VDL Bus International b.v.

Pitcat diagnosis

0708

Pitcat screens ZF EST46 / EST146

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DW05075702

VDL Bus International b.v.

Pitcat diagnosis

ZF EST46 ECOMAT 2 MAIN MENU PREVIOUS SELECT NEXT ZF EST46 ECOMAT 2 READ ERRORS PREVIOUS SELECT NEXT ERROR:5521(D) HZ: 10 ERROR:3715(H) A: * INFO QUIT NEXT

Choose from main menu ZF EST46

ZF EST46 ECOMAT 2 TEST INPUTS PREVIOUS SELECT NEXT 63 REV GEAR EN : OFF 20 NBS : OFF 64 PROGRAM SW. : OFF PREVIOUS QUIT NEXT 67 GEAR ENABLE 44 EXT. NEUTRAL 66 RET OFF SW. PREVIOUS QUIT :OFF :OFF :OFF NEXT ZF EST46 ECOMAT 2 TEST OUTPUTS PREVIOUS SELECT NEXT ZF EST46 ECOMAT 2 TEST OUTPUTS DETAIL READ QUIT WRITE G F E D C B A WK 0 0 0 0 0 0 0 0 PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 30 VALVE G RESPONS PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 29 VALVE F RESPONS PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 54 VALVE E RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 09 VALVE D RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 05 VALVE C RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 04 VALVE B RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 10 VALVE A RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 11 VALVE WK RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 51 RET VALVE RESPONSE PREVIOUS QUIT NEXT

ENGING TORQ.: 3000Nm OUTPUT SPEED:2500RPM LS 70% LC: EXB PREVIOUS QUIT NEXT TORQUE CONV.: 3456 KIND OF FAULT: 00 HOUR: 00 SUMP: 61 C PREVIOUS QUIT NEXT ENGINE TORQUE: Nm OUTPUT SPEED: RPM TORQ-C: LS: % PREVIOUS QUIT NEXT CAN FAULT: ELEC SYS FAULT KIND OF FAULT: PREVIOUS QUIT Legend READ ERRORS: HZ => OCCURRENCE COUNTER A: * => ACTUEL, - NOT ACTUEL

DNR SWITCH -D21 42 28 50 41 1 0 0 1 0 PREVIOUS QUIT NEXT RPMIN : RPMOUT: GEAR : PREVIOUS 00 LS: 00% 00 LC: EXB 01 QUIT NEXT

51 RET VALVE : OFF 08 ACCUMULATOR : OFF 32 V-SIGNAL : OFF PREVIOUS QUIT NEXT 53 OILTEMP LIGHT:OFF 57 RESTR. VALVE :OFF PREVIOUS QUIT NEXT

NEXT

BATTERY : 24.8 V TEMP RET : 40 C TEMP SUMP: 45 C PREVIOUS QUIT NEXT RET PED PLATE : RET DEMAND : RET DEMAMD CAN: PREVIOUS QUIT 000% 000% 000% NEXT

06 PROP. VALVE : OFF 56 DNR LIGHT : OFF PREVIOUS QUIT NEXT

TORQUE ENGINE : 000Nm TURBINE EFF. : 000Nm PREVIOUS QUIT NEXT ROTOR TORQUE EFF. RETARDER : 000Nm NOM. RETARDER: 000NM PREVIOUS QUIT NEXT

Legenda TEST INPUTS: 63 REV GEAR EN = REVERSE GEAR ENABLE 20 NBS = NEUTRAL AT STANDSTILL DNR SWITCH DECODING: 21 = DNR B1 42 = DNR B2 28 = DNR B3 50 = DNR V 41 = DNR R RPMIN =INPUT SPEED (RPM) RPMOUT=OUTPUT SPEED (RPM) GEAR : 1-5 NOTE 1=FORWARD OR REVERSE LS = LOADSENSOR 0-100% LC = LOAD CONDITION: -EXB = EXHAUST BRAKE -RET = RETARDER -OVR = OVERRUN -PT1 = PART LOAD 1 -PT2 = PART LOAD 2 -PT3 = PART LOAD 3 -FUL = FULL LOAD

