Order - No.

: 5872 993 026

Diagnostic Inspection and Trouble shooting Instruction

ZF-ERGOPOWER with EST-37

4/6 WG – 110/130/160/190/210/260/310

Z F P a s s a u G m b H
Donaustraße 25 - 71
D - 94034 Passau Edition: ASTI – 06/2001
Subject to Modifications!
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 2. Connection possibilities of the Testers
1= Mobi Dig 2001 (Order - No.: 6008 307 001)
2= Terminal Tester (Order - No.: 6008 304 038)
3= Multimeter (Order - No.: 5870 221 158) Vehicle
4= EST - 37
5= Cable harness (Order - No.: 5870 221 156)
6= DPA 03 (Order - No.: 5870 211 102)
(Note: No.4 and No.5 are only necessary for the Test bench!)

1 5
Lap-Top
6
4
Transmission

EST - 37 for:
4 WG 130/210
6 WG 130/210
(No.: 5870 221 161)
(No.: 5870 221 160) 2
4 WG 260/310 (No.: 5870 221 159)
6 WG 260/310 (No.: 5870 221 155)

Temperature sensor
Shift unit: Retarder
Ergo-Control
optional
1
3
3.Read out Fault storage

Cable harness

Vehicle
Shift control

Transmiossion

EST - 37
Mobi Dig 2001 Lap - Top

1.) Connect Mobi Dig or Lap–Top with „Diagnosis“- plug of the

cable harness
2.) Select under „Diagnosis“ the group „Read Fault storage“
3.) Find error, resp. Error code in the Appendix

Tip: At step „Read out Fault storage“ print out the page!
4.Cancel Fault storage

Cable harness

Vehicle
Shift control

Transmiossion

EST - 37
Mobi Dig 2001 Lap - Top

1.) Connect Mobi Dig or Lap–Top with „Diagnosis“- plug of the

cable harness
2.) Select under „Diagnosis“ the group „Cancel Fault storage“
3.) Acknowledge with „YES“
5.1 Check of the 3 Inductive transmitters for Engine,
Turbine and Central gear train with Terminal tester and
Multimeter for Resistance

Vehicle

1.) Ignition „OFF“

2.) Separate EST - 37 from cable harness of the vehicle
3.) Connect Terminal tester with cable harness of the vehicle
4.) Connect Multimeter with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
5.) Read Measuring value (Nominal data see Data sheet No. 11/12)
⇒ not O.K.: check cable connection
→ O.K.: replace Transmitter (WG -130→210)
check Contact gap (WG-260/310)
→ O.K.: replace Transmitter
5.2 Check of the 3 Inductive transmitters for
Engine, Turbine and Central gear train with
Terminal tester and Multimeter for HZ

Vehicle

1.) Ignition „OFF“

2.) Connect Terminal tester with EST - 37 and cable harness of the vehicle
3.) Ignition „ON“ and start the engine
4.) Connect Multimeter with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
5.) Read Hz-Display
6.) Reading must increase uniformly with the output speed
⇒ not O.K.: check cable connection
→ O.K.: replace Transmitter (WG -130→210)
check Contact gap (WG-260/310)
→ O.K.: replace Transmitter

Tip: • At transmitter for Central gear train, a speed must be engaged and
the wheels must spin.
6.1 Check of the 3 Inductive transmitters for
Engine, Turbine and Central gear train with
Terminal tester and Mobi Dig for Resistance

Vehicle

1.) Ignition „OFF“

2.) Separate EST - 37 from cable harness of the vehicle
3.) Connect Terminal tester with cable harness of the vehicle
4.) Connect Mobi Dig with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
5.) Read Measuring value (Nominal data see Data sheet No. 11/12)
⇒ not O.K.: check cable connection
→ O.K.: replace Transmitter (WG -130→210)
check Contact gap (WG-260/310)
→ O.K.: replace Transmitter
6.2 Check of the 3 Inductive transmitters for
Engine, Turbine and Central gear train with
Terminal tester and Mobi Dig for Hz

