Grúa Tadano Faun ATF 130 G5

Simple troubleshooting D1-1.
Engine
Engine-specific faults and their remedy are given in the operating manual of the engine manufacturer.
Fault Possible cause Rectification
The engine cannot be started. A gear has been engaged. Set the gear level to the neutral
(For other causes, see the position "N".
Electrical equipment section.)

No electrical connection between Switch on the battery main switch.
the battery and the consumer.
The key-operated switch is at an Set the key-operated switch to

incorrect switch position. switch position 1 (carrier).
The engine is running irregularly or The air cleaner is contaminated. Replace the filter insert; clean the
the power is too less. filter head.
Air-inlet pipes are leaky. Check the inlet system for leak
tightness, tighten the hose clamps.
The injection system and the turbo Get it checked in a specialist

charger are not functioning workshop.
correctly.
Excessive coolant temperature Cooler fins are contaminated. Clean the fins by blowing with
even if the engine is not loaded compressed air or a steam-jet air
(The temperature gauge shows ejector.
over 100 °C).

Drain plug loosened or leaky. Tighten the drain plug and replace
the sealing tape if required; fill the
coolant.
Coolant level is too low (indicator Leaky cooling water hose Tighten the hose clamps.
on the CMV display lights up). connections
The pressure relief valve of the Check the functioning of the

expansion tank is defective. pressure relief valve and replace it
if required.
Porous cooling water hoses. Replace all cooling water hoses.
Fill the remaining volume of cooling

water.
The engine cannot be stopped. Electrical connections are loose or Insert the cable lugs or replace the
the switch is defective. switch.
ATF130G-5 2046102
04-10 Engine
1/1
Simple troubleshooting D1-1.2
Gearbox
For instructions and the error list, refer to the operating manual (gearbox and Intarder) provided by the
gearbox manufacturer
Keep the following in mind before reading the error codes:
▪ Stopping the mobile crane
▪ Stopping the engine
▪ The gear lever in the neutral position
▪ Engage the parking brake
▪ Switch on the battery main switch
▪ Ignition on
– Apply the service brake
– Move the jogging lever to the left
Error codes are displayed on the gearbox display.
ATF130G-5 2046102
04-10 Gearbox
1/1
Transfer gearbox
The on-road gear to the off-road Pneumatic switch pressure is too Supply pressure of the
gear switchover is not possible. low. compressed air system (at least 6
bar (87 PSI)).
The rocker tip switch or electrical Replace the switch and check the
connections are defective or loose. connections.
The solenoid valve is defective. Replace the valve.
The change-over valve is in the Set the change-over valve to the

neutral position. on-road gear.
The vehicle cannot be moved. The change-over valve is in the Set the change-over valve to the
neutral position. on-road gear.
The transfer gearbox becomes too The oil level is too low. Checking leak tightness. Top up
hot. oil.
Incorrect oil types. Follow the oil recommendation and

replace the oil if required.
ATF130G-5 2046102
04-10 Transfer box
1/1
Differential locks, axles and drive
Differential locks and the 2nd axle Pneumatic switch pressure is too Supply pressure of the
drive (10x8) cannot be activated. low. compressed air system (at least 6
bar (87 PSI)).
The rocker tip switch or electrical Replace the switch and check the
connections are defective or loose. connections.
The solenoid valve is defective. Replace the solenoid valve.
Drive units generate humming The oil level is too low. Check the leak tightness, top up
noises. oil.
Incorrect oil types. Follow the oil recommendation and

replace the oil if required.
Balancing plates on propeller Replace the propeller shafts.

shafts are missing.
Propeller shafts are deflected. Replace the propeller shafts.
ATF130G-5 2046102
04-10 Differential locks, axles and drive
1/1
Chassis hydraulic system - general
Excessive noises of the hydraulic Hydraulic pump is defective. Repair or replace the hydraulic
pump. pump.
The inlet pipe of the hydraulic oil Clean the hydraulic oil tank.
tank is clogged.
Hydraulic pump is sucking air. Stop the hydraulic pump

immediately. Check the leak
tightness and the oil level of the
hydraulic system and top up oil if
required.
Intermittent operation of the Air in the hydraulic system. Check the oil level, bleed the
hydraulic system. hydraulic cylinders.
The hydraulic pump bracket is Tighten the screws.

loose.
The suction pipe is leaky Tighten the screw couplings,

replace the gaskets.
Oil in the hydraulic oil tank lathers. Check the hydraulic oil level; top
up oil if required.
The pump pressure is incorrect. Check the pressure at the test

connection.
The valve block or solenoid valves Repair the valve block or replace
and pressure limiting valves of the the valves in the block.
valve block are defective.
Worn-out or damaged hydraulic Replace the hydraulic cylinders.

cylinders.
The hydraulic system does not Control pressure is too low. Check the pressure at the test
deliver the complete output. connection.
Pressure limiting valves or solenoid Remove the valves, check them for
valves are contaminated or contamination and replace them if
defective. required.
ATF130G-5 2046102
04-10 Chassis hydraulic system - general
1/2
The oil viscosity is incorrect. Fill in the prescribed oil depending

on the ambient temperature.
Hydraulic oil temperature is too The oil cooler is contaminated. Cleaning the oil cooler.
high (the symbol on the CMV (For other possible causes, see the
display lights up). Electrical system section.)
ATF130G-5 2046102
04-10 Chassis hydraulic system - general
2/2
Suspension hydraulics
The axle suspension cannot be The rocker switch is defective or Replace the rocker tip switch;
blocked; the symbol does not light the electric cable is broken. check the cable connection.
up.
The key-operated switch is at an Set the key-operated switch to
incorrect switch position. switch position 2 (superstructure
operation).
The fuse is defective. Replace the fuse.
The suspension cannot be blocked The valve block and/or solenoid Replace the valve block and/or the
even if the pilot lamp is lit up. valves in the valve block are solenoid valves (conduct the
defective (blocking valve on every electrical test if required).
cylinder).
The suspension block is defective. Replace the valve block.
The front axle lateral leveling does The fuse is defective. Replace the fuse.
not actuate.
The electro-hydraulic ball valve is Replace the ball valve.
defective (front axle).
The lock pin in the superstructure Check the pin.

is not retracted completely; the
proximity switch is not actuated.
The proximity switch is defective. Replace the proximity switch.
The leveling valve is defective Replace the valve.

(front axles).
Check the solenoid valve on the Replace the solenoid valve.

blocking valves of front axles.
The axle blocking cylinder lowers. The valve block of the axle Replace the valves and gaskets.
blocking cylinder is leaky.
The screw coupling is leaky. Check the screw coupling for firm
fit.
Leveling valves are leaky or Replace the valve.

defective.
ATF130G-5 2046102
04-10 Suspension hydraulics
1/2
Cylinder is defective. Replace the cylinder.
The hydraulic accumulator is Check the pre-charging pressure

defective. and replace the accumulator if
required.
DANGER! Before checking the

pressure, the accumulator must be
de-pressurized on the oil-side.
Check the pressure through the

test connection on the valve block
of every cylinder.
The suspension system has an air Bleed by lowering the vehicle

lock. multiple times and actuating the
leveling.
Hydraulic hoses are porous. Replace the hydraulic hoses.
The suspension is too hard. The nitrogen accumulator pressure Check the accumulator pressure.
in the hydro-accumulator is not DANGER! Before checking the
adequate. pressure, the accumulator must be
de-pressurized on the oil-side.
Set the pre-charging pressure or

get it filled in a specialist workshop.
The suspension is too hard. The hydro-accumulator is leaky. Replace the accumulator.
Solenoid valves in the valve block Replace the solenoid valves.

of every cylinder are defective.
ATF130G-5 2046102
04-10 Suspension hydraulics
2/2
Inclination adjustment and leveling
The inclination of the mobile crane The rocker tip switch is defective. Replace the rocker tip switch.
cannot be adjusted and the crane
The axle suspension is not blocked Actuate the rocker switch (the
cannot be lowered.
using the rocker switch. symbol must light up).
The valve block or the solenoid Check the valve block and replace
valve in the block is defective. the valve if required.
The return pipe does not have any Check the reflux to the hydraulic oil
flow. tank (including bleeding).
Leveling is not possible. The axle suspension is still blocked Disable the axle blocking using the
using the rocker switch. rocker switch (the symbol should
not light up).
The rocker tip switch is defective. Replace the rocker tip switch.
The leveling valve is defective. Replace the valve.
The valve block is defective or the Replace the valve block.

pressure control valve in the valve
block is defective.
The suspension cylinder is leaky or Check the leak tightness of

the screw coupling is loose. cylinders; check the screw
couplings and tighten them if
required.
The pump pressure is too low. Check the pressure at the test
connection; if the pressure is too
low, get the fault repaired in a
specialist workshop.
ATF130G-5 2046102
04-10 Inclination adjustment and leveling
1/1
Outrigger hydraulic system
The outrigger cannot be extended The key-operated switch is in the Set the key-operated switch in the
or retracted. incorrect switch position. chassis to position 2.
Lock pins are not yet inserted. Remove the pins from the beam.
The outrigger electronic system is Get the error corrected in a

defective. specialist workshop.
The fuse is defective. Replace the fuse.
The "Beam-outrigger change-over" Replace the relay.

relay is defective.
The outrigger beam/jack cylinder Replace the solenoid valve.

solenoid valve is defective.
The diode is defective. Replace the diode.
The pump is defective. Replace the pump.
The pressure limiting valve in the Clean the valve, check it and
valve block is contaminated or replace it if required.
defective.
The jack cylinder retracts when the The solenoid valve is defective. Replace the valve.
device is supported.
The lock control valve of the Clean the valve, check it and
cylinder is leaky or contaminated. replace it if required.
The piston seal of the cylinder is Replace the seal set and, if
defective. required, the cylinder.
Air in the cylinder or line. Bleed the cylinder.
The retracted outrigger cylinder The lock control valve of the Clean the valve, check it and
moves down. outrigger cylinder is leaky or replace it if required.
ATF130G-5 2046102
04-10 Outrigger hydraulic system
1/2
contaminated.
The line or the hose is leaky. Check the screw couplings and
tighten them if required; replace
the hose.
The solenoid valve is defective. Replace the valve.
The outrigger can be retracted or The engine speed is too low. Increase the speed.
extended only slowly.
The reflux to the hydraulic oil filter Check the return pipe and clean it
or the hydraulic oil filter is if required; replace the return filter.
contaminated.
The inlet pipe of the pump is leaky. Check the screw couplings and
tighten them if required.
The solenoid valve is jammed. Replace the valve.
The viscosity of the hydraulic oil is Fill in the prescribed oil depending
too high. on the ambient temperature.
ATF130G-5 2046102
2/2
Steering
Steering - mechanical part
Excessive backlash of the steering The track rod connection is loose. Reset and tighten.
wheel.
Backlash in the steering gear. Check the backlash and reset it if
required.
Ball-and-socket joints of the track Replace the ball-and-socket joints.

or steering rod have a backlash.
Adjustable steering wheel - Check the rocker tip switch on the

steering column is loose. steering wheel and actuate it.
Excessive tire wear, wheels Incorrect track. Set the track to ± 0.

wobble.
Incorrect air pressure. Check the pressure and correct it if
required.
Defective wheel bearing. Check the wheel bearing and

replace it if required.
Lateral and radial movements of Check in a specialist workshop and

the rim or the disk wheel. replace the rims in the specialist
workshop if required.
The piston rod of the steering Replace the steering cylinder or

cylinder or the track rod is bent. the track rod.
Wheel nuts are loosened. Check the wheel nuts for firm fit
and tighten them if required.
Steering - hydraulic/electrical part
The steering does not move The feed to the steering Check the rated pressure at the
freely. hydraulic pump and the test connections using the
pressure are too low. pressure gauge
M1 = 1st steering circuit and
M2 = 2nd steering circuit.
ATF130G-5 2046102
1/2
The piston sealing ring of the Replace the steering cylinder.