GEARBOX VALVES: G = PIN 30 F = PIN 29 E = PIN 54 D = PIN 09 C = PIN 05 B = PIN 04 A = PIN 10 WK = PIN 11

0708

Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

ZF EST46 TEST OUT. 08 ACCUMULATOR RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 32 V-SIGNAL RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 53 OILTEMP LIGHT RESPONSE PREVIOUS QUIT NEXT ZF EST46 TEST OUT. 56 DNR LIGHT RESPONSE PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ERASE ERRORS PREVIOUS SELECT NEXT ZF EST46 ECOMAT 2 ERASE STORED ERRORS! ARE YOU SURE ? PREVIOUS SELECT NEXT ZF EST46 ECOMAT 2 READ ID CODE PREVIOUS SELECT NEXT ZF EST46 ECOMAT 2 ID 1: 6009078054 ID 2: 6009378001 PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ID 3: 6009378079 ID 4: 5HP502C PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ID 5: A76G991206S ID 6: i=3,43-0,83 PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ID 7: ID 8: PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ID 9: xyz ID 10: PREVIOUS QUIT NEXT IDENTIFICATION : ID 1: ID 2: ID 3: ID 4: ID 5: ID 6: ID 7: ID 8: ID 9: ID 10: ID 12: ID 12: ID 13: ID 14: SYST. ID 15: ID 16: ID 17: ID 18: ID 19: ID 20: ZF ECU EST 46 IDENTIFICATION NUMBER HARDWARE IDENTIFICATION NUMBER SOFTWARE IDENTIFICATION NUMBER TYPE OF GEARBOX SW VERSION TRANSMISSION RATIO RANGE NORMALLY RESERVED / NAME OF EOL FILE RESERVED OEM ORDER NUMBER OF ECU RESERVED VERSION OF DIAGNOSIS RESERVED PROJECT NUMBER IN PARAM. MANAGEMENT SYST. STRUCTURE NUMBER IN PARAM. MANAGEMENT RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED ZF EST46 ECOMAT 2 ID 11: 5 ID 12: PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ID 13: 6009F78 ID 14: D010330V001 PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ID 15: ID 16: PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ID 17: ID 18: PREVIOUS QUIT NEXT ZF EST46 ECOMAT 2 ID 19: ID 20: PREVIOUS QUIT NEXT

Pitcat diagnosis

ZF EST46 ECOMAT 2 QUIT COMMUNICATION PREVIOUS SELECT NEXT

0708

Pitcat screens ZF EST46 / EST146

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DW05075702

VDL Bus International b.v.

Pitcat diagnosis

Error FMI Error description

Error type

Cause of fault

Minimum Maximum value value 1

Maximu m value 2

14

14

4 Retarder "Hand" Voltage error low sensor (Retarder control 3 lever A12) Voltage error high

Voltage is less than: 0,2 Voltage is greater than: Voltage is less than: 0,2 Voltage is greater than:

4,5

15

15

4 Retarder "Foot" Voltage error low sensor (Analog retarder 3 pedal plate A13) Voltage error high

4,5

16

Retarder switch 2 (digital retarder Impermissible coding pedal plate S12)

Incorrect signal combination: Each stage of the pedal plate delivers a certain combination of 3 digital signals which can be read in via 3 EST digital inputs. These signal combinations are parameterized as permissible. All other combinations are parameter

17

17

Retarder temperature sensor (B4)

Voltage error low

Voltage is less than: 0,5 Voltage is greater than: Voltage is less than: 2,6 Voltage is greater than:

Voltage error high

4,8

18

18

Sump temperature sensor (B14)

Voltage error low

Voltage error high

4,8

V << 10 Ohm to low source (ditto for all ADs)

