ZF Intarder EST-42 Troubleshooting 68-Pole

8/18/2019 ZF Intarder EST-42 Troubleshooting 68-Pole

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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

3


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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 '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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7

8

9

10

Intarder 'ON'display lamp H1

Flashing codeH2 display

Brake lamprelayK1

Water temperaturesensor B2





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

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ZF IntarderElectrical troubleshooting

Checklist

Display lamp

Relais

Temperature sensor

+ – 15 13Ω

+ – 1 11Ω

+ – 2 13Ω

+ – 4 12Ω


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11

12

13

Braking levelselector A2Level '0'



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



11


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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12


Checklist


14

15

16




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



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








+ – 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



17

18

19

20


Braking levelselector A2Level '0',Bremsomat'actuated'

Flashing code button A30'OFF'

Flashing code button A30'ON'


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





Short-circuit, cable harnessA30 defective

Cable harness lineinterrupted/short-circuit toearth (ground),

plug loose,not fitted


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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21

22

23

24

Solenoid valveY2

Relay K1

Display lampIntarder 'ON'

Display lampflashing codeH2

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


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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Documents

ZF Intarder EST-42 Troubleshooting 68-Pole