Etronic Failuretree Iveco V623

ZF Failure number: 010
Failure description: TCU temperature below -40°C

(U_TEMP_CA)
Failure detection: ambient temperature below threshold
ZF-internal name: ELC_U_TEMP_CA
ZF-internal type: DI_ET_UNDERVOLTAGE
System reaction: ErrorLevel 1 („Reduced Gear” Mode)

Failure reset condition: TCU temperature higher than threshold
If failure reset condition is fulfilled: System reaction is reset after ignition off
Signal path: TCU internal

Pertained component: TCU
Steps to repair:
Failure Number: 010

ELC_U_TEMP_CA
Check TCU Change TCU

Use KIT Transmission Control Unit
ZF Part Number 1323 298 013
Failure description: TCU temperature above +120°C

(U_TEMP_CA)
Failure detection: load on system and ambient temperature very
high
ZF-internal name: ELC_U_TEMP_CA
ZF-internal type: DI_ET_OVERVOLTAGE
System reaction: ErrorLevel 1 („Reduced Gear“ Mode)

Failure reset condition: TCU temperature lower than threshold
Signal path: TCU internal

Steps to repair:
Failure Number: 011

ELC_U_TEMP_CA

Failure description: Physical failure in vehicle CAN BUS,

Interruption of vehicle CAN
Failure detection: no CAN communication
ZF-internal name: e_FZG_CAN_BUSOFF
ZF-internal type: DI_ET_Device_Error
System reaction: ErrorLevel 5 ("Crank-the-Engine" Mode)

Failure reset condition: No Failure Signal
Signal path: harness, CAN Bus TCU

Pertained component: vehicle CAN connectors, vehicle CAN harness, TCU
Steps to repair:
Failure Number: 012

e_FZG_CAN_BUSOFF
Check vehicle CAN connectors Repair vehicle CAN

and CAN harness connectors, CAN harness

Failure description: Physical failure in ZF CAN BUS,

Failure detection: no CAN communication
ZF-internal name: e_ZF_CAN_BUSOFF
System reaction: ErrorLevel 3 (“No Driving Direction” Mode)

Signal path: ZF CAN Bus TCU

Pertained component: CAN connectors, CAN harness, TCU
Steps to repair:
Failure Number: 013

e_ZF_CAN_BUSOFF
Check CAN connection, cable Change CAN connectors,

to EDC connectors and CAN CAN harness
harness

Failure description: CAN EEC1 timeout

Failure detection: Engine Controller, Cable to EDC
ZF-internal name: e_DI_CAN_EEC1_TIMEOUT
ZF-internal type: DI_ET_ABOVE_MAX_THRES
System reaction: ErrorLevel 1 ("Reduced Gear" Mode)

Signal path: cable to EDC Engine controller

Pertained component: Cable to EDC, EDC
Steps to repair:
Failure Number: 030

e_DI_CAN_EEC1_TIMEOUT
Check CAN connection, Repair connection, cable

cable to EDC
Check Engine Controller - EDC Change Engine Controller -

EDC

System reaction: ErrorLevel 2 ("Limp-Home by Shift Lever" Mode)

Signal path: Engine Controller Cable to EDC

Pertained component: Engine Controller, Cable to EDC
Steps to repair:
Failure Number: 031

Check CAN connection, cable Repair connecting cable

to EDC

EDC
Failure description: CAN CCVS timeout

ZF-internal name: e_DI_CAN_CCVS_TIMEOUT

Signal path: Engine ControllerCable to EDC

Steps to repair:
Failure Number: 032

e_DI_CAN_CCVS_TIMEOUT
Check CAN connection, Repair connecting cable

cable to EDC

EDC


Signal path: Engine Controller Cable to EDC

Steps to repair:
Failure Number: 033


cable to EDC

EDC
Failure description: CAN EBC1 timeout

ZF-internal name: e_DI_CAN_EBC1_TIMEOUT
System reaction: ErrorLevel 0 ("Normal" Mode)


Steps to repair:
Failure Number: 034

e_DI_CAN_EBC1_TIMEOUT

cable to EDC

EDC
Failure description: CAN EngConfMPM timeout

ZF-internal name: e_DI_CAN_ENGCFG_TIMEOUT


Steps to repair:
Failure Number: 035

e_DI_CAN_ENGCFG_TIMEOUT

cable to EDC

EDC
Failure description: CAN HRW timeout

ZF-internal name: e_DI_CAN_HRW_TIMEOUT


Steps to repair:
Failure Number: 036

e_DI_CAN_HRW_TIMEOUT

cable to EDC

EDC
Failure description: CAN SL_2_TCU timeout

Failure detection: Timeout of ZF CAN
ZF-internal name: e_DI_CAN_SL_2_TCU_TIMEOUT
System reaction: ErrorLevel 3 ("No Driving Direction " Mode)

Signal path: shift leverTCU

Pertained component: shift lever, TCU
Steps to repair: Check connection of shift lever and TCU
Failure Number: 037

e_DI_CAN_SL_2_TCU_TIMEOUT
Check shift lever Change shift lever
Check harness Change harness

Failure description: CAN VDC1

ZF-internal name: e_DI_CAN_VDC1_TIMEOUT


Steps to repair:
Failure Number: 038

e_DI_CAN_VDC1_TIMEOUT

cable to EDC

EDC
Failure description: CAN VDC2

ZF-internal name: e_DI_CAN_VDC2_TIMEOUT


Steps to repair:
Failure Number: 039

e_DI_CAN_VDC2_TIMEOUT

to EDC

EDC
Failure description: Error on ”Engine speed” signal (EEC1)

Failure detection: CAN-Signal Error Indicator
ZF-internal name: e_ENGCTRL_ENGSPEED_STATE_ERROR
ZF-internal type: DI_ET_INVALID_SIGNAL

