ZF Fault Codes Latest PDF Free

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Zusatzbenennung: description of fault codes for Ergo control A4 von 38
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K3 ZFN 904 ÄNDERUNGEN
Erstellt: Geprüft: Freigegeben :
Name: Plank Sieger
Abteilung: ACETS TE-AB
Datum: 2011-02-21 03-10-01
Description
of the
fault codes
for
ERGO-Control EST37
document created for customer "Hyundai construction machineries" 2011-02-21

ZF Friedrichshafen AG 11-02-21
Faultcodes ERGO-Control EST37A
Index of changes:
date index comment software version
TE-AB Seite 2 von 38

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.

ZF Friedrichshafen AG
description of fault codes for ERGO-Control 11-02-21
3 table of fault codes
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
10 5001 12 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 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 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
13 5020 12 LOGICAL ERROR AT ENGINE DERATING after selecting neutral, TCU • check engine derating device This fault is reset after power
DEVICE changes to OP-Mode limp home up of TCU
TCU detected no reaction of engine while
derating device activ

(hex)
14 5030 12 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
• one of the cables from status-switch to
electronic box is broken
• one of the status-switches is defective
15 5040 12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to • check the cables from TCU to shift lever fault is taken back if TCU
SIGNAL 2. SHIFT LEVER neutral if selector activ 2 detects a valid neutral signal
TCU detected a wrong signal combination OP-Mode: transmission • check signal combinations of shift lever for the direction at the shift
for the direction shutdown if selector activ positions F-N-R lever
• cable from shift lever 2 to TCU is
broken
16 5050 12 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal • check the cables from TCU to feedback
feedback axle connection measured by axle connection switch
TCU and output signal axle connection • check signals of the feedback axle
don't fit connection switch
• axle can’t be connected or
disconnected due to mechanical
problem
• one of the cables from feedback axle
connection -switch to TCU is broken
25 5110 3 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, • check the cable from TCU to the sensor
TRANSMISSION SUMP TEMPERATURE TCU uses default temperature • check the connectors
SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too high:

(hex)
battery voltage
• cable has no connection to TCU
• temperature sensor has an internal
defect
• connector pin is contacted to battery
voltage or is broken
26 5110 4 S.C. TO GROUND AT TRANSMISSION SUMP no reaction, • check the cable from TCU to the sensor
TEMPERATURE SENSOR INPUT TCU uses default temperature • check the connectors
the measured voltage is too low: OP-Mode: normal • check the temperature sensor
vehicle ground
defect
• connector pin is contacted to vehicle
ground
27 5120 3 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, • check the cable from TCU to the sensor
RETARDER / TORQUECONVERTER TCU uses default temperature • check the connectors
TEMPERATURE SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too high:
battery voltage
defect
28 5120 4 S.C. TO GROUND AT RETARDER / no reaction, • check the cable from TCU to the sensor
TORQUECONVERTER TEMPERATURE TCU uses default temperature • check the connectors
SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too low:
vehicle ground

(hex)
defect
ground
29 5130 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value • check the cable from TCU to the sensor
PARKING BRAKE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the parking brake sensor
battery voltage
• sensor has an internal defect
2A 5130 4 S.C. TO GROUND PARKING BRAKE SENSOR TCU uses default value • check the cable from TCU to the sensor
INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the parking brake sensor
vehicle ground
ground
2B 5313 12 INCHSENSOR-SIGNAL MISMATCH During inching mode: TCU shifts • check the cable from TCU to the sensor
the measured voltage from CCO and to neutral • check the connectors
CCO2 signal don’t match: While not inching: no change • check sensor
• cable is defective OP-Mode: normal
2C 5135 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value • check the cable from TCU to the sensor
DLM TRACTION ADJUST DASHBOARD OP-Mode: normal • check the connectors
DEVICE INPUT • check the DLM Traction Adjust
the measured voltage is too high: dashboard device

(hex)
battery voltage
2D 5135 4 S.C. TO GROUND DLM TRACTION ADJUST TCU uses default value • check the cable from TCU to the sensor
DASHBOARD DEVICE INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the DLM Traction Adjust
• cable is defective and is contacted to dashboard device
vehicle ground
ground
2E 5137 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value • check the cable from TCU to the sensor
DLM STEERING ANGLE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the DLM STEERING ANGLE
• cable is defective and is contacted to SENSOR
battery voltage
2F 5137 4 S.C. TO GROUND DLM STEERING ANGLE TCU uses default value • check the cable from TCU to the sensor
SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the DLM STEERING ANGLE
• cable is defective and is contacted to SENSOR
vehicle ground
ground

