Description of The Fault Codes For ERGO-Control EST37: ZF FRIEDRICHSHAFEN Aktiengesellschaft

ZF FRIEDRICHSHAFEN Aktiengesellschaft
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Name: Schwarz Sieger
Abteilung: TE-AB TE-AB
Datum: 03-05-13 03-10-01
Description
of the
fault codes
for
ERGO-Control EST37
ZF Friedrichshafen AG 14-01-09
Faultcodes ERGO-Control EST37A
Index of changes:
date index comment software version
97-12-12 first document based on error.doc dated 97-11-03
98-03-18 corrections
98-04-02 adjusted for document automation
98-05-04 inserted internal faultcode-numbers, completed
reaction of TCU for s.c to Battery at K1..KR
98-05-15 inserted fault code F6
98-05-25 inserted fault code BB, BD .. BF
98-07-08 inserted fault code for additional customer specific
functions
98-07-24 add customer Sisu
98-09-07 inserted fault code 15
98-10-06 add description of conditions for taking faults back
98-10-20 overlie fault code 55 for DeviceNet
replace retarder request signal with aeb request signal,
retarder request was not used
99-02-09 inserted internal faultcode-number 173 and 174,
add customer Kalmar,
add fault code for difflock
99-08-05 7 add display description
99-09-06 8 remove faults in display description (sz) V826
99-11-18 insert high/low voltage limits for 12V / 24 V devices
99-12-16 add fault code for overtemp torqueconverter
00-01-14 change SCT and DCT (sz)
00-01-25 several corrections (so)
00-02-11 engine derating fault (sz)
00-03-28 add customer JCB
00-05-12 9 remove faultcodes 0x66-0x68, 0x6C, 0x6D (sz) V828
add faultcode 0xC4-0xC6 joystick status indicator
00-06-29 10 add custommer O&K
add O&K specific faults
00-09-14 11 remove faults in display description (sz)
add O&K faultcode E6
00-09-27 12 Add faultcode 0xc7-0c9 for overtemp Neutral signal V829

00-11-02 13 Add faultcode 0xb9 for Customer Case
01-02-06 14 remove faultcode 0x6F V836
01-10-12 15 add software version in index V839
Add faultcode 0xCA and 0xCB
02-07-16 16 modify possible reason for fault detection for fault V904
codes 0x71, 0x72, 0x74, 0x75, 0x77, 0x78, 0x81,
0x82, 0x84, 0x85, 0x87, 0x88
03-03-28 17 Add J1939-73, DM1 FMI and SPN V912
Add faultcode 0x2B
03-05-13 18 Correct FMI and SPN for faultcode 0x2B V912
03-10-08 19 Include description for inchpedal calibration V913
04-07-23 20 Open circuit fault code Shift lever 1 and 2 , (0xE1, V914
0xE2)
add faultcode 0xBC and 0xC2
04-10-15 21 Add customer 4WG-tag to some faultcodes V914
04-12-07 22 Add DLM fault codes V915
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05-01-31 Add warning code for high velocity and high load
05-02-18 23 Add engine torque / power overload and output torque V916
overload faultcodes
Change FMI from 15 to 0
05-06-20 24 Add warning code for high output torque V917
06-04-11 25 change description of lockup clutch failure V918
07-04-27 26 Add SSM1 Timeout fault code Vxxx
Modify description CCO/Inchsensorfault
07-10-17 27 Additional description S.C. to ground at converter V919K17
lock up clutch solenoid if connected at AIP7
08-01-31 28 Modify description S.C. to ground at converter lock V922, V922a, V923,
up clutch solenoid V924
08-04-02 29 Add description for BB fault V925
08-09-26 30 No changes V926
08-10-24 31 Add JSS Timeout fault code, 0x5B removed V927
08-11-25 32 Modify “reaction of the TCU” at park brake fault All
09-05-04 33 New fault code for 3rd shift lever V928
New fault code for Instrument-Timeout
New fault code for AEB-Request and Parkbrake-Test
at the same time
09-10-22 34 Modify description of 0x11 fault V930

10-03-22 35 New fault code for Operation Mode: Substitute V931
Clutch Control
10-06-17 36 Remove faultcodes 0x2C, 0x2D, 0x2E, 0x2F, 0x59, V932
change SPN for DISPID1_TIMEOUT
Add description for additional operating modes
11-03-03 37 Modify/Add description of 0x2B fault V935
11-07-07 38 Add note regarding ignition key cycles V936
12-03-01 39 Add fault code 0x59 V938
Change description of 0xC0 fault
remove faultcodes 0x7D, 0x7E, 0x7F, 0x13
13-06-28 40 Modify description of 0xF7 fault V941
Modify FMI of 0x59 fault
1 Introduction
1.1 Abbreviations
o.c. open circuit

s.c. short circuit
OP-Mode operating mode
TCU transmission control unit
EEC electronic engine controller
PTO power take off
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
(special symbols a-h)
1.3 Display during operation

Symbol meaning remarks
1F, 1R actual gear and direction
2F, 2R left digit shows actual gear
3F, 3R right digit shows actual direction
4F
5F
6F
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing direction F or R selected while turbine CAUTION gear will engage if turbine speed drops
speed is too high
NN not neutral, waiting for neutral after to engage a gear, first move shift selector to neutral
power up or a severe fault position and again to F or R position
** oil temperature too low, no gear warm up engine / transmission
available
*N oil temperature low, only one gear warm up engine / transmission
available
1 bar (special manual mode 1st gear
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,
(spanner)
WT warning torque converter temperature changes between actual gear/direction while driving,
(spanner)
WE warning high engine speed changes between actual gear/direction while driving,
(spanner)
WV warning high output speed (velocity) changes between actual gear/direction while driving,
(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
1.4 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 clutch K1..K4, KV or KR,
, KW KW is lockup clutch
_ and Kx wait for start, initialization of clutch Kx,
x: 1, 2, 3, 4, V, R, W
≡ 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, you have to restart the
TCU (ignition off/on) after removing AEB-Starter
STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have to restart the
TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmissions stays in neutral, you have to restart the
calibrated TCU (ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, you have to restart the
∆E engine speed too low,
raise engine speed
∇E engine speed too high,
lower engine speed
∆T transmission oil temperature too low,
heat up transmission
∇T transmission oil temperature too high
cool down transmission
FT transmission temperature not in defined Transmissions stays in neutral, you have to restart the
range during calibration TCU (ignition off/on)
FB operating mode not NORMAL or Transmissions stays in neutral, you have to restart the
transmission temperature sensor TCU (ignition off/on)
defective or storing of Calibrated values
to EEPROM-has failed.
FO Outputspeed_not_zero Transmissions stays in neutral, you have to restart the
FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the
FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart the
STOP AEB - Starter was used incorrect or is Transmissions stays in neutral, you have to restart the
defective. Wrong device or wrong cable TCU (ignition off/on)
used
1.5 Display during Inchpedal Calibration