Signal path: CAN-BUSABS

Pertained component: CAN-BUS, ABS
Steps to repair:
Failure Number: 050

e_ENGCTRL_ENGSPEED_STATE_ERROR

to EDC
Check ABS Change ABS
Check Engine Controller - Change Engine Controller -

EDC EDC
Failure description: Error on ”Drivers demand engine percent

torque” (EEC1)
Failure detection: CAN-Signal out of thresholds
ZF-internal name: e_ENGCTRL_ENGDRVDEMAND_STATE_ERROR
ZF-internal tip: DI_ET_INVALID_SIGNAL

Signal path: EDCTCU

Pertained component: EDC, TCU
Steps to repair:
Failure Number: 052

e_ENGCTRL_ENGDRVDEM_STATE_ERROR

to EDC

EDC
Failure description: Error on ”Accelerator pedal position”

(EEC2)
ZF-internal name: e_ACCPedalPos_ERROR
System reaction: ErrorLevel 2 ("Limp-Home by Shift Lever" Mode)

Signal path: EDC Accelerator pedal

Pertained component: EDC, Accelerator pedal
Steps to repair:
Failure Number: 054

e_ACCPedalPos_ERROR
Check Accelerator pedal Change Accelerator pedal

to EDC

EDC
Failure description: Error on "Brake switch" signal (CCVS)

Failure detection: CAN-Signal defect
ZF-internal name: e_Brake_ERROR

Signal path: EDCconnectors and harness and brake pedal

Pertained component: EDC, connectors and harness and brake pedal
Steps to repair:
Failure Number: 056

e_Brake_ERROR
Check connectors Change connectors
Check brake pedal Change brake pedal
Check Engine Controller - Change Engine Controller -

EDC EDC
Failure description: Error on "Engine/Retarder Torque Mode"

(EEC1)
ZF-internal name: e_ENGCTRL_ENG_TORQUE_MODE_STATE_ERROR

Signal path: EDCCAN connection

Pertained component: EDC, CAN connection
Steps to repair:
Failure Number: 057

e_ENGCTRL_ENG_TORQUE_MODE_STATE_ERROR

to EDC

EDC
Failure description: Error on "Actual Engine - Percent Torque"

(EEC1)
ZF-internal name: e_ENGCTRL_ENGTORQUE_STATE_ERROR


Steps to repair:
Failure Number: 058

e_ENGCTRL_ENGTORQUE_STATE_ERROR

to EDC

EDC
Failure description: Error on "Nominal Friction - Percent

Torque" (EEC3)
ZF-internal name: e_ENGCTRL_ENGFRICTION_STATE_ERROR


Steps to repair:
Failure Number: 060

e_ENGCTRL_ENGFRICTION_STATE_ERROR

to EDC

EDC
Failure description: Error on "Reference Engine Torque"

(ENG_CONF_MPM)
ZF-internal name: e_ENGCTRL_T_REF_STATE_ERROR

Signal path: EDC

Pertained component: EDC
Steps to repair:
Failure Number: 062

e_ENGCTRL_T_REF_STATE_ERROR

to EDC

EDC
Failure description: Error on "Rear axle, left wheel speed"

(HRW)
ZF-internal name: e_vRearLeft_ERR
System reaction: Error Level 5 ("Crank the Engine")

If failure reset condition is fulfilled:
Signal path:
Pertained component:
Steps to repair:
Failure Number: 066

e_vRearLeft_ERR
Check sensor Change sensor

Failure description: Error on "Rear axle, right wheel speed"

(HRW)
ZF-internal name: e_vRearRight_ERR

System reaction: ErrorLevel 5 ("Crank the Engine")

Signal path:
Steps to repair:
Failure Number: 067

e_vRearRight_ERR

Failure description: Differential speed between rear wheels and

gearbox output detected
Failure detection: CAN-Signal Error Indicator, B7 signal from
cluster (n_out-sensor) or wheel speed wrong
ZF-internal name: e_nOut_Plausi_ERR


Steps to repair:
Failure Number: 077

e_nOut_Plausi_ERR
Change Sensor
Check Sensor
Check harness Repair/Change harness

to EDC

EDC
Failure description: short circuit ground, electrical motor select

(EDRIVE_SELECT)
Failure detection: electrical failure in select motor, in harness, in
TCU
ZF-internal name: ELC_EDRIVE_SELECT
ZF-internal type: DI_ET_SC_GROUND
System reaction: ErrorLevel 4 ("Limited Gear Range" Mode)

Signal path: connectors harnessgearbox actuatorTCU

Pertained component: connectors, harness, gearbox actuator, TCU
Steps to repair:
Failure Number: 100

ELC_EDRIVE_SELECT
Change gearbox actuator Select Motor

Check gearbox actuator Use Electric motor ZF Part Number
Select Motor
1323 298 012
Change TCU
Check TCU Use KIT Transmission Control Unit
Failure description: short circuit plus, electrical motor select

(EDRIVE_SELECT)
TCU
ZF-internal type: DI_ET_SC_PLUS

Signal path: connectorsharnessgearbox actuatorTCU

Steps to repair:
Failure Number: 101

ELC_EDRIVE_SELECT
Check gearbox actuator Change gearbox actuator Select Motor

Select Motor Use Electric motor ZF Part Number
1323 298 012
Change TCU
Failure description: open circuit, electrical motor select

(EDRIVE_SELECT)
TCU
ZF-internal type: DI_ET_EL_INT


Steps to repair:
Failure Number: 102

ELC_EDRIVE_SELECT
Change gearbox actuator Select Motor

Check gearbox actuator Use Electric motor ZF Part Number
Select Motor 1323 298 012

Failure description: U_ADVP voltage too high

Failure detection: short circuit excess voltage of diagnosis tool
or Sensoric of select- or shift device
ZF-internal name: ELC_U_ADVP

Signal path: harnessgearbox actuatordiagnosis toolTCU

Pertained component: harness, gearbox actuator, diagnosis tool, TCU
Steps to repair:
Failure Number: 103