(hex)
31 5140 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the sensor
ENGINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 • check the speed sensor
V at speed input pin
battery voltage
• speed sensor has an internal defect
voltage or has no contact
32 5140 4 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
TCU measures a voltage less than 0.45V control • check the connectors
at speed input pin • check the speed sensor
• cable / connector is defective and is
contacted to vehicle ground
33 5140 12 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power
TCU measures a engine speed over a control • check the connectors up of TCU
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

(hex)
35 5150 4 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 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 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

(hex)
39 5160 12 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power
TCU measures a internal speed over a control • check the connectors up of TCU
threshold and at the next moment the • check the speed sensor
measured speed is zero • check the sensor gap
• cable / connector is defective and has
bad contact
3A 5170 3 S.C. TO BATTERY VOLTAGE OR O.C. AT special mode for gear selection • check the cable from TCU to the sensor
OUTPUT SPEED INPUT OP-Mode: substitute clutch • check the connectors
TCU measures a voltage higher than 12.5 control • check the speed sensor
V at speed input pin if a failure is existing at turbine
• cable is defective and is contacted to speed,
battery voltage TCU shifts to neutral
• cable has no connection to TCU OP-Mode: limp home
3B 5170 4 S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear selection • check the cable from TCU to the sensor
TCU measures a voltage less than 1.00V OP-Mode: substitute clutch • check the connectors
at speed input pin control • check the speed sensor
• cable / connector is defective and is if a failure is existing at turbine
contacted to vehicle ground speed,
• speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
3C 5170 12 LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear selection • check the cable from TCU to the sensor This fault is reset after power
TCU measures a output speed over a OP-Mode: substitute clutch • check the connectors up of TCU
threshold and at the next moment the control • check the speed sensor
measured speed is zero if a failure is existing at turbine • check the sensor gap
• cable / connector is defective and has speed,
bad contact TCU shifts to neutral

(hex)
• speed sensor has an internal defect OP-Mode: limp home
3E 5180 2 OUTPUT SPEED ZERO DOESN’T FIT TO special mode for gear selection • check the sensor signal of output speed This fault is reset after power
OTHER SPEED SIGNALS OP-Mode: substitute clutch sensor up of TCU
if transmission is not neutral and the control • check the sensor gap of output speed
shifting has finished, if a failure is existing at turbine sensor
TCU measures outputspeed zero and speed, • check the cable from TCU to the sensor
turbine speed or internal speed not equal TCU shifts to neutral
to zero. OP-Mode: limp home
54 5260 9 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
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
55 5270 9 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 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

(hex)
battery voltage
57 5290 9 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 EEC3 TIMEOUT OP-Mode: substitute clutch • check EEC controller

Timeout of CAN-message EEC3 from control • check wire of CAN-Bus
• CAN wire/connector is defective an
battery voltage
59 5310 2 AEB-REQUEST AND PARKBRAKETEST no reaction • check programming of vehicle controller

SIGNALS ON AT THE SAME TIME
CAN signal for AEB-Request and for
ParkbrakeTest are ON at the same time
61 5390 2 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 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

(hex)
69 5440 2 REFERENCE ENGINE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for reference of engine torque control • check wire of CAN-Bus
is defective • check cable to engine controller
• engine controller is defective
6A 5450 2 ACTUAL ENGINE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for actual engine torque is control • check wire of CAN-Bus
defective • check cable to engine controller
6B 5460 2 NOM FRICTION TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for nominal friction torque is control • check wire of CAN-Bus
defective • check cable to engine controller
6E 5470 2 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 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the see chapter 4
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

(hex)
• regulator has an internal defect gearbox
1)
72 5480 4 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the see chapter 4
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 O.C. AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the see chapter 4
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
1)
too high. pending TCU
1)

(hex)
the TCU
1)
gearbox
1)
1)
the TCU
1)

(hex)
gearbox
7A 5540 3 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 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 O.C. AT CONVERTER CLUTCH no reaction • check the cable from TCU to the valve
OP-Mode: normal • check the regulator resistance 1)
1)
1)
the TCU

(hex)
1)
gearbox
1)
84 5520 3 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 4
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 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 4
is out of limit, the voltage at KV valve is if failure at another clutch is • check the connectors from gearbox to
the TCU
1)
86 5520 5 O.C. AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 4
gearbox

(hex)
1)
87 5530 3 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 4
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 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 4
is out of limit, the voltage at KR valve is if failure at another clutch is • check the connectors from gearbox to
the TCU
1)
89 5530 5 O.C. AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 4
gearbox
1)
8A 5535 4 S.C. TO GROUND AT DLM TRANSVERSAL output will be on until TCU • check the cable from TCU to the valve see chapter 4
OUTPUT power down even if fault • check the connectors
TCU detected a wrong voltage at the vanishes (loose connection) • check the resistance of valve
output pin, that looks like a s.c. to vehicle OP-Mode: normal
ground
vehicle ground
• device has an internal defect

