Diagnostic software aids transmission reliability

Edited by the Engineeringtalk editorial team Dec 6, 2007

The ZF TestmanPro diagnostic program is an essential tool in any company's preventive maintenance programme.

It is a truism that prevention is better than cure, and, it should be said, nowhere near as expensive.

To illustrate this point, the cost of a wheel loader standing idle due to a breakdown can run into many thousands of pounds a day.

This cost relates not just to the wheeloader itself; rather it takes into account the usual "multiplier" effect of the breakdown, where typical items such as crushers and fleet vehicles stand idle.

In these cases the accumulated costs are extremely serious for the operator; possibly resulting in penalty clauses, lost contracts and a reputation for unreliability that can prejudice future business.

Although many problems can be rectified on-site, the growing consensus is that repairs are often a "sticking plaster" solution that addresses the effects rather than the causes of problems.

This is certainly so with transmission systems, which are critical to the operation of every wheel loader, crane, backhoe dumper truck, et al.

Today's transmissions are highly complex: an optimised synergy of electronics, hydraulics and mechanics that make the job of the operator easier, at the same time as optimising the operation of the off highway vehicle itself.

Happily, along with complexity, the transmissions are highly reliable if looked after properly.

Unfortunately, with pressurised on-site conditions this is not always the case, and failures do occur for a number of reasons, most of which would be easy to avoid if the operator had greater transparency of the operation of his system.

ZF is providing this transparency with its ZF TestmanPro diagnostic programme.

The programme provides an advanced solution to the problem of unscheduled downtime, allowing for preventative maintenance and, hence, maintenance times to be planned.

ZF TestmanPro is designed for use with ZF's latest transmissions, which feature state-of-the art electronic control systems.

These enable important operational data to be downloaded by ZF personnel to a laptop PC.

The data are then analysed using the diagnostic software.

Conveniently with ZF TestmanPro, data can be collected with the vehicle stationary or on the move; and it can be transferred to a remote location for offsite analysis and storage via a mobile phone network.

Importantly, every contemporary ZF transmission has a transmission control unit (TCU) which is like a black box recorder for recording transmission faults.

In conjunction with ZF TestmanPro, the memory of the TCU can be checked for errors and downloaded, if required.

In addition, up to 20 parameters such as oil temperatures and pressures are measured, and diagnostics on the functions of components such as solenoids and speed sensors is provided.

This information is complemented by historical data as to how the transmission has performed in the past and, in respect of the error memory, a list of next steps together with tips on fault limitation is provided.

ZF TestmanPro can be provided directly by ZF personnel, or alternatively via its three UK drive centres in Birmingham, Manchester or Glasgow, and one covering the whole of Ireland.

In addition, ZF provides staff training for larger users, providing a cost effective and simple way to improve the performance of their fleets.

"The ZF TestmanPro diagnostic program is an essential tool in any company's preventive maintenance programme", says Mike Goatley, ZF Sales Manager for Off-Highway Products.

"It can make a difference to the reliable performance of any off-highway vehicle; but its biggest contribution has to be to fleet users, enabling them to be aware of potential problems in their fleets and providing timely data to enable them to plan how to overcome them".