symbol meaning remarks
push down the pedal slowly until
IP ⇓ endposition is reached and hold this
position
Release the pedal slowly until
IP ⇑ endposition is reached
A problem occurred, release the pedal If the expected enposition could not be reached,
IP ⇑ flashing slowly until endposition is reached release the pedal and try again
OK Finished inchpedal calibration
successful
FN and Stop Shift lever not in Neutral position Calibration is aborted
FS and Stop sensor supply voltage AU1 is out of Calibration is aborted
the specified range
FO and Stop Outputspeed is not zero Calibration is aborted
SL and Stop sensor voltage below specified Calibration is aborted
rangel
SU and Stop sensor voltage above specified Calibration is aborted
rangel
IL and Stop sensor position for released pedal Calibration is aborted
out of specified range
IU and Stop sensor position for pressed pedal Calibration is aborted
out of specified range
TO and Stop time-out calibration, pedal not Calibration is aborted
moved after calibration start
DL and Stop angle between pedalpositions Calibration is aborted
released and pressed to small
DU and Stop angle between pedalpositions Calibration is aborted
released and pressed to big
FI and Stop sensor signal 1 and 2 don't match Calibration is aborted
together
2 Definition of operating modes

NORMAL:
There's no failure detected in the transmission-system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations. (see following
table)
SUBSTITUTE CLUTCH CONTROL:

TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU
uses the substitute strategy for clutch control. All modulations are only time controlled. (Comparable
with EST 25)
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.
TCU Key Off:

The ignition key if switched off and the TCU stores internal values to EEPROM. After finishing this
the TCU is switched off.
TCU Idle:
The ignition key has been switched on and the TCU does some startup tests.
3 Note regarding ignition key cycles

