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Service Manual ZF: EST-37 Trouble Shooting
Service Manual ZF: EST-37 Trouble Shooting
Oranje Nassaustraat 10
P.O. Box 2 > 3405 ZG Benschop
The Netherlands
T > +31 (0) 348 45 92 11
F > +31 (0) 348 45 19 34
I > www.terbergbenschop.nl
E > info@terbergbenschop.nl
SERVICE MANUAL
ZF
EST-37
Trouble Shooting
WG211
Description
of the
fault codes
for
ERGO-Control EST37
document created for customer "Terberg 6WG-211 4657 066 003 /004 Ro Ro Schlepper with prop
WK" 2005-09-26
ZF Friedrichshafen AG 05-09-23
Faultcodes ERGO-Control EST37A
Index of changes:
date index comment software version
1 Introduction
1.1 Abbreviations
1.2 ZF - Display:
If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault
code, if the gear selector is on neutral position.
If more than one fault is detected, each fault code is shown for about 1 second.
left right
h f e d character character
S
T
O
P
a b c g
symbol)
2 bars manual mode 2nd gear
3 bars manual mode 3rd gear
4 bars manual mode 4th gear and also 5th and
6th gear in 6WG
4 bars and 2 automatic mode
arrows
Bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed above a certain
limit and lockup clutch not activated
4 WG: Downshift mode activ
Spanner at least one fault activ select neutral to get fault code displayed
Fault code see faultcode list
WS warning sump temperature changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WR warning retarder temperature changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WT warning torque converter temperature changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WE warning high engine speed changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WV warning high output speed (velocity) changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WL warning high transmission input torque changes between actual gear/direction while driving,
(load) in neutral only displayed if no fault is detected
(spanner)
WO warning high transmission output torque changes between actual gear/direction while driving,
(load) in neutral only displayed if no fault is detected
(spanner)
PN direction F or R selected while parking transmission in neutral until parking brake is released
brake engaged CAUTION: vehicle starts to move after release of
parking brake
EE flashing no communication with display checked wiring from TCU to display
LIMP-HOME:
The detected failure in the system has strong limitations to transmission control. TCU can engage
only one gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator
must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector
into forward or reverse, the TCU will select the limp-home gear .
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home
gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of
the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The
operator has to slow down the vehicle and must shift the gear selector into neutral position.
TRANSMISSION-SHUTDOWN:
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to Neutral. The park brake will operate normally, also the other functions which
use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU-SHUTDOWN:
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The
park brake will engage, also all functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
11 5000 12 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to • check the cables from TCU to shift lever failure cannot be detected in
TCU detected a wrong signal combination neutral • check signal combinations of shift lever systems with DW2/DW3 shift
for the gear range OP-Mode: transmission positions for gear range lever
• cable from shift lever to TCU is broken shutdown
fault is taken back if TCU
• cable is defective and is contacted to detects a valid signal for the
battery voltage or vehicle ground position
• shift lever is defective
12 5010 12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to • check the cables from TCU to shift lever fault is taken back if TCU
SIGNAL neutral • check signal combinations of shift lever detects a valid signal for the
TCU detected a wrong signal combination OP-Mode: transmission positions F-N-R direction at the shift lever
for the direction shutdown
• cable from shift lever to TCU is broken
• cable is defective and is contacted to
battery voltage or vehicle ground
• shift lever is defective
13 5020 12 LOGICAL ERROR AT ENGINE DERATING after selecting neutral, TCU • check engine derating device This fault is reset after power
DEVICE changes to OP-Mode limp home up of TCU
TCU detected no reaction of engine while
derating device activ
15 5040 12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to • check the cables from TCU to shift lever fault is taken back if TCU
SIGNAL 2. SHIFT LEVER neutral if selector activ 2 detects a valid neutral signal
TCU detected a wrong signal combination OP-Mode: transmission • check signal combinations of shift lever for the direction at the shift
for the direction shutdown if selector activ positions F-N-R lever
• cable from shift lever 2 to TCU is
broken
• cable is defective and is contacted to
battery voltage or vehicle ground
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• shift lever is defective
16 5050 12 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal • check the cables from TCU to feedback
feedback axle connection measured by axle connection switch
TCU and output signal axle connection • check signals of the feedback axle
don't fit connection switch
• axle can’t be connected or
disconnected due to mechanical
problem
• one of the cables from feedback axle
connection -switch to TCU is broken
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• check the cable from TCU to ADM4
1)
1C 5070 5 O.C. AT ADM4 GEAR DEP. SIGNAL customer specific see chapter 4
TCU detected a wrong voltage at the gear dep. signal device
output pin, that looks like a o.c. for this • check the connectors from ADM4 gear
output pin dep. signal device to TCU
• cable is defective and has no • check the resistance of ADM4 gear dep.
