AS-Tronic 2 Diagnostics

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.
BKS-I/BKS-R AS-Tronic 2 Diagnostics Page 1
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 Table of Contents

Short circuit/Interruption TA* 3 2, 3, 4, 5, 6, 7, 8,9,10,17, 34, 35, 36, Page 5

37, 38, 39, 40, 41, 42, 49, 66, 67,68,
69, 70, 71, 72, 74, 81
Short circuit ADVP* 22 Page 6
Driveline retarder torque (CAN) 28 Page 7
Measurement on diagnostic code 28 28 Page 8
Input shaft speed defective 98 Page 9
Speed error 99, 100, 101, 28 Page 10
ZF-CAN Timeout 110 Page 11
Harsh engagement partially 114 Page 12
Measurement on diagnostic code 114 partially 114 Page 13
Clutch self learning error 117 Page 14
Measurement on diagnostic code 117 117 Page 15
Clutch self learning error 117 in connection with 155 Page 16
Air leakages 118, 145, 151, 154 Page 17
Clutch does not engage 119 in connection with 124 Page 18
Signal error clutch travel 124 Page 19
Measurement on diagnostic code 124 124 Page 21
Clutch travel error, noise 124 in connection with 102 Page 22
Oil temperature sensor 128 Page 23
Self adjustment error of shift sensor 132 in connection with 154 Page 24
GV (splitter group) does not disengage 148 Page 25

* TA = Transmission Actuator; *ADVP = Output Digital Power Supply to High Source (+)

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 Table of Contents
GV (splitter group) does not change 149 Page 26
Measurement on diagnostic code 149 149 Page 27
Wabco transmission actuator < 15000 145, 146, 147, 149, 154, 156, 158 Page 28
Selector cylinder jammed 151, 153 Page 29
Main transmission not engaging 155 Page 30
No starting gear N-D/R 155 Page 31
Leaving of engaged position (GE,GV,GP) 158, 159, 160 Page 32
Gear leaves engaged position 158 Page 33
Gear leaves engaged position 158 in connection with 101 Page 34
GV (splitter) leaves engaged position 160 in connection with 101 Page 35
Datalogger measurement to FC 160 / 101 160 in connection with 101 Page 36
Evo- Baureihe CC400 163 Page 37
Signal error ignition lock 175 Page 38
CAN Bus off 178 Page 39
EvoBus, after SW Pak 7 Update 188 Page 40
EEProm error while traveling 190, 191, 192 Page 41
EEProm error after programming 190, 191, 192 Page 42
EEProm error after engine start 192 Page 43
CAN Error various Page 44

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 Table of Contents

Complaints without diagnostics entry:

Engine start not possible Page 45

Engine start not possible Page 46
Transmission does not shift Page 47
Clutch judder Page 48
TC-Tronic; Juddering while starting movement Page 49
Defective clutch actuator Page 50
Limited positions outside of tolerance Page 51
High level of clutch wear / burned clutch Page 52
Too high tilt clearance at the DMF (dual mass flywheel) Page 53
Strong noise during Intarder operation Page 54
Over speeding of engine Page 55
Gear-hunting Page 56
Gear-hunting; no full throttle possible Page 57
EvoBus model range 300 Page 58
Long Check Phase (CH) Page 59

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 Short Circuit/Interruption
Shift 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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 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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 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)
speed signal EST 42
amplifier
Signal chain (1 speed pulse distributor):
Speedsensor Tachograph speed signal EST 42
amplifier

(also refer to measurements on next page) Further ECUs

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 Measurement on Diagnostic Code 28

Engine speed

Output speed
(peak)

Control parameters (measured at Intarder ECU):

engine speed (unfiltered) = Motordrehzahl

output shaft speed (filtered) = Abtriebsdrehzahl

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 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 the
transmission 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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 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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 ZF-CAN Timeout

Diagnostic code: 110

Actions & Measures:

For EvoBus vehicles, check the speed range selector in line with the ServiceLine
instructions.
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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 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 190 165
1 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!

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 Measurement to Harsh Engagement

Toth on toth situation inside the

main transmission (sensor[0].messwert)

input speed (n_sek)

increases to 345 rev/min
harsh engagement
judder of cabine

clutch (s_kup)
leaps up to 40 %

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 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

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.

