veh.circuit 'ON',Intarder switch 'ON'
ECU unplugged, veh.circuit 'ON',Intarder switch 'ON'
ECU unplugged, veh.circuit 'ON',Intarder switch 'OFF'
ECU unplugged, veh.circuit 'ON',Intarder switch 'ON'
ECU unplugged, veh.circuit 'OFF'
ECU unplugged, veh.circuit 'OFF'
24 V
24 V
0 V
0 V
23-33 Ω
51-73 Ω
Newvalves:
120-130 Ω
Fuse defective, lineinterrupted,Intarder switch 'ON'defective
Fuse defective, lineinterrupted,Intarder switch 'ON'defective
Intarder switch'ON' defective
Intarder switch 'ON'defective,ABS signal present,ABS relay defective
Cable harness lineinterrupted/short-circuit,
plug loose, proportional solenoid valveY1 defective
Cable harness lineinterrupted/short-circuit,
plug loose,solenoid valve Y2 defective
9
ChecklistZF IntarderElectrical troubleshooting
+ – V1 13
+ – V1 25
+ – V1 25
+ – V1 21
ABS signal
Vehicle circuit
Proportional solenoid valve
Solenoid valve
+ – 14 23Ω
+ – 3 13Ω
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No. Name Pre-set position Measure. dev. Rated Cause if not attest connection value rated value
7
8
9
10
Intarder 'ON'display lamp H1
Flashing codeH2 display
Brake lamprelayK1
Water temperaturesensor B2
ECU unplugged, veh.circuit 'OFF'
ECU unplugged, veh.circuit 'OFF'
ECU unplugged, veh.circuit 'OFF'
ECU unplugged, veh.circuit 'OFF'
approx.46 Ω
approx.46 Ω
278-330 Ω
at 20 °Capprox.50 k Ωat 80 °Capprox.3.5 k Ωat 120 °Capprox.1 k Ω
Cable harness lineinterrupted/short-circuitlamp H1 defective,lamp H1 loose
Cable harness lineinterrupted/short-circuitlamp H2 defective,lamp H2 loose
Cable harness lineinterrupted/short-circuitrelay K1 loose,relay K1 defective,not fitted
Cable harness lineinterrupted/short-circuit
plug loose,water temperature sensor defective
10
ZF IntarderElectrical troubleshooting
Checklist
Display lamp
Relais
Temperature sensor
+ – 15 13Ω
+ – 1 11Ω
+ – 2 13Ω
+ – 4 12Ω
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No. Name Pre-set position Measure. dev. Rated Cause if not attest connection value rated value
11
12
13
Braking levelselector A2Level '0'
Braking levelselector A2Level '1'
Braking levelselector A2Level '2'
ECU unplugged,veh. circuit 'ONLevel '0'
ECU unplugged,veh. circuit 'ONIntarder switch 'ON'Level '1'
ECU unplugged,veh. circuit 'ONIntarder switch 'ON'Level '2'
0 V
0 V
0 V
0 V
0 V
0 V0 V
24 V
0 V
0 V
0 V
0 V
0 V
0 V
24 V
24 V
0 V
0 V
0 V
0 V
0 V
Braking level selector A2defectiveShort-circuit in 24 V line
Cable harness lineinterrupted/short-circuit to24 V / earth (ground),
plug loose, braking level selector A2defective
Cable harness lineinterrupted/short-circuit to24 V / earth (ground),
plug loose, braking level selector A2defective
11
ChecklistZF IntarderElectrical troubleshooting
Braking level selector
+ – V10 13
+ – V22 13
+ – V9 13
+ – V8 13
+ – V7 13
+ – V6 13
+ – V19 13
+ – V10 13
+ – V22 13
+ – V9 13
+ – V8 13
+ – V7 13
+ – V6 13
+ – V19 13
+ – V10 13
+ – V22 13
+ – V9 13
+ – V8 13
+ – V7 13
+ – V6 13
+ – V19 13
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ZF IntarderElectrical troubleshooting
Checklist
No. Name Pre-set position Measure. dev. Rated Cause if not attest connection value rated value
14
15
16
Braking levelselector A2Level '3'