Vehicle

1.) Ignition „OFF“

2.) Connect Terminal tester with EST - 37 and cable harness of the vehicle
3.) Ignition „ON“ and start the engine
4.) Connect Mobi Dig with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
5.) Read Hz-Display
6.) Reading must increase uniformly with the output speed
⇒ not O.K.: check cable connection
→ O.K.: replace Transmitter (WG -130→210)
check Contact gap (WG-260/310)
→ O.K.: replace Transmitter

Tip: • At transmitter for Central gear train, a speed must be

engaged and the wheel must spin.
7.Check of the Hall-Sensor with Terminal tester
and Multimeter for Hz

Vehicle

1.) Ignition „OFF“

2.) Connect Terminal tester with EST - 37 and cable harness of the vehicle
3.) Ignition „ON“ and start the engine
4.) Connect Multimeter with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
5.) Read Hz-Display
6.) Reading must increase uniformly with the output speed
⇒ not O.K.: check cable connection
→ O.K.: replace Sensor (WG -130→210)
check Contact gap (WG-260/310)
→ O.K.: replace Sensor

Tip: At the Hall-Sensor Check, a speed must be engaged and the wheels
must spin.
8. Check of the Hall-Sensor with Terminal tester
and Mobi Dig for Hz

Vehicle

1.) Ignition „OFF“

2.) Connect Terminal tester with EST - 37 and cable harness of the vehicle
3.) Ignition „ON“ and start the engine
4.) Connect Mobi Dig with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
5.) Reading Hz-Display
6.) Reading must increase uniformly with the output speed
⇒ not O.K.: check cable connection
→ O.K.: replace Sensor (WG -130→210)
check Contact gap (WG-260/310)
→ O.K.: replace Sensor

Tip: At the Hall-Sensor Check, a speed must be engaged and the wheels
must spin.
9.1 Check of the Proportional valves, the
temperature sensors sump and retarder, if
available, with Terminal tester and Multimeter for
Resistance

Vehicle

1.) Ignition „OFF“

2.) Separate EST - 37 from cable harness of the vehicle
3.) Connect Terminal tester with cable harness of the vehicle
4.) Connect Multimeter with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
5.) Read Measuring value (Nominal data see Data sheet No. 11/12/13)
⇒ not O.K.: check cable connection
→ O.K.: replace: - either Proportional valve
- or Temperature sensor sump
(complete cable harness)
- or Temperature sensor retarder
9.2 Check of the Proportional valves, the
temperature sensors sump and retarder, if
available, with Terminal tester and Multimeter for
Current

Vehicle

1.) Ignition „OFF“

2.) Connect Terminal tester with EST - 37 and cable harness of the vehicle
3.) Connect Multimeter with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
4.) Open bridge on Terminal tester
5.) Ignition „ON“
6.) Read Measuring value (Nominal data see Data sheet No. 11/12/13)
⇒ not O.K.: check cable connection
→ O.K.: replace: - either Proportional valve
- or Temperature sensor sump
(complete cable harness)
- or Temperature sensor retarder

Tip: • At Neutral position of the Controller lever, the Proportional valves

are already pressurized with little current (app. 100 mA)
• After engagement of a speed the value must increase
10. Check of the Proportional valves, the
temperature sensors sump and retarder, if
available, with Terminal tester and Mobi Dig for
Resistance

Vehicle

1.) Ignition „OFF“

2.) Separate EST - 37 from cable harness of the vehicle
3.) Connect Terminal tester with cable harness of the vehicle
4.) Connect Mobi Dig with Terminal tester at the corresponding pins
(See Circuit diagram in the corresponding operator`s manual!)
5.) Read Measuring value (Nominal data see Data sheet No. 11/12/13)
⇒ not O.K.: check cable connection
→ O.K.: replace: - either Proportional valve
- or Temperature sensor sump
(complete cable harness)
- or Temperature sensor retarder
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