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ZF Transmission Controls
110610
6WG260 – TA25
6WG260 – TA27
6WG310 – TA30
Retarder
(Optional) Control Valve
Lock-Up Solenoid
Converter
Differential Lock
ZF TRANSMISSION CONTROLS
7
ZF EST Circuit
Electro-Hydraulic
Shift Unit
Speed Sensors x 4
ZF TRANSMISSION CONTROLS
8
ZF EST Schematic
-
p o w e r
+ s u p p ly
s p e e d s e n s o r e n g in e
lo c k -u p
s p e e d s e n s o r tu r b in e
re ta rd e r
s p e e d s e n s o r in te r n a l w a r n in g la m p
s p e e d s e n s o r o u tp u t b a c k u p a la r m
F
N
Inputs g e a r
s e le c to r
R
B 1 / T +
d is p la y Outputs
B 2 / T - s p e e d o m e te r
B 3 (O p tio n ) E S T -3 7 d ia g n o s tic in te r fa c e
Y 1
Y 2
s ig n a l d e c lu tc h Y 3 tra n s -
b in -u p Y 4 m is s io n
Y 5
re ta rd e r re q u e s t Y 6
d iff.lo c k r e q u e s t
T e m p .
k ic k d o w n
S u m p
-
- Inputs
T e m p .
lo a d s e n s o r R e ta rd e r / C o n v .O u t
C A N -
In te r fa c e
ZF TRANSMISSION CONTROLS
9
ZF EST Generic Schematic
K2 (K17)REVERSE RELAY
F1 BATTERY FUSE - CONSTANT (F10)
H3 WARNING LAMP
S28 DIFF-LOCK SW.
S4 KICKDOWN SW.
S1 RETARDER SW.
F2 IGNITION FUSE (F11)
DIAGNOSTIC
OUTPUT SPEED 22 INTERFACE
SENSOR
GEAR SHIFT
CONTROLLER
DISPLAY
A9 SPEEDO OUTPUT
K1 (K14) START
INTERLOCK
E?? Inputs
X2 X7
Gear Lever Interface
Connection
X8
Interface
X9
Interface
X1 16-Pin
T.C.U. Hydraulic
Connection Control Valve
Connection X25
Diagnostic Connection
VIEW
ZF TRANSMISSION CONTROLS
12
Interface Harness Connections
B
A
ZF TRANSMISSION CONTROLS
13
Interface Harness Connections
Internal Splicing to
ZF Harness
ZF TRANSMISSION CONTROLS
15
ZF Interface
X7 Plug
X7 828 Wire
8 Pin
Connects with X1 Plug
30 Pin
X1
ZF TRANSMISSION CONTROLS
16
X2/X6/X7 Connection - Schematic
ZF TRANSMISSION CONTROLS
17
X8/9 Connection - 6WG260/310
ZF TRANSMISSION CONTROLS
18
TCU and Connection Locations
X1
N
ZF TRANSMISSION CONTROLS
22
Power Circuit
ZF TRANSMISSION CONTROLS
23
Power Circuit
ZF TRANSMISSION CONTROLS
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ZF Control Software - EST37(A)
Electronic Control For Automatic Transmissions
EST Software;
EST 37 6009 065 XXX - Historical
EST 37A 6009 092 XXX - Current Build
SOFTWARE PROGRAMS ARE NOT COMPATIBLE
EST Hardware;
EST 37 6009 365 005 - Historical
EST 37A 6009 365 007 - Current Build
*NEVER USE 6009 365 001
LUBE +
STANDBY
PRESSURE
LUBE
PRESSURE
ZF TRANSMISSION CONTROLS
27
Gear Selected
ZF TRANSMISSION CONTROLS
29
ZF Operating Codes
• 5 OPERATING LEVELS
1. Normal
•Case: There is no fault detected by the TCU or the fault has no or slight
effect on the transmission control. Fault could be on a
secondary device, i.e. torque converter lockup clutch
defective.
•Effect: TCU will work without or with little limitations.
Secondary device cannot be used, truck may have some
performance limitations, ie power, speed and temperature.
i.e. lockup clutch cannot be closed running in converter
continually.