21

Output to gear 4 component A valve (Y17)

Shorted to low source

Voltage is less than: 19,0 V

0708

Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2 < 99 kOhm to high source (ditto for all ADs) > 10 kOhm to low source (ditto for all ADs)

21

Shorted to high source

Voltage is greater than:

7,5

21

Disconnection

Voltage is greater than:

4,5

22

4 Output to gear 3 component B valve (Y16) 5

Shorted to low source

Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V

22

Shorted to high source

7,5

22

Disconnection

4,5

23

4 Output to gear 3 component C valve (Y15) 5

Shorted to low source

23

Shorted to high source

7,5

23

Disconnection

4,5

24

4 Output to gear 3 component D valve (Y14) 5

Shorted to low source

24

Shorted to high source

7,5

24

Disconnection

4,5

25

4 Output to gear 3 component E valve (Y13) 5 Output to gear 4 component F valve (Y12)

Shorted to low source

25

Shorted to high source

7,5

25

Disconnection

4,5

26

Shorted to low source

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Pitcat screens ZF EST46 / EST146

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DW05075702

VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

26

Shorted to high source

Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than:

7,5

26

Disconnection

4,5

27

4 Output to gear 3 component G valve (Y11) 5

Shorted to low source

27

Shorted to high source

7,5

27

Disconnection

4,5

28

Shorted to low source

28

Output to converter lockup 3 clutch valve Shorted to high source (Y18) 5 Disconnection

7,5

28

4,5

29

4 Output to retarder 3 accumulator valve (Y2) 5

Shorted to low source

29

Shorted to high source

7,5

29

Disconnection

4,5

31

4 Output to 3 exhaust brake relay (K1) 5

Shorted to low source

31

Shorted to high source

7,5

31

Disconnection Output to gear Shorted to low source signal relay (K2) Shorted to high source

4,5

32

32

7,5

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Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

32

Disconnection

Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than:

4,5

33

4 Output to gear 3 signal 2 relay 5

Shorted to low source

33

Shorted to high source

7,5

33

Disconnection

4,5

34

Shorted to low source

34

Output to v3 signal relay (K3) Shorted to high source 5 Disconnection

7,5

34

4,5

35

4 Output to v3 signal 2 relay 5

Shorted to low source

35

Shorted to high source

7,5

35

Disconnection

4,5

36

4 Output to PTO 3 valve (Y3) 5

Shorted to low source

36

Shorted to high source

7,5

36

Disconnection

4,5

37

4 Output to 3 Antigas valve (Y4) 5

Shorted to low source

37

Shorted to high source

7,5

37

Disconnection

4,5

0708

Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

38

4 Output to load 3 enable relay (K11) 5

Shorted to low source

Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 16,5 V

38

Shorted to high source

7,5

38

Disconnection

4,5

39

4 Output to lock 3 solenoid relay (K4) 5

Shorted to low source

39

Shorted to high source

7,5

39

Disconnection

4,5

91

Shorted to low source

91

Digital test help 1 3 (parameterizable Shorted to high source special functions) 5 Disconnection

7,5

91

4,5

41

4 Output to selector lamp

Shorted to low source

41

Shorted to high source

7,5

41

Disconnection

4,5

42

4 ADVP output 3 (continuous signal) 5

Shorted to low source

42

Shorted to high source

7,5

42

Disconnection Output to status Shorted to low source monitor (H1)

4,5

85

0708

Pitcat screens ZF EST46 / EST146

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DW05075702

VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

85

Shorted to high source

Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than:

5,0

85

Disconnection

19,5

43

4 Output to retarder relay 3 - brake lamp (K10) 5

Shorted to low source

43

Shorted to high source

7,5

43

Disconnection

4,5

44

4 Output to proportional 3 solenoid valve D1 (Y20) 5

Shorted to low source

44

Shorted to high source

7,5

44

Disconnection

4,5

45

4 Output to retarder 3 proportional solenoid valve (Y1) 5

Shorted to low source

45

Shorted to high source

7,5

45

Disconnection

4,5

46

2 Selector (A2)

Coding not permitted

Coding impermissible: Each button on the pushbutton switch delivers a certain combination of 5 digital signals which can be read in via 5 digital EST inputs (ED10 to ED14). These signal combinations are parameterized as permissible. All other combinations