Switching ignition key (KL15) off/on faster than t=1.5s or cranking the engine with a too weak
battery may lead to wrong diagnostic information regarding the transmission solenoids (ZF-fault
codes 72, 75, 78, 82, 85, 88), the output speed sensor (ZF-fault code 3A) and the ZF-Display (ZF-
fault code E4). The fault codes related to these components can be ignored if they show up due to a
too fast key off/on cycle or a cranking of the engine with a too weak battery. Unfortunately these
situations could not be completely covered by software. We strongly recommend using a (intelligent)
terminal control system which does not allow this situation. Many control units have this problem;
there is no software solution possible for the single control units without loosing diagnostic function.
ZF Friedrichshafen AG
description of fault codes for ERGO-Control 14-01-09
4 table of fault codes
Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code Code possible reason for fault detection
(hex) (dec)
10 5001 12 143 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to • check the cables from TCU to shift lever fault is cleared if TCU detects
SIGNAL 3RD SHIFT LEVER neutral if selector activ 3 a valid neutral signal for the
TCU detected a wrong signal combination OP-Mode: transmission • check signal combinations of shift lever direction at the shift lever
for the direction shutdown if selector activ positions F-N-R
• cable from shift lever 3 to TCU is • if shift lever is a CAN shift lever check
broken CAN cable/shifter/device
• cable is defective and is contacted to
battery voltage or vehicle ground
• shift lever is defective
11 5000 12 48 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to • check the cables from TCU to shift lever
fault is taken back if TCU
TCU detected a wrong signal combination neutral • check signal combinations of shift lever detects a valid signal for the
for the gear range OP-Mode: transmission positions for gear range position
• cable from shift lever to TCU is broken shutdown
12 5010 12 46 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
14 5030 12 169 LOGICAL ERROR AT PARKBRAKE STATUS TCU shifts transmission to DCO- • check the cables from electronic boxes
Parkbrake-status-signal measured by TCU State to status switches
and parkbrake-status-signal send by CAN OP-Mode: normal • check signals of the status switches
don't fit
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Seite 10 von 52
(hex) (dec)
• one of the cables from status-switch to
electronic box is broken
• one of the status-switches is defective
15 5040 12 176 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
16 5050 12 178 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
1)
17 5060 4 148 S.C. TO GROUND AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to customer see chapter 5
FUNCTION NO. 1 specific function no. 1 device
TCU detected a wrong voltage at the • check the connectors from customer
output pin, that looks like a s.c. to vehicle specific function no. 1 to TCU
ground • check the resistance of customer specific
• cable is defective and is contacted to function no. 1 device
vehicle ground
• customer specific function no. 1 device
has an internal defect
• connector pin is contacted to vehicle
ground
Seite 11 von 52
(hex) (dec)
1)
18 5060 3 150 S.C. TO BATTERY VOLTAGE AT CUSTOMER customer specific • check the cable from TCU to customer see chapter 5
SPECIFIC FUNCTION NO. 1 specific function no. 1 device
output pin, that looks like a s.c. to battery specific function no. 1 to TCU
voltage • check the resistance of customer specific
battery voltage
• connector pin is contacted to battery
voltage
1)
19 5060 5 149 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. customer specific • check the cable from TCU to customer see chapter 5
1 specific function no. 1 device
output pin, that looks like a o.c. for this specific function no. 1 device to TCU
output pin • check the resistance of customer specific
• cable is defective and has no function no. 1 device
connection to TCU
• connector has no connection to TCU
1)
1A 5070 4 151 S.C. TO GROUND AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to customer see chapter 5
output pin, that looks like a s.c. to vehicle specific function no. 2 device to TCU
vehicle ground
ground
Seite 12 von 52
(hex) (dec)
1)
1B 5070 3 153 S.C. TO BATTERY VOLTAGE AT CUSTOMER customer specific • check the cable from TCU to customer see chapter 5
output pin, that looks like a s.c. to battery specific function no. 2 device to TCU
battery voltage
voltage
1)
1C 5070 5 152 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. customer specific • check the cable from TCU to customer see chapter 5
connection to TCU
1)
1D 5080 4 154 S.C. TO GROUND AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to customer see chapter 5
vehicle ground
ground
Seite 13 von 52
(hex) (dec)
1)
1E 5080 3 156 S.C. TO BATTERY VOLTAGE AT CUSTOMER customer specific • check the cable from TCU to customer see chapter 5
SPECIFIC FUNCTION NO. 3 specific customer specific function no. 3
TCU detected a wrong voltage at the device
output pin, that looks like a s.c. to battery • check the connectors from customer
voltage specific function no. 3 device to TCU
• cable is defective and is contacted to • check the resistance of customer specific
battery voltage function no. 3 device
• customer specific function no. 3
device has an internal defect
voltage
1)
1F 5080 5 155 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. customer specific • check the cable from TCU to customer see chapter 5
connection to TCU
• customer specific function no. 3
device has an internal defect
21 5090 3 32 S.C. TO BATTERY VOLTAGE AT CLUTCH clutch cutoff / inching function • check the cable from TCU to the sensor
CUTOFF / INCHPEDAL INPUT is disabled • check the connectors
the measured voltage is too high: OP-Mode: normal • check the clutch cutoff / inch pedal
• cable is defective and is contacted to sensor
battery voltage
• clutch cut off / inch pedal sensor has
an internal defect
voltage
Seite 14 von 52
(hex) (dec)
22 5090 4 29 S.C. TO GROUND OR O.C. AT CLUTCH clutch cutoff / inching function is • check the cable from TCU to the sensor
CUTOFF / INCHPEDAL INPUT disabled • check the connectors
the measured voltage is too low: OP-Mode: normal • check the clutch cutoff / inch pedal
• cable is defective and is contacted to sensor
vehicle ground
• cable has no connection to TCU
• clutch cut off / inch pedal sensor has
an internal defect
ground or is broken
23 5100 3 69 S.C. TO BATTERY VOLTAGE AT LOAD retarder function is affected • check the cable from TCU to the sensor availability of retarder
SENSOR INPUT TCU uses default load • check the connectors depends on default load
the measured voltage is too high: OP-Mode: normal • check the load sensor sensor
• cable is defective and is contacted to • check the assembly tolerances of load
battery voltage sensor
• load sensor has an internal defect
voltage
24 5100 4 70 S.C. TO GROUND OR O.C. AT LOAD SENSOR retarder function is affected • check the cable from TCU to the sensor availability of retarder
INPUT TCU uses default load • check the connectors depends on default load
the measured voltage is too low: OP-Mode: normal • check the load sensor sensor
• cable is defective and is contacted to • check the assembly tolerances of load
vehicle ground sensor
• load sensor has an internal defect
ground or is broken
25 5110 3 33 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:
Seite 15 von 52
(hex) (dec)
battery voltage
• temperature sensor has an internal
defect
voltage or is broken
26 5110 4 30 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
vehicle ground
defect
ground
27 5120 3 76 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
the measured voltage is too high:
battery voltage
defect
28 5120 4 74 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:
vehicle ground
Seite 16 von 52
(hex) (dec)
defect
ground
29 5130 3 31 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
battery voltage
• sensor has an internal defect
2A 5130 4 28 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
vehicle ground
ground
2B 5313 12 135 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 or are out of While not inching: no change • check sensor
range OP-Mode: normal
• cable is defective
31 5140 3 38 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
Seite 17 von 52
(hex) (dec)
TCU measures a voltage higher than 7.00 • check the speed sensor
V at speed input pin
battery voltage
• speed sensor has an internal defect
voltage or has no contact
32 5140 4 34 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
33 5140 12 42 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
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
• sensor gap has the wrong size
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
Seite 18 von 52
(hex) (dec)
35 5150 4 35 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
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 43 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
INTERNAL SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 • check the speed sensor
V at speed input pin
battery voltage
38 5160 4 36 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
at speed input pin • check the speed sensor
• cable / connector is defective and is
Seite 19 von 52
(hex) (dec)
39 5160 12 44 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
3A 5170 3 41 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
3B 5170 4 37 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 45 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
Seite 20 von 52
(hex) (dec)
• speed sensor has an internal defect OP-Mode: limp home
3E 5180 2 72 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
40 5200 2 146 FCAN MESSAGE ‘GEAR RANGE SELECT gear range set from 1st to 5th • check FWD controller
(ZF_3_IDENT)’ contains invalid data • check wire of CAN-Bus
41 5210 2 147 TCU RECEIVES MESSAGES ‘GEAR RANGE ignore FWD commands • reconfigure with
SELECT (ZF_3_IDENT)’ AND ‘FRONT TCU Configuration Command (ID PC)
WHEEL DRIVE STATUS’
(V_IDENT_FWD) ALTHOUGH
CONFIGURATION STATES THAT FWD
CONTROLLER IS NOT INSTALLED
52 5240 9 101 INSTRUMENT TIMEOUT AEB abouts if active • check Instrument controller
Timeout of CAN-message Instrument OP-Mode: normal • check wire of CAN-Bus
from Instrument • check cable to Instrument
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
54 5260 9 103 DCT1 TIMEOUT OP-Mode: normal • check display computer