steering cylinder is damaged.
The piston rod of a steering Replace the steering cylinder.

cylinder is bent.
The Ist or IInd circuit of the Replace the pump.

pump is defective.
The valve block or the multiway Repair, clean the multiway valve
valve in the block is defective or or replace it.
contaminated.
Steering block is leaky. Check the screw couplings and

gaskets; top up oil if required.
The pilot lamp of a steering The flow indicator is defective. Replace.

circuit lights up.
The flow limiting valve is Replace.
defective.
The hose assembly is leaky. Replace the hoses.
The screw coupling in the Check the screw couplings for

steering system is loose, oil firm fit and gaskets; top up oil if
loss. required.
Excessive noises in the steering The pump is defective. Repair the pump or replace it.
pump.
The pump is sucking air. Check the leak tightness and
screw couplings.
The suction pipe is leaky. Check the screw couplings.
Rear axles cannot be steered The pump pressure is too low Check the pressure at the test
(crab steering). (the pump is defective; check connection.
the leak tightness, the return
filter, etc.).
The emergency pump pilot lamp The flow indicator or the flow Replace.
lights up even when both limiting valve is defective.
steering circuits are intact.
The emergency steering pump Replace.
is defective.
ATF130G-5 2046102
2/2
Braking system
The supply pressure is not reached The air compressor delivery output Conduct the functional check in a
(the "Service brake" warning lamp is too low. specialist workshop.
lights up). The reading on the CMV
The pressure governor does not Conduct the functional check in a
display is below 5.5 bar (79.8 PSI).
switch off or blows off continuously. specialist workshop. Check the
setting of the switch-off pressure.
The compressed air system is Get it replaced in a specialist

leaky. workshop.
The air tank drain valve is Replace the drain valve.

defective.
Defect in the spring-loaded cylinder Conduct the check in a specialist

circuit. workshop.
The "Service brake" warning lamp The pressure switch in the BBA Replace the switch.
lights up even when the indicator (service brake circuit) I or II is
on the CMV display shows a value defective.
greater than 5.5 bar.
The brake cylinders (spring-loaded The parking brake is not released
section) are not aerated completely.
completely.
Defect in the spring-loaded cylinder Conduct the check in a specialist

circuit, function of valves. workshop.
Poor braking effect despite the Brake linings worn out (the "Brake Get the brake linings replaced in a
correct supply pressure. lining wear" symbol lights up or specialist workshop.
contaminated (oily).
High lining wear; brakes become No or very little air gap between Conduct the check in a specialist
hot. the brake lining and the brake disc. workshop.
The breather of brake valves or Clean

brake cylinders is contaminated.
The foot pedal has no or very little Check the setting and correct it.
backlash.
The Wheel sensors warning lamp Sensors, seat are not correct; Check and correct if required;
ATF130G-5 2046102
04-10 Braking system
1/2
(monitored by the ABS symbol) cable connections are not proper. replace the damaged parts.
does not go out after switching on Electric cables are damaged.
the ignition. The driving and
braking behavior changes. The electronics system is Conduct the check in a specialist
defective. workshop.
ATF130G-5 2046102
04-10 Braking system
2/2
Electrical system
Batteries are not or inadequately Batteries are defective. Replace the batteries.
charged.
Cables are detached or defective. Tighten or replace the cable.
The battery main switch is not Check the switch and replace it if
switched on correctly or the cable necessary.
is loose. Check the cable and tighten it.
The generator is defective. (See: Check the generator and replace it

the "Generator" symbol on the if required.
CMV display lights up or flashes
when the engine is running.)
The "Generator" symbol on the The cable has a ground connection Insulate and tighten the cable.
CMV display lights up or flashes or is loose.
when the engine is running.
The controller is defective. Replace the controller.
The generator is defective. Check the generator and replace it

if required.
No current when the ignition is No connection between the Switch on the battery main switch
switched on. negative pole of the battery and the (actuate the rocker switch on the
ground. instrument panel).
The battery relay is defective or the Replace the battery relay and/or fix
cables are loose. the cables.
The ground strap is loose. Fix the ground strap.
The engine cannot be started. The ignition starter switch is Replace the switch.
defective.
The relay is defective. Replace the relay.
Batteries are defective or Replace or charge the batteries. If

discharged. the batteries are replaced, ensure
that the ones with the same
capacity are used.
The gear lever is not in the neutral Set the gear lever to the neutral
ATF130G-5 2046102
04-10 Electrical system
1/2
position. position.
The start block relay is defective if Replace the relay.

the gear lever is in the neutral
position.
Hydraulic oil temperature is too The temperature switch of the Replace the switch.
high (the symbol on the CMV cooler motor is defective.
display lights up).
The cooler controller relay is Replace the relay (also see the
defective. Relay chart, chapter C
Maintenance and repair of carrier).
The cooler motor or the fuse is Replace the motor or the fuse (also
defective. see Fuses, chapter C Maintenance
and repair of carrier).
ATF130G-5 2046102
04-10 Electrical system
2/2
Eddy-current brake
The eddy-current brake does not The hand switch or the contact is Get the switch replaced in a
respond when the hand switch is defective. specialist workshop.
actuated; the warning lamp does
The fuse is defective. Replace the fuse in the fuse-box.
not light up.
The relay or the diode in the relay Get the relay box checked in a
box is defective. specialist workshop; replace the
defective parts.
The fuse in the relay box is Replace the fuse.

defective.
The fuse in the battery Replace the fuse.

compartment is defective.
Poor braking effect in all gear Insulation and condition of wiring, Get it checked in a specialist
levels. or the ground connection is loose. workshop and change the wiring if
required.
The backlash between the rotors Get it measured, tested and

and stator is too high, the air gap is repaired in a specialist workshop.
too large, silent blocks are worn
out.
Coils of the stator are defective. Get it measured, tested and

repaired in a specialist workshop.
Current consumption of batteries is The hand switch is not in the "0" Set the hand switch to the "0"
too high when the vehicle or the position. position. Switch off the main switch
engine is at a standstill. As a result, of the battery in case of longer
eddy-current brake is heated. standstill periods (e.g. overnight).
The "Eddy-current brake" symbol Incorrect control in the eddy Get it tested and repaired in a
lights up when the steering column current brake. specialist workshop.
switch is not actuated.
ATF130G-5 2046102
04-10 Eddy-current brake
1/1
Emergency operation D1-2.1
Towing
Towing the mobile crane is permitted only after a prior consent by the After-Sales Service.
Setting the distribution gear to the “Neutral” position
The transfer gearbox must be set to the "Neutral" position so that the vehicle can be towed.
The change-over valve is provided between the 3rd and the 4th axles on the left side of the vehicle.
1 Lever towards the front in the driving direction 3 Cir clip

= driving position
2 Lever towards the back opposite to the

driving direction = neutral position
Change the transfer gearbox to the neutral position "N"

a) Bend the cir clip (3) upwards.
b) Set the reversing lever from position (1) to position (2).
⇨ After changing over to the neutral position, the on-road or off-road gear symbol in the Control & Service
System deactivates.
After the towing process or after repairing the mobile crane, reset the reversing lever of the transfer gearbox
to the driving position (1) and bend back the cir clip (3).
ATF130G-5 2046102
04-10 Towing
1/1
Emergency control of outriggers
In case of malfunctions in different control or actuating elements or faults in the electric system, failed
functions can sometimes be executed using emergency controls.
1 Solenoid valves for the outrigger emergency 3 Solenoid valves for the emergency control of
control the rear-axle steering
A Extend the outrigger cylinder pushbutton G Right turn pushbutton for the 5th axle
B Extend the outrigger beam pushbutton H Left turn pushbutton for the 5th axle
C Retract the outrigger cylinder pushbutton I Right turn pushbutton for the 4th axle
D Retract the outrigger beam pushbutton J Left turn pushbutton for the 4th axle
2 Solenoid valve for the emergency control of K Right turn pushbutton for the 3rd axle
oil supply
E Oil supply pushbutton L Left turn pushbutton for the 3rd axle
F Knurled screw for restricting the oil pressure
ATF130G-5 2046102
04-10 Emergency control of outriggers
1/2
Prerequisites:
▪ The vehicle is secured against inadvertent rolling.
▪ Parking brake (hand brake) is engaged.
▪ Gear has been set to the neutral position "N".
▪ The engine has been started.
▪ The engine speed has been set to the idling speed.
Retracting/extending the outrigger cylinder

a) Press the pushbutton (E) and keep it pressed until the outrigger cylinder is retracted or extended (by the
assistant).
b) Press the pushbutton (A) to retract the outrigger cylinder or press the pushbutton (C) to extend the
outrigger cylinder.
Retracting the outrigger beams

a) Press the pushbutton (E) and keep it pressed until the outrigger beam is retracted (by the assistant).
b) Press the pushbutton (D) to retract the outrigger beam.
Extending the outrigger beams

a) Loosen the knurled screw (F).
b) Press the pushbutton (E) and keep it pressed until the outrigger beam is extended (by the assistant).
c) Press the pushbutton (B) to extend the outrigger beam.
d) Tighten the knurled screw (F).
ATF130G-5 2046102
04-10 Emergency control of outriggers
2/2
Emergency control of the rear-axle steering
WARNING
Risk of crushing!
Rear axles are steered when the pushbuttons (G to L) are actuated and
there is a risk of crushing.
a) Do not wear loose clothes.
b) Actuate the pushbutton carefully.
Prerequisites:
➢ The vehicle is secured against inadvertent rolling.
➢ Parking brake (hand brake) is engaged.
➢ Gear has been set to the neutral position "N".
a) Unlatch the front cover in the driver's cab, open and secure it.
b) Pull out the plug from socket X511 and insert it into the free socket X512.
ATF130G-5 2046102
04-10 Emergency control of the rear-axle steering
1/2
G Right turn pushbutton for the 5th axle H Left turn pushbutton for the 5th axle
I Right turn pushbutton for the 4th axle J Left turn pushbutton for the 4th axle
K Right turn pushbutton for the 3rd axle L Left turn pushbutton for the 3rd axle
c) Start the engine and set the engine speed to idling speed.
d) Bring the axles to the straight position. For this, press the pushbutton (G) or (H) for the left/right turn of
the 5th axle; press the pushbutton (I) or (J) for the left/right turn of the 4th axle; press the pushbutton (K)
or (L) for the left/right turn of the 3rd axle.
e) Turn off the engine.
f) Pull out the plug from socket X512 again.
g) Deactivate the upshifting lock. For this, pull out the plug from socket X515.
After completing the repairs, reinsert the plug into its initial position.
ATF130G-5 2046102
2/2
Emergency engine start/stop function
WARNING
Risk of injuries due to rotating parts!
If you come in contact with rotating parts when the engine is running or
if you come too close to them, parts of your body may get sucked in and
get crushed or tear off.
a) Remove the engine covers only in case of an emergency or when
carrying out the maintenance activities.
b) Carry out maintenance work only when the engine is not running.
c) When working in the immediate vicinity of the engine, ensure that
you do not come in contact with rotating parts or come too close to
them.
d) Do not wear loose clothes; tie long hair and protect them with a hair
net.
CAUTION
Risk of burns!
The engine and lines are hot when the engine is running.
a) Do not touch hot parts when operating the emergency start/stop
function of the engine.
CAUTION
The emergency start/stop function of the engine may only be used to
drive the mobile crane out of a danger zone. It may not be used for
longer drives.
ATF130G-5 2046102
04-10 The emergency start/stop function of the engine
1/2
1 Engine start pushbutton 2 Engine stop pushbutton
Pushbuttons for the emergency start/stop function are provided at the front side of the engine.
Starting/stopping the engine using the emergency start/stop function

