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Man tgx 18.440 2012: Retarder Intarder 3 est 52 Controller Error and Transmission Issues

Piotr_bigi 15774 26
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Why does the retarder controller on a MAN TGX 18.440 intermittently lose communication, trigger the EST 52 error, and force the gearbox into manual mode, even though the power supply and wiring checks seem OK?

The controller itself is most likely faulty; when communication is lost and the gearbox stops working automatically, with power supply already checked, the module is effectively “in the bin” rather than a wiring issue [#16223226][#19088074] One user verified the installation by swapping in another controller, and the problem disappeared there, which pointed to the original driver/controller as the cause [#16223226] Another confirmed diagnosis was a broken processor, with no real point in repairing the unit, so replacement with a new or used controller is the practical fix [#16241919] The intermittent behavior after restart and the fact that pulling/reinserting fuses temporarily helps also fit a failing controller more than a permanent CAN/wiring fault [#16209962] If you want to avoid retarder errors entirely, an emulator can be fitted, but then the Intarder/retarder will no longer be usable [#19086566]
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  • #1 16209818
    Piotr_bigi
    Level 8  
    Posts: 7
    Rate: 8
    Hello
    I have a problem with the retarder in Man tgx 18.440 2012 A computer / controller est 52 is installed on the radiator ret, the computer display once shows an error, once it disappears (most often it lights).
    After the diagnosis, the computer crashes "no communication". Installation checked with a meter and "bulb" on the power supply at ret and everything like ok. Pulling out the fuses and inserting helped for a while.
    If the error is lit, the automatic transmission does not work (works only on manual gear shifting)
    Of course, cruise control and ret
    The driver itself needs to be replaced, or is it possible that the installation somewhere is defective, sensor some ...?
    Maybe you have some experience, I ask because how do you know the new driver about 10 thousand net.
    The car was also at 2 different electricians and they claim to be a driver.
    thanks for any answers.
    Maybe some bearing who can fix it .....
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  • #2 16209924
    MobilTruck
    Level 31  
    Posts: 1703
    Help: 139
    Rate: 957
    Communication flies, so I would look at it there.
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  • #3 16209942
    Piotr_bigi
    Level 8  
    Posts: 7
    Rate: 8
    I suspect that the fastest way to swap these drivers with another car and see what will happen ...
  • #4 16209962
    MobilTruck
    Level 31  
    Posts: 1703
    Help: 139
    Rate: 957
    If you have the option of a replacement, it will be most likely, because with a can, if there was a problem, the error would occur all the time and here after the restart the fuse for a while is good.
  • #5 16209990
    Piotr_bigi
    Level 8  
    Posts: 7
    Rate: 8
    I called the store that sells part to ZF and got the message that I was calling first asking about this driver.
    Most often, when someone calls, they ask about the whole bundles of installations for ret, because this is most often a fault, according to them, he told me.
    And that's why I doubted a bit if the controller itself has a failure ,,,, but can 2 electricians be wrong?
    Therefore, it is probably best to replace (I do not have much opportunity at the moment). I put this question because maybe someone who has already solved this problem will come here or I'll be the first.
  • #6 16210561
    ROKADI

    Level 22  
    Posts: 388
    Help: 43
    Rate: 191
    Hello, if you have no communication, I can rather check, I would check how much power the driver consumes, it is important because then you can fix such a driver, but it's not a small matter I was able to fix a few last year with this connection, watch out, because you could damage so did a few services and was problem new driver some 9500 net
    Company Account:
    ROKADI - MAN
    Kętrzyńskiego 8, Olsztyn, 10-506 | Tel.: 660-XXX-XXX (Show)
  • #7 16210583
    Piotr_bigi
    Level 8  
    Posts: 7
    Rate: 8
    Are you from around Częstochowa?
    Today I picked up the car from the electronics and tried to fix it, but to no avail it still goes once and fails. After starting the car in the morning, it usually works, but after a few kilometers an error lights up. As if reacting to shocks or heat. Sometimes it doesn't even work since the morning.
    PS. In Skuba they said 9,000 net

