How to use AEB starter and Why you need it.

AEB starter 0501211778, 0501.211.778, 0501-211-778, 0501298522, 0501.298.522, 0501-298-522 for ZF transmissions 

For ERGOPOWER transmissions WG110-310 with electronic control unit EST-37, beginning from software - version V8.12

The AEB has the task to compensate tolerances (plate clearance and pressure level) which are influencing the fiIling procedure of the clutches.
For each clutch, the correct filling parameters are determined in one test cycle for period of the quick-fllling time level of the filling compensating pressure

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Implementation
After the transmission has been mounted, the program installed in the electronic system for AEB cycle MUST be started.
After any replacement of a transmission or electronic component in the vehicle, transmission oil change, the correct adaptation will be achieved by starting the AEB cycle.
ZF recommends to start the AEB cycle after 100 operating hours and after 1000 hours each to keep shifting quality at the highest level.
Implementation of AEB cycle lasts approximately 3-4 minutes

Before starting the AEB cycle:

On the display:     - Select  Menu  →  Adjustment         - Push  “AEB”  during 2 seconds

#

Order

Display message

Remark

1

Warm up transmission about 10 to 20 minutes

 

Warm up the transmission ( 70°C < Temp. of  T/M > 80°C

2

Turn off ignition key

 

 

3

Plug in AEB starter to AEB cobbector located at the seat base closest to the cab door.

 

 

4

Put transmission gear selector lever to NEUTRAL position.

 

 

5

Engage park brake

 

 

6

Start Engine

"PL"

Transmission Control Unit recognize "PL" for at least 2 seconds before you press AEB button

7

On idling RPM

"PL"

Make sure that RPM is between 900 - 1000

8

Press button of the AEB Starter

"ST"

The button must not be released before TCU has started the AEB or quit with an error code (see Error code list)

9

Hold button until AEB has been started

"K1" (information about the AEB state)

TCU has started the AEB, and goes on adjusting K1, K2,…, KR. (Button may be released from starting)

10

Wait until AEB has been finished

"OK" (AEB has been successful)

 

11

Turn off ignition and unplug AEB Starter

 

 

 

How to warm-up the T/M ?

1) E/G start.
2) Parking release.
3) Forward direction → gear shift to 4th stage (with brake pedal push). 
3-1) Push acceleration pedal 10~20sec → Release acceleration pedal 10sec.
4) Reverse direction → gear shift to 3rd stage (brake pedal push). 
4-1) Push acceleration pedal 10~20sec → Release acceleration pedal 10sec.
5) Finish the warm-up of T/M when the oil temperatore is reached to 70~80℃.

Display during AEB-Mode

Symbol

Meaning

Remarks

PL

AEB - Starter is plugged at the diagnostic plug

 

ST

AEB Starter button is pressed

 

K1..K4,KV,KR

Calibrating each clutch K1..K4,KV,KR

 

_ and Kx

Wait for start, initialization of clutch Kx, x : 1, 2, 3, 4, V, R

 

≡ and Kx

fast fill time determination of clutch Kx

 

_= and Kx

compensating pressure determination of clutch Kx

 

OK

calibration for all clutches finished

Transmissions stays in neutral, have to restart the TCU (ignition off/on) after removing AEB-Starter

STOP

AEB canceled (activation stopped)

Transmissions stays in neutral, have to restart the TCU (ignition off/on)

STOP and Kx

AEB stopped, clutch Kx can't be calibrated

Transmissions stays in neutral, have to restart the TCU (ignition off/on)

Spanner and Kx

Kx couldn't be calibrated, AEB finished

Transmissions stays in neutral, have to restart the TCU (ignition off/on)

↑ E

Engine speed too low,

E/G RPM should be raised

↓ E

↓ E

E/G RPM should be down

↑ T

Transmission oil temperature too low

Warm up Transmission

↓ T

Transmission oil temperature too high

Cool down Transmission

FT

T/M temp not in defined range during calibration

T/M stays in neutral, have to restart the TCU (key off/on)

FB

Operating mode not NORMAL or T/M temp sensor defective or storing of Calibrated values to EEPROM-has failed

T/M stays in neutral, have to restart the TCU (key off/on)

FO

Output speed not zero

Transmissions stays in neutral, have to restart the TCU (ignition off/on)

FN

Shift lever not in Neutral position

Transmissions stays in neutral, have to restart the TCU (ignition off/on)

FP

Parking brake not applied

Transmissions stays in neutral, have to restart the TCU (ignition off/on)

STOP

AEB - Starter was used incorrect or is defective

Transmissions stays in neutral, have to restart the TCU (ignition off/on)

Theory of AEB setting

1) Speed sensors on Transmission

2) Hydraulic Circuits 
3) Proportional Valve 
4) Clutch shift graph 

※ K1 → K2 Shift

5) Shift setting factors
 

6) Fast Fill Time setting

7) Compensation pressure setting

Frequency of Speed sensor

Shaft rpm = (Hz/Z) X 60
You can measure the frequency with an electric multi meter.

Machine Speed (km/hr)

- Hz Frequency from Speed Sensor
- Z Number of Ring gear Teeth
- r total Total Reduction Ratio of Axle (r diff X r hub)
- R Tire Radius in meter

 

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