Prerequisites:
➢ Parking brake is engaged. Secure the mobile crane using wheel chocks if required.
➢ The ignition in the carrier has been switched on.
➢ The gear is in the neutral position "N".
➢ The engine cover has been removed.
a) Starting the engine: Press the engine start pushbutton (1).
⇨ The engine will start and run at the idling speed.
b) Stopping the engine: Press the engine stop pushbutton (2) or press the engine start pushbutton (1)
again.
⇨ The engine will stop.
Starting the engine and increasing the engine speed:

a) Press the engine start pushbutton (1) and keep it pressed.
⇨ The engine will start and run in the idle mode. The speed increases to the maximum within three
seconds of starting the engine.
b) Release the engine start pushbutton (1) after reaching the required engine speed.
⇨ The engine will continue to run at the current engine speed.
ATF130G-5 2046102
2/2
Fuel hand pump – fuel filter with a water separator
The fuel filter with a water separator and a built-in hand pump are provided on the right side of the vehicle.
If dirt and/or air enter the fuel system, replace the filter element, clean the fuel system and bleed it.
The system needs to be bled and fuel needs to be fed using the hand pump
▪ after emptying the fuel tank,
▪ if leakages develop in the fuel system,

▪ after replacing the fuel filter (for replacing the filter, see Part "Servicing and maintenance of carrier")
1 Bleed screw 2 Pump tappet
Bleeding the system and feeding the fuel

Prerequisite:
➢ Adequate fuel has been topped up.
➢ Leakages have been rectified.
➢ Filter cartridge has been replaced as described in Part "Servicing and maintenance of carrier".
a) Loosen the bleed screw (1).
b) Actuate the pump tappet (2) until the fuel emerging is free of air bubbles (collect the overflowing fuel in a
suitable container and pour it in the fuel tank).
c) Then tighten the vent screw (1) firmly.
d) Start the engine. In case of starting troubles, ask an assistant to actuate the pump tappet until the engine
starts running.
ATF130G-5 2046102
04-10 Fuel hand pump – fuel filter with a water separator
1/1
Fan drive
The speed of the fan used for cooling the engine coolant is controlled by the electronic engine controller
"depending on the engine speed".
A valve block is provided below the cover (1). The plug (2) must be inserted.
If the electronic engine controller fails or is defective, it may so happen that the fin runs at a reduced speed
and the cooling effect for the engine is not achieved.
In order to achieve the cooling effect, you can disconnect the plug (2) and set the control to the uncontrolled
"engine speed-dependant" mode.
The "Coolant level" icon should not light up and the pointer of the "engine temperature display" instrument
should not be in the critical range even in case of the engine speed dependant" mode.
ATF130G-5 2046102
04-10 Fan drive
1/1
Overheated drive unit
If the temperature display shows a value of 95 °C or higher, the warning light for the engine malfunction
lights up and an alarm signal for the engine/steering malfunction is triggered.
NOTICE
Reheating the drive unit!
Do not stop the engine immediately. The water temperature may
increase steeply and cause damage under certain conditions.
a) Stop the mobile crane at a safe place and let the engine run at the idling speed.
b) Stop the engine only when the temperature display of the engine has reached a lower value.
Filling the coolant
WARNING
Risk of injuries due to hot coolant!
The cooling system is under excess pressure. Hot coolant can gush out
when opening and scald your skin and eyes.
➢ The coolant tank may be opened only when the coolant temperature
drops below 90 °C.
a) Loosen the cap slowly using safety gloves or a cloth and release the
excess pressure completely before opening.
ATF130G-5 2046102
04-10 Overheated drive unit
1/2
NOTICE
Cold shock due to excessively cold coolant!
If excessively cold water is filled in the overheated engine too quickly,
the engine may get damaged. Always fill the cooling water gradually.
If the coolant is not available, tap water can also be used temporarily.
The tap water must be replaced with a regular coolant and, if required,
the cooling system must be cleaned in the nearest workshop.
a) Remove the cap (1) of the coolant tank. If the coolant level is too low, fill the coolant in the coolant tank
up to the 'Half' mark.
b) Check whether the coolant is flowing out of the engine. Check whether the V-belt is damaged and the
radiator is clogged. Other problems may occur.
ATF130G-5 2046102
04-10 Overheated drive unit
2/2
Using the shunt cables
NOTICE
Overvoltage!
Erroneous execution of these processes may damage the generator.
The repair vehicle must be equipped with a 24 V system whose power
must be equivalent to at least the broken down vehicle (i.e. the
discharged battery).
Do not touch the bare parts of cable clamps and ensure that the plus
cable (+) does not come in contact with any metal part of the vehicle
body.
If the engine does not start owing to the discharged battery, you can start the engine using the batteries of
another vehicle and jump leads. Only the specially designed jump leads having an adequate cross-section
must however be used.
Batteries are provided behind the driver's cab on the left side of the vehicle.
Receiver: vehicle that cannot be started owing to the discharged starter battery.
Donor: vehicle that can be started owing to the charged battery.

➢ Secure the receiver and donor vehicles if required (warning triangle, accident prevention, traffic safety).
➢ Connect the batteries to the system in the vehicle as prescribed. An interruption may damage the
generator rectifier.
➢ Both vehicles must be equipped with 24 V systems. The total capacity (Ah) of batteries of the donor
vehicle may not be considerably less than that of the receiver.
➢ Position the donor vehicle such that it comes closer to the batteries. Vehicle bodies should not touch.
There should not be any connection between the vehicles in order to avoid a possible current flow.
ATF130G-5 2046102
04-10 Using the shunt cables
1/3
a) Open the access to the batteries (battery cover, pole protection caps).
b) Switch off the radio and other devices that consume energy (in the donor and receiver vehicles).
Connecting the jump lead
Follow the sequence for connecting the jump lead.
1 Plus pole (+) of the receiver battery 4 Minus pole (-) of the receiver battery
2 Plus pole (+) of the donor battery 5 Donor battery
3 Minus pole (-) of the donor battery 6 Receiver battery
a) Connect the red clamp (+) of the jump lead to the plus pole (+) of the receiver battery.
b) Connect the other red clamp (+) to the plus pole (+) of the donor battery.
c) Connect the black clamp (-) of the jump lead to the minus pole (-) of the donor battery.
d) Connect the other black clamp (-) to the minus pole (-) of the receiver battery.
e) Start the engine of the donor vehicle and let it run.
f) Attempt to start the receiver: switch on the battery main switch, switch on the ignition and start the engine.
g) After starting the engine successfully, let it run for a few minutes.
Detaching the jump lead
Follow the sequence for detaching the jump lead
CAUTION
Risk of burns
Clamps of the jump lead may heat up due to high currents.
a) Do not touch the bare parts of the cable clamps.
ATF130G-5 2046102
2/3
a) Detach the black clamp (-) from the minus pole (-) of the receiver battery.
b) Detach the black clamp (-) from the minus pole (-) of the donor battery.
c) Detach the red clamp from the plus pole (+) of the donor battery.
d) Detach the red clamp from the plus pole (+) of the receiver battery.
e) Stow away the jump lead, close the battery cover and pole protection caps.
f) Remove the warning triangles/safety aids and stow them away.
g) Let the engine run continuously for a specific time to charge the battery.
ATF130G-5 2046102
3/3
Error code list D1-3.1
Engine error code screen
• This page is just an example, as it is not possible to record all faults of the engine
• The error code must still be read out using the Minidiag
• Only errors occurring during operation will be displayed here
• If the error is generated before the CAN Bus is active (the first 7s after “ignition ON”), the error is
not recorded and cannot be displayed here. In this case, the Minidiag must be used.
• No error codes are saved
Item 1:
Item 3:
Item 2:
• Item1 = Error code which is present at the moment

• Item2 = Explanation of the error present above
• Item3 = To scroll through the errors which are currently present, actuate the central menu button
• Should errors be generated permanently (at intervals of 1 second), the screen can be stopped via the
lower menu button on the right. To read out the error description ...
Error Code Device description

54/3 decompression valve MBR_KD open circuit
54/4 decompression valve MBR_KD shorted to ground
84/3 vehicle speed signal C3 open circuit
84/4 vehicle speed signal C3 shorted to ground
84/14 vehicle speed signal C3 value not plausible
91/0 analog accelerator pedal accelerator pedal not adjusted
91/2 analog accelerator pedal voltage not plausible
91/3 analog accelerator pedal voltage too high or shorted to battery voltage
91/4 analog accelerator pedal AFPS voltage too low or shorted to ground
98/0 oil level oil level too high
98/1 oil level low oil level
98/14 oil level oil level too low
100/1 oil pressure sensor low oil pressure
100/14 oil pressure sensor oil pressure too low
107/0 air filter sensor air pressure too high
107/3 air filter sensor open circuit
107/4 air filter sensor shorted to ground
110/0 coolant temperature high coolant temperature
110/14 coolant temperature coolant temperature too high
111/1 coolant level low coolant level
111/3 coolant level open circuit
111/4 coolant level shorted to ground
158/0 terminal 15 (ignition) over voltage
158/1 terminal 15 (ignition) under voltage
558/5 idle switch (analog pedal) both switches open circuit(GAS2+ GAS1 open)
558/12 idle switch (analog pedal) both switches closed (GAS2 + GAS1 closed)
599/12 cruise control switch CC+ and CC- both switches closed
601/12 cruise control switch CC+ and CC- both switches closed
620/3 power supply analog pedal (AFP+) voltage too high
620/4 power supply analog pedal (AFP+) voltage too low
625/2 CAN link ADM2 - MR no communication with MR
625/14 CAN link ADM2 - MR one wire mode
629/12 ADM2 internal error
677/5 output relay 1 open circuit
677/6 output relay 1 shorted to ground
grid heater: no increasing boost temperature
730/0 output relay 2 after activation
730/1 output relay 2 grid heater: relay permanently closed
730/2 output relay 2 grid heater: relay permanently closed
730/3 output relay 2 voltage too high or shorted to battery voltage
730/4 output relay 2 voltage too low or shorted to ground
974/2 remote pedal HFG supplyvoltage out of range
and max. remotepedal HFGvolt.too high or shorted to
974/3 Minimum value: 4.8V value:5.2V battery voltage
974/4 remote pedal HFG voltage too low or shorted to ground
1004/3 output relay 4 open circuit
1004/4 output relay 4 shorted to ground
1005/3 output PWM pedal supply or transmis. open circuit
1005/4 output PWM pedal supply or transmis. shorted to ground
1006/3 exhaust brake valve MBR_BK open circuit
1006/4 exhaust brake valve MBR_BK shorted to ground
639/2 J1939 CAN-interface CAN identifiers ETC#1 or ACC#1 missing
1015/1 PWM accelerator pedal no supply voltage
1015/2 PWM accelerator pedal both signals missing (GAS1 and GAS2)
1015/3 PWM accelerator pedal signal GAS2, not available
1015/4 PWM accelerator pedal signal GAS1, not available
1015/5 PWM accelerator pedal accelerator pedal not adjusted
1015/6 PWM accelerator pedal idle position out of adjusted range
1015/7 PWM accelerator pedal accelerator pedal out of adjusted range

ZF FRIEDRICHSHAFEN Aktiengesellschaft
Description: techn. Kundeninformation Nr.: DIN Page 1
Degraded Modes ASTRONIC 2 4231 xxx xxx A4 of 35
This technical document may not be copied
or disclosed to third persons without
permission of ZF Index No. Date Name Film
K2 ZFN 904 M O D I F I C A T I O N S
Issued: Checked: Approved:
Name: K. Hensinger
Dept.: ST-ST
Date: 2009-10-02
Failure Reactions
FAUN SAE-CAN (GS3.3)
────────────────────────────────────────────────────────────────────────
Date Pages Remarks Date Pages Remarks