connection to TCU signal device
• ADM4 gear dep. signal device has an
internal defect
• connector has no connection to TCU
25 5110 3 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, • check the cable from TCU to the sensor
TRANSMISSION SUMP TEMPERATURE TCU uses default temperature • check the connectors
SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too high:
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• temperature sensor has an internal
defect
• connector pin is contacted to battery
voltage or is broken
26 5110 4 S.C. TO GROUND AT TRANSMISSION SUMP no reaction, • check the cable from TCU to the sensor
TEMPERATURE SENSOR INPUT TCU uses default temperature • check the connectors
the measured voltage is too low: OP-Mode: normal • check the temperature sensor
• cable is defective and is contacted to
vehicle ground
• temperature sensor has an internal
defect
• connector pin is contacted to vehicle
ground
27 5120 3 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, • check the cable from TCU to the sensor
RETARDER / TORQUECONVERTER TCU uses default temperature • check the connectors
TEMPERATURE SENSOR INPUT OP-Mode: normal • check the temperature sensor
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
the measured voltage is too high:
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• temperature sensor has an internal
defect
• connector pin is contacted to battery
voltage or is broken
28 5120 4 S.C. TO GROUND AT RETARDER / no reaction, • check the cable from TCU to the sensor
TORQUECONVERTER TEMPERATURE TCU uses default temperature • check the connectors
SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too low:
• cable is defective and is contacted to
vehicle ground
• temperature sensor has an internal
defect
• connector pin is contacted to vehicle
ground
29 5130 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value • check the cable from TCU to the sensor
PARKING BRAKE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the parking brake sensor
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• sensor has an internal defect
• connector pin is contacted to battery
voltage or is broken
2A 5130 4 S.C. TO GROUND PARKING BRAKE SENSOR TCU uses default value • check the cable from TCU to the sensor
INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the parking brake sensor
• cable is defective and is contacted to
vehicle ground
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• sensor has an internal defect
• connector pin is contacted to vehicle
ground
2B 5313 12 INCHSENSOR-SIGNAL MISMATCH During inching mode: TCU shifts • check the cable from TCU to the sensor
the measured voltage from CCO and to neutral • check the connectors
CCO2 signal don’t match: While not inching: no change • check sensor
• cable is defective OP-Mode: normal
• sensor has an internal defect
2C 5135 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value • check the cable from TCU to the sensor
DLM TRACTION ADJUST DASHBOARD OP-Mode: normal • check the connectors
DEVICE INPUT • check the DLM Traction Adjust
the measured voltage is too high: dashboard device
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• sensor has an internal defect
• connector pin is contacted to battery
voltage or is broken
2D 5135 4 S.C. TO GROUND DLM TRACTION ADJUST TCU uses default value • check the cable from TCU to the sensor
DASHBOARD DEVICE INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the DLM Traction Adjust
• cable is defective and is contacted to dashboard device
vehicle ground
• sensor has an internal defect
• connector pin is contacted to vehicle
ground
2E 5137 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value • check the cable from TCU to the sensor
DLM STEERING ANGLE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the DLM STEERING ANGLE
• cable is defective and is contacted to SENSOR
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
battery voltage
• cable has no connection to TCU
• sensor has an internal defect
• connector pin is contacted to battery
voltage or is broken
2F 5137 4 S.C. TO GROUND DLM STEERING ANGLE TCU uses default value • check the cable from TCU to the sensor
SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the DLM STEERING ANGLE
• cable is defective and is contacted to SENSOR
vehicle ground
• sensor has an internal defect
• connector pin is contacted to vehicle
ground
31 5140 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the sensor
ENGINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 • check the speed sensor
V at speed input pin
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• speed sensor has an internal defect
• connector pin is contacted to battery
voltage or has no contact
32 5140 4 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
TCU measures a voltage less than 0.45V control • check the connectors
at speed input pin • check the speed sensor
• cable / connector is defective and is
contacted to vehicle ground
• speed sensor has an internal defect
33 5140 12 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power
TCU measures a engine speed over a control • check the connectors up of TCU