ELC_U_ADVP
Change gearbox actuator Select Motor,

Check gearbox actuator Shift Motor
Select Motor, Shift Motor Use Transmission actuator ZF Part
Number 1323 298 011 or Use Electric
motor ZF Part Number 1323 298 012
Check diagnosis tool Change diagnosis tool
Change TCU
Failure description: U_ADVP voltage too low

Failure detection: short circuit ground of diagnosis tool or
Sensoric of select- or shift device
ZF-internal name: ELC_U_ADVP
ZF-internal type: DI_ET_SC_GROUND, DI_ET_BELOW_MIN_THRES

Signal path: harnessgearbox actuatordiagnosis toolTCU

Pertained component: harness, gearbox actuator, diagnosis tool, TCU
Steps to repair:
Failure Number: 104

ELC_U_ADVP
Change gearbox actuator, Select

Check gearbox actuator Motor, Shift Motor
Select Motor, Shift Motor Use Transmission actuator ZF Part
Number 1323 298 011 or Use Electric
motor ZF Part Number 1323 298 012
Check diagnosis tool Change diagnosis tool
Change TCU
Failure description: Select sensor short to ground (riEF3)

Failure detection: failure of current or position sensor in select
motor electrical failure in harness, in TCU
ZF-internal name: ELC_EF3

Signal path: harnessgearbox actuatorTCU

Pertained component: harness, gearbox actuator, TCU
Steps to repair: ignition off/on
Failure Number: 105

ELC_EF3
Change gearbox actuator, Change

select Motor
Check gearbox actuator Use Transmission actuator ZF Part
Check select Motor Number 1323 298 011 or Use
Electric motor ZF Part Number 1323
298 012

Failure description: Select sensor short to plus/open circuit

(riEF3)
Failure detection: failure of current or position sensor in select
motor electrical failure in harness, in TCU


Failure Number: 106

ELC_EF3

select Motor
Check select Motor
Number 1323 298 011 or Use
298 012
Change TCU
Failure description: Select Drive plausi Error

Failure detection: electrical failure in select motor, in harness,
electrical failure in TCU
ZF-internal name: e_TCU_UKL_SELECT


Failure Number: 107

e_TCU_UKL_SELECT

Select motor , TCU
Change gearbox actuator, Select

Motor
Select Motor Number 1323 298 011 or Use
298 012
Change TCU
Failure description: Over current select

Failure detection: Actuator out of order. Measurement of
current defect.
ZF-internal name: e_TCU_OVER_CURRENT_SELECT

Signal path: gearbox actuatorTCU

Pertained component: gearbox actuator, TCU
Steps to repair:
Failure Number: 120

e_TCU_OVER_CURRENT_SELECT
Change actuator
Number 1323 298 011
Change TCU
Failure description: Over temperature select (Transistor,

estimated)
Failure detection: TCU too hot. Energy in select control System
is too high. Input values for estimated
algorithm corrupt.
ZF-internal name: e_TCU_OVER_TEMPERATURE_SELECT

Signal path: TCU

Steps to repair: TCU has been shut off, wait to start ignition off/on again
Failure Number: 121

e_TCU_OVER_TEMPERATURE_SELECT

Failure description: mechanical stuck select

Failure detection: gearbox actuator or transmission are stuck no
more motion possible
ZF-internal name: e_MECH_STUCK_SELECT_ERR
ZF-internal type: DI_ET_NOT_PLAUSIBLE

Signal path: gearbox actuator

Pertained component: gearbox actuator
Steps to repair: ignition off/on, check movements of select, change gearbox actuator
Failure Number: 130

e_MECH_STUCK_SELECT_ERR
Check gearbox actuator Change gearbox actuator

Use Transmission actuator ZF Part
Number 1323 298 011
Check gearbox Change gearbox

Use KIT Transmission ZF Part
Number 1323 010 005
Failure description: mechanical break select

Failure detection: electrical select motor, gearbox actuator or
transmission are broken. Target positions can
not be reached
ZF-internal name: e_MECH_BRAKE_SELECT_ERR

Signal path: gearbox actuatorgearboxTCU

Pertained component: gearbox actuator, gearbox, TCU
Steps to repair:
Failure Number: 131

e_MECH_BRAKE_SELECT_ERR
Check gearbox actuator Change gearbox actuator

Select Use Transmission actuator ZF Part
Number 1323 298 011

Number 1323 010 005
Failure description: position control failure select

Failure detection: target position can not be reached
ZF-internal name: e_POSCTRL_SELECT_ERR

Signal path: TCU

Failure Number: 132

e_POSCTRL_SELECT_ERR
Check acutuator Change actuator

Number 1323 298 011

Change Gearbox
Check Gearbox Use KIT Transmission ZF Part
Number 1323 010 005
Failure description: SelectFailure, GATE_ONLY_SHIFT

Failure detection: Pseudo error
ZF-internal name: e_GATE_ONLY_SHIFT_ERR

Signal path:
Steps to repair:
No action is needed
Failure description: SelectFailure , UNDEF_NO_SHIFT

Failure detection: Pseudoerror
ZF-internal name: e_UNDEF_NO_SHIFT_ERR
System reaction: ErrorLevel 6

Signal path:
Steps to repair:
No action is needed
Failure description: one or more EOL select measure values are

out of tolerance
Failure detection: gearbox geometry is out of tolerance
ZF-internal name: e_SEL_GEAR_OUT_OF_TOL_ERR
System reaction: ErrorLevel 0 (‘Normal’ Mode)

Signal path: gearbox

Pertained component: gearbox
Steps to repair:
Failure Number:181
e_SEL_GEAR_OUT_OF_TOL_ERR
Check EOL procedure Redo EOL procedure
Change gearbox
Checkgearbox
Number 1323 010 005
Failure description: short circuit ground, electrical motor shift