Timeout of CAN-message DCT1 from • check wire of CAN-Bus
display computer • check cable to display computer
Seite 21 von 52
(hex) (dec)
battery voltage
55 5270 9 177 JSS TIMEOUT TCU shifts to neutral while • check Joystick steering controller
Timeout of CAN-message JSS from Joystick Steering is active • check wire of CAN-Bus
Joystick Steering Controller OP-Mode: normal • check cable to Joystick steering
• interference on CAN-Bus controller
battery voltage
56 5280 9 105 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
battery voltage
57 5290 9 106 EEC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller
Timeout of CAN-message EEC1 from control • check wire of CAN-Bus
EEC controller • check cable to EEC controller
battery voltage
58 5300 9 107 EEC3 TIMEOUT OP-Mode: substitute clutch • check EEC controller
Timeout of CAN-message EEC3 from control • check wire of CAN-Bus
EEC controller
Seite 22 von 52
(hex) (dec)
• interference on CAN-Bus • check cable to EEC controller
• CAN wire/connector is defective an
battery voltage
59 5310 9 138 ENGINE SPEED LIMIT FUNCTION DOES NOT OP-Mode: normal • check engine controller
WORK PROPERLY After selection neutral only • check wire of CAN-Bus
• engine controller is defective limited gears available, • check cable to engine controller
• interference on CAN-Bus depending on application • engine controller may ignore torque- or
speed limit command from TCU via
TSC1 message
5A 5320 2 109 PARKBRAKE STATUS SIGNAL no reaction ???? • check cluster controller
CAN signal for parkbrake status is • check wire of CAN-Bus
defective • check cable to cluster controller
• cluster controller is defective
5C 5340 2 111 AUTO DOWNSHIFT SIGNAL last selection is kept • check cluster controller
CAN signal for automatic downshift is • check wire of CAN-Bus
defective • check cable to cluster controller
5D 5350 2 112 MANUAL DOWNSHIFT SIGNAL last selection is kept • check cluster controller
CAN signal for manual downshift is • check wire of CAN-Bus
defective • check cable to ???? controller
5E 5360 2 113 CCO REQUEST SIGNAL last selection is kept • check cluster controller
CAN signal for CCO request is defective • check wire of CAN-Bus
• cluster controller is defective • check cable to ???? controller
Seite 23 von 52
(hex) (dec)
5F 5370 2 114 SHIFT LEVER SIGNAL TCU shifts to neutral and uses • check I/O controller
CAN signal for shift lever is defective informations from substitute shift • check wire of CAN-Bus
• I/O controller is defective lever • check cable to I/O controller
• interference on CAN-Bus OP-Mode: normal
61 5390 2 116 AEB REQUEST SIGNAL no reaction • check I/O controller

CAN signal for AEB request is defective OP-Mode: normal • check wire of CAN-Bus
• I/O controller is defective Last selection is kept • check cable to I/O controller
65 5430 2 120 ENGINGE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for engine torque is defective control • check wire of CAN-Bus
• engine controller is defective • check cable to engine controller
69 5440 2 124 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
6A 5450 2 125 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
6B 5460 2 126 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
Seite 24 von 52
(hex) (dec)
6E 5470 2 144 EEC2 TIMEOUT no reaction, • check EEC controller
Timeout of CAN-message EEC2 from TCU uses default signal • check wire of CAN-Bus
EEC controller accelerator pedal in idle position • check cable to EEC controller
• interference on CAN-Bus OP-Mode: normal
battery voltage
1)
71 5480 3 22 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the see chapter 5
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at K1 valve is if failure at another clutch is • check the connectors from TCU to the
too high. pending gearbox
• 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
1)
72 5480 4 10 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the see chapter 5
is out of limit, the voltage at K1 valve is if failure at another clutch is • check the connectors from gearbox to
too low. pending TCU
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
1)
73 5480 5 16 O.C. AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the see chapter 5
is out of limit. if failure at another clutch is
• check the connectors from gearbox to
• cable / connector is defective and has pending TCU
no contact to TCU TCU shifts to neutral • check the regulator resistance 1)
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
Seite 25 von 52
(hex) (dec)
1)
too high. pending TCU
1)
the TCU
1)
is out of limit. if failure at another clutch is • check the connectors from gearbox to
gearbox
1)
Seite 26 von 52
(hex) (dec)
1)
the TCU
1)
gearbox
7A 5540 3 78 S.C. TO BATTERY VOLTAGE AT CONVERTER no reaction • check the cable from TCU to the valve
CLUTCH OP-Mode: normal • check the regulator resistance 1)
7B 5540 4 79 S.C. TO GROUND AT CONVERTER CLUTCH CONVERTER LOCK UP CLUTCH • check the cable from TCU to the valve
SOLENOID CONNECTED AT • check the regulator resistance 1)
ADMX:
TCU switch off VPS2
OP-mode: normal
CONVERTER LOCK UP CLUTCH