0708

Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

86

4 "NBS active" output

Shorted to low source

Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than:

86

Shorted to high source

7,5

86

Disconnection

4,5

47

4 Speedo signal output via pin SD2 (A10)

Shorted to low source

High (positive) output, low (ground) read. Voltage less than:

3,1

47

Shorted to high source

Low (ground) output, high (positive) read. voltage greater than

7,9

49

Operating hours 14 counter Data not plausible checksum

An incorrect checksum was discovered during reading out of the fault memory from the EEPROM

51

12

F_CAN_2 _BCAN

Data not plausible

An incorrect checksum was discovered during reading out of the fault memory from the EEPROM, e.g. terminal 30 and terminal 15 switched off simultaneously.

52

System error ECU 11 EST46/47 C (accumulative error)

Data not plausible

See "Environment blocks", "Electronic system errors" chart.

53

Fault SAE J Data not plausible 1708 (BUSOFF)

Multiple send errors

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Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

54

Fault SAE J Data not plausible 1708 (warning)

Multiple send or receive errors

55

Vehicle CAN 2 (accumulative error)

Data not plausible

- total CAN failure OR - CAN overload OR - message timeout OR - signal error

56

Shorted to low source

Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than:

56

Output to 3 retarder engage Shorted to high source valve (Y19) 5 Disconnection

7,5

56

4,5

58

Output speed input (B11): - Disconnection 2 - Shorted to low Data not plausible source - Shorted to high source

U_RL (readback) is less than 0.7 V (shorted to low source) OR U_RL (readback) is greater than 7 V and less 0,7 than 16 V (disconnection) OR U_RL (readback) is greater than 16 Vt (shorted to high source).

7,0

16,0 V

0708

Pitcat screens ZF EST46 / EST146

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DW05075702

VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

59

Input for transmission input speed (B12): 2 - Disconnection Data not plausible - Shorted to low source - Shorted to high source

U_RL (readback) is less than 0.7 V (shorted to low source) OR U_RL (readback) is greater than 7 V and less 0,7 than 16 V (disconnection) OR U_RL (readback) is greater than 16 V (shorted to high source).

7,0

16,0 V

58

Output speed 11 measurement (B11)

Threshold exceeded

Calculated sum too large, e.g. because of falsified measured quantities due to EMC (value > 10737 rpm).

59

Transmission input speed 11 measurement (B12)

Threshold exceeded

Calculated sum too large, e.g. because of falsified measured quantities due to EMC (value > 10737 rpm).

62

3 Retarder identifier (B16)

Voltage error high

U_Ein (U_On) is greater than:

4,4

62

Voltage error low

Voltage is less than: 0,4

0708

Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

44

Output to proportional 2 solenoid valve D1 (Y20)

Resistance less than "minimum threshold" Resistance not permitted or greater than 5,0 Ohm 2000 Ohm "maximum threshold 1".

45

Output to retarder 2 proportional solenoid valve (Y1)

Resistance less than "minimum threshold" Resistance not permitted or greater than 10,0 Ohm 600 "maximum threshold 1".

Ohm

63

14

Transmission coding

Coding not permitted

- transmission coding indicates transmission without overdrive (without ground jumper in the int. wiring harness, i.e. U_RL >= 1 V) and drive program indicates transmission with overdrive - transmission coding indicates transmission with overdrive (with g

65

Temperature 0 overheating retarder outlet

Threshold 2 exceeded

Temperature greater than: Value depends on application.

66

Sump 0 temperature overheating

Threshold 2 exceeded

Temperature greater than: Value depends on application.