3. Limp Home
•Case: The detected fault in the system has severe limitations to
transmission control. i.e. clutch defective
4. Transmission Shutdown
•Case: The TCU has detected a safety critical fault. The TCU will shut
down all solenoid valves for clutch activation by disabling the
common power supply (VPS1). i.e. gear selector failure
VPS1 - Wire #434 Output to X8:13 - X1:56
•Effect: Transmission shifts to Neutral when the fault is detected first
and a fault code is displayed. The operator must slow the
vehicle to a stop. The vehicle cannot move further on as long
as fault persists.
ZF TRANSMISSION CONTROLS
32
ZF Failure Operating Levels
5. TCU Shutdown
•Case: Safety critical fault, the transmission TCU has detected a severe fault that
can/will disable the control of the EST system.
•Effect: Transmission shifts to Neutral when the fault is detected and a fault code is
displayed. Power supply for all solenoids is switched off and also all common voltage
supplies VPS1 and VPS2. All functions controlled by outputs ADM1 to ADM8 are also
disabled. The vehicle cannot move further on.
• VPS1 Voltage supply to clutch activation solenoids
VPS1 - Wire #434 Output to X8:13 - X1:56
•VPS2 Voltage supply to auxiliary functions
VPS2 to Lock-Up - Wire #534 Output to X9:8 – X1:8 / 53
VPS2 to Retarder - Wire #544 Output to X9:10 – X1:8 / 53
VPS2 to Diff-Lock - Wire #554 Output to X9:12 – X1:8 / 53
•ADM1 to ADM8 Output signals to auxiliary functions
ADM1 to Warning Lamp - Wire #844 Output to X7:12 – X1:52
ADM2 to Reverse Warning - Wire#808 Output to X7:3 – X1:7
ADM4 to Sound Power 1st Gear Restriction - Wire#848 Output to X7:13 – X1:5
ADM5 to Retarder - Wire#540 Output to X9:9 – X1:57
ADM6 to Diff-Lock - Wire#550 Output to X9:11 – X1:11
ADM7 to Lock-Up - Wire#530 Output to X9:7 – X1:34
ZF TRANSMISSION CONTROLS
33
Checking Fault Codes
Fault Meaning of Code TCU Reaction Checks
Code Possible Reasons For Faults
B1 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral ·check pressure at clutch K1
TCU calculates a differential speed at closed clutch K1. OP-Mode: limp home ·check main press. in system
If this calculated value is out of range, TCU interprets if failure at another ·check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
·low pressure at clutch K1 TCU shifts to neutral ·check sensor gap at output
·low main pressure OP-Mode: TCU shutdown speed sensor
·wrong signal at internal speed sensor ·check signal at internal
·wrong signal at output speed sensor speed sensor
·wrong size of the sensor gap ·check signal at output
·clutch is defective speed sensor
·replace clutch
D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 •check cables and connectors
TCU measures more than 6V at the pin AU1 to sensors, supplied from
(5V sensor supply) AU1
•check power supply at pin
AU1 (should be approx. 5V)
D5 ERROR AT SWITCH 1 FOR VALVE SUPPLY VPS1 Shift to Neutral ·Check Fuse
TCU switched on VPS1 and measured VPS1 is off or OP-Mode: TCU Shutdown ·check cables from gearbox
TCU switched off VPS1 and measured VPS1 is on to TCU
*Cable or connectors are defect and are contacted to ·check connectors
battery voltage ·replace TCU
*Cable or connectors are defect and are contacted to
vehicle ground
*Permanent power supply at KL30 missing
*TCU defect
ZF TRANSMISSION CONTROLS
34
Sensors
ZF TRANSMISSION CONTROLS
35
6WG260/310 Sensors
9 10 2
4
4 K2 KR KV K4
5 K3 K1
6 Y
8
7
1 DETAIL Y
3
1. Retarder Oil Temp. Sensor 2. Main Control Valve 3. Diff. Lock Solenoid 4. Lock Up Solenoid
5. Engine Speed Sensor 6. Output Speed Sensor 7. Central Gear Train Sensor 8. Turbine Speed Sensor
9. Oil Temp. Sensor (Gauge) 10.Breather KV, KR, K1 etc. Supply Ports to Multi-Disc Clutches
ZF TRANSMISSION CONTROLS
36
6WG260/310 Speed Sensors
Inductive Transmitters
(Engine, Turbine & Central Gear Train)
Resistance 1050Ω (±10%) @ 20°C
Temperature Range -40°C to +150°C
Torque Limit 30Nm
Data for ‘Hall-Sensor’ of the Output
(At sensor or with X8 / X9 disconnected)
Temperature Range -40°C to +150°C
Working Range 2hz - 5khz
Supply / Return ∞
Supply / Signal ∞
Signal / Return 460 kΩ
Supply Voltage 24V
ZF TRANSMISSION CONTROLS
38
Speed Sensor Check Locations
Engine Sensor
0.5+0.3mm
Temperature
Gauge Sender
Retarder
Temperature
Switch (B32)
Retarder Temp.