SOLENOID CONNECTED AT AIP7:
TCU switch off VPS2
OP-mode: normal
7C 5540 5 80 O.C. AT CONVERTER CLUTCH no reaction • check the cable from TCU to the valve
OP-Mode: normal • check the regulator resistance 1)
1)
the measured resistance value of the valve OP-Mode: limp home
Seite 27 von 52
(hex) (dec)
is out of limit, the voltage at K4 valve is if failure at another clutch is gearbox
too high. pending • check the connectors from gearbox to
• cable / connector is defective and has TCU shifts to neutral TCU
contact to battery voltage OP-Mode: TCU shutdown • check the regulator resistance 1)
• regulator has an internal defect • check internal wire harness of the
gearbox
1)
the TCU
1)
gearbox
1)
84 5520 3 26 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 5
is out of limit, the voltage at KV valve is if failure at another clutch is • check the connectors from gearbox to
1)
85 5520 4 14 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 5
is out of limit, the voltage at KV valve is if failure at another clutch is • check the connectors from gearbox to
Seite 28 von 52
(hex) (dec)
the TCU
1)
86 5520 5 20 O.C. AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 5
gearbox
1)
87 5530 3 27 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 5
is out of limit, the voltage at KR valve is if failure at another clutch is • check the connectors from gearbox to
1)
88 5530 4 15 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 5
is out of limit, the voltage at KR valve is if failure at another clutch is • check the connectors from gearbox to
the TCU
Seite 29 von 52
(hex) (dec)
1)
89 5530 5 21 O.C. AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 5
gearbox
1)
8A 5535 4 140 S.C. TO GROUND AT DLM TRANSVERSAL output will be on until TCU • check the cable from TCU to the valve see chapter 5
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
vehicle ground
• device has an internal defect
ground
1)
8B 5535 3 142 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the valve see chapter 5
TRANSVERSAL OUTPUT OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the • check the resistance of valve
output pin, that looks like a s.c. to battery
voltage
battery voltage
voltage
1)
8C 5535 5 141 O.C. AT DLM TRANSVERSAL OUTPUT no reaction • check the cable from TCU to the valve see chapter 5
TCU detected a wrong voltage at the OP-Mode: normal • check the connectors
output pin, that looks like a o.c. for this • check the resistance of valve
output pin
• cable is defective and has no
connection to TCU
Seite 30 von 52
(hex) (dec)
1)
8D 5536 4 180 S.C. TO GROUND AT DLM INDICATOR output will be on until TCU • check the cable from TCU to the device see chapter 5
LAMP OUTPUT power down even if fault • check the connectors
TCU detected a wrong voltage at the vanishes (loose connection) • check the resistance of device
ground
vehicle ground
ground
1)
8E 5536 3 182 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the device see chapter 5
INDICATOR LAMP OUTPUT OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the • check the resistance of device
voltage
battery voltage
voltage
1)
8F 5536 5 181 O.C. DLM INDICATOR LAMP OUTPUT no reaction • check the cable from TCU to the device see chapter 5
OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the • check the resistance of device
output pin, that looks like a o.c. for this
output pin
connection to TCU
Seite 31 von 52
(hex) (dec)
1)
91 5560 4 1 S.C. TO GROUND AT RELAY REVERSE backup alarm will be on until • check the cable from TCU to the backup see chapter 5
WARNING ALARM TCU power down even if fault alarm device
TCU detected a wrong voltage at the vanishes (loose connection) • check the connectors from backup alarm
output pin, that looks like a s.c. to vehicle OP-Mode: normal device to TCU
ground • check the resistance 1) of backup alarm
• cable is defective and is contacted to device
vehicle ground
• backup alarm device has an internal
defect
ground
1)
92 5560 3 3 S.C. TO BATTERY VOLTAGE AT RELAY no reaction • check the cable from TCU to the backup see chapter 5
REVERSE WARNING ALARM OP-Mode: normal alarm device
TCU detected a wrong voltage at the • check the connectors from backup alarm
output pin, that looks like a s.c. to battery device to TCU
voltage • check the resistance 1) of backup alarm
• cable is defective and is contacted to device
battery voltage
defect
voltage
1)
93 5560 5 2 O.C. AT RELAY REVERSE WARNING ALARM no reaction • check the cable from TCU to the backup see chapter 5
TCU detected a wrong voltage at the OP-Mode: normal alarm device
output pin, that looks like a o.c. for this • check the connectors from backup alarm
output pin device to TCU
• cable is defective and has no • check the resistance 1) of backup alarm
connection to TCU device
defect
1)
94 5570 4 4 S.C. TO GROUND AT RELAY STARTER no reaction • check the cable from TCU to the starter see chapter 5
Seite 32 von 52
(hex) (dec)
INTERLOCK OP-Mode: normal interlock relay
TCU detected a wrong voltage at the • check the connectors from starter
output pin, that looks like a s.c. to vehicle interlock relay to TCU
ground • check the resistance 1) of starter
• cable is defective and is contacted to interlock relay
vehicle ground
• starter interlock relay has an internal
defect
ground
1)
95 5570 3 6 S.C. TO BATTERY VOLTAGE AT RELAY no reaction • check the cable from TCU to the starter see chapter 5
STARTER INTERLOCK OP-Mode: normal interlock relay
TCU detected a wrong voltage at the • check the connectors from starter
output pin, that looks like a s.c. to battery interlock relay to TCU
voltage • check the resistance 1) of starter
• cable is defective and is contacted to interlock relay
battery voltage
defect
voltage
1)
96 5570 5 5 O.C. AT RELAY STARTER INTERLOCK no reaction • check the cable from TCU to the starter see chapter 5
TCU detected a wrong voltage at the OP-Mode: normal interlock relay
output pin, that looks like a o.c. for this • check the connectors from starter
output pin interlock relay to TCU
• cable is defective and has no • check the resistance 1) of starter
connection to TCU interlock relay
defect
1)
9A 5590 4 66 S.C. TO GROUND AT CONVERTER LOCK UP CONVERTER LOCK UP CLUTCH • check the cable from TCU to the see chapter 5
CLUTCH SOLENOID SOLENOID CONNECTED AT converter clutch solenoid
Seite 33 von 52
(hex) (dec)
TCU detected a wrong voltage at the ADMX: • check the connectors from converter
output pin, that looks like a s.c. to vehicle TCU switch off VPS2 clutch solenoid to TCU
ground OP-mode: normal • check the resistance 1) of converter
• cable is defective and is contacted to clutch solenoid
vehicle ground CONVERTER LOCK UP CLUTCH
• converter clutch solenoid has an SOLENOID CONNECTED AT AIP7:
internal defect TCU switch off VPS2
• connector pin is contacted to vehicle OP-mode: normal
ground
1)
9B 5590 3 67 O.C. AT CONVERTER LOCK UP CLUTCH converter clutch always open, • check the cable from TCU to the see chapter 5
SOLENOID retarder not available converter clutch solenoid
TCU detected a wrong voltage at the OP-mode: normal • check the connectors from converter
output pin, that looks like a o.c. for this clutch solenoid to TCU
output pin • check the resistance 1) of converter
• cable is defective and has no clutch solenoid
connection to TCU
• converter clutch solenoid has an
internal defect
1)
9C 5590 5 68 S.C. TO BATTERY VOLTAGE AT CONVERTER no reaction • check the cable from TCU to the see chapter 5
LOCK UP CLUTCH SOLENOID OP-mode: normal converter clutch solenoid
TCU detected a wrong voltage at the • check the connectors from converter
output pin, that looks like a s.c. to battery clutch solenoid to TCU
voltage • check the resistance 1) of converter
• cable is defective and is contacted to clutch solenoid
battery voltage
• converter clutch solenoid has an
internal defect
voltage
1)
9D 5600 4 81 S.C. TO GROUND AT RETARDER SOLENOID no reaction • check the cable from TCU to the see chapter 5
TCU detected a wrong voltage at the OP-mode: normal retarder solenoid
Seite 34 von 52
(hex) (dec)
output pin, that looks like a s.c. to vehicle • check the connectors from retarder
ground solenoid to TCU
• cable is defective and is contacted to • check the resistance 1) of retarder
vehicle ground solenoid
• retarder solenoid has an internal
defect
ground
1)
9E 5600 3 82 O.C. AT RETARDER SOLENOID no reaction • check the cable from TCU to the see chapter 5
TCU detected a wrong voltage at the OP-mode: normal retarder solenoid
output pin, that looks like a o.c. for this • check the connectors from retarder
output pin solenoid to TCU
• cable is defective and has no • check the resistance 1) of retarder
connection to TCU solenoid
defect
1)
9F 5600 5 83 S.C. TO BATTERY VOLTAGE AT RETARDER no reaction • check the cable from TCU to the see chapter 5
SOLENOID OP-mode: normal retarder solenoid
TCU detected a wrong voltage at the • check the connectors from retarder
output pin, that looks like a s.c. to battery solenoid to TCU
voltage • check the resistance 1) of retarder
• cable is defective and is contacted to solenoid
battery voltage
defect
voltage
1)
A1 5610 4 84 S.C. TO GROUND AT DIFFLOCK OR AXLE no reaction • check the cable from TCU to the see chapter 5
CONNECTION SOLENOID OP-mode: normal difflock solenoid
TCU detected a wrong voltage at the • check the connectors from difflock
output pin, that looks like a s.c. to vehicle solenoid to TCU
Seite 35 von 52
(hex) (dec)
ground • check the resistance 1) of difflock
vehicle ground
• difflock solenoid has an internal defect
ground
1)
A2 5610 3 85 S.C. TO BATTERY VOLTAGE AT DIFFLOCK OR no reaction • check the cable from TCU to the see chapter 5
AXLE CONNECTION SOLENOID OP-mode: normal difflock solenoid
voltage • check the resistance 1) of difflock
battery voltage
voltage
1)
A3 5610 5 86 O.C. AT DIFFLOCK OR AXLE CONNECTION no reaction • check the cable from TCU to the see chapter 5
SOLENOID OP-mode: normal difflock solenoid
output pin, that looks like a o.c. for this solenoid to TCU
output pin • check the resistance 1) of difflock
• cable is defective and has no solenoid
connection to TCU
1)
A4 5620 4 96 S.C. TO GROUND AT WARNING SIGNAL no reaction • check the cable from TCU to the see chapter 5
OUTPUT OP-mode: normal warning device
TCU detected a wrong voltage at the • check the connectors from warning
output pin, that looks like a s.c. to vehicle device to TCU
ground • check the resistance 1) of warning device
vehicle ground
Seite 36 von 52
(hex) (dec)
• warning device has an internal defect
ground
1)
A5 5620 5 97 O.C. AT WARNING SIGNAL OUTPUT no reaction • check the cable from TCU to the see chapter 5
TCU detected a wrong voltage at the OP-mode: normal warning device
output pin, that looks like a o.c. for this • check the connectors from warning
output pin device to TCU
• cable is defective and has no • check the resistance 1) of warning device
connection to TCU
1)
A6 5620 3 98 S.C. TO BATTERY VOLTAGE AT WARNING no reaction • check the cable from TCU to the see chapter 5
SIGNAL OUTPUT OP-mode: normal warning device
TCU detected a wrong voltage at the • check the connectors from warning
output pin, that looks like a s.c. to battery device to TCU
voltage • check the resistance 1) of warning device
battery voltage
voltage
1)
A7 5630 4 157 S.C. TO GROUND AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to customer see chapter 5
vehicle ground
ground
Seite 37 von 52
(hex) (dec)
1)
A8 5630 3 159 S.C. TO BATTERY VOLTAGE AT CUSTOMER customer specific • check the cable from TCU to customer see chapter 5
battery voltage
voltage
1)
A9 5630 5 158 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. customer specific • check the cable from TCU to customer see chapter 5
connection to TCU
1)
AA 5640 4 160 S.C. TO GROUND AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to customer see chapter 5
vehicle ground
ground
Seite 38 von 52
(hex) (dec)
1)
AB 5640 3 162 S.C. TO BATTERY VOLTAGE AT CUSTOMER customer specific • check the cable from TCU to customer see chapter 5
battery voltage
voltage
1)
AC 5640 5 161 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. customer specific • check the cable from TCU to customer see chapter 5
connection to TCU
1)
AD 5650 4 163 S.C. TO GROUND AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to function 6 see chapter 5
FUNCTION NO. 6 device
ground • check the resistance of function 6 device
vehicle ground
ground
Seite 39 von 52
(hex) (dec)
1)
AE 5650 3 165 S.C. TO BATTERY VOLTAGE AT CUSTOMER customer specific • check the cable from TCU to customer see chapter 5
battery voltage
voltage
1)
AF 5650 5 164 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. customer specific • check the cable from TCU to customer see chapter 5
connection to TCU
B1 5660 2 60 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral • check pressure at clutch K1

TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
closed clutch K1. If this calculated value is if failure at another clutch is • check sensor gap at internal speed
out of range, TCU interprets this as pending sensor
slipping clutch. TCU shifts to neutral • check sensor gap at output speed sensor
• low pressure at clutch K1 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
Seite 40 von 52
(hex) (dec)
• clutch is defective



TCU calculated a difference speed at TCU OP-Mode: limp home • check main pressure in the system
calculates a differential speed at closed if failure at another clutch is • check sensor gap at internal speed
clutch K4. If this calculated value is out of pending sensor
range, TCU interprets this as slipping TCU shifts to neutral • check sensor gap at turbine speed sensor
clutch. OP-Mode: TCU shutdown • check signal at internal speed sensor
• low pressure at clutch K4 • check signal at turbine speed sensor
• low main pressure • replace clutch
Seite 41 von 52
(hex) (dec)
• wrong signal at internal speed sensor
• wrong signal at turbine speed sensor
B5 5680 2 64 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV

closed clutch KV. If this calculated value if failure at another clutch is • check sensor gap at internal speed
is out of range, TCU interprets this as pending sensor
slipping clutch. TCU shifts to neutral • check sensor gap at turbine speed sensor
• low pressure at clutch KV OP-Mode: TCU shutdown • check signal at internal speed sensor
• low main pressure • check signal at turbine speed sensor
B6 5685 2 65 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR

closed clutch KR. If this calculated value if failure at another clutch is • check sensor gap at internal speed
is out of range, TCU interprets this as pending sensor
slipping clutch. TCU shifts to neutral • check sensor gap at turbine speed sensor
• low pressure at clutch KR OP-Mode: TCU shutdown • check signal at internal speed sensor
• low main pressure • check signal at turbine speed sensor
B7 5700 0 87 OVERTEMP SUMP no reaction • cool down machine