09-10-02 35 1st release
────────────────────────────────────────────────────────────────────────
Type : 4231; 4232
File : SLH_FAUN_SAE_GS33_en.DOC
ZF-Friedrichshafen AG Degraded Modes ASTRONIC 2 2009-10-02
Remark to titles in table:
Int. ZF-fault-number dec/hex - defined by ZF.
Calculated ISMA-starting gear - (0=NO, 1=YES) Intelligent Shift Management (ISMA) suggests starting gear.
ISMA available - (0=NO, 1=YES) Intelligent Shift Management available
Warning-buzzer - (0=NO, 1=YES) recommendation by ZF to activate warning-buzzer
Display spanner-symbol - (0=NO, 1=YES) recommendation by ZF to indicate spanner-symbol (Display)
Display stop - (0=NO, 1=YES) recommendation by ZF Display to indicate stop-symbol (Display)
Shift schemes of transmissions

Y6
1 Y6 3 2 R 4
10/12-Gear Scheme 16-Gear Scheme
Y4 Y5 Y4 Y5
Y2 Splitter K2
Y3 Splitter K1
Y8 Range (GP) low
Y9 Range (GP) high; Y7
Y7
R 2 1 3
2 of 35
fault-discription fault detection system reaction fault-recovery
symbol (spanner)
display service-
ISMA available
condition
ISMA Starting
display stop-
failureNo. (dec)
ASTronic ZF-
symbol
gear
2 Short circuit to ground at by ECU hardware,if output Driving: Gear remains engaged, gears with present short-circuit at failure is no longer 0 1 0 1
output stage to Y2 (Valve is activated the shift-valve outputs are blocked, engagement of chosen detected or after
Splitter; DD: high, OD: low) alternative gears is possible. Driving and shifting: If the failure RESET
occurs during shifting, gear remains engaged or ECU tries to shift
an adequate gear dependent on the current driving conditions. If this
is impossible the Main-Transmission is tried to shift to 'neutral'.
Gears with present short-circuit at the shift-valve outputs are
blocked, ECU attemps to engage the chosen alternative gears if
possible.
Splitter; DD: low, OD: high) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
Select) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
3 of 35
possible.
Shift) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
possible.
Range) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
4 of 35
Range) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
10 Short circuit to ground at by ECU hardware,if output No gearshifting possible! No neutral shifting possible! Selected gear After RESET and no 0 1 1 1
output stage to Y10 (Main is activated remains engaged; Vehicle start permitted in engaged gear. After short circuit to ground
valve) ignition on, system not available
11 Short circuit to ground at by ECU hardware,if output Warning-Buzzer permanently active After RESET and no 1 1 0 1
output stage to warning is activated short circuit to ground
buzzer (E-Module)
12 Short circuit to ground at by ECU hardware,if output ECU output switched off. No reverse light activation possible. No After RESET and no 1 1 0 1
output stage to reverse light is activated further system restrictions short circuit to ground
relay (E-Module)
13 Short circuit to ground at by ECU hardware,if output ECU output switched off. PTO1 not available. PTO1-engagement- After RESET and no 1 1 0 1
output stage to PTO 1 is activated Error will be surpressed. PTO1-request is not accepted. No further short circuit to ground
restrictions.
15 Short circuit to ground at by ECU hardware,if output no activation of output possible After RESET and no 0 0 0 1
output tADM2 is activated short circuit to ground
17 Short circuit to ground at by ECU hardware,if output ECU output switches off. Driving: Upshifts during driving are After RESET and no 0 1 0 1
output stage to Y1 (inertia is activated controlled like downshifts. Input speed will be synchronized by short circuit to ground
brake valve) engine speed. Upshifts blocked, when input target speed is below
engine idle speed. Increased shifting time. Stationary: Increased self
adjustment time. Increased shifting time when shifting out of neutral.
Increased PTO engagement time.
18 Short circuit to ground at by ECU hardware,if output ECU output switches off. Function taken on by valve Y16 (clutch After RESET and no 0 1 0 1
output stage to Y17 (valve is activated disengage fast). Decreased comfort for clutch functions. short circuit to ground
clutch disengage slow)
19 Short circuit to ground at by ECU hardware,if output ECU valve output switches off. Function taken on by valve Y14 After RESET and no 0 1 0 1
output stage to Y15 (valve is activated (clutch engage fast). Decreased comfort for clutch functions. short circuit to ground
clutch engage slow)
5 of 35
output stage to Y16 (valve is activated (clutch disengage, slow). Increased shifting time. Decreased comfort short circuit to ground
clutch disengage fast) for clutch functions.
output stage to Y14 (valve is activated (clutch engage slow). Increased shifting time. Decreased comfort short circuit to ground
clutch engage fast) for clutch functions.
22 Short circuit to ground at by ECU hardware,if output ECU output switches off. E-Modul switches off. No shift lever After RESET and no 0 0 1 1
output ADVP (wakeup is activated information. No display information (display dark), warning buzzer short circuit to ground
control signal for E-module, not available; warning lamp not available. Subsequent failures from
voltage supply to display, E-Modul will be suppressed. Output speed signal 1 will be replaced
warning lamp, warning by redundant information. Driving: Gearshifting blocked. Stationary:
buzzer, output speed sensor ECU tries to open the clutch, when coming to standstill. Neutral
1) automatically engaged at standstill. Gearshifting blocked, continued
driving not possible. System not available.
26 CAN engine configuration After timeout of the Applied substitute parameters (P1 to P7) from data application field After receiving a 1 1 0 1
timeout message, failure is set will be taken. Reduced functionality for automatic mode and start correct message or
gear calculation, if deviation of substitute parameters and real after RESET.
values is high. Target speed for downshifting can be reduced.
Quality of clutch disengagement for stopping can be reduced.
27 Error on ”engine Signal faulty or missing. Applied substitute parameters (P1 to P7) from data application field After receiving a 1 1 0 1
configuration message” will be taken. Reduced functionality for automatic mode and start correct message or
(engine configuration) gear calculation, if deviation of substitute parameters and real after RESET.
values is high. Target speed for downshifting can be reduced.
Quality of clutch disengagement for stopping can be reduced.
28 CAN signal error on ”Actual Signal faulty or missing. No calculation of driving resistance possible. No automatic After receiving a 0 0 0 1
driveline retarder - percent calculation of start off gear. When coming to standstill, medium start correct message or
torque” signal off gear will be shifted. No other functional restrictions. after RESET.
29 CAN signal error on ”Engine Signal faulty or missing. There are no downshift requests coming from retarder to increase After receiving a 1 1 0 1
coolant load increase” engine speed to improve cooling power. correct message or
signal after RESET.
30 CAN signal error: ”Driveline Signal faulty or missing. No calculation of driving resistance possible. No automatic After receiving a 0 0 0 1
retarder configuration calculation of start off gear. When coming to standstill medium start correct message or
message” off gear will be shifted. No other functional restrictions. after RESET.
6 of 35
31 Error on ”Actual engine Signal faulty or missing. No calculation of driving resistance possible. No automatic Signal available or 0 0 0 1
retarder - percent torque” calculation of start off gear. When coming to standstill medium start after RESET.
signal (ERC1_ER) off gear will be shifted. No other functional restrictions. No
information about engine brake torque. If exhaust brake is active,
shifting quality at start of shifting may be poor. Engine brake is
considered not active.
32 Error on ”Engine retarder Signal faulty or missing. No calculation of driving resistance possible. No automatic Signal available or 0 0 0 1
configuration message” calculation of start off gear. When coming to standstill medium start after RESET.
(Engine retarder off gear will be shifted. No other functional restrictions.
configuration)
33 CAN ”Engine retarder After timeout of the No calculation of driving resistance possible. No automatic After receiving a 0 0 0 1
configuration” timeout message, failure is set calculation of start off gear. When coming to standstill medium start correct message or
off gear will be shifted. No other functional restrictions. after RESET.
34 Interruption at output stage by ECU hardware,if output Driving: Gear remains engaged, gears with present short-circuit at failure is no longer 0 1 0 1
to Y2 (Valve Splitter) not activated the shift-valve outputs are blocked, engagement of chosen detected or after
alternative gears is possible. Driving and shifting: If the failure RESET
possible.
to Y3 (Valve Splitter) not activated the shift-valve outputs are blocked, engagement of chosen detected or after
possible.
7 of 35
to Y4 (Valve Select) not activated the shift-valve outputs are blocked, engagement of chosen detected or after
possible.
to Y5 (Valve Select) not activated the shift-valve outputs are blocked, engagement of chosen detected or after
possible.
to Y6 (Valve Shift) not activated the shift-valve outputs are blocked, engagement of chosen detected or after
possible.
to Y7 (Valve Shift) not activated the shift-valve outputs are blocked, engagement of chosen detected or after
possible.
8 of 35
to Y8(Valve Range) not activated the shift-valve outputs are blocked, engagement of chosen detected or after
possible.
to Y9 (Valve Range) not activated the shift-valve outputs are blocked, engagement of chosen detected or after
possible.
42 Interruption at output stage by ECU hardware,if output No gearshifting possible! No neutral shifting possible! Selected gear No interruption and 0 1 1 1
to Y10 (Main valve) not activated remains engaged; Vehicle start permitted in engaged gear. After output not activated
ignition on, system not available or after RESET.
43 Interruption at output of the by ECU hardware,if output Warning -Buzzer can not be activated No interruption and 0 0 0 1
e-module to the warning not activated output not activated
buzzer or after RESET.
44 Interruption at output of the by ECU hardware,if output No reverse light activation possible. No further system restrictions No interruption and 0 0 0 1
shift-lever to the reverse not activated output not activated
light relay. or after RESET.
45 Interruption at output stage by ECU hardware,if output PTO1 not available. PTO1-engagement-Error will be surpressed. No interruption and 1 1 0 1
to PTO 1 not activated PTO1-request is not accepted. No further restrictions. output not activated
or after RESET.
47 Interruption at output to by ECU hardware,if output Ausgang nicht aktivierbar No interruption and 0 0 0 1
ADM 2 not activated output not activated
or after RESET.
9 of 35
49 Interruption at output stage by ECU hardware,if output Driving: Upshifts during driving are controlled like downshifts. Input No interruption and 0 1 0 1
to Y1 (inertia brake valve) not activated speed will be synchronized by engine speed. Upshifts blocked, output not activated
when input target speed is below engine idle speed. Increased or after RESET.
shifting time. Stationary: Increased self adjustment time. Increased
shifting time when shifting out of neutral.
50 Interruption at output stage by ECU hardware,if output Function taken on by valve Y16 (clutch disengage fast) Decreased No interruption and 0 1 0 1
valve Y17 (clutch disengage not activated comfort. output not activated
slow) or after RESET.
51 Interruption at output stage by ECU hardware,if output Function taken on by valve Y14 (clutch engagement slow) No interruption and 0 1 0 1
valve Y15 (clutch engage not activated Decreased comfort. output not activated
slow) or after RESET.
52 Interruption at output stage by ECU hardware,if output Function taken on by valve Y17 (clutch disengage slow). Increased No interruption and 0 1 0 1
valve Y16 (clutch disengage not activated shifting time. Decreased comfort. output not activated
fast) or after RESET.
53 Interruption at output stage by ECU hardware,if output Function taken on by valve Y15 (clutch engage slow). Increased No interruption and 0 1 0 1
to large Y14 (clutch engage not activated shifting time. Decreased comfort. output not activated
fast) or after RESET.
54 Interruption at output ADVP by ECU hardware,if output 1. After ignition off/on. Failure will be detected during initialization. E- No interruption or 1 1 1 1
(wakeup control signal for not activated (detection Modul does not switch on. No shift lever information. No display after RESET.
E-module, voltage supply to only during initialization) information (display dark), warning buzzer not available; warning
display, warning lamp, lamp not available. System not available. 2. During operation:
warning buzzer, output Failure can not be detected. E-Modul switches off. No shift lever
speed sensor 1) information. No display information (display dark), warning buzzer
not available; warning lamp not available. ZF-CAN timeout error will
be detected. Output speed signal 1 will be replaced by redundant
information. No gear shifting during driving. At standstill, t/m will be
shifted automatically to neutral. System not available.
59 Acknowledge fault of PTO 1 If acknowledge signal PTO - no acknowledge of 1 1 0 1