Braking levelselector A2Level '4'
Braking levelselector A2Level '5'
ECU unplugged,veh. circuit 'ON'Intarder switch 'ON'Level '3'
ECU unplugged,veh. circuit 'ON'Intarder switch 'ON'Level '4'
ECU unplugged,veh. circuit 'ON'Intarder switch 'ON'Level '5'
24 V
24 V
24 V
0 V
0 V
0 V0 V
24 V
24 V
24 V
24 V
0 V
0 V
0 V
24 V
24 V
24 V
24 V
24 V
0 V
0 V
Cable harness lineinterrupted/short-circuit to24 V / earth (ground),
plug loose, braking level selector A2defective
Cable harness lineinterrupted/short-circuit to24 V / earth (ground),
plug loose, braking level selector A2defective
Cable harness lineinterrupted/short-circuit to24 V / earth (ground),
plug loose, braking level selector A2defective
Braking level selector
+ – V10 13
+ – V22 13
+ – V9 13
+ – V8 13
+ – V7 13
+ – V6 13
+ – V19 13
+ – V10 13
+ – V22 13
+ – V9 13
+ – V8 13
+ – V7 13
+ – V6 13
+ – V19 13
+ – V10 13
+ – V22 13
+ – V9 13
+ – V8 13
+ – V7 13
+ – V6 13
+ – V19 13
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13
ChecklistZF IntarderElectrical troubleshooting
No. Name Pre-set position Measure. dev. Rated Cause if not attest connection value rated value
17
18
19
20
Braking levelselector A2Level '6'
Braking levelselector A2Level '0',Bremsomat'actuated'
Flashing code button A30'OFF'
Flashing code button A30'ON'
ECU unplugged,veh. circuit 'ON'Intarder switch 'ON'Level '6'
ECU unplugged,veh. circuit 'ON'Intarder switch 'ON'Bremsomat 'ON'
ECU unplugged, veh.circuit 'ON', flashingcode button'OFF'
ECU unplugged, veh.circuit 'ON', flashingcode button'ON'
24 V
24 V
24 V
24 V
24 V
24 V0 V
0 V
0 V
0 V
0 V
0 V
0 V
24 V
0 V
24 V
Cable harness lineinterrupted/short-circuit to24 V / earth (ground),
plug loose, braking level selector A2defective
Cable harness lineinterrupted/short-circuit to24 V / earth (ground),
plug loose, braking level selector A2defective
Short-circuit, cable harnessA30 defective
Cable harness lineinterrupted/short-circuit toearth (ground),
plug loose,not fitted
Braking level selector
Flashing code button
+ – V10 13
+ – V22 13
+ – V9 13
+ – V8 13
+ – V7 13
+ – V6 13
+ – V19 13
+ – V10 13
+ – V22 13
+ – V9 13
+ – V8 13
+ – V7 13
+ – V6 13
+ – V19 13
+ – V1 20
+ – V1 20
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No. Name Pre-set position Measure. dev. Rated Cause if not attest connection value rated value
21
22
23
24
Solenoid valveY2
Relay K1
Display lampIntarder 'ON'
Display lampflashing codeH2
ECU unplugged, veh.circuit 'ON'
ECU unplugged, veh.circuit 'ON'
ECU unplugged, veh.circuit 'ON'
ECU unplugged, veh.circuit 'ON'
1 3
1 2
1 15
11 13
Accumul. pressur-ized
Brakelamp lit
Intarder displaylamp 'ON'lit
Flashingcodedisplaylamp lit
Solenoid valve Y2 defective,no air pressure,
piston sticking
Relay K1 defective, brake lamp defective,not connected
Display lamp H1 defective,not connected
Display lamp H2 defective,not connected
14
ZF IntarderElectrical troubleshooting
Checklist
Solenoid valve, relay valve, display lamps
NOTE: Do not test proportional solenoid valve Y1 with voltage or it will be damaged.
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ZF IntarderElectrical trouble-shooting Notes
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