(hex)
ground
1)
8B 5535 3 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the valve see chapter 4
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 O.C. AT DLM TRANSVERSAL OUTPUT no reaction • check the cable from TCU to the valve see chapter 4
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
• connector has no connection to TCU
1)
8D 5536 4 S.C. TO GROUND AT DLM INDICATOR output will be on until TCU • check the cable from TCU to the device see chapter 4
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 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the device see chapter 4
INDICATOR LAMP OUTPUT OP-Mode: normal • check the connectors

(hex)
TCU detected a wrong voltage at the • check the resistance of device
voltage
battery voltage
voltage
1)
8F 5536 5 O.C. DLM INDICATOR LAMP OUTPUT no reaction • check the cable from TCU to the device see chapter 4
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
1)
91 5560 4 S.C. TO GROUND AT RELAY REVERSE backup alarm will be on until • check the cable from TCU to the backup see chapter 4
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 S.C. TO BATTERY VOLTAGE AT RELAY no reaction • check the cable from TCU to the backup see chapter 4
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

(hex)
voltage • check the resistance 1) of backup alarm
• cable is defective and is contacted to device
battery voltage
defect
voltage
1)
93 5560 5 O.C. AT RELAY REVERSE WARNING ALARM no reaction • check the cable from TCU to the backup see chapter 4
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 S.C. TO GROUND AT RELAY STARTER no reaction • check the cable from TCU to the starter see chapter 4
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 S.C. TO BATTERY VOLTAGE AT RELAY no reaction • check the cable from TCU to the starter see chapter 4
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

(hex)
• cable is defective and is contacted to interlock relay
battery voltage
defect
voltage
1)
96 5570 5 O.C. AT RELAY STARTER INTERLOCK no reaction • check the cable from TCU to the starter see chapter 4
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)
A4 5620 4 S.C. TO GROUND AT WARNING SIGNAL no reaction • check the cable from TCU to the see chapter 4
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
• warning device has an internal defect
ground
1)
A5 5620 5 O.C. AT WARNING SIGNAL OUTPUT no reaction • check the cable from TCU to the see chapter 4
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

(hex)
1)
A6 5620 3 S.C. TO BATTERY VOLTAGE AT WARNING no reaction • check the cable from TCU to the see chapter 4
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
B1 5660 2 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
• clutch is defective


(hex)


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
• wrong signal at internal speed sensor
• wrong signal at turbine speed sensor
B5 5680 2 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

(hex)
B6 5685 2 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 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
BA 5730 0 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
BC 5745 15 OVERSPEED OUTPUT No reaction

TCU messures an transmission output OP-Mode: normal
speed above the defined threshold
C0 5751 0 ENGINE TORQUE OR ENGINE POWER OP-Mode: normal
OVERLOAD
TCU calculates an engine torque or engine

(hex)
power above the defined thresholds
C1 5752 0 TRANSMISSION OUTPUT TORQUE OP-Mode: normal
OVERLOAD
TCU calculates an transmission output
torque above the defined threshold
C2 5755 15 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 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 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 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

(hex)
voltage
C6 5770 5 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 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 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

(hex)
voltage
C9 5780 5 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 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 ERC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller

Timeout of CAN-message ERC1 from control • check wire of CAN-Bus
battery voltage
D1 5810 3 S.C. TO BATTERY VOLTAGE AT POWER see fault codes no. 21 to 2C • check cables and connectors to sensors, fault codes no. 21 to no. 2C
SUPPLY FOR SENSORS which are supplied from AU1 may be a reaction of this fault
TCU measures more than 6V at the pin • check the power supply at the pin AU1

(hex)
AU1 (5V sensor supply) (should be appx. 5V)
D2 5810 4 S.C. TO GROUND AT POWER SUPPLY FOR see fault codes no. 21 to 2C • check cables and connectors to sensors, fault codes no. 21 to no. 2C
SENSORS which are supplied from AU1 may be a reaction of this fault
TCU measures less than 4V at the pin • check the power supply at the pin AU1
AU1 (5V sensor supply) (should be appx. 5V)
D3 5820 4 LOW VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is lower OP-Mode: TCU shutdown • check cables from batteries to TCU
than 10 V (12V device) • check connectors from batteries to TCU
lower than 18 V (24V device)
D4 5820 3 HIGH VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is OP-Mode: TCU shutdown • check cables from batteries to TCU
higher than 18 V (12V device) • check connectors from batteries to TCU
higher than 32.5 V (24V device)
D5 5830 2 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral • check fuse
TCU switched on VPS1 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 • check connectors from gearbox to TCU
and measured VPS1 is still on • replace TCU
• cable or connectors are defect and are
contacted to battery voltage
• permanent power supply KL30 missing
• TCU has an internal defect
D6 5840 2 ERROR VALVE POWER SUPPLY VPS2 shift to neutral • check fuse
TCU switched on VPS2 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
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

