Checklist AS-Tronic / AS – Mid

Editor:       Date:      

Vehicle data:
Vehicle operator:      
Vehicle manufacturer:      
Chassis number (VIN):      
Engine type:       Engine power :      
Mileage:       Date in service:     
Model type :       License no.:      

Transmission data:
Transmission type:       Spec. list:      
Serial number:      
TCU No. (ZF):       Wabco GS No.:      
Clutch actuator no.:      

Software: 6009 374       P1:      .hex P2:      .hex

Complaint:      
     
Exception:
Oil temperature by complain resp. error warning:      C
Problem with communication: Communication in order
No communication via vehicle diagnose interface
No communication via table modus adapter
Interrupt via programming P1
Interrupt via programming P2
Error memory:
Error code Frequency Countdown Natural language text
                       
                       
                       
                       
                       
                       
                       
                       
                       
                       
!! Do not delete the error memory in replaced transmission actuators !!

Clutch data: (Has to read out if the transmission is removed due to clutch problems)
Clutch type:      
Clutch disc:      
Pressure plate:      
Release bearing:      
Release fork:      

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 Checklist AS-Tronic / AS – Mid

10-Speed DD 10-Speed OD 12 - Speed 16 - Speed

Limit positions (GS 3):
Action Signal Nominal Actual
4-7-1-3 GS 3 GS 3.3 AS-Tronic AS-Mid
10 – speed DD
1st gear engaged High value Front left < 590 Ink    
3rd gear engaged Low value Rear right > 80 Ink    
5th gear engaged High value Front right < 590 Ink    
1st reverse engaged Low value Rear left > 80 Ink    
Difference 1st gear – 1st reverse < 500 Ink 0
Difference 5th gear – 3rd gear < 500 Ink 0
Action Signal Nominal Actual
4-7-1-3 GS 3 GS 3.3 AS-Tronic AS-Mid
10 – speed OD
5th gear engaged High value Front left < 590 Ink    
1st gear engaged Low value Rear right > 80 Ink    
3rd gear engaged High value Front right < 590 Ink    
1st reverse engaged Low value Rear left > 80 Ink    
Difference 5th gear – 1st reverse < 500 Ink 0
Difference 3rd gear – 1st gear < 500 Ink 0
Action Signal Nominal Actual
4-7-1-3 GS 3 GS 3.3 AS-Tronic AS-Mid
12 – speed
1st gear engaged High value Front left < 590 Ink    
3rd gear engaged Low value Rear right > 80 Ink    
5th gear engaged High value Front right < 590 Ink    
1st reverse engaged Low value Rear left > 80 Ink    
Difference 1st gear – 1st reverse < 500 Ink 0
Difference 5th gear – 3rd gear < 500 Ink 0
Action Signal Nominal Actual
4-7-1-3 GS 3 GS 3.3 AS-Tronic AS-Mid
16 – speed
1st gear engaged Low value Rear left > 80 Ink    
3rd gear engaged High value Front left < 590 Ink    
5th gear engaged Low value Rear right > 80 Ink    
7th gear engaged High value Front right < 590 Ink    
1st reverse engaged High value none < 590 Ink    
Difference 3rd gear – 1st gear < 500 Ink 0
Difference 7th gear – 5th gear < 500 Ink 0

Action Signal Nominal Actual

4-7-1-3 AS-Tronic AS - Mid AS - Tronic AS - Mid
Limit positions
gate, group, split
Gate (1/2) (1/R) Low value 70 – 120 Ink    
Gate (3/4) (2/3) High value 500 – 580 Ink    
Group low Low value High value 80 – 130 Ink    
Group high High value Low value 490 – 590 Ink    
Splitter low (overdrive) Low value 70 – 140 Ink    
Splitter high (overdrive) High value 500 – 650 Ink    
Splitter low (direct drive) High value 500 – 650 Ink    
Splitter high (direct drive) Low value 70 – 140 Ink    

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 Checklist AS-Tronic / AS – Mid