(EDRIVE_SHIFT)
Failure detection: electrical failure in shift motor, in harness,
failure in TCU
ZF-internal name: ELC_EDRIVE_SHIFT


Steps to repair:
Failure Number: 200

ELC_EDRIVE_SHIFT

shift Motor
Check Shift Motor Number 1323 298 011 or Use
298 012
Change TCU
Failure description: short circuit plus, electrical motor shift

(EDRIVE_SHIFT)
failure in TCU


Steps to repair:
Failure Number: 201

ELC_EDRIVE_SHIFT

shift Motor
Check shift Motor Number 1323 298 011 or Use
298 012
Change TCU
Failure description: open circuit, electrical motor shift

(EDRIVE_SHIFT)
failure in TCU


Steps to repair:
Failure Number: 202

ELC_EDRIVE_SHIFT

shift Motor
298 012
Change TCU
Failure description: Shift sensor short to ground (riEF4)

Failure detection: failure of current or position sensor in shift
motor, electrical failure in harness, in TCU


Failure Number: 205

ELC_EF4

shift Motor
298 012
Change TCU
Failure description: Shift Drive plausi Error

electrical failure in TCU
ZF-internal name: e_TCU_UKL_SHIFT


Failure Number: 206

e_TCU_UKL_SHIFT

Shift Motor, TCU
Change gearbox actuator, Shift

Motor
Check gearbox actuator
Shift Motor
298 012
Change TCU
Failure description: Shift sensor short to plus/open circuit (riEF4)

Failure detection: failure of current or position sensor in shift
motor, electrical failure in harness, in TCU


Failure Number: 207

ELC_EF4

shift Motor
Check shift Motor
298 012
Change TCU
Failure description: Over current shift

current is defected.
ZF-internal name: e_TCU_OVER_CURRENT_SHIFT

Signal path: gearbox actuatorTCU

Pertained component: gearbox actuator, TCU
Steps to repair:
Failure Number: 220

e_TCU_OVER_CURRENT_SHIFT
Change gearbox actuator

Number 1323 298 011
Change TCU
Failure description: Over temperature shift (Transistor,

estimated)
Failure detection: TCU too hot. Energy in shift control system is
too high. Input values for estimated algorithm
corrupt.
ZF-internal name: e_TCU_OVER_TEMPERATURE_SHIFT

Signal path: TCU

Failure Number: 221

e_TCU_OVER_TEMPERATURE_SHIFT

Failure description: mechanical stuck shift

Failure detection: gearbox actuator or transmission are stuck no
more motion possible.
ZF-internal name: e_MECH_STUCK_SHIFT_ERR

Signal path: gearbox actuatortransmission

Pertained component: gearbox actuator, transmission
Steps to repair:
ignition off/on, check movements of shift change gearbox actuator
Failure Number: 230

e_MECH_STUCK_SHIFT_ERR

Number 1323 298 011
Change gearbox
Check gearbox Use KIT Transmission ZF Part
Number 1323 010 005
Failure description: mechanical break shift

Failure detection: electrical select motor, gearbox actuator or
transmission are broken. Target positions can
not be reached
ZF-internal name: e_MECH_BRAKE_SHIFT_ERR

Signal path: gearbox actuatorgearbox

Pertained component: gearbox actuator, gearbox
Steps to repair:
Failure Number: 231

e_MECH_BRAKE_SHIFT_ERR

Shift
Shift Number 1323 298 011 or Use
298 012
Change TCU

Number 1323 010 005
Failure description: Position Control Failure Shift

Failure detection: Target positions can not be reached
ZF-internal name: e_POSCTRL_SHIFT_ERR

Signal path: TCU

Failure Number: 232

e_POSCTRL_SHIFT_ERR
ChangeActuator
Check actuator Use Transmission actuator ZF Part
Number 1323 298 011
Change TCU
Change Gearbox
Check Gearbox Use KIT Transmission ZF Part
Number 1323 010 005
Failure description: ShiftFailure, GEAR_NO_SHIFT

ZF-internal name: e_GEAR_NO_SHIFT_ERR

Signal path:
Steps to repair:
No action is needed
Failure description: ShiftFailure, NEUTRAL_NO_SHIFT

ZF-internal name: e_NEUTRAL_NO_SHIFT_ERR

Signal path:
Steps to repair:
No action is needed
Failure description: Shifting Gear Failure Gear 1

Failure detection: Gear not engagable
ZF-internal name: Shifting Gear Failure Gear 1

Signal path: Check actuator, check TCU, check synchronization

Pertained component: actuator, check TCU, synchronization
Steps to repair:
Failure Number: 252

Shifting Gear Failure Gear 1
Change actuator
Number 1323 298 011

Check synchronization Change synchrronization




Pertained component: actuator, TCU, synchronization
Steps to repair:
Failure Number: 253

Change actuator
Number 1323 298 011

Check synchronization Change synchronization




Steps to repair:
Failure Number: 254

Change actuator
Number 1323 298 011


ZF Failure number: Shifting Gear Failure Gear 4
Failure description: Position Control Failure Shift

ZF-internal name: e_POSCTRL_SHIFT_ERR


Steps to repair:
Failure Number: 255

Change actuator
Number 1323 298 011





Steps to repair:
Failure Number: 256

Change actuator
Number 1323 298 011





Steps to repair:
Failure Number: 257

Change actuator
Number 1323 298 011


Failure description: Shifting Gear Failure backward Gear

ZF-internal name: Shifting Gear Failure backward Gear


Steps to repair:
Failure Number: 258

Shifting Gear Failure
backward Gear
Change actuator
Number 1323 298 011


Failure description: TeachIn Request Gearbox Boundary

Override
Failure detection: Position out of range
ZF-internal name: e_TEACHIN_REQ_BOUND_OVERRIDE