1 is active, but PTO 1 PTO 1
output is not active and
PTO 1 request not active,
then the acknowledge
signal will be considered as
not correct.
10 of 35
61 Disengagement fault of PTO No switch off of Driving: Gearshifting blocked. Stationary: ECU tries to open the failure is no longer 0 1 1 1
1 acknowledge PTO 1 after clutch, when coming to standstill. Neutral automatically engaged at detected or after
switch off request standstill. Gearshifting blocked, continued driving not possible. RESET
System not available.
63 Engagement fault of PTO1 No acknowledge signal of PTO activation is switched off. No PTO 1 available. No further Correct acknowledge 1 1 0 1
PTO 1 after request and system restrictions signal after PTO 1
valve activated request
66 Short circuit to positive at by ECU hardware,if output Driving: Gear remains engaged, gears with present short-circuit at failure is no longer 0 1 0 1
output stage to Y2 (Valve not activated the shift-valve outputs are blocked, engagement of chosen detected or after
Splitter) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
Splitter) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
possible.
11 of 35
possible.
possible.
possible.
range low) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
12 of 35
range high) alternative gears is possible. Driving and shifting: If the failure RESET
possible.
74 Short circuit to positive at by ECU hardware,if output Driving: Gearshifting of all gears possible. Stationary: All starting No short circuit to 0 1 0 1
output stage to Y10 (Main not activated gears can be engaged. Driving with start off gear possible. positive and output
valve) not activated or after
RESET.
75 Short circuit to positive at by ECU hardware,if output Warning-Buzzer not available After RESET and no 1 1 0 1
output stage to warning not activated short circuit to
buzzer (E-Module) positive.
76 Short circuit to positive at by ECU hardware,if output Reverse light permanently switched on. No other functional After RESET and no 1 1 0 0
output stage to reverse light not activated restrictions. short circuit to
relay (E-Module) positive.
77 Short circuit to positive at by ECU hardware,if output Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 1 1 1 1
output stage to PTO 1 not activated clutch, when coming to standstill. Neutral automatically engaged at failure will not be
standstill. Gearshifting blocked, continued driving not possible. sensed
79 Short circuit to positive at by ECU hardware,if output output permanent active after RESET, if the 0 0 0 1
output to ADM 2 not activated failure will not be
sensed
81 Short circuit to positive at by ECU hardware,if output Driving: Gearshifting blocked. Stationary: Shift of start off gears No short circuit to 0 1 0 1
output stage to Y1 (inertia not activated possible. Main valve will be only activated during shifting, if clutch is positive and output
brake valve) opened. Start off possible. not activated or after
RESET.
82 Short circuit to positive at by ECU hardware Gearshifting generally blocked, system not available. Driving and no short circuit to 0 1 1 1
output stage to valve Y17 gear engaged: Attempt to keep clutch engaged (prevention with positive or after
(clutch disengage slow) engagement valves). Stationary: Engagement valves are switched RESET.
off, automatic neutral shifting when clutch is disengaged.
83 Short circuit to positive at by ECU hardware Gearshifting generally blocked, system not available. Driving: no short circuit to 0 1 1 1
output stage to valve Y15 Required clutch position maintained via disengagement valve. positive or after
(clutch engage slow) Stationary: Automatic neutral shifting after a certain time. RESET.
13 of 35
84 Short circuit to positive at by ECU hardware E-Modul switches off. No shift lever information. No display no short circuit to 0 1 1 1
output stage to valve Y16 information (display dark), warning buzzer not available; warning positive or after
(clutch disengage fast) lamp not available. Output speed signal 1 will be replaced by RESET.
redundant information. Output ADVP is switched off, Failure is set
back. ISMA is available but no detection of shift lever position over
E-modul; failure display is not possible
85 Short circuit to positive at by ECU hardware Gearshifting generally blocked, system not available. Driving: no short circuit to 0 1 1 1
output stage to valve Y14 Required clutch position maintained via disengagement valve. positive or after
(clutch engage fast) Stationary: Automatic neutral shifting after a certain time. RESET.
86 Short circuit to positive at by ECU hardware,if output 1. After ignition off/on Failure will be detected during initialization. E- After RESET 1 1 0 1
output ADVP (wakeup not activated (detection Modul does not switch off. Display can not be switched off. No
control signal for E-module, only during initialization) restrictions on system availability. After ignition off, display is
voltage supply to display, flashing EE. 2. During operation No restrictions on system
warning lamp, warning availability.
buzzer, output speed sensor
1)
89 Short circuit to positive at Rereading of transmitted display flashing "EE". No system restrictions. no short circuit to 1 1 0 0
output SD to display signal positive or after
RESET.
90 Communication error 1. Timeout detection, if no Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 0 0 1 1
between controller 1 and datas are coming from clutch, when coming to standstill. Neutral automatically engaged at failure will not be
controller 2 (ECU failure) other processor. 2. standstill. Gearshifting blocked, continued driving not possible. sensed
Checksum error of data System not available.
messages between P1 and
P2. 3. If initialization datas
from P1 are not complete
received in P2, P2 does
request datas again with a
defined repetition number.
If data transfer failed after
repetition attempts, failure
will be set.
91 CAN EBC1 timeout After timeout of the No calculation of driving resistance possible. No automatic After receiving a 0 0 0 1
message, failure is set calculation of start off gear. When coming to standstill medium start correct message or
14 of 35
93 Error on ”ASR engine Signal faulty. No calculation of driving resistance possible. No automatic Signal available or 0 0 0 1
control active” signal calculation of start off gear. When coming to standstill medium start after RESET.
(EBC1) off gear will be shifted. No other functional restrictions.
94 Error on ”ASR brake control Signal faulty. No calculation of driving resistance possible. No automatic Signal available or 0 0 0 1
active” signal (EBC1) calculation of start off gear. When coming to standstill medium start after RESET.
off gear will be shifted. No other functional restrictions.
95 Error on ”Cruise control Signal faulty or missing. No other functional restrictions Signal available or 0 1 0 1
active” signal (CCVS) after RESET.
96 Error on ”Cruise control setSignal faulty or missing. No other functional restrictions, gear hunting in cruise control Signal available or 1 1 0 0
speed” (CCVS) possible after RESET.
97 Error on ”Engine speed” 1.Signal faulty or missing Driving: Time based control of clutch during shifting. Decreased 1.Signal available and 0 1 0 1
signal (EEC1) 2.Engine speed > plausible clutch comfort after shifting. Clutch does open below fixed value (No engine speed <
threshold clutch opening according coasting condition) Engine speed governor plausible threshold
during upshift does not work. Stationary: No special manoeuvering 2.After Reset
operation possible. Time based control of clutch during starting off.
Decreased clutch comfort of manoeuvering and starting.
98 Error on transmission input 1.Speed gradient > upper Driving: Increased shifting time. During upshifting and downshifting 1.Input_speed > 0 1 0 1
speed signal limit clutch will be partially closed when t/m in neutral to substitute input minimum speed and
2.input rpm > plausible speed by engine speed. If gear is engaged, input speed is clutch is closed and
value substituted by output speed. Stationary: Increased shifting time. difference between
3. input rpm = 0 and gear is Decreased clutch comfort in manoeuvering and starting. input_speed and
engaged and outputspeed difference speed and
> minimum threshold input_speed >
4.During selfadjust-ment minimujm speed.
when clutch is closed and 2.Input_speed >
input_speed < minimum minimum speed and
threshold and eng. speed > output_speed >
minimum threshold 5.Gear minimum speed and
is engaged and clutch is gear engaged and
closed and difference difference between
speed between input and input speed and
engine speed > minimum outputspeed*i_gear <
difference and difference speed
outputspeed > minimum 3.After RESET
speed
15 of 35
99 Error on output speed signal 1.Output speed 1 gradient Output speed signal will be calculated depending on system 1.No gradient failure 1 1 0 1
1 >upper limit 2.Output application from redundant output speed information. Redundant detection and
speed 1 >plausible speed speed information will be taken depending on application from difference Output
3.Output speeds not vehicle speed signal via CAN OR output speed signal from CAN speed_1 and output
plausible with each other. tachograph. Manual shifting of all gears possible. speed_2 < threshold
Erronous output speed and both output
defined by plausibility test speeds > minimum
with input speed value and both
speeds < plausible
threshold
2.After RESET
(including gradient
failure detection)
100 Error on output speed signal Signal faulty or missing. If outspeed signal 1 is available, no functional restrictions of Signal available or 1 1 0 1
2 system. after RESET.
101 Error on both output speed 1.Output speed 1 and 2 = Driving: Gearshifting blocked. Stationary: Clutch opens, when after RESET, if the 0 0 1 1
signals 0, gear engaged and coming to standstill. Neutral automatically engaged at standstill. failure will not be
input_speed > minimum Gearshifting blocked, continued driving not possible. System not sensed
threshold 2.Output speed 1 available.
and 2 = 0, gear engaged
and clutch closed and
engine _speed > minimum
threshold 3.Output speed
signal 1 and output speed
2 are faulty
102 Plausibility error between No shifting running and Driving: Gearshifting blocked during driving including neutral shift After RESET 0 1 0 1
transmission input speed engaged gear > test gear attempt. Stationary: Start off gears can be engaged. Driving with
and out-put speed and difference between start off gear possible.
input speed and
output_speed_1*i_gear >
differencial threshold (ratio
input speed to output
speed not according to
ratio of engaged gear).
103 CAN CCVS Error on wheel Signal faulty or missing In automatic mode the initiation of down shifts can be delayed or Signal availible OR 1 1 0 1
based vehicle speed prematured. No further system restrictions. after RESET
16 of 35
104 High voltage (Vehicle Circuit voltage at key 30 > No system restrictions while driving. circuit voltage within 1 1 0 1
electrical system voltage too limit threshold If fault occurs before 'Ignition ON' (key 15) the transmission does not valid range or after
high) get out of the check phase. RESET.
105 Low voltage (Vehicle Circuit voltage at key 15 < Driving: Gearshifting blocked. Clutch valves will be controlled circuit voltage within 0 1 1 1
electrical system voltage too limit threshold independent on voltage level. If PTO is engaged and relay cannot valid range or after
low) be kept active, PTO will be disengaged. Subsequent failure RESET.
detection of all failures during low voltage will be supressed.
Stationary: Gearshifting blocked. If PTO is engaged and relay
cannot be kept active, PTO will be disengaged. If gear is engaged
and driver switches off ignition, attempt to shift to neutral is allowed
independent on voltage level. Subsequent failure detection of all
failures during low voltage will be supressed. ECU will be switched
off independent on successful neutral shifting after time out.
107 Stabilised voltage supply at Voltage AU out of range Driving: Clutch is disengaged and engaged by time control. Voltage at AU within 0 1 0 1
output AU (clutch sensor Stationary: Manoeuvering not possible. If start does not occur within valid range and
supply) out of valid range certain time, transmission is automatically shifted to neutral. New RESET
start off gear must be engaged by selector lever. Decreased clutch
comfort during start off.
108 Error in selector lever or tip By plausibility test of Following item describes failure reaction of ZF selector lever with 1. Valid shift lever 1 1 0 1
lever switches in selector lever. three D-positions , one N and one R position and tip lever with neutral signal (rotary
position G (middle position) , S (search function) , + and -.General switch at neutral) 2.
function (also without failure active): After ignition off/on , a gear can After Reset
be only shifted, if rotary switch once has been in neutral position.
Failure reaction is depending on driving situation and on gear
engaged. 1.Failure on tip lever:-> No shifting possible. At standstill,
start off gear selected by rotary switch will be engaged. Driving with
selected start off gear possible (forward and reverse). 2.Failure on
rotary switch: If a gear is engaged during driving, no gear shifting is
possible. At standstill start off gear according last known (stored)
Dx position will be shifted. Driving with selected start off gear
possible. If at standstill neutral is engaged, no gearshifting is