67

Digital output (AD) with no 3 function assigned

Shorted to high source

U_RL (readback) is greater than:

7,5

0708

Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

68

12 ECU_REST

Data not plausible

- Before central shutoff component (ZAE) is activated by the HP/watchdog/monitor processor, voltage is present after the central shut-off component (greater than or equal to 14.0 V) or - Once central shutoff component (ZAE) has been activated by the HP/

71

4 Temperature 3 warning output Stage 1 5

Shorted to low source

Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than:

71

Shorted to high source

7,5

71

Disconnection

4,5

72

Oil level sensor 14 PWM signal Data not plausible (B15)

Signal error for 5 sec. or mark-space ratio less than minimum 17,0 % threshold or greater than "maximum threshold 1".

83

73

4 Temperature 3 warning output Stage 2 5 Temperature 4 warning output Stage 3 3

Shorted to low source

Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than:

73

Shorted to high source

7,5

73

Disconnection

4,5

74

Shorted to low source

74

Shorted to high source

7,5

0708

Pitcat screens ZF EST46 / EST146

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DW05075702

VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

74

Disconnection

Voltage is greater than:

4,5

65

Excessive 14 temperature retarder outlet

Threshold exceeded

Temperature greater than: Value depends on application.

66

14

Excessive sump Threshold exceeded temperature

Temperature greater than: Value depends on application.

105

75

Retarder "Hand" sensor 12 (digital retarder Coding not permitted control lever S12)

Coding impermissible -->see Ret_TrPl_dig for description

76

Gear component 0 slip time Threshold exceeded powershift 1 - 2

Residual slip (difference in speed between nT and nAb) after end of shift plus parameterizable time is greater than threshold value (value parameterizable). Residual slip (difference in speed between nT and nAb) after end of shift plus parameterizable time is greater than threshold value (value parameterizable).

76

Gear component 0 slip time Threshold exceeded powershift 2 - 3

0708

Pitcat screens ZF EST46 / EST146

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DW05075702

VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

76

Gear component 0 slip time Threshold exceeded powershift 3 - 4

Residual slip (difference in speed between nT and nAb) after end of shift plus parameterizable time is greater than threshold value (value parameterizable).

76

Gear component 0 slip time Threshold exceeded powershift 4 - 5

Residual slip (difference in speed between nT and nAb) after end of shift plus parameterizable time is greater than threshold value (value parameterizable).

76

Gear component 0 slip time Threshold exceeded powershift 5 - 6

Residual slip (difference in speed between nT and nAb) after end of shift plus parameterizable time is greater than threshold value (value parameterizable). Voltage less than: Voltage greater than: 17,7 V 32,3 V

79 79

Operating voltage 0 (terminal 30)

Voltage error low Voltage error high

81

Digital selector 4 interface, line V Shorted to low source (forwards) AD10

Voltage is less than: 19,0 V

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Pitcat screens ZF EST46 / EST146

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VDL Bus International b.v.

Error FMI Error description Error type Cause of fault

Pitcat diagnosis

Minimum Maximum value value 1

Maximu m value 2

81

Shorted to high source

Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: Voltage is less than: 19,0 V Voltage is greater than: Voltage is greater than: An error occurred during reading out of the data from the customer 3 CAN EEPROM domain (incorrect checksum or impermissible data).

7,5

81

Disconnection

4,5

82

Shorted to low source

82

Digital selector 3 interface, line B1 Shorted to high source (range 1) AD11 5 Disconnection

7,5

82

4,5

83

Shorted to low source

83

Digital selector 3 interface, line R Shorted to high source (reverse) AD12 5 Disconnection

7,5

83

4,5

84

Customer 2 EEPROM data (checksum)

Data not plausible

87

U_kl15 off while Data not plausible engine running

Incorrect checksum established during reading out of the correction parameters from the EEPROM.

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Pitcat screens ZF EST46 / EST146

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DW05075702