Signal path: actuator, gearbox

Pertained component: actuator, gearbox
Steps to repair:
Failure Number: 259

e_TEACHIN_REQ_BOUN
D_OVERRIDE
Change actuator
Number 1323 298 011
Change gearbox
Number 1323 010 005
Failure description: TeachIn Request Gearbox Neutral Position

Failure
Failure detection: Position failure or mech. stuck
ZF-internal name: e_TEACHIN_REQ_N_POS_FAILURE

Signal path: actuator, gearbox

Pertained component: actuator, gearbox
Steps to repair:
Failure Number: 260

e_TEACHIN_REQ_N_POS_FAILURE
Change actuator
Number 1323 298 011
Change gearbox
Check gearbox
Number 1323 010 005
Failure description: one or more EOL shift measure values are out
of tolerance
Failure detection: gearbox geometry is out of tolerance
ZF-internal name: e_SHIFT_GEAR_OUT_OF_TOL_ERR

Signal path:
Steps to repair:
Failure Number: 281

e_SHIFT_GEAR_OUT_OF_TOL_ERR
Change gearbox
Number 1323 010 005
Failure description: gearbox geometry not symmetrical

Failure detection: Error detecting Neutral, origin was set wrong
ZF-internal name: e_SHIFT_GEARBOX_ASYMETRIC_ERR

Signal path:
Steps to repair:
Failure Number: 282

e_SHIFT_GEARBOX_ASYMETRIC_ERR
Change gearbox
Number 1323 010 005
Failure description: gear not shiftable

Failure detection: mechanical stuck
ZF-internal name: e_TEACHIN_REQ_N_POS_FAILURE

Signal path:
Steps to repair:
Failure Number: 282

e_SHIFT_GEARBOX_ASYMETRIC_ERR
Change gearbox
Number 1323 010 005
Failure description: short circuit ground, electrical motor clutch

(EDRIVE_CLUTCH)
Failure detection: electrical failure in clutch motor, in harness
or in TCU
ZF-internal name: ELC_EDRIVE_CLUTCH

Signal path: harnessclutch actuatorTCU

Pertained component: harness, clutch actuator, TCU
Steps to repair:
Failure Number: 300

ELC_EDRIVE_CLUTCH
Check clutch actuator Change clutch actuator

Use KIT Clutch actuator ZF Part
Number 1323 298 009
Change TCU
Failure description: short circuit plus, electrical motor clutch

(EDRIVE_CLUTCH)
or in TCU


Steps to repair:
Failure Number: 301

ELC_EDRIVE_CLUTCH

Number 1323 298 009

Failure description: open circuit, electrical motor clutch

(EDRIVE_CLUTCH)
or in TCU


Steps to repair:
Failure Number: 302

ELC_EDRIVE_CLUTCH
Change clutch actuator

Check clutch actuator Use KIT Clutch actuator ZF Part
Number 1323 298 009
Change TCU
Failure description: U_AU voltage too low

Failure detection: short circuit ground of sensoric clutch
actuator
ZF-internal name: ELC_U_AU


Steps to repair:
Failure Number: 303

ELC_U_AU

Check clutch actuator
Number 1323 298 009

Failure description: Over current clutch

current is defected.
ZF-internal name: e_TCU_OVER_CURRENT_CLUTCH

Signal path: clutch actuatorTCU

Pertained component: clutch actuator, TCU
Steps to repair:
Failure Number: 320

e_TCU_OVER_CURRENT_CLUTCH

Number 1323 298 009
Change TCU
Failure description: Over temperature clutch (Transistor, temp.

estimated)
Failure detection: TCU too hot. Energy in clutch control system
is too high. Input values for estimated
algorithm corrupt.
ZF-internal name: e_TCU_OVER_TEMPERATURE_CLUTCH

Signal path: TCU

Failure Number: 321

e_TCU_OVER_TEMPERATURE_CLUTCH
Change TCU
Failure description: mechanical disconnection electrical motor

clutch
Failure detection: At clutch teach-in procedure
ZF-internal name: TEACHIN_TIMEOUT_FAILURE

Signal path: TCU

Steps to repair: ignition on/off
Failure Number: 330

TEACHIN_TIMEOUT_FAILURE

Number 1323 298 009
Failure description: mechanical block at clutch position

Failure detection: Detected during clutch open or closing
procedure
ZF-internal name: POSCTRL_ENDPOS_FAILURE

Signal path: TCU

Steps to repair: ignition on/off
Failure Number: 331

POSCTRL_ENDPOS_FAILURE

Number 1323 298 009
Failure description: failure position control performance clutch

Failure detection: Detected during position control
ZF-internal name: POSCTRL_MECH_FAILURE

Signal path: TCU

Failure Number: 350

POSCTRL_MECH_FAILURE

Number 1323 298 009
Failure description: plausibility error clutch end position

Failure detection: Wrong end position at open or closed position
after teach-in
ZF-internal name: TEACHIN_OPEN_FAILURE,
TEACHIN_CLOSED_FAILURE

Signal path: clutch actuator

Pertained component: clutch actuator
Steps to repair:
Failure Number: 351

TEACHIN_OPEN_FAILURE,
TEACHIN_CLOSED_FAILURE

Number 1323 298 009
Failure description: Clutch Drive Plausi Error

Failure detection: failure of position sensor in clutch motor,
electrical failure in harness or in TCU
ZF-internal name: e_TCU_UKL_CLUTCH
System reaction: ErrorLevel 5 ("Crank-the-Engine" Mode)


Pertained component: harness, clutch actuator TCU
Failure Number: 352

e_TCU_UKL_CLUTCH

Number 1323 298 009
Change TCU
Failure description: multiple input speed plausibility error

Failure detection: Multiple gearbox speed plausibility error at
closed clutch condition
ZF-internal name: e_CL_MULTIPLE_FAILURE_RATIO