possible -> system not available.
109 Error in selector lever of By plausibility test of Only driving from lower cabin possible 1. Valid shift lever 1 1 0 0
upper cabin switches in selector lever neutral signal (rotary
switch at neutral) 2.
After Reset
17 of 35
110 ZF CAN timeout ZF-CAN informations can`t 1. After ignition off/on: Failure will be detected during initialization. After receiving a 1 1 0 1
be transmitted and No shift lever information. Failure code will be indicated correct message or
received; failure after automatically on display alternating with gear information. System after RESET.
timeout not available. 2. During operation: No gearchange possible. When
coming to standstill, last selected (via rotary switch) startoff gear will
be automatically engaged. Continuous driving only with startoff gear
possible. If reverse gear has been engaged, t/m will automatically
shifted to neutral. No shift lever information. Failure code will be
indicated automatically on display alternating with gear information.
113 CAN message ”Driveline After timeout of the Standstill: Forced shift to neutral. When in Neutral, no other system After receiving a 1 1 0 1
retarder configuration” message, failure is set restrictions. With rotary switch further driving is possible after correct message or
timeout selector has been switched "D->N->D" after RESET.
114 Clutch engaged Clutch engaged Standstill: shift to neutral, after neutral system available After RESET, after 0 0 1 1
unintentionally in standstill, unintentionally in standstill, neutral, clutch open
gear engaged gear engaged
115 Failure at the steering not correct no manuell gear shifting or gear correction correct tipp signal 1 1 0 1
column switch signalcombination at the from the steering
steering column switch column switch
117 Error in clutch self- No clutch stroke change in System not available After RESET 0 0 1 1
adjustment process spite of piloted valves
Condition.: no clutch
stroke sensor failure no
engine_rpm error, no
input_rpm error
118 Clutch does not disengage No clutch stroke change in Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 0 1 1 1
spite of piloted clutch, when coming to standstill. Neutral automatically engaged at failure will not be
disengagement valves standstill. Gearshifting blocked, continued driving not possible. sensed
condition: no engine_rpm System not available.
failure, no input_rpm
failure, no clutch stroke
sensor failureengine_rpm
and input _rpm > min. rpm,
clutch not disengaged,
allowed switch-on-time
eceeded
18 of 35
119 Clutch does not engage / Driving / Stationary:Clutch Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 0 1 1 1
does not transmit engine sensor does not recognize clutch, when coming to standstill. Neutral automatically engaged at failure will not be
torque OR slipping closed engagementEng._rpm <> standstill. Gearshifting blocked, continued driving not possible. sensed
clutch input_rpmCondition: no System not available.
eng._rpm failure, no
input_rpm failure, no clutch
stroke sensor failure,
engine_rpm and input_rpm
> n_min., clutch not
engaged, allowed switch-
on-time eceeded
120 Mechanical failure of small Clutch does not disengage Function taken on by redundant valve.Decreased clutch comfort After RESET 0 1 0 1
disengagement clutch valve in spite of piloted valves (3
times)
121 Mechanical failure of large Clutch does not disengage Function taken on by redundant valve.Decreased clutch comfort After RESET 0 1 0 1
disengagement clutch valve in spite of piloted valves (3
times)
122 Mechanical failure of small Clutch does not engage in Function taken on by redundant valve.Decreased clutch comfort After RESET 0 1 0 1
engagement clutch valve spite of piloted valves (3
times)
123 Mechanical failure of large Clutch does not engage in Function taken on by redundant valve.Decreased clutch comfort After RESET 0 1 0 1
engagement clutch valve spite of piloted valves (3
times)
19 of 35
124 Error on clutch travel signal Clutch stroke sensor signal Driving: Clutch is disengaged and engaged by time control. After RESET and 0 1 0 1
out of range Stationary: Manoeuvering not possible. If start does not occur within plausible voltage
or certain time, transmission is automatically shifted to neutral. New signal
Increase of input shaft start off gear must be engaged by selector lever. Decreased clutch
speed while take up if comfort during start off.
clutch position signal
indicates an open clutch
or
Decrease of difference
beween engine speed and
input shaft speed in
standstill if clutch position
or
decrease of engine speed
below idle speed while stop
if clutch position signal
or
big gradient of the signal
and signal remains under
the threshold for
interruption of the ground
signal
125 Error on pressure reduction Pressure after pressure No system restrictions 1.If pressure level is 1 1 0 1
valve reduction valve exceeds lower than threshold
threshold in a checkup max_druck_zulaessig
phase (checkup phase 2.After Reset
once in a driving cycle).
126 Error on pressure sensor Voltage at analog input out No system restrictions on availability, íf external air supply is If voltage level is 1 1 0 1
signal of range sufficient. No air pressure indication AL on display in case, air within plausibel range
pressure is not sufficient. Self adjustment of transmission and clutch or after RESET.
is done time based and not related to the sensor signal. Time for
adjustment could be longer.
127 Error on ECU temperature Voltage level is out of No system restrictions on availability. If voltage level is 0 1 0 1
sensor signal range within plausibel range
or after RESET.
20 of 35
128 Error on oil temperature Voltage level is out of No system restrictions on availability. Shift monitoring time will be If voltage level is 1 1 0 0
sensor signal range depending on ECU temperature signal. within plausibel range
or after RESET.
129 No shift sensor signal (Short by ECU hardware Driving: When failure occurs during shifting, gear engaged signal is After RESET 0 1 0 1
circuit to positive) transmitted based on time control. Further gearshifting blocked.
Only shifting out of neutral possible Stationary: Neutralshifting will
be verified by select test procedure. Engagement of starting gears
possible. Change of starting gears possible. Main valve and gear
valves remain active until clutch engagement exceeds defined
threshold or driving condition is detected (to overcome tooth-to-
tooth)
130 No shift sensor signal (Short by ECU hardware Driving: When failure occurs during shifting, gear engaged signal is After RESET 0 1 0 1
circuit to ground) transmitted based on time control. Further gearshifting blocked.
tooth)
131 No shift sensor signal by ECU hardware Driving: When failure occurs during shifting, gear engaged signal is After RESET 0 1 0 1
(Interruption) transmitted based on time control. Further gearshifting blocked.
tooth)
21 of 35
132 Self adjustment error of shift Sensor value outside of With ignition off, t/m will be automatically switched to neutral. With After RESET 0 1 0 1
sensor self adjustment range with ignition on, valve Y6 and Y7 (neutral) will be switched on together
sufficient air pressure and with main air valve Y10. If sensor value is outside of neutral self
three attempts to teach in adjustment range and air pressure is sufficient, ECU tries three
had been not successful. times to adjust neutral position. If neutral position could not be
Sensor value outside of adjusted, self adjustment failure will be set. If air pressure is not
self adjustment range with sufficient and neutral could not be adjusted, no adjustment failure
faulty air pressure sensor, will be set. If air pressure sensor is faulty, N will be adjusted one
and a maximum number of time. If neutral could not be reached, a waiting time will be started.
attempts to teach in had After waiting time has past, neutral adjustment will be tried again.
been not successful. The adjustment procedure will be repeated until a defined number of
attempts. If the maximum number of attempts will be exceeded,
then self adjustment failure will be set. Stationary: Engagement of
starting gears out of neutral possible, if air pressure is sufficient.
(Gear engaged signal created via time control) Neutral position will
be verified by select procedure. If air pressure is not sufficient,
shifting is blocked. Driving: Gearshifting blocked
133 No gate select sensor signal by ECU hardware Driving: Only forward gears can be selected, which are allocated in After RESET 0 1 0 1
(Short circuit to positive) opposite shift-position of the reverse gear. If failure occurs during
shifting, the target gate will be engaged by time control. Stationary:
All allowed starting gears can be switched, whose positions are
allocated in opposite shift-position of the reverse gear. No reverse
gear shiftable.
(Short circuit to ground) opposite shift-position of the reverse gear. If failure occurs during
gear shiftable.
(Interruption) opposite shift-position of the reverse gear. If failure occurs during
gear shiftable.
22 of 35
136 Gate select sensor self Sensor value outside self With ignition off select cylinder will be switched into the gate of high 1. After successful 1 1 0 1
adjustment error adjustment range with forward-gears. In case of electrical fault at select valve, only engagement of gate
sufficient air pressure and possible gate will be adjusted. 2. After RESET
three attempts to teach in If select sensor value is outside of self adjustment range and air
had been not successful pressure is sufficient, then ECU tries once to adjust gate allocated to
Sensor value outside self the high forward-gears. If it's not possible to adjust this gate, the
adjustment range with gate allocated to the low forward-gears will be selected. If this
faulty air pressure after adjustment is also not possible, ECU selects again the previous
waiting time and a gate. The adjustment procedure will be repeated three times. If no
maximum number of adjustment is possible at all, after third attempt a self adjustment
attempts to teach in had error will be set. If select sensor value is outside of self adjustment
been not successful. range and air pressure is not sufficient, no select position will be
adjusted.
Engine running: If select sensor value is outside of self adjustment
range and air pressure is not sufficient or air pressure sensor is
faulty, then ECU tries once to adjust gate allocated to the high
forward-gears. If it's not possible to adjust this gate, the gate
allocated to the low forward-gears will be selected. If this adjustment
is also not possible, ECU selects again the previous gate. The
adjustment procedure will be repeated three times. If no adjustment
is possible at all, after third attempt a waiting time will be started.
After waiting time has past, gate adjustment will be tried again. The
adjustment procedure will be repeated until a defined number of
then self adjustment failure will be set. For all cases: If no gate could
be adjusted, no gear shifting is possible. System is not available. If
only one gate could be adjusted, gear shiftings in this gate are
possible. Attempt to shift gear into not adjusted position during
driving and standstill is allowed If select cylinder reaches adjustment
range, adjustment failure will be reset. If select cylinder does not
reach adjustment range, last gear will be reengaged. Subsequent
select shifting failure will be supressed.
23 of 35
137 No range change group by ECU hardware Driving: Range group shift during driving blocked. Only gears in After RESET 0 1 0 1
(GP) sensor signal (Short engaged range group can be changed. If failure occurs during range
circuit to positive) shifting, range group will be engaged by time control. Only gears in
engaged range group can be shifted. Stationary: All start off gears
can be engaged. Low range group will be engaged by time control.
Main valve and range valve remain active until clutch engagement
exceeds defined threshold or driving condition is detected (to
overcome tooth-to-tooth of range group)
(GP) sensor signal (Short engaged range group can be changed. If failure occurs during range
circuit to ground) shifting, range group will be engaged by time control. Only gears in
(GP) sensor signal engaged range group can be changed. If failure occurs during range
(Interruption) shifting, range group will be engaged by time control. Only gears in
24 of 35
140 Self adjustment error of Sensor value outside self With ignition off , range group remains in last engaged position. 1.After successful 1 1 0 1
range change group sensor adjustment range With ignition on ECU checks the range sensor value. If sensor value range group
in position fast is within defined end position range high or low, the appropriate engagement 2.After
range valve combination will be activated and together with main RESET
valve Y10 range end position will be adjusted. If range position is
not within defined end position range and air supply is sufficient,
ECU tries to shift once into high position. If range position is not
within defined end position range and air supply is not sufficient or
air pressure sensor is faulty, no range position will be shifted.
Engine running: If range position is not within defined end position
range , clutch remains closed and ECU tries to shift into high
position. If high position could not be engaged, range shifts into low
position. If low position could not be engaged, ECU tries three times
to engage high or low position. If air supply is sufficient and all
attempts failed to engage range, a self adjustment failure will be