Sw. Removed (B32)
Harness Remains
Fan Drive Temp.
Switch (B35)
Temp. Gauge
Sender (B21)
To VDO Panel
SENSOR DATA
B21
RESISTANCE
1000Ω - 1500Ω
CHECK (B21)
Plug X8 Pins 14 & 15
ZF TRANSMISSION CONTROLS
43
Sensor Electrical Checks - Schematical
ZF TRANSMISSION CONTROLS
44
Temperature Warning Trigger Points
SUMP TEMPERATURE
WARNING ON WARNING OFF FAULT ON FAULT OFF
WS B7
6WG210 102 100 112 110
6WG260 111 108 115 113
6WG310 111 108 115 113
RETARDER TEMPERATURE
WARNING ON WARNING OFF FAULT ON FAULT OFF
WR B8
6WG210 ~ ~ ~ ~
6WG260 145 140 150 145
6WG310 145 140 150 145
CONVERTER TEMPERATURE
WARNING ON WARNING OFF FAULT ON FAULT OFF
WT C3
6WG210 120 115 125 120
6WG260 120 115 125 120
6WG310 120 115 125 120
(°C)
ZF TRANSMISSION CONTROLS
45
6WG260/310
ZF TRANSMISSION CONTROLS
47
Proportional Control Valves
CHECK
Plug X8
Pins 7 thru 13
PLUG X8:
PIN 13 COMMON
VREF
PIN7 Y1 GND
PIN8 Y2 GND
PIN9 Y3 GND
PIN10 Y4 GND
PIN11 Y5 GND
PIN12 Y6 GND
ZF TRANSMISSION CONTROLS
51
6WG260/310 Hydraulic Pressure Measurement
(K4)
(KV)
(KR) (K2)
S
ZF TRANSMISSION CONTROLS
Gear shift Control – Selecting Gear
Function
Button
To select gear the procedure is as follows:
NOTE: When in manual mode, if the engine RPM drops below lock
up disengaging rpm the transmission will automatically downshift
to the next lowest gear. A manual up shift will only be accepted if
the transmission is in lock up.
ZF TRANSMISSION CONTROLS
Gear shift Control – Stall / Clutch Test Function
Button
When performing a stall test the following
procedure has to carried out to allow manual
Forward
selection of individual gears with the truck at
Upshift
standstill.
Continuity Check
N - Pins 2 & 5
F - Pins 2 & 4
R - Pins 2 & 6
Up - Pins 2 & 7
Down - Pins 2 & 8
Button - Pins 2 & 10
2
3 Plug X2
1
Z.F. Harness
4
7
3, 2, 1
10 6, 5, 4
9, 8, 7
N - Pins 2 & 5 12, 11, 10
F - Pins 2 & 4
R - Pins 2 & 6
Up - Pins 2 & 7
Down - Pins 2 & 8
Button - Pins 2 & 10
ZF TRANSMISSION CONTROLS
58
Clutch Calibration
X25
Y
ZF TRANSMISSION CONTROLS
Sound Power Circuit Fault Codes 63
Kickdown Function
ZF TRANSMISSION CONTROLS
Kickdown Function
Kickdown
function is
activated by
switch S74.
X7: Pin 16
to
X1: Pin 22
ZF TRANSMISSION CONTROLS
67
Differential Lock
ZF TRANSMISSION CONTROLS
68
activated.
Y7
ZF TRANSMISSION CONTROLS
Cross Axle Differential Lock Solenoid 70
Definitions:
Y7 Diff. Lock Solenoid (X-Axle)
40 bar from port DL on Main
Valve. Generated by Pressure
Reducing Valve (9).
S107
Y7
Definitions;
Torque Split 1:3
(Dis-Engaged) VA Output Front Axle
Differential lock
is requested
through switch
S60.
X7: Pin 8
to
X1: Pin 30
Vehicle speed
must be below
5kph before the
TCU will engage
the diff-lock.