Signal path: EDC

Steps to repair:
Failure Number: 354

e_CL_MULTIPLE_FAILURE_RATIO

to EDC

EDC
Check clutch and clutch release Change clutch

system
Failure description: multiple clutch torque plausibility error

Failure detection: Multiple clutch torque plausibility error at
slipping clutch condition
ZF-internal name: e_CL_MULTIPLE_FAILURE_TORQUE

Signal path: EDC

Steps to repair:
Failure Number: 355

e_CL_MULTIPLE_FAILURE_TORQUE

to EDC
Change Engine Controller -

Check Engine Controller - EDC EDC
Change clutch and clutch release system

Check clutch and clutch release
Use Clutch release ZF Part Number
system
1323 298 010
Change gearbox
Check gearbox (e.g. Use KIT Transmission ZF Part
synchronizer) Number 1323 010 005
Failure description: Engine does not react on TCU's torque

command
Failure detection: TCU torque command has been replaced by
other vehicle components like ESP or ASR for
an inadmissible space of time
ZF-internal name: e_ENGCTRL_TORQE_MODE_FAILURE

Signal path: EDC

Steps to repair:
Failure Number: 356

e_ENGCTRL_TORQE_MODE_FAILURE

to EDC
Check Engine Controller - EDC Change Engine Controller - EDC

Failure description: ErrorEOL_ClutchTimeOut

Failure detection: clutch actuator with high friction, clutch with
high shift friction, no movement because of
electrical malfunction at EOL procedure
ZF-internal name: e_EOL_ERROR_CLUTCHTIMEOUT

Signal path: clutch system

Pertained component: clutch system
Steps to repair:
Failure Number: 380

e_EOL_ERROR_CLUTCHTIME
OUT
Check clutch system

Change clutch system
Failure description: ErrorEOL_S_ClutchOverrun

Failure detection: overrun of clutch system movement
limitations while EOL procedure
ZF-internal name: e_EOL_ERROR_S_CLUTCHOVERRUN


Steps to repair:
Failure Number: 381

e_EOL_ERROR_S_CLUTCHOV
ERRUN
Check clutch system Change clutch system

Failure description: ErrorEOL_S_ClutchUnderrun

Failure detection: underrun of clutch system movement
limitations while EOL procedure
ZF-internal name: e_EOL_ERROR_UNDERRUN


Steps to repair:
Failure Number: 382

e_EOL_ERROR_UNDERRUN

Failure description: ErrorEOL_S_ClutchEEPROMstat

Failure detection: EEProm problems while EOL procedure
ZF-internal name: e_EOL_INTERNALERROR_5_CLUTCH


Steps to repair:
Failure Number: 383

e_EOL_INTERNALERROR_5_C
LUTCH

Failure description: ErrorTeachInClose

Failure detection: TeachInClose problems while EOL procedure
ZF-internal name: e_EOL_ERROR_TEACHINCLOSED


Steps to repair:
Failure Number: 384

e_EOL_ERROR_TEACHINCLOSED

Failure description: ErrorTeachInOpen

Failure detection: TeachInOpen problems while EOL procedure
ZF-internal name: e_EOL_ERROR_TEACHINOPEN


Steps to repair:
Failure Number: 385

e_EOL_ERROR_TEACHINOPEN

Failure description: e_TOUCHP_SEARCH_FAILED_EOL

Failure detection: e_TOUCHP_SEARCH_FAILED_EOL
ZF-internal name: e_TOUCHP_SEARCH_FAILED_EOL


Steps to repair:
Failure Number: 386

e_TOUCHP_SEARCH_FAILED_
EOL

Failure description: short circuit plus starter inhibit (iADM1)

Failure detection: cable is defective and is contacted to battery
voltage, starter device has an internal defect,
connector pin is contacted to battery voltage
ZF-internal name: ELC_ADM1

Signal path: harness from TCU to starterconnectors from starter to

TCUthe resistance of starter relay
Pertained component: harness from TCU to starter, connectors from starter to TCU,
the resistance of starter relay
Steps to repair:
Failure Number: 400

ELC_ADM1
Check harness from TCU to Change harness from TCU to

starter starter
Check connectors from Change connectors from

starter to TCU starter to TCU
Check the resistance of Change the resistance of

starter relay starter relay
Failure description: short circuit plus reverse light (iADM2)

voltage, reverse light has an internal defect,



TCUthe resistance of starter relay
the resistance of starter relay
Steps to repair:

reverse light reverse light

reverse light to TCU reverse light to TCU

reverse light reverse light
Failure description: short circuit plus PTO engage (iADM3)

voltage, PTO device has an internal defect,

Signal path: harness from TCU to PTOconnectors from PTO-ECU to

TCUresistance of PTO-ECU
Pertained component: harness from TCU to PTO-ECU, connectors from PTO-ECU
to TCU, resistance of PTO-ECU
Steps to repair:
Failure Number: 402

ELC_ADM3

PTO-ECU PTO-ECU
Check the resistance of Change PTO-ECU

PTO-ECU
Failure description: UVPE_HS voltage too high

Failure detection: short circuit on current supply of bridges
excess voltage
ZF-internal name: ELC_UVPE_HS

Signal path: vehicle battery / alternator

Pertained component: vehicle battery / alternator
Steps to repair:
Failure Number: 403

ELC_UVPE_HS
Check vehicle battery Change vehicle battery

Failure description: UVPE_HS voltage too low

Failure detection: short circuit ground on current supply of E-
Motor-Inputs
ZF-internal name: ELC_UVPE_HS
ZF-internal type: DI_ET_BELOW_MIN_THRES, DI_ET_OPEN_CIRCUIT

Signal path: vehicle battery / alternator

Pertained component: vehicle battery / alternator
Steps to repair:
Failure Number: 404

ELC_UVPE_HS

Failure description: UKL30_HS voltage too high

Failure detection: voltage supply of TCU core too high
ZF-internal name: ELC_UKL30_HS

Signal path: vehicle battery, harness, connectors, TCU

Pertained component: vehicle battery, harness, connectors, TCU
Steps to repair: check vehicle battery, check harness, check connectors, change TCU
Failure Number: 405