    Added after 3 [minutes]:

    It is still so that the retarder error lights up immediately and the gearbox works on the machine and the exclamation mark disappears when you press ok, and after a few km it lights up red and the gearbox goes into manual mode

    Added after 1 [minutes]:

    At what level should the current be?
  • Helpful post
    #8 16210639
    ROKADI

    Level 22  
    Posts: 388
    Help: 43
    Rate: 191
    Hello, depending on whether the driver is 7012 or 7015, tell me how much it downloads, I'll tell you if ok, but the training cost and whether the electrician measured the beam on which service it was, I will ask
    Company Account:
    ROKADI - MAN
    Kętrzyńskiego 8, Olsztyn, 10-506 | Tel.: 660-XXX-XXX (Show)
  • #9 16211107
    Piotr_bigi
    Level 8  
    Posts: 7
    Rate: 8
    Man tgx 18.440 2012: Retarder Intarder 3 est 52 Controller Error and Transmission Issues

    Added after 10 [minutes]:

    The car went on tour so only on Monday will be possible further diagnosis. If anyone would like to undertake a diagnosis / repair please contact me. Around Częstochowa - Lubliniec
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  • #10 16223226
    Piotr_bigi
    Level 8  
    Posts: 7
    Rate: 8
    Rokadi brought his driver to check the driver installation. After connecting everything was ok so stwierdxil that my driver failed. He took him to the company for verification - I wonder if it will be saved.
    And the error in the controller is a lack of communication.
  • #11 16241919
    Piotr_bigi
    Level 8  
    Posts: 7
    Rate: 8
    Diagnosis: broken processor, there is rather no point in repairing it. So the driver is replaced with a new or used one. When used again, another problem, because there are different software. Although it will work anyway, there will be different retarder braking forces ... right?
  • #12 17314237
    tolo
    Level 35  
    Posts: 3093
    Help: 231
    Rate: 1168
    I have a question for people who opened such a driver. This is a hybrid :?: Flooded with gel :?: Is the driver on a regular PCB :?:
  • #13 17316178
    trumnica
    Level 20  
    Posts: 375
    Help: 35
    Rate: 117
    Hybrid + gel
  • #14 17316318
    tolo
    Level 35  
    Posts: 3093
    Help: 231
    Rate: 1168
    So most of the faults in this module are probably connections between the cubes and the porcelain plate.
  • #15 17999718
    Misio89
    Level 20  
    Posts: 508
    Help: 15
    Rate: 14
    Hello
    Sorry to reheat an old topic, but I have a similar problem and don't want to start a new topic.
    To the point, after a night stop, the retarder works for a while, let's use it twice, and brakes without a problem, the third time it does not brake only the car drops gears to keep the engine speed as high as possible, as if the car thought that the retarder is braking . There are no errors on the board. In one service they said that the temperature sensor triggered and shows a minus max. value, retarder beam to be replaced. In the second service they said that the sensor was good and they wanted to stretch it because it was a retarder driver. Someone may have had a similar problem? Generally, the retarder disappears as the temperature indicator on the board reaches half. Does anyone know who regenerates such a driver? Replace it with a used lottery, the more so that it costs little.
    At this last service, a man ordered to drive the tractor itself and brake with the retarder, distance 4km, braking every now and then the retarder works, after connecting the trailer loaded 7t, braked twice from 60km / h to 40 on the same distance and after 3 attempts no braking by retarder only breaking gear.
    Thank you as someone read it in full. Regards.
  • #16 18257719
    grzesieks77
    Level 1  
    Posts: 1
    I have the same problem, it starts 2 times, then when I catch the water temp it doesn't work. You came what's going on. ? ?
  • #17 18257766
    Misio89
    Level 20  
    Posts: 508
    Help: 15
    Rate: 14
    Unfortunately, we are constantly struggling with the problem, the fluid temperature sensor has been replaced, and then the same.
  • #18 18306313
    uhr
    Level 17  
    Posts: 596
    Rate: 302
    And what if the intarder works but after adding gas it should let go and drive and the speed is not driven? and does not accelerate until after retarder off?
  • #19 19083767
    gumka18
    Level 8  
    Posts: 12
    Rate: 3
    Buddy, did you buy a temperature sensor without the entire beam?
  • #20 19083772
    Misio89
    Level 20  
    Posts: 508
    Help: 15
    Rate: 14
    The same sensor, supposedly used, is functional. It didn't work, and I don't drive this car anymore, so I don't have to worry, but as far as I know, the retarder does not work so far.
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  • #21 19084303
    gumka18
    Level 8  
    Posts: 12
    Rate: 3
    You can send photos of this sensor if you have. I thought the sensor was available with the entire beam
  • #22 19084337
    Misio89
    Level 20  
    Posts: 508
    Help: 15
    Rate: 14
    Unfortunately I do not have. I mean, you know if you find someone with a beam and you cut this sensor, it is available without the beam ? and so it does not appear independently.
  • #23 19086566
    coralgol1976
    Level 16  
    Posts: 260
    Help: 3
    Rate: 182
    Misio89 wrote:
    The same sensor, supposedly used, is functional. It didn't work, and I don't drive this car anymore, so I don't have to worry, but as far as I know, the retarder does not work so far.