ZF TRANSMISSION CONTROLS
Differential Lock - Output 74
S107
ZF TRANSMISSION CONTROLS
Differential Lock Coil Ratings 75
Definitions:
Y3 Retarder Solenoid
Y7 Diff. Lock Solenoid (X-Axle)
CT3 Pressure Reducing Valve
5.5 bar MAX
Y3
S107
Y7
CT3
ZF TRANSMISSION CONTROLS
Transmission Retarder (Option)
Operation of the retarder request switch
sends a signal to the transmission ECU
requesting activation of the transmission
retarder. Retarder
Request
• Operating parameters S81
X8 X9
Y3 RETARDER SOLENOID
CHECK PLUG X9 PINS 9/10
RATINGS;
14 Watts
41
0.6 Amp
ZF TRANSMISSION CONTROLS
81
Activation Pressure
Retarder Valve Not Switched
To Lubricant
From Heat Exchanger
To Retarder
Breather
From Retarder
To Heat Exchanger
After Converter
To Lubrication
ZF TRANSMISSION CONTROLS
Retarder Layout 84
ZF TRANSMISSION CONTROLS
85
Communication
ZF TRANSMISSION CONTROLS
J1939 CAN_Bus Circuit 86
Plug X4
ZF TRANSMISSION CONTROLS
CAN_Bus Circuit - Transmission Side Check transmission CAN resistance direct @
87
CAN H (+) Pin 25 TCU across Pins 25/27 with X1 connector off.
To Engine
ECM
Target figure = 120Ω
Connection CAN L (-) Pin 26 With X1 connected - Pins 26/27 are internally
Shield Pin 28 bridged via the WP harness splice.
With X1 connected - the 120 Ω resistance could be
checked at pins 25/26 or 25/27
ZF TRANSMISSION CONTROLS
CAN_Bus Circuit – TCU Resistance Check 88
Transmission TCU
23 1
45 24
68 46
Check transmission CAN resistance direct @ TCU across Pins 25/27 with X1 connector off.
Target figure = 120Ω
With the X1 connected - Pins 26/27 are internally bridged via the WP harness splice.
With the X1 connected - the 120Ω resistance could be checked at pins 25/26 or 25/27
With the X1 connected, the 120Ω TCU resistance can also be checked at the X4 connection Pins 1/2.
Remember to disconnect the engine harness from the X4.
ZF TRANSMISSION CONTROLS
CAN_Bus Fault Codes 89
ZF Fault Codes
56 - Timeout of CAN message Engine CONF from Engine ECM
57 - Timeout of CAN message EEC1 from Engine ECM
58 - Timeout of CAN message EEC3 from Engine ECM
65 - CAN signal for engine torque is defective
66 - CAN signal for engine torque is defective
69 - CAN signal for reference of engine torque is defective
6A - CAN signal for actual engine torque is defective
6B - CAN signal for nominal friction torque is defective
6E - Timeout of CAN message EEC2 from Engine ECM
CA – Engine retard config timeout
CB – ERC1 Timeout
ZF TRANSMISSION CONTROLS
CAN_Bus Fault Codes 90
• Interference on CAN_Bus
56,57,
• Engine controller is defective
58,6E,
CA,CB • CAN wire/connector is broken
• CAN wire/connector defective / has contact to vehicle
ground or battery voltage
CODES CAN BE CAUSED BY LOW ENGINE RPM & DIRTY FUEL FILTER
ZF TRANSMISSION CONTROLS
Measurement On CAN_Bus 91
QSM
Engine 50-Pin OEM Connection on QSM engines. 50 PIN OEM
CONNECTION
50 PIN OEM
CONNECTION
Transmission X1 Connection
ZF TRANSMISSION CONTROLS
95
Oil Filtration
ZF TRANSMISSION CONTROLS
6WG260/310 Transmission Filter 96
1000 Hr.
TEL No: 15274198
Code BA
ZF TRANSMISSION CONTROLS
Filter Bypass Switch 97
ACCEPT NO SUBSTITUTE
ZF TRANSMISSION CONTROLS
Transmission Oil Levels 99
Diagnostic Tools
ZF TRANSMISSION CONTROLS
102
ZF Diagnostic Tools
ZF TestMan Part Number:
15501299
6WG210/260/310 Software
Part Number:
15501300
15273664
ZF TRANSMISSION CONTROLS
103
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