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.

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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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 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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 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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 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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 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 n_sek increase though

clutch adjusting starts n_mot < 400 rev/min
adjusting procedure failed

diagnostic code 124 is active

proposal of measurement
parameters:

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 activ
Bit 3 = Clutch adjusting finished

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 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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 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 starter
interlock. But while self adjustment or shifting neutral will not be reconized.

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 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 190 165

1 KG: 0671 190 050

Note: Remove excess grease! Also refer to SI 16/04c.

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 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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 Measurement on Diagnostic Code 149

Splitter blocked at 457 inc.

Diagnostic code 149

is set
Clutch does engage
to disengage the blocking

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 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!

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 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.

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 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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 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 gear

Remedy:
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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 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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 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: 1-2-1

If 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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 Datalogger Measurement to DC 160 /
101

Accelerator pedal is actuated;

input speed is on the increase.

GV (splitter group) does not engage;

remains stopped at 244inc.

Error is set.

Clutch closes

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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 engine
rpm between on and off. Signal does toggle.
Because of toggling, the engine does not accept the transmission request

Remedy:

SW Update SW Paket 7 Stand V33_4g (MB Nr.A0014462109) in case of complain

no generell field action

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 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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 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: MAN

The 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 are
incompatible 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 26
1337 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 6
1337 044 004 A001 260 31 00 300 UL OM457 hLA 260kW 8
1337 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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 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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 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:
Configuration
Additional 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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 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 the

transmission 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 of
unusual incoming frequency

Remedy

serial introduction steel shim week 14 / 2005

serial no. GS3
- 20pin plug Standard: 131495
- 18pin plug variant: 5284
in case of complain or any diagnostic procedure, please verify the sensor increment value
in Neutral:
(if the value is >345 IC, the repair kit 0501 322 388 for the complete main transmission
piston must be exchanged)

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As of:December 07 , 2005
 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.

BKS-I/BKS-R AS-Tronic 2 Diagnostics Page 47

As of:December 07 , 2005
 Clutch Stick-Slip Problems (Clutch
Judder / Shudder)
Diagnostic code: None

Actions & Measures:

Ground flywheel: Tendency for juddering is reinforced. OEM

Wrong clutch installed (also refer to ZF-ServiceLine / Checklist). ) OEM
Release 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!

BKS-I/BKS-R AS-Tronic 2 Diagnostics Page 48

As of:December 07 , 2005
 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_sek
s_kup alpha_fp
n_ab sollgang

Activate handtrigger while the complaint occurs.

Records and checklist have to be send to Klaus.Graf@zf.com

BKS-I/BKS-R AS-Tronic 2 Diagnostics Page 49

As of:December 07 , 2005
 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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As of:December 07 , 2005
 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: 200249
12 AS 2301: 203953 and/or without IT: 1518
16 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-R AS-Tronic 2 Diagnostics Page 51
As of:December 07 , 2005
 High Level of Clutch Wear
Burned 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-R AS-Tronic 2 Diagnostics Page 52

As of:December 07 , 2005
 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-R AS-Tronic 2 Diagnostics Page 53

As of:December 07 , 2005
 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-R AS-Tronic 2 Diagnostics Page 54

As of:December 07 , 2005
 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-R AS-Tronic 2 Diagnostics Page 55

As of:December 07 , 2005
 Gear-Hunting

Diagnostic code: None

Actions & Measures:

Check the kick-down signal.
Important: For MAN vehicles: Kick-down is only deactivated again after <80% of the accelerator
pedal position.
Check accelerator pedal.
EvoBus:
For vehicles from the model range 300, it must be checked whether a DMF (Dual Mass Fly) has
been installed or not. -> Contact the BKS-R dept.

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As of:December 07 , 2005
 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-R AS-Tronic 2 Diagnostics Page 57

As of:December 07 , 2005
 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-R AS-Tronic 2 Diagnostics Page 58

As of:December 07 , 2005
 Long Check Phase (CH)

complaint: Long CH check phase, long shifting times, delay in the clutch learning
process, bad shift quality

cause: Air compressor contaminates the air system with hot engine oil with the
result 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 with
straight 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 charged
towards EvoBus.

BKS-I/BKS-R AS-Tronic 2 Diagnostics Page 59

As of:December 07 , 2005