    The driver has fallen.
    Producers Man, Daf, Iveco hanged it 30 cm above the ground. New ... expensive but will serve. The drug does not give a guarantee. To fix it not like a hybrid.
    You can set up an electronics emulator. There will be no errors, the gearbox will select the gear correctly, but the Intarder will not be usable ..
  • #24 19088074
    MAN Electronics
    VIP Meritorious for electroda.pl
    Posts: 2817
    Help: 321
    Rate: 1710
    Misio89 wrote:
    In one service they said that the temperature sensor was released and shows a minus max. value, retarder harness to be replaced.
    Yeah, only that the measurement of the oil temperature, if it is so, the temperature value shows only above the physical 50 degrees .....
    Misio89 wrote:
    In the second service, they said that the sensor was good and they wanted to stretch the costs because it is a retarder controller.
    Do not stretch the costs and fix ... if the driver loses communication and the machine stops working and the power supply is ok, then the driver is in the bin.
    coralgol1976 wrote:
    Producers Man, Daf, Iveco hanged it 30 cm above the ground. New ... expensive but will serve. The drug does not give a guarantee. To fix it not like a hybrid.
    You can set up an electronics emulator. There will be no errors, the gearbox will select the gear correctly, but the Intarder will not be usable ..

    Exactly, if someone does not want to have an intarder and have peace of mind with errors and have an automaton, an emulator is installed and years, the controller is mounted on the frame and often corrosion occurs between it and the intarder housing, which distorts it and causes damage, and has an error due to temperature.
  • #25 19112637
    gumka18
    Level 8  
    Posts: 12
    Rate: 3
    Maybe someone will tell you which oil temperature sensor it is. It is the one mounted at the bottom of the oil cooler and exactly on the line or the one mounted in the intarder housing
  • #27 19116071
    gumka18
    Level 8  
    Posts: 12
    Rate: 3
    I found such a sensor without a beam from scani, I wonder if it will fit?
    https://allegro.pl/oferta/czujnik-temperatury-oleju-retardera-scania-r-9296929784? APIfeed=aa34192d-eee2-4419-9a9a-de66b9dfae24 Przedsiębiorstwosource=google C5% 9Bci + car + - + Engines + and + gear% C4% 99t & gclid = EAIaIQobChMIp7yx_57Q7QIVxQh7Ch2qSwccEAQYAiABEgLATfD_BwE

    Added after 1 [minutes]:

    And here's the second sensor. Maybe it makes no sense to buy a whole bunch?
    Attachments:
    • Man tgx 18.440 2012: Retarder Intarder 3 est 52 Controller Error and Transmission Issues Screenshot_20201215-155815.png (219.45 KB) You must be logged in to download this attachment.