TCU measured a temperature in the oil OP-Mode: normal • check oil level
sump that is over the allowed threshold. • check temperature sensor
B8 5710 0 88 OVERTEMP RETARDER TCU disables retarder • cool down machine
Seite 42 von 52
(hex) (dec)
TCU measured a temperature in the OP-Mode: normal • check oil level
retarder oil that is over the allowed • check temperature sensor
threshold.
B9 5720 0 89 OVERSPEED ENGINE retarder applies if configured -

OP-Mode: normal
BA 5730 0 90 DIFFERENTIAL PRESSURE OIL FILTER no reaction • check oil filter
TCU measured a voltage at differential OP-Mode: normal • check wiring from TCU to differential
pressure switch out of the allowed range pressure switch
• oil filter is polluted • check differential pressure switch
• cable/connector is broken or (measure resitance)
cable/connector is contacted to battery
voltage or vehicle ground
• differential pressure switch is defective
BB 5740 2 172 SLIPPAGE AT CONVERTER LOCKUP CLUTCH Lockup Clutch is disabled • check pressure at converter lockup
TCU calculates a differential speed at immediately. After fault code clutch
closed converter lockup clutch. If this was displayed while transmission • check main pressure in the system
calculated value is out of range, TCU is in Neutral the Lockup Clutch • check sensor gap at engine speed sensor
interprets this as slipping clutch. will be enabled again. • check sensor gap at turbine speed sensor
• low pressure at converter lockup • check signal at engine speed sensor
clutch • check signal at turbine speed sensor
• low main pressure • replace clutch
• wrong signal at engine speed sensor
BC 5745 15 92 OVERSPEED OUTPUT No reaction

TCU messures an transmission output OP-Mode: normal
speed above the defined threshold
1)
BD 5750 4 169 S.C. TO GROUND AT ENGINE BRKAE no reaction • check the cable from TCU to the engine see chapter 5
SOLENOID OP-mode: normal brake solenoid
TCU detected a wrong voltage at the • check the connectors from engine brake
output pin, that looks like a s.c. to vehicle
Seite 43 von 52
(hex) (dec)
ground solenoid to TCU
• cable is defective and is contacted to • check the resistance 1) of engine brake
vehicle ground solenoid
• engine brake solenoid has an internal
defect
ground
1)
BE 5750 3 171 S.C. TO BATTERY VOLTAGE AT ENGINE no reaction • check the cable from TCU to the engine see chapter 5
BRAKE OP-mode: normal brake solenoid
TCU detected a wrong voltage at the • check the connectors from engine brake
voltage • check the resistance 1) of engine brake
battery voltage
defect
voltage
1)
BF 5750 5 170 O.C. AT ENGINE BRAKE no reaction • check the cable from TCU to the engine see chapter 5
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
defect
C0 5751 0 183 ENGINE TORQUE OR ENGINE POWER OP-Mode: normal • engine controller may ignore Torque or
OVERLOAD After selection neutral only speedlimit command from TCU via
TCU calculates an engine torque or engine limited gears available, TSC1 message
power above the defined thresholds depending on application
Seite 44 von 52
(hex) (dec)
C1 5752 0 184 TRANSMISSION OUTPUT TORQUE OP-Mode: normal
OVERLOAD
TCU calculates an transmission output
torque above the defined threshold
C2 5755 15 93 TRANSMISSION INPUT TORQUE OVERLOAD programmable :No reaction or
TCU calculates an transmission input shift to neutral
torque above the defined threshold OP-Mode: normal
C3 5760 0 91 OVERTEMP CONVERTER OUTPUT no reaction • cool down machine
TCU measured a oil temperature at the OP-Mode: normal • check oil level
converter ouput that is over the allowed • check temperature sensor
threshold.
C4 5770 4 129 S.C. TO GROUND 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 s.c. to vehicle status indicator to TCU
ground • check the resistance 1) of joystick status
• cable is defective and is contacted to indicator
vehicle ground
• joystick status indicator has an
internal defect
ground
C5 5770 3 131 S.C. TO BATTERY VOLTAGE AT JOYSTICK no reaction • check the cable from TCU to joystick
STATUS INDICATOR OP-Mode: normal status indicator
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
internal defect
voltage
Seite 45 von 52
(hex) (dec)
C6 5770 5 130 O.C. AT JOYSTICK STATUS no reaction • check the cable from TCU to joystick
INDICATOR OP-Mode: normal status indicator
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
internal defect
C7 5780 4 132 S.C. TO GROUND AT OVERTEMP no reaction • check the cable from TCU to
NEUTRAL INDICATOR OP-Mode: normal OVERTEMP NEUTRAL INDICATOR
TCU detected a wrong voltage at the • check the connectors from OVERTEMP
output pin, that looks like a s.c. to vehicle NEUTRAL INDICATOR to TCU
ground • check the resistance 1) of OVERTEMP
• cable is defective and is contacted to NEUTRAL INDICATOR
vehicle ground
• overtemp status indicator has an
internal defect
ground
C8 5780 3 134 S.C. TO BATTERY VOLTAGE AT no reaction • check the cable from TCU to
OVERTEMP NEUTRAL INDICATOR OP-Mode: normal OVERTEMP NEUTRAL INDICATOR
output pin, that looks like a s.c. to battery NEUTRAL INDICATOR to TCU
voltage • check the resistance 1) of OVERTEMP
• cable is defective and is contacted to NEUTRAL INDICATOR
battery voltage
• overtemp status indicator has an
internal defect
Seite 46 von 52
(hex) (dec)
voltage
C9 5780 5 133 O.C. AT OVERTEMP NEUTRAL no reaction • check the cable from TCU to
INDICATOR OP-Mode: normal OVERTEMP NEUTRAL INDICATOR
output pin, that looks like a o.c. for this NEUTRAL INDICATOR to TCU
output pin • check the resistance 1) of OVERTEMP
• cable is defective and has no NEUTRAL INDICATOR
connection to TCU
• OVETEMP status indicator has an
internal defect
CA 5790 9 121 ENGINE_RETARDER CONFIG_TIMEOUT OP-Mode: substitute clutch • check EEC controller
Timeout of CAN-message control • check wire of CAN-Bus
ENGINE_RETARDER CONFIG from EEC • check cable to EEC controller
controller
battery voltage
CB 5800 9 122 ERC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller
Timeout of CAN-message ERC1 from control • check wire of CAN-Bus
EEC controller • check cable to EEC controller
battery voltage
D1 5810 3 54 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
Seite 47 von 52
(hex) (dec)
AU1 (5V sensor supply) (should be appx. 5V)
D2 5810 4 55 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 53 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 52 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 57 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
• permanent power supply KL30 missing
• TCU has an internal defect
D6 5840 2 58 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
VPS2 is off or TCU switched off VPS2 • check connectors from gearbox to TCU
and measured VPS2 is still on • replace TCU
contacted to battery voltage
• permanent power supply KL30 missing
Seite 48 von 52
(hex) (dec)
• TCU has an internal defect
1)
D7 5545 4 S.C. TO GROUND AT DLM LONGITUDINAL output will be on until TCU • check the cable from TCU to the valve see chapter 5
OUTPUT power down even if fault • check the connectors
TCU detected a wrong voltage at the vanishes (loose connection) • check the resistance of valve
ground
vehicle ground
ground
1)
D8 5545 3 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the valve see chapter 5
LONGITUDINAL OUTPUT OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the • check the resistance of valve
voltage
battery voltage
voltage
1)
D9 5545 5 O.C. AT DLM LONGITUDINAL OUTPUT no reaction • check the cable from TCU to the valve see chapter 5
TCU detected a wrong voltage at the OP-Mode: normal • check the connectors
output pin, that looks like a o.c. for this • check the resistance of valve
output pin
connection to TCU
E3 5860 3 50 S.C. TO BATTERY VOLTAGE AT DISPLAY no reaction • check the cable from TCU to the display
OUTPUT OP-Mode: normal
Seite 49 von 52
(hex) (dec)
TCU sends data to the display and • 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 battery voltage
• display has an internal defect
E4 5860 4 49 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
E5 5271 9 104 DISPID1_TIMEOUT TCU select parameter set with • check display controller
Timeout of CAN-message DISPID1 from ID0 • check wire of CAN-Bus
display controller OP-Mode: Limp Home • check cable to display controller
battery voltage
E6 5880 2 94 ILLEGAL ID REQUEST VIA CAN transmission stay neutral