Action Signal Nominal Actual

4-7-2
Clutch actuator
Input speed (low idle aktiv) Clutch engaged = engine
N_sek     
speed (1/min)
Relative clutch stroke in neutral
S_kup (%) In neutral = 100%
to absolute clutch travel (clutch is    %    mm
S_Kup_abs (mm) 100% = 27 – 60mm
engaged)
Absolute clutch transfer point Between 12 and 45mm
S_kup_ap_abs   mm
(depend of wear / milage) (= 0% S_Kup)
Absolute clutch stroke (mm)
Difference
(Difference between absolute clutch S_kup_abs 0
app. 15 – 19 mm
transfer point and clutch engaged)
Relative clutch travel (mm) gear S_kup (%) Clutch open = app. 0%
   %      mm
engaged to absolute clutch stroke (%) S_kup_abs (mm) ___% = ___mm
Length of pressing rod Part list no. Length (mm)
Measurement is only necessary if the absolute clutch travel (mm) is out of tolerance.
Bova, DAF, Dennis, Evobus, Neoplan, VDL 1328 302 033 119,1
RVI, Irisbus 1328 368 008 123,1
Deawoo, HMC, KIA 1314 268 002 124
MAN (Bus/truck) 1328 368 003 127,1
MAN TC-Tronic 1328 368 007 130
Irisbus (Cursor 10 F3A) 1314 268 002 136
Meritor, MCI, Prevost, Spartan, , Van Hool (USA) 1328 368 009 144,9
IVECO 1314 268 002 adjustable
Action Signal Nominal Actual
4-7-4
Operating voltage
Terminal 30 18V – 29,5V      
Terminal 15 (ignition) 18V – 29,5V      

Action Signal Nominal Actual

4-7-1-1
Check term 30 / 15
Vehicle stop with engaged gear and During ignition off with engaged gear the
     
ignition off: transmission must shift hearable into Neutral
Range group position high GPS (AS-Tronic) 490 Ink – 590 Ink
     
GPS (AS – Mid)
Gear position neutral Gear sensor 300 Ink – 345 Ink      
4-7-5
Acc. pedal (MAN FFR)
Not activ = 0%      
Accelerator position Alpha_fp
Depressed pedal = 100%      
Kickdown feeling point Alpha_fp 88 – 92 %      
Kickdown activ Z_Sonder_status Accelerator > app. 95%      
Decrease of KD-signal by
Kickdown inactiv Z_Sonder_status      
accelerator < 80 %
Low idle switch aktiv Z_Sys_Status_1_UFB Accelerator < 8%      
Accelerator pedal (without FFR)
Not activ = 0%      
Accelerator position Alpha_fp
Depressed pedal = 100%      
Kickdown activ Z_Sonder_status Accelerator 100%      
Decrease of KD-signal by
Kickdown inactiv Z_Sonder_status      
accelerator < 100 %
Low idle switch activ Z_sys_Status_1_UFB Accelerator < 13%      

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 Checklist AS-Tronic / AS – Mid

4-7-7
System pressure (GS3)
System pressure Druck_Luft 7,0 – 7,8 bar      
4-5-1
Sig. brake pedal switch
Z_sys_Status_1_UFB      
7-5-1
Signal exhaust brake
Z_sys_Status_1_UFB      
4-5-1
Power take off (PTO)
Measurement of this signal is only necessary if there are any problems regarding PTO
Request PTO switch SN1A Signal activ 1      
check signal ECU Astronic SN1F Signal activ 1      
PTO engaged (feedback) SN1R Signal activ 1      
2-1-9
Statistic memory
Data get of vehicle value memory
123456.sta      
(Filename = serial number gearbox)

CAN - measurement
Measurement of the CAN is only necessary if there are any problems regarding CAN-errors
Measurement CAN H and CAN L 59 - 61 Ohm
Short circuit H to L
Interrupt connection to resistance actual app. 0 Ohm      
Interrupt both resistances actual app. 120 Ohm
app. infinite Ohm

Remarks / Measures:

     

Note: You have to add the tag 1327 754 701 for faulty parts or the checklist to the
replaced parts!

Protokoll of Datalogger Recordings

Filename Remarks
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 Checklist AS-Tronic / AS – Mid

      .dat      

      .dat      

Remarks:

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