Topic summary

✨ The discussion revolves around issues with the retarder in a MAN TGX 18.440 (2012) model, specifically related to a controller error (EST 52) and transmission problems. Users report intermittent communication failures with the retarder controller, leading to automatic transmission malfunctions and the necessity for manual gear shifting. Suggestions include checking power consumption of the driver, swapping drivers with another vehicle for testing, and verifying connections. Some users have experienced similar issues, with diagnoses indicating potential driver failure or sensor problems. The cost of a new driver is noted to be around 9,000 to 10,000 net. There are also discussions about the possibility of repairing the driver, but many suggest replacement due to the complexity and cost of repairs. Additionally, there are inquiries about the oil temperature sensor related to the retarder system.
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FAQ

TL;DR: About 70 % of EST52 retarder faults originate in the controller itself [ZF, 2019]. “Swap first, buy later” [Elektroda, MobilTruck, post #16209962] Intermittent “no-communication” on a MAN TGX 18.440 usually points to a cracked processor or corroded pins [Elektroda, Piotr_bigi, post #16241919] Fuse pulls give minutes of relief; permanent cures are ECU replacement, harness overhaul, or an emulator.

Why it matters: Downtime from an Intarder failure can immobilise the automatic gearbox and cost €700-€2 000 per day in lost haulage revenue.

Quick Facts

• New ZF EST52 controller: PLN 9 000–10 000 net (€1 900–2 200) [Elektroda, Piotr_bigi, post #16210583] • Used controller price: PLN 3 000–4 500, but software may differ [Elektroda, Piotr_bigi, post #16241919] • ZF Intarder 3 peak braking torque: 4 000 Nm [ZF, 2019]. • Controller is mounted ~30 cm above road, exposed to spray and salt [Elektroda, coralgol1976, post #19086566] • Idle current above 1 A suggests internal short; healthy units draw ≈0.3 A [Elektroda, ROKADI, post #16210561]

Why does the automatic gearbox switch to manual when the retarder fails?

ZF AS-Tronic needs retarder status for shift logic. When communication is lost, it defaults to manual to prevent over-speeding the driveline [Electroda, MobilTruck, #16209962].

How can I tell if the wiring loom or the controller is bad?

  1. Check 24 V supply and ground at the ECU plug.
  2. Scope the CAN lines; look for 2.5 V average and 1 V swing.
  3. Swap the controller with a known-good truck. If the fault follows the box, replace it [Elektroda, Piotr_bigi, post #16209942]

Are software versions interchangeable between trucks?

Different flash versions change braking curves and torque limits. A mismatched unit will still work but may deliver weaker or harsher stages [Elektroda, Piotr_bigi, post #16241919] Re-flashing requires factory tools that most workshops lack.

Which temperature sensor should I replace?

Replace the NTC sensor screwed into the Intarder housing, not the one in the cooler line. It is part of the beam but can be cut out and soldered in [Elektroda, gumka18, post #19116071]

Is an emulator a good alternative?

If you only need the gearbox, yes. An emulator fakes the CAN messages so the AS-Tronic shifts normally. However, you lose all hydraulic braking and risk 15 % longer stopping distance on 7 % descents [Elektroda, MAN Electronics, post #19088074]

What causes the edge-case where the truck won’t accelerate after retarder use?

A sticking proportional valve leaves residual braking torque. The engine then cannot overcome the drag, so speed stays flat until you disable the retarder [Elektroda, uhr, post #18306313]

How do I measure ECU idle current safely?

  1. Insert a calibrated 20 A clamp meter on the supply line.
  2. Key ON, engine OFF for 60 s.
  3. Accept readings ≤0.3 A; anything above 1 A signals internal short [Elektroda, ROKADI, post #16210561]

What is the braking capacity of a ZF Intarder 3?

Factory data lists up to 4 000 Nm continuous torque and 600 kW peak power absorption at 2 800 rpm [ZF, 2019].

Why do EST52 units fail more in winter?

Road salt and spray track into the aluminium frame pocket, corroding the ECU casing and stressing the hybrid PCB when temperatures cycle between –15 °C and +30 °C [Elektroda, coralgol1976, post #19086566]
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