OP-Mode: TCU shutdown
F1 5890 2 51 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
F2 5900 13 56 CONFIGURATION LOST transmission stay neutral • Reprogramm the correct configuration
TCU has lost the correct configuration and OP-Mode: TCU shutdown for the vehicle (e.g. with cluster
can't control the transmission. controller,...)
• interference during saving data on non
Seite 50 von 52
(hex) (dec)
volatile memory
• TCU is brand new or from another
vehicle
F3 5910 13 59 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
F4 5920 13 73 LIMP HOME REQUEST shift to neutral • The external controller has to cancel the
no fault! indicates that another computer OP-Mode: limp home request
requested limp home via CAN
F5 5930 7 173 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 13 174 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
F7 5940 11 110 SUBSTITUTE CLUTCH CONTROL OP-Mode : substitute clutch • check engine retarder torque sent via
• transmission input torque out of control CAN
allowed range • check engine torque send via CAN
• engine retarder torque wrong • check speed sensors
• engine torque wrong
• speed signal(s) defective
Seite 51 von 52
5 measuring of resistance at actuator/sensors and cable
5.1 actuator:
1
2
G
open circuit: R12 ≈ R1G ≈ R2G ≈ ∞

short cut to ground: R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 (for s.c. to ground, G is connected to vehicle ground)
short cut to battery: R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 (for s.c. to battery, G is connected to battery voltage)
5.2 cable:
UBat
P (power supply)
TCU
Actuator /
1 2
Sensor
C (chassis)
Gnd
open circuit: R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞

short cut to ground: R12 ≈ 0; R1C ≈ R2C ≈ 0, R1P ≈ R2P ≈ ∞
short cut to battery: R12 ≈ 0, R1C ≈ R2C ≈ ∞, R1P ≈ R2P ≈ 0
Seite 52 von 52

Description of The Fault Codes For ERGO-Control EST37: ZF FRIEDRICHSHAFEN Aktiengesellschaft

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Description of The Fault Codes For ERGO-Control EST37: ZF FRIEDRICHSHAFEN Aktiengesellschaft

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ZF FRIEDRICHSHAFEN Aktiengesellschaft

Benennung: fault codes Nr.: DIN Seite 1

00-09-27 12 Add faultcode 0xc7-0c9 for overtemp Neutral signal V829

09-10-22 34 Modify description of 0x11 fault V930

o.c. open circuit

(special symbols a-h)

1.3 Display during operation

1.4 Display during AEB-Mode

1.5 Display during Inchpedal Calibration

2 Definition of operating modes

SUBSTITUTE CLUTCH CONTROL:

TCU Key Off:

3 Note regarding ignition key cycles

4 table of fault codes

54 5260 9 103 DCT1 TIMEOUT OP-Mode: normal • check display computer

61 5390 2 116 AEB REQUEST SIGNAL no reaction • check I/O controller

CONVERTER LOCK UP CLUTCH

B1 5660 2 60 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral • check pressure at clutch K1

B2 5665 2 61 SLIPPAGE AT CLUTCH K2 TCU shifts to neutral • check pressure at clutch K2

B3 5670 2 62 SLIPPAGE AT CLUTCH K3 TCU shifts to neutral • check pressure at clutch K3

B4 5675 2 63 SLIPPAGE AT CLUTCH K4 TCU shifts to neutral • check pressure at clutch K4

B5 5680 2 64 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV

B6 5685 2 65 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR

B7 5700 0 87 OVERTEMP SUMP no reaction • cool down machine

B8 5710 0 88 OVERTEMP RETARDER TCU disables retarder • cool down machine

B9 5720 0 89 OVERSPEED ENGINE retarder applies if configured -

BC 5745 15 92 OVERSPEED OUTPUT No reaction

D1 5810 3 54 S.C. TO BATTERY VOLTAGE AT POWER see fault codes no. 21 to 2C

E6 5880 2 94 ILLEGAL ID REQUEST VIA CAN transmission stay neutral

5 measuring of resistance at actuator/sensors and cable

open circuit: R12 ≈ R1G ≈ R2G ≈ ∞

open circuit: R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞

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