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
threshold and the next moment the • check the speed sensor
measured speed is zero • check the sensor gap
• cable / connector is defective and has
bad contact
• speed sensor has an internal defect
• sensor gap has the wrong size
34 5150 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the sensor
TURBINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 if a failure is existing at output • check the speed sensor
V at speed input pin speed,
• cable is defective and is contacted to TCU shifts to neutral
battery voltage OP-Mode: limp home
• cable has no connection to TCU
• speed sensor has an internal defect
• connector pin is contacted to battery
voltage or has no contact
35 5150 4 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
TCU measures a voltage less than 0.45V control • check the connectors
at speed input pin if a failure is existing at output • check the speed sensor
• cable / connector is defective and is speed,
contacted to vehicle ground TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
36 5150 12 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power
TCU measures a turbine speed over a control • check the connectors up of TCU
threshold and at the next moment the if a failure is existing at output • check the speed sensor
measured speed is zero speed, • check the sensor gap
• cable / connector is defective and has TCU shifts to neutral
bad contact OP-Mode: limp home
• speed sensor has an internal defect
• sensor gap has the wrong size
37 5160 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the sensor
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
INTERNAL SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 • check the speed sensor
V at speed input pin
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• speed sensor has an internal defect
• connector pin is contacted to battery
voltage or has no contact
38 5160 4 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
TCU measures a voltage less than 0.45V control • check the connectors
at speed input pin • check the speed sensor
• cable / connector is defective and is
contacted to vehicle ground
• speed sensor has an internal defect
39 5160 12 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power
TCU measures a internal speed over a control • check the connectors up of TCU
threshold and at the next moment the • check the speed sensor
measured speed is zero • check the sensor gap
• cable / connector is defective and has
bad contact
• speed sensor has an internal defect
• sensor gap has the wrong size
3A 5170 3 S.C. TO BATTERY VOLTAGE OR O.C. AT special mode for gear selection • check the cable from TCU to the sensor
OUTPUT SPEED INPUT OP-Mode: substitute clutch • check the connectors
TCU measures a voltage higher than 12.5 control • check the speed sensor
V at speed input pin if a failure is existing at turbine
• cable is defective and is contacted to speed,
battery voltage TCU shifts to neutral
• cable has no connection to TCU OP-Mode: limp home
• speed sensor has an internal defect
• connector pin is contacted to battery
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
voltage or has no contact
3B 5170 4 S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear selection • check the cable from TCU to the sensor
TCU measures a voltage less than 1.00V OP-Mode: substitute clutch • check the connectors
at speed input pin control • check the speed sensor
• cable / connector is defective and is if a failure is existing at turbine
contacted to vehicle ground speed,
• speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
3C 5170 12 LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear selection • check the cable from TCU to the sensor This fault is reset after power
TCU measures a output speed over a OP-Mode: substitute clutch • check the connectors up of TCU
threshold and at the next moment the control • check the speed sensor
measured speed is zero if a failure is existing at turbine • check the sensor gap
• cable / connector is defective and has speed,
bad contact TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
• sensor gap has the wrong size
3E 5180 2 OUTPUT SPEED ZERO DOESN’T FIT TO special mode for gear selection • check the sensor signal of output speed This fault is reset after power
OTHER SPEED SIGNALS OP-Mode: substitute clutch sensor up of TCU
if transmission is not neutral and the control • check the sensor gap of output speed
shifting has finished, if a failure is existing at turbine sensor
TCU measures outputspeed zero and speed, • check the cable from TCU to the sensor
turbine speed or internal speed not equal TCU shifts to neutral
to zero. OP-Mode: limp home
• speed sensor has an internal defect
• sensor gap has the wrong size
56 5280 9 ENGINE CONF TIMEOUT OP-Mode: substitute clutch • check engine controller
Timeout of CAN-message ENGINE control • check wire of CAN-Bus
CONF from engine controller • check cable to engine controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
battery voltage
69 5440 2 REFERENCE ENGINE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for reference of engine torque control • check wire of CAN-Bus