set.If air supply is not sufficient or air pressure sensor is faulty and
range sensor is not within defined end position range , clutch
remains closed and ECU tries to shift into high position. If high
position could not be engaged, range shifts into low position. If low
position could not be engaged, ECU tries three times to engage high
or low position. If range could not be engaged, ECU waits a defined
time and retry range adjustment in high or low position. The
then self adjustment failure will be set. For all cases:If no range
position could be adjusted, no gear shifting is possible. System is
not available. If only low range could be adjusted, gear shifting in
low range group is possible. If only high range could be adjusted,
gear shifting in high range group is possible. Start off only in lowest
gear in high range position possible. Attempt to shift gear into not
adjusted positionduring driving and standstill is allowed. If range
cylinder reaches adjustment range, adjustment failure will be reset.
If range cylinder does not reach adjustment range, last gear will be
reengaged. Subsequent range shifting failure will be supressed
25 of 35
141 No splitter group (GV) by ECU hardware Shifting of splitter group blocked. Further driving only possible with After RESET 0 1 0 1
sensor signal (Short circuit last selected splitter group position. If desired gear is not shiftable,
to positive) next higher gear will be engaged. If failure occurs during shifting,
splitter will be engaged by time control
sensor signal (Short circuit last selected splitter group position. If desired gear is not shiftable,
to ground) next higher gear will be engaged. If failure occurs during shifting,
sensor signal (Interruption) last selected splitter group position. If desired gear is not shiftable,
next higher gear will be engaged. If failure occurs during shifting,
26 of 35
144 Splitter group (GV) sensor Sensor value outside self With ignition off, splitter remains in last engaged position. 1.After successful 1 1 0 1
self adjustment error adjustment range With ignition on ECU checks the splitter sensor value. If sensor range group
value is within defined end position range high or low, the engagement 2.After
appropriate splitter valve combination will be activated and together RESET
with main valve Y10 splitter end position will be adjusted. If splitter
position is not within defined end position range and air supply is
sufficient, ECU tries to shift once into high position. If splitter position
is not within defined end position range and air supply is not
sufficient or air pressure sensor is faulty, no splitter position will be
shifted.
Engine running: If splitter position is not within defined end position
range , clutch remains closed and ECU tries to shift into high
position. If high position could not be engaged, splitter shifts into low
position. If low position could not be engaged, ECU tries three times
to engage high or low position. If air supply is sufficient and all
attempts failed to engage splitter, a self adjustment failure will be
set. If air supply is not sufficient or air pressure sensor is faulty and
splitter sensor is not within defined end position range ,clutch
remains closed and ECU tries to shift into high position. If high
position could not be engaged, splitter shifts into low position. If low
position could not be engaged, ECU tries three times to engage high
or low position. If splitter could not be engaged, ECU waits a defined
time and retry splitter adjustment in high or low position. The
then self adjustment failure will be set. For all cases: If no splitter
position could be adjusted, no gear shifting is possible. System is
not available. If only low splitter could be adjusted, gear shifting in
low splitter group is possible. If only high splitter couldbe adjusted,
gear shifting in high splitter group is possible. Attempt to shift gear
into not adjusted positionduring driving and standstill is allowed. If
splitter cylinder reaches adjustment range, adjustment failure will be
reset. If splitter cylinder does not reach adjustment range, last gear
will be reengaged. Subsequent splitter shifting failures will be
supressed.
27 of 35
145 Range change group (GP) Range change group does Driving: When shifting from low range group to high group, the 1.After successful 0 1 0 1
disengagement error not leave the previous highest gear in low range group will be shifted. When shifting from range change group
position within defined high range group to low group, the lowest gear in high range group shift 2.After RESET
time. will be shifted. Stationary: If it is not possible to select low range
group, the lowest gear in high range group is selected as starting
gear. New attempt to shift range group is allowed under all driving
conditions. No reverse gear in high range group possible.
146 Changeover error during Range change group does Driving and stationary: If selected range group could not be 1.After successful 0 1 0 1
range change group (GP) not change over to new engaged, range cylinder tries to repeat engagement three times. If range change group
shifting position within defined time selected range group could not be engaged, following gear will be shift 2.After RESET
shifted: When shifting from low range group to high group, the
highest gear in low range group will be shifted. When shifting from
high range group to low group, the lowest gear in high range group
will be shifted. Stationary: If it is not possible to select low range
group, the lowest gear in high range group is selected as starting
gear. New attempt to shift range group is allowed under all driving
conditions.
147 Range change group (GP) Range change group does Driving and stationary: If selected range group could not be 1.After successful 0 1 1 1
does not engage not reach end stop neither engaged, range cylinder tries to repeat engagement three times. If range change group
in new nor in old position selected gear could not be engaged, old range position will be shift 2.After RESET
selected.If engagement into old range position failed, failure will be
set.T/m shifts to neutral. New attempt to shift range group is allowed
under all driving conditions.
148 Splitter (GV) does not Splitter group does not If failure occurs, t/m shifts into next upper gear. Following gear 1.After successful 0 1 0 1
disengage leave the previous position restrictions are valid: Driving: The highest gear which can be splitter group shift
within defined time. selected, is the highest gear in last engaged splitterposition.The 2.After RESET
lowest gear which can be selected is the lowest gear in last
engaged splitterposition. Stationary:The highest gear which can be
selected, is the highest start off gear in last engaged
splitterposition.The lowest gear which can be selected is the lowest
start off gear in last engaged splitterposition.
28 of 35
149 Change over error during Splitter group does not If failure occurs, t/m shifts into next upper gear. Following gear 1.After successful 0 1 0 1
splitter shifting change over to new restrictions are valid: Driving: The highest gear which can be splitter group shift
position within defined selected, is the highest gear in last engaged splitterposition.The 2.After RESET
time. lowest gear which can be selected is the lowest gear in last
engaged splitterposition. Stationary:The highest gear which can be
selected, is the highest start off gear in last engaged
splitterposition.The lowest gear which can be selected is the lowest
start off gear in last engaged splitterposition.
150 Splitter (GV) does not Splitter group does not System not available. New attempt to shift splitter group is allowed 1.After successful 0 1 1 1
engage reach end stop neither in under all driving conditions. splitter group shift
new nor in old position. 2.After RESET
detection only in standstill,
during driving is GV -
shifting active up to
stillstand
151 Selector cylinder does not Selector cylinder does not Driving: When failure occurs during shifting, t/m shifts back into the 1.After successful 0 1 0 1
disengage leave the previous position last gear. If last gear is not shiftable because of overspeed selection process
condition, the next possible target gear, which is next to last gear 2.After RESET
will be shifted. When highest shiftable gear could not be shifted
because of overspeed condition, then t/m shifts to neutral.
Stationary: If target select position could not be engaged,t/m shifts
into neutral. New shifting of start off gear must be initiated by
selector switch.
152 Change over error during Selector cylinder does not Driving: When failure occurs during shifting, gate cylinder shifts back 1.After successful 0 1 0 1
gate selection procedure change over to new gate into last gate position and t/m shifts back into the last gear. If last selection process
gear is not shiftable because of overspeed condition, the next 2.After RESET
possible target gear, which is next to last gear will be shifted. When
highest shiftable gear could not be shifted because of overspeed
condition, then t/m shifts to neutral. Stationary: If target select
position could not be engaged,t/m shifts into neutral. New shifting of
start off gear must be initiated by selector switch.
29 of 35
153 Selector cylinder does not Selector cylinder does not Driving and stationary: T/m shifts into neutral position. New shifting 1.After successful 0 1 1 1
engage engage neither in new gate of gear must be initiated by selector switch. If no gate could be selection process
end position nor in old gate engaged, system not available. 2.After RESET
end position. The
demanded new endposition
AND the starting position
cannot be engaged/sensed
AND after additional new
shifting trials the demanded
endposition cannot be
engaged/sensed. If after
these new shifting trials no
endposition is
engaged/sensed the failure
will be set.
154 Main transmission gear Gear engaged signal does Driving: Clutch engages in previous gear. Next attempt to shift must 1.Neutral position 0 1 0 1
does not disengage not disappear when clutch be initiated by selector switch. Stationary: Gearshifting only could be reached
is dis-en-gaged and permitted after neutral signal has been reached. Start off and driving 2.After RESET
Neutral is requested can be tried with engaged gear, if gear is equal or lower than lowest
gear in range high position.
155 Main transmission gear Driving: 1.Shift cylinder Driving: T/m remains into neutral, if neutral position could not be left. 1.Any main gear 0 1 0 1
does not engage does not leave neutral New shifting of gear must be initiated by selector switch. If neutral could be engaged
position. Stationary: position has been left, but gear does not engage within defined time, 2.After RESET
1.Shift cylinder does not shift cylinder will be shifted back into neutral position and same main
leave neutral position gear will be tried to engage again. This procedure will be repeated
2.Clutch exceeds after continuously. Stationary: T/m remains into neutral, if neutral position
several gearshifts defined could not be left. If neutral position has been left, clutch starts to
engagement threshold close to overcome tooth-to-tooth contact. If gear does not engage
during tooth-to-tooth after several gearshifts if clutch has exceeded a maximum
contact and gear does not engagement stroke, t/m will be shifted back to neutral. New shifting
engage. of start off gear must be initiated by selector switch.
156 Wrong gear shifting Shift sensor detects shifting Automatic neutral shifting. Clutch remains opened, if neutral could 1.Correct gear shifting 0 1 0 0
into wrong shift direction not be shifted. New shifting of gear must be initiated by selector 2.After RESET
switch
30 of 35
157 Selector sensor signal Selector sensor stroke Main valve will be activated automatically together with selector 1.Selector end 1 1 0 0
leaves engaged position exceeds maximum allowed valves to shift into end position (in cycles). position has been
stroke without shifting reached 2.After Reset
active.
158 Shift sensor signal leaves Main gear sensor stroke Main valve will be activated automatically together with gear valves 1.gear Gear end 1 1 0 1
engaged position during exceeds maximum allowed to shift into end position. If gear has been disengaged completely, a position has been
driving stroke during vehicle suitable gear depending on speed condition will be shifted reached 2.After Reset
operation without shifting automatically.
active.
159 Range-change group Range sensor stroke Main valve will be activated automatically together with gear valves 1.Range end position 1 1 0 1
sensor signal leaves exceeds maximum allowed to shift into end position. If gear has been disengaged completely, a has been reached.
engaged position during stroke during vehicle suitable gear depending on speed condition will be shifted 2.After Reset
driving operation without shifting automatically.
active.
160 Splitter sensor signal leaves Splitter sensor stroke Main valve will be activated automatically together with gear valves 1.Splitter end position 1 1 0 1
engaged position during exceeds maximum allowed to shift into end position. If gear has been disengaged completely, a has been reached
driving stroke during vehicle suitable gear depending on speed condition will be shifted 2.After Reset
operation without shifting automatically.
active.
163 Engine does not react on No change of engine speed Driving: Gearshifting blocked. Stationary: Starting allowed. 1. Engine speed 0 1 0 1