(hex)
• 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 4
OUTPUT power down even if fault • check the connectors
TCU detected a wrong voltage at the vanishes (loose connection) • check the resistance of valve
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 4
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 4
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 S.C. TO BATTERY VOLTAGE AT DISPLAY no reaction • check the cable from TCU to the display
OUTPUT OP-Mode: normal • check the connectors at the display

(hex)
TCU sends data to the display and • change display
measures allways a high voltage level on
the connector
• cable or connectors are defective and
are contacted to battery voltage
• display has an internal defect
E4 5860 4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction • check the cable from TCU to the display
TCU sends data to the display and OP-Mode: normal • check the connectors at the display
measures allways a high voltage level on • change display
the connector
• cable or connectors are defective and
are contacted to vehicle ground
• display has an internal defect
F1 5890 2 GENERAL EEPROM FAULT no reaction • replace TCU often shown together with
TCU can't read non volantile memoy OP-Mode: normal fault code F2
• TCU is defective
F2 5900 13 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
volatile memory
• TCU is brand new or from another
vehicle
F3 5910 13 APPLICATION ERROR transmission stay neutral • replace TCU !! This fault occurs only if an
something of this application is wrong OP-Mode: TCU shutdown test engineer did something
wrong in the application of
the vehicle
F5 5930 7 CLUTCH FAILURE transmission stay neutral • check clutch TCU shows also the affected
AEB was not able to adjust clutch filling OP-Mode: TCU shutdown clutch on the Display
parameters
• One of the AEB-Values is out of limit

(hex)
F6 5930 13 CLUTCH ADJUSTMENT DATA LOST OR default values = 0 for AEB • execute AEB
INCHPEDAL CALIBRATION DATA LOST offsets used
TCU was not able to read correct clutch OP-Mode: normal
adjustment parameters no Inchmode available
• interference during saving data on non
volatile memory
• TCU is brand new
F7 5940 11 SUBSTITUTE CLUTCH CONTROL OP-Mode : substitute clutch • check engine retarder torque
• transmission input torque wrong control • check speed sensors
• engine retarder torque wrong
• speed signal(s) defective

4 measuring of resistance at actuator/sensors and cable
4.1 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)
4.2 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

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ZF FRIEDRICHSHAFEN Aktiengesellschaft

Benennung: fault codes Nr.: DIN Seite 1

document created for customer "Hyundai construction machineries" 2011-02-21

TE-AB Seite 2 von 38

o.c. open circuit

(special symbols a-h)

1.3 Display during operation

TE-AB Seite 3 von 38

TE-AB Seite 4 von 38

1.4 Display during AEB-Mode

TE-AB Seite 5 von 38

1.5 Display during Inchpedal Calibration

TE-AB Seite 6 von 38

2 definition of operating modes

SUBSTITUTE CLUTCH CONTROL:

TE-AB Seite 7 von 38

3 table of fault codes

TE-AB Seite 8 von 38

TE-AB Seite 9 von 38

TE-AB Seite 10 von 38

TE-AB Seite 11 von 38

TE-AB Seite 12 von 38

TE-AB Seite 13 von 38

TE-AB Seite 14 von 38

TE-AB Seite 15 von 38

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

TE-AB Seite 16 von 38

57 5290 9 EEC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller

58 5300 9 EEC3 TIMEOUT OP-Mode: substitute clutch • check EEC controller

59 5310 2 AEB-REQUEST AND PARKBRAKETEST no reaction • check programming of vehicle controller

65 5430 2 ENGINGE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller

TE-AB Seite 17 von 38

6E 5470 2 EEC2 TIMEOUT no reaction, • check EEC controller

TE-AB Seite 18 von 38

TE-AB Seite 19 von 38

TE-AB Seite 20 von 38

CONVERTER LOCK UP CLUTCH

TE-AB Seite 21 von 38

TE-AB Seite 22 von 38

TE-AB Seite 23 von 38

TE-AB Seite 24 von 38

TE-AB Seite 25 von 38

TE-AB Seite 26 von 38

TE-AB Seite 27 von 38

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

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

TE-AB Seite 28 von 38

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

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

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

TE-AB Seite 29 von 38

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

B7 5700 0 OVERTEMP SUMP no reaction • cool down machine

BA 5730 0 DIFFERENTIAL PRESSURE OIL FILTER no reaction • check oil filter

BC 5745 15 OVERSPEED OUTPUT No reaction

TE-AB Seite 30 von 38

TE-AB Seite 31 von 38

TE-AB Seite 32 von 38

CA 5790 9 ENGINE_RETARDER CONFIG_TIMEOUT OP-Mode: substitute clutch • check EEC controller

CB 5800 9 ERC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller

TE-AB Seite 33 von 38

TE-AB Seite 34 von 38

TE-AB Seite 35 von 38