is defective • check cable to engine controller
• engine controller is defective
• interference on CAN-Bus
6A 5450 2 ACTUAL ENGINE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for actual engine torque is control • check wire of CAN-Bus
defective • check cable to engine controller
• engine controller is defective
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• interference on CAN-Bus
6B 5460 2 NOM FRICTION TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for nominal friction torque is control • check wire of CAN-Bus
defective • check cable to engine controller
• engine controller is defective
• interference on CAN-Bus
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• check the cable from TCU to the
1)
77 5500 3 S.C. TO BATTERY VOLTAGE AT CLUTCH K3 TCU shifts to neutral see chapter 4
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at K3 valve is if failure at another clutch is • check the connectors from gearbox to
too high. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to battery voltage OP-Mode: TCU shutdown • check internal wire harness of the
• regulator has an internal defect gearbox
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at K4 valve is if failure at another clutch is • check the connectors from gearbox to
too low. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to vehicle ground OP-Mode: TCU shutdown • check internal wire harness of the
• cable / connector is defective and has gearbox
contact to another regulator output of
the TCU
• regulator has an internal defect
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• check the cable from TCU to the valve
1)
8A 5535 4 S.C. TO GROUND AT DLM TRANSVERSAL output will be on until TCU see chapter 4
OUTPUT power down even if fault • check the connectors
TCU detected a wrong voltage at the vanishes (loose connection) • check the resistance of valve
output pin, that looks like a s.c. to vehicle OP-Mode: normal
ground
• cable is defective and is contacted to
vehicle ground
• device has an internal defect
• connector pin is contacted to vehicle
ground
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
TCU detected a wrong voltage at the • check the resistance of device
output pin, that looks like a o.c. for this
output pin
• cable is defective and has no
connection to TCU
• device has an internal defect
• connector has no connection to TCU
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• cable is defective and is contacted to interlock relay
battery voltage
• starter interlock relay has an internal
defect
• connector pin is contacted to battery
voltage
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
connection to TCU
• converter clutch solenoid has an
internal defect
• connector has no connection to TCU
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
defect
• connector has no connection to TCU
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
voltage
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
output pin, that looks like a s.c. to battery device to TCU
voltage • check the resistance 1) of warning device
• cable is defective and is contacted to
battery voltage
• warning device has an internal defect
• connector pin is contacted to battery
voltage
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
output pin dep. signal device to TCU
• cable is defective and has no • check the resistance of ADM3 gear dep.
connection to TCU signal device
• ADM3 gear dep. signal device has an
internal defect
• connector has no connection to TCU
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• cable is defective and has no • check the resistance of ADM2 gear dep.
connection to TCU signal device
• ADM2 gear dep. signal device has an
internal defect
• connector has no connection to TCU
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• low pressure at clutch K3 OP-Mode: TCU shutdown • check signal at internal speed sensor
• low main pressure • check signal at output speed sensor
• wrong signal at internal speed sensor • replace clutch
• wrong signal at output speed sensor
• wrong size of the sensor gap
• clutch is defective
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
is out of range, TCU interprets this as pending • check sensor gap at internal speed
slipping clutch. TCU shifts to neutral sensor
• low pressure at clutch KR OP-Mode: TCU shutdown • check sensor gap at turbine speed sensor
• low main pressure • check signal at internal speed sensor
• wrong signal at internal speed sensor • check signal at turbine speed sensor
• wrong signal at turbine speed sensor • replace clutch
• wrong size of the sensor gap
• clutch is defective
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
clutch • check signal at turbine speed sensor
• low main pressure • replace clutch
• wrong signal at engine speed sensor
• wrong signal at turbine speed sensor
• wrong size of the sensor gap
• clutch is defective
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
TCU detected a wrong voltage at the OP-mode: normal brake solenoid
output pin, that looks like a o.c. for this • check the connectors from engine brake
output pin solenoid to TCU
• cable is defective and has no • check the resistance 1) of engine brake