ELC_UKL30_HS
Change TCU
Failure description: UKL30_HS voltage too low

Failure detection: voltage supply of TCU core too high
ZF-internal name: ELC_UKL30_HS
ZF-internal type: DI_ET_BELOW_MIN_THRES, DI_ET_EL_INT

Signal path: vehicle battery, harness, connectors, TCU

Pertained component: vehicle battery, harness, connectors, TCU
Steps to repair:
Failure Number: 406

DI_ET_BELOW_MIN_THRES,
DI_ET_EL_INT
Change TCU
Failure description: UKL15 voltage too high

Failure detection: Ignition voltage too high
ZF-internal name: ELC_UKL15

Signal path: vehicle power supplyignition switch

Pertained component: vehicle power supply, ignition switch
Steps to repair:
Failure Number: 407

ELC_UKL15
Check vehicle power supply Change vehicle battery or

alternator
Check ignition switch Change ignition switch

Failure description: UVDD12 voltage too high

Failure detection: internal 12V Supply problem
ZF-internal name: ELC_UVDD12

Signal path: TCU

Steps to repair:
Failure Number: 409

ELC_UVDD12
Change TCU
Failure description: UVDD12 voltage too low

Failure detection: internal 12V Supply problem
ZF-internal name: ELC_UVDD12
ZF-internal type: DI_ET_BELOW_MIN_THRES, DI_ET_EL_INT

Signal path: TCU

Steps to repair:
Failure Number: 410

ELC_UVDD12
Change TCU
Failure description: UKL30 voltage too low

Failure detection: short circuit ground of TCU voltage supply
ZF-internal name: ELC_VPE1, ELC_VPE2

Signal path: vehicle battery / harness / connector / TCU

Pertained component: vehicle battery
Steps to repair:
Failure Number: 411

ELC_VPE1
ELC_VPE2

Failure description: UKL30 voltage open circuit

Failure detection: disconnection of TCU voltage supply / harness
or connector

Signal path: vehicle battery / harness / connector / TCU

Steps to repair:
Failure Number: 412

ELC_VPE1
ELC_VPE2

Failure description: riEF2

Failure detection: short circuit ground of gearbox output sensor

Signal path: harness, sensor, TCU

Pertained component: harness, sensor, TCU
Steps to repair:
Failure Number: 413

ELC_EF2

Failure description: Sensor Error n_Out

Failure detection: sensor or harness failure
ZF-internal name: e_nOut_EF2_ERR

Signal path: harness, sensor

Pertained component: harness, sensor
Steps to repair:
Failure Number: 415

e_nOut_EF2_ERR

Failure description: short cut ground at ER1

Failure detection: tbd
ZF-internal name: ELC_ER1

Signal path: harness, connectors, external component, TCU

Pertained component: harness, connectors, external component, TCU
Steps to repair:
Failure Number: 416

ELC_ER1
Check connector Change connector
Check external comp Change external comp

Failure description: short cut plus at ER1



Steps to repair:
Failure Number: 417

ELC_ER1

Failure description: open circuit at ER1

ZF-internal type: DI_ET_OPEN_CIRCUIT


Steps to repair:
Failure Number: 418

ELC_ER1




Steps to repair:
Failure Number: 419

ELC_ER2




Steps to repair:
Failure Number: 420

ELC_ER2




Steps to repair:
Failure Number: 421

ELC_ER2




Steps to repair:
Failure Number: 422

ELC_ER3


System reaction: ErrorLevel 0)


Steps to repair:
Failure Number: 423

ELC_ER3




Steps to repair:
Failure Number: 424

ELC_ER3




Steps to repair:
Failure Number: 425

ELC_ER4




Steps to repair:
Failure Number: 426

ELC_ER4




Steps to repair:
Failure Number: 427

ELC_ER4




Steps to repair:
Failure Number: 428

ELC_ER5

Failure description: short cut plus at ER5 (Uprog)



Steps to repair:
Failure Number: 429

ELC_ER5

Failure description: open circuit at ER5 (Uprog))



Steps to repair:
Failure Number: 430

ELC_ER5




Steps to repair:
Failure Number: 431

ELC_ER6




Steps to repair:
Failure Number: 432

ELC_ER6




Steps to repair:
Failure Number: 433

ELC_ER6

Failure description: voltages at TCU pins VPE1, VPE2 and VPI

are different
Failure detection: 1. voltages are different because at failure at
vehicle harness and power supply
2. TCU defect

Signal path: harness TCU

Pertained component: harness, TCU
Steps to repair:
Switch on ignition, measure voltages at VPE1, VPE2, VPI. If not equal, change harness. Otherwise
replace TCU
Failure Number: 434

ELC_VPE1
ELC_VPE2


Failure detection: voltage of EF2 not plausible
ZF-internal type: DI_ET_NOT_PLAUSILBLE

Signal path: check harness, check sensor, check TCU

Steps to repair:
Failure Number: 435

ELC_EF2


Failure detection: voltage of position sensor select motor not
plausible

Signal path: harnesssensorTCU

Steps to repair:
Failure Number: 436

ELC_EF3
Check sensor Change select motor

at select motor Use Electric motor ZF Part Number
1323 298 012


Failure detection: voltage of position sensor shift motor not
plausible

Signal path: harnesssensorTCU

Steps to repair:
Failure Number: 437

ELC_EF4
Check sensor at shift motor Change shift motor

Use Electric motor ZF Part Number
1323 298 012

Failure description: short cut ground starter inhibit (iADM1)

voltage, starter device has an internal defect,


TCU relays
relays
Steps to repair:
Failure Number: 438

ELC_ADM1
Check harness from TCU to Change harness from TCU

starter to starter


starter relay starter relay
Failure description: voltage below threshold (starter inhibit

iADM1)
Failure detection: cable is defective and is contacted to ground,
connector pin is contacted to ground
ZF-internal type: DI_ET_BELOW_THRES