connection to TCU solenoid
• engine brake solenoid has an internal
defect
• connector has no connection to TCU
C5 5770 3 S.C. TO BATTERY VOLTAGE AT JOYSTICK no reaction • check the cable from TCU to joystick
STATUS INDICATOR OP-Mode: normal status indicator
TCU detected a wrong voltage at the • check the connectors from joystick
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
output pin, that looks like a s.c. to battery status indicator to TCU
voltage • check the resistance 1) of joystick status
• cable is defective and is contacted to indicator
battery voltage
• joystick status indicator has an
internal defect
• connector pin is contacted to battery
voltage
C6 5770 5 O.C. AT JOYSTICK STATUS no reaction • check the cable from TCU to joystick
INDICATOR OP-Mode: normal status indicator
TCU detected a wrong voltage at the • check the connectors from joystick
output pin, that looks like a o.c. for this status indicator to TCU
output pin • check the resistance 1) of joystick status
• cable is defective and has no indicator
connection to TCU
• joystick status indicator has an
internal defect
• connector has no connection to TCU
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
• CAN wire/connector is defective an
has contact to vehicle ground or
battery voltage
D1 5810 3 S.C. TO BATTERY VOLTAGE AT POWER see fault codes no. 21 to 2C • check cables and connectors to sensors, fault codes no. 21 to no. 2C
SUPPLY FOR SENSORS which are supplied from AU1 may be a reaction of this fault
TCU measures more than 6V at the pin • check the power supply at the pin AU1
AU1 (5V sensor supply) (should be appx. 5V)
D2 5810 4 S.C. TO GROUND AT POWER SUPPLY FOR see fault codes no. 21 to 2C • check cables and connectors to sensors, fault codes no. 21 to no. 2C
SENSORS which are supplied from AU1 may be a reaction of this fault
TCU measures less than 4V at the pin • check the power supply at the pin AU1
AU1 (5V sensor supply) (should be appx. 5V)
D3 5820 4 LOW VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is lower OP-Mode: TCU shutdown • check cables from batteries to TCU
than 10 V (12V device) • check connectors from batteries to TCU
lower than 18 V (24V device)
D4 5820 3 HIGH VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is OP-Mode: TCU shutdown • check cables from batteries to TCU
higher than 18 V (12V device) • check connectors from batteries to TCU
higher than 32.5 V (24V device)
D5 5830 2 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral • check fuse
TCU switched on VPS1 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 • check connectors from gearbox to TCU
and measured VPS1 is still on • replace TCU
• cable or connectors are defect and are
contacted to battery voltage
• cable or connectors are defect and are
contacted to vehicle ground
• permanent power supply KL30 missing
• TCU has an internal defect
D6 5840 2 ERROR VALVE POWER SUPPLY VPS2 shift to neutral • check fuse
TCU switched on VPS2 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
VPS2 is off or TCU switched off VPS2 • check connectors from gearbox to TCU
and measured VPS2 is still on • replace TCU
• cable or connectors are defect and are
contacted to battery voltage
• cable or connectors are defect and are
contacted to vehicle ground
• permanent power supply KL30 missing
• TCU has an internal defect
E3 5860 3 S.C. TO BATTERY VOLTAGE AT DISPLAY no reaction • check the cable from TCU to the display
OUTPUT OP-Mode: normal • check the connectors at the display
TCU sends data to the display and • change display
measures allways a high voltage level on
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
the connector
• cable or connectors are defective and
are contacted to battery voltage
• display has an internal defect
E4 5860 4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction • check the cable from TCU to the display
TCU sends data to the display and OP-Mode: normal • check the connectors at the display
measures allways a high voltage level on • change display
the connector
• cable or connectors are defective and
are contacted to vehicle ground
• display has an internal defect
F1 5890 2 GENERAL EEPROM FAULT no reaction • replace TCU often shown together with
TCU can't read non volantile memoy OP-Mode: normal fault code F2
• TCU is defective
F3 5910 13 APPLICATION ERROR transmission stay neutral • replace TCU !! This fault occurs only if an
something of this application is wrong OP-Mode: TCU shutdown test engineer did something
wrong in the application of
the vehicle
F5 5930 7 CLUTCH FAILURE transmission stay neutral • check clutch TCU shows also the affected
AEB was not able to adjust clutch filling OP-Mode: TCU shutdown clutch on the Display
parameters
• One of the AEB-Values is out of limit
F6 5930 13 CLUTCH ADJUSTMENT DATA LOST OR default values = 0 for AEB • execute AEB
INCHPEDAL CALIBRATION DATA LOST offsets used
TCU was not able to read correct clutch OP-Mode: normal
adjustment parameters no Inchmode available
• interference during saving data on non
volatile memory
• TCU is brand new
4.1 actuator:
1
2
G
4.2 cable:
UBat
P (power supply)
TCU
Actuator /
1 2
Sensor
C (chassis)
Gnd