TCUrelays
relays
Steps to repair:
Failure Number: 439

ELC_ADM1

starter to starter

Check relays Change relays

Failure description: no_redundance_shiftlever

Failure detection: shift lever self diagnosis, single failure, no
more redundancies
ZF-internal name: e_SL_single
ZF-internal type: DI_ET_DEVICE_ERROR

Signal path: Shift lever TCU

Pertained component: Shift lever, connectors, ZF CAN, TCU
Steps to repair:
Failure Number: 440

e_SL_single
Check connectors and Repair vehicle harness

harness and / or connectors

Read shift lever positions by Use KIT Transmission Control Unit
tester ZF Part Number 1323 298 013
Failure description: doublefailure_shiftlever

Failure detection: shift lever self diagnosis, double failure or
checksum failure, no information of shift
lever position
ZF-internal name: e_SL_double
ZF-internal type: DI_ET_DEVICE_ERROR
System reaction: ErrorLevel 3 ("No Driving Direction" Mode )

Failure reset condition: Shift lever sends no failure

Steps to repair:
Failure Number: 441

e_SL_double
Check connectors and Repair vehicle harness

harness and / or connectors
Check TCU
Read shift lever Change TCU
positions by tester Use KIT Transmission Control Unit
Failure description: positionfailure_shiftlever

Failure detection: position of shift lever is undefined
ZF-internal name: e_SL_UndefPos
System reaction: ErrorLevel 3 ("No Driving Direction " Mode)


Steps to repair:
Failure Number: 442

e_SL_UndefPos
Check connectors and Repair vehicle harness and /

harness or connectors
Check TCU
Read shift lever Change TCU
positions by tester Use KIT Transmission Control Unit
Failure description: short cut ground Reverse light

ZF-internal type: DI_ET_SC_GROUND, DI_ET_BELOW_THRES

Signal path: harness from TCU to reverse lightconnectors

Pertained component: harness from TCU to reverse light, connectors
Steps to repair:
Failure Number: 443

ELC_ADM2

reverse light to reverse light

Failure description: short cut ground PTO engage


Signal path: harness from TCU to PTOconnectors

Pertained component: harness from TCU to PTO, connectors
Steps to repair:
Failure Number: 444

ELC_ADM3

PTO to PTO

Failure description: Shift lever fixed in interim position

Failure detection: driver misuse
ZF-internal name: e_SL_Intermediate

Signal path: shift lever

Pertained component: shift lever
Steps to repair:
Failure Number: 445

e_SL_Intermediate

Failure description: Checksum failure, failure in structure,

position of topic is displaced
Failure detection: read or write failure on EEPROM
ZF-internal name: e_EEPROM_ERROR

Signal path: TCU

Steps to repair:
Failure Number: 450

e_EEPROM_ERROR
Change TCU

Etronic Failuretree Iveco V623

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Etronic Failuretree Iveco V623

Uploaded by

Copyright:

Available Formats

ZF Failure number: 010

Failure description: TCU temperature below -40°C

System reaction: ErrorLevel 1 („Reduced Gear” Mode)

Signal path: TCU internal

Failure Number: 010

Check TCU Change TCU

Failure description: TCU temperature above +120°C

System reaction: ErrorLevel 1 („Reduced Gear“ Mode)

Signal path: TCU internal

Failure Number: 011

Check TCU Change TCU

Failure description: Physical failure in vehicle CAN BUS,

System reaction: ErrorLevel 5 ("Crank-the-Engine" Mode)

Signal path: harness, CAN Bus TCU

Failure Number: 012

Check vehicle CAN connectors Repair vehicle CAN

Check TCU Change TCU

Failure description: Physical failure in ZF CAN BUS,

System reaction: ErrorLevel 3 (“No Driving Direction” Mode)

Signal path: ZF CAN Bus TCU

Failure Number: 013

Check CAN connection, cable Change CAN connectors,

Check TCU Change TCU

Failure description: CAN EEC1 timeout

System reaction: ErrorLevel 1 ("Reduced Gear" Mode)

Signal path: cable to EDC Engine controller

Failure Number: 030

Check CAN connection, Repair connection, cable

Check Engine Controller - EDC Change Engine Controller -

Failure description: CAN EEC2 timeout

System reaction: ErrorLevel 2 ("Limp-Home by Shift Lever" Mode)

Signal path: Engine Controller Cable to EDC

Failure Number: 031

Check CAN connection, cable Repair connecting cable

Check Engine Controller - EDC Change Engine Controller -

Failure description: CAN CCVS timeout

System reaction: ErrorLevel 1 ("Reduced Gear" Mode)

Signal path: Engine ControllerCable to EDC

Failure Number: 032

Check CAN connection, Repair connecting cable

Check Engine Controller - EDC Change Engine Controller -

Failure description: CAN EEC3 timeout

System reaction: ErrorLevel 1 ("Reduced Gear" Mode)

Signal path: Engine Controller Cable to EDC

Failure Number: 033

Check CAN connection, Repair connecting cable

Check Engine Controller - EDC Change Engine Controller -

Failure description: CAN EBC1 timeout

System reaction: ErrorLevel 0 ("Normal" Mode)

Signal path: Engine ControllerCable to EDC

Failure Number: 034

Check CAN connection, Repair connecting cable

Check Engine Controller - EDC Change Engine Controller -

Failure description: CAN EngConfMPM timeout

System reaction: ErrorLevel 1 ("Reduced Gear" Mode)

Signal path: Engine ControllerCable to EDC

Failure Number: 035

Check CAN connection, Repair connecting cable

Check Engine Controller - EDC Change Engine Controller -

Failure description: CAN HRW timeout

System reaction: ErrorLevel 1 ("Reduced Gear" Mode)

Signal path: Engine ControllerCable to EDC

Failure Number: 036