torque intervention when intervention via CAN Decreased clutch functionality and comfort. increase
interface possible(Test will be
started automatically
each time with t/m in
Neutral) 2.After
RESET
164 Error on ”Drivers demand Signal faulty or missing. Driving: No calculation of vehicle weight and driving resistance Signal available or 0 0 0 1
engine percent torque” possible. No calculation of startoff gear possible. Drivers demand after RESET.
(EEC1) will be substituted by accelerator pedal position information. After
shifting finished, fuel quantity will be released up to accelerator
pedal value. Clutch engagement quality could be reduced. During
cruise contol operation no fuel quantity release is possible, because
accelerator pedal value is 0. After clutch is engaged, fuel quantity
will be released by EDC. => Bad shift quality after shifing.
Stationary: Start off possible. When coming to standstill, medium
start off gear will be shifted. No other functional restrictions.
31 of 35
165 Error on ”Accelerator pedal Signal faulty or missing. Driving: No calculation of vehicle weight and driving resistance Signal available or 0 0 0 1
position” (EEC2) possible. No calculation of startoff gear possible. Accelerator pedal after RESET.
position will be substituted by drivers demand information. Shift
quality could be reduced. Stationary: Start off possible. When
coming to standstill, medium start off gear will be shifted.
Manoeuvering and startoff quality could be reduced.
166 Permanent idle signal Accelerator pedal position Driving: Shifting during driving allowed. Stationary: No After RESET 1 1 0 1
> coast position (defined manoeuvering and startoff possible. System not available.
threshold) and idle signal
active
167 Error on ”Percent load at Signal faulty or missing. No other functional restrictions Signal available or 0 1 0 1
current speed” signal after RESET.
(EEC2)
168 No idle signal or error on Idle signal faulty or missing Driving: No functional restrictions during driving. Stationary: After Signal available or 1 1 0 1
”idle signal switch” signal RESET AP or FP is shown on display as long as accelerator pedal after RESET.
(EEC2) or never active "idle value is in coast condition and idle signal is off. If idle signal does
signal" not appear within defined time, failure will be set and display
indication AC or FP disappears. ECU checks point P1 from engine
configuration (low idle speed).Start off will be allowed, if ECU
detects accelerator pedal value > threshold and engine speed
exceeds idle speed + defined speed threshold (-> verification of start
off intention)
169 Cut-off relay in ECU does During system start test: Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 0 0 1 1
not switch off When cut-off relay is clutch, when coming to standstill. Neutral automatically engaged at failure will not be
switched off, digital outputs standstill. Gearshifting blocked, continued driving not possible. sensed
can be switched on. System not available.
170 No voltage supply at pin 30 During system start Driving and Standstill: block shifting and clutchfunction - System not Voltage Key 30 over 0 0 1 1
or cut-off relay in ECU does test:When ignition is on, no available. State of clutch and transmission remains unchanged. minimum or after
not switch on voltage to power supply RESET
pins
171 Error on ”Actual engine Signal faulty or missing. Driving: No calculation of vehicle weight and driving resistance Signal available or 0 0 0 1
percent torque” signal possible. No calculation of startoff gear possible. Actual engine after RESET.
(EEC1) percent torque will be substituted by drivers demand information.
Shift quality (fuel load reduction and fuel load release) could be
reduced. Stationary: Start off possible. When coming to standstill,
medium start off gear will be shifted. Warning for clutch overload
detection and reaction on overload detection could appear earlier.
32 of 35
172 Signal error: "Retarder lever Signal faulty or missing. Engine brake is considered to be not active and consequently there Signal available or 1 1 0 1
position" is no downshifting when engine brake is active. No other functional after RESET.
restrictions.
173 Error on ”Brake switch” Signal faulty or missing OR Foot brake is considered active and in consequence, clutch Signal available OR 0 0 0 1
signal (CCVS) Foot brake signal disengages always at foot brake related engine speed (higher with decreasing signal
permanent on. Condition: engine revolution) edge or after RESET.
No plausibility error idle
signal with accelerator
pedal, idle signal not
active, accelerator above
threshold.
174 Signal error: ”Kickdown Signal faulty or missing. No Kickdown operation mode possible. No other functional Signal available or 0 0 0 1
switch” signal restrictions. after RESET.
175 Error on ”Ignition lock” No ignition signal and Driving: Gearshifting in general blocked, as soon as no ignition on If ignition signal is on 0 1 0 1
signal (Key 15) engine running signal is detected (failure detection might be delayed). Standstill: If (rising signal edge) or
engine is running , ECU does not switch off. Start off gear shiftable after RESET.
(forward and reverse). Driving with start off gear possible. If engine
is not running, t/m will be automatically shifted to neutral and ECU
switches off. No initialization of system possible. System not
available.
177 System-CAN Busoff error System-CAN informations Driving: Gearshifting blocked. Stationary: ECU tries to open the failure is no longer 0 0 1 1
can`t be transmitted and clutch, when coming to standstill. Neutral automatically engaged at detected or after
received; failure after standstill. Gearshifting blocked, continued driving not possible. RESET
timeout System not available.
178 CAN Errorwarning ERRWARNING Flag from Driving: Gearshifting blocked. Stationary: ECU tries to open the failure is no longer 0 0 1 1
the CAN-Controller clutch, when coming to standstill. Neutral automatically engaged at detected or after
standstill. Gearshifting blocked, continued driving not possible. RESET
179 CAN queue overrun Not all relevant CAN Driving: Gearshifting blocked. Stationary: ECU tries to open the failure is no longer 0 0 1 1
informations can be clutch, when coming to standstill. Neutral automatically engaged at detected or after
transmitted within one standstill. Gearshifting blocked, continued driving not possible. RESET
cycle of the ECU System not available.
180 CAN EEC1 timeout After timeout of the Driving: Gearshifting blocked. Stationary: ECU tries to open the failure is no longer 0 0 1 1
message, failure is set clutch, when coming to standstill. Neutral automatically engaged at detected or after
33 of 35
181 CAN EEC2 timeout After timeout of the Driving: Gearshifting blocked. Stationary: ECU tries to open the failure is no longer 0 0 1 1
message, failure is set clutch, when coming to standstill. Neutral automatically engaged at detected or after
182 CAN CCVS timeout After timeout of the Wheel based vehicle speed missing (redundant output speed After receiving a 0 0 0 1
message, failure is set information 2, if output speed will not be taken from 2nd output correct message or
speed sensor or CAN tachograph). Service brake signal missing. In after RESET.
coast condition service brake signal is considered as active. Cruise
control active information missing. No calculation of vehicle weight
and driving resistance possible. No calculation of start off gear
possible. Subsequent single failure of message variables are
suppressed. Clutch disengages always at foot brake related engine
speed (higher engine revolution)
183 CAN ERC1_ER timeout After timeout of the No calculation of vehicle weight and driving resistance possible. No After receiving a 0 0 0 1
message, failure is set calculation of startoff gear possible. No information about engine correct message or
brake torque. If exhaust brake is active, shifting quality at start of after RESET.
shifting may be poor. Engine brake is considered as not active. No
further functional restrictions.
184 CAN message ERC1_DR After timeout of the No calculation of vehicle weight and driving resistance possible. No After receiving a 1 1 0 1
(driveline retarder) timeout message, failure is set calculation of startoff gear possible. Medium start off gear will be correct message or
shifted. No further functional restrictions. after RESET.
188 ECU fault - wrong interrupt by software Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 0 0 1 1
clutch, when coming to standstill. Neutral automatically engaged at failure will not be
189 ECU fault - stack watch by software Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 0 0 1 1
clutch, when coming to standstill. Neutral automatically engaged at failure will not be
190 EOL EEPROM parameter by software EOL values out Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 0 0 1 1
out of valid range of range detection with clutch, when coming to standstill. Neutral automatically engaged at failure will not be
initialization (ignition on). standstill. Gearshifting blocked, continued driving not possible. sensed
191 EOL EEPROM parameter by software checksum of Driving: Gearshifting blocked. Stationary: ECU tries to open the after RESET, if the 0 0 1 1
checksum error EOL parameter not correct clutch, when coming to standstill. Neutral automatically engaged at failure will not be
detection with initialization standstill. Gearshifting blocked, continued driving not possible. sensed
(ignition on). System not available.
34 of 35
193 ECU temperature too high ECU temperature on circuit Driving: Gearshifting blocked. Stationary: Clutch opens, when After RESET AND 0 0 1 1
board > threshold and oil coming to standstill. Neutral automatically engaged at standstill. ECU temperature
temperature > threshold Gearshifting blocked, continued driving not possible. Special display below threshold_1
(plausibility check) and indication for ECU temperature too high alternating with gear
failures 128 not active. information. System not available.
After debouncing time
failure will be set.
194 Both sources for front axle Both sources for front axle ISMA is turned off. No other functional restrictions. One of both sources 0 0 0 1
speed not available speed are not available is available
197 Error on "Front axle speed" Signal faulty or missing and No calculation of driving resistance possible. No automatic Signal available or 1 1 0 1
(WSI) WSI is selected as source calculation of start off gear. When coming to standstill, medium start after RESET.
for front axle speed off gear will be shifted. No other functional restrictions.
198 Error on "Relative wheel Signal faulty or missing and No other functional restrictions Signal available or 1 1 0 1
speeds" (WSI) WSI is selected as source after RESET.
for front axle speed
199 CAN WSI timeout After timeout of the No calculation of driving resistance possible. No automatic After receiving a 1 1 0 1
message, failure is set calculation of start off gear. When coming to standstill, medium start correct message or
228 Plausibility failure activation Both status lines are Only driving from lower cabin possible After RESET 1 1 0 0
of lower / upper cabin electricaly high or low
250 Internal shifter error (new Shifter internal error No functional restrictions. No failure or RESET. 1 1 0 0
standard shifter) detected.
251 E-Modul2 internal Faillure Internal error in the e- No PTO funtionality, no funtion of the warning buzzer, no kickdown Correct terms, error 1 1 0 0
(E-Modul as extension module detected. signal is detected. no longer detected or
modul) RESET
35 of 35
Flash Code Output
3.7 Flash Code Output and Deleting Error Memory
Flash code (error number) output and deletion of the error 4. Move the brake step lever to two steps below the
memory can triggered using the brake step lever. The flash max. brake step (in this case position 3) and then
code is output via the Intarder monitoring display. move it back to the position one step below the max.
brake step (in this case position 4) within the next
Triggering flash code output 5 seconds.
Example using 5-step brake step lever. 5. Wait for the flash code output (refer to: “Functions of
the Intarder monitoring display”.
1. Switch off ignition.
2. Move brake step lever to one step below the max. In addition to its normal function, the Intarder monitoring
brake step, in this case position 4. display is also used to output the flash code (error
3. Switch ignition on and wait for the Intarder numbers).
monitoring display to light up continuously If flash code output is triggered via the brake step lever,
(3 seconds) or flash (5 seconds). the error numbers saved in the error memory are output in
order once the lamp test has been completed and/or once
(if an error is present).
Example taking error number 23
lamp test Double-figure point Single-figure point
ON
OFF
3 5 1 1 1 3 12 ... 12 5 t s
019 638
6085 758 102 - 2004-03 22

Delete the Error Memory
Deleting the Error Memory
1. Switch ignition off.

2. Move brake step lever to position 4
(max. position -1).
3. Switch ignition on and wait for Intarder
monitoring display to light up permanently
(3 seconds) or flash (5 seconds).
4. Within the next 5 seconds, move the brake step lever
into position 3 (max. position -2), back to position 4
(max. position -1) and then to position 0.
5. All errors to be displayed via flash code output are
deleted for flash code output.
Only those errors from the control unit which impair

function can be called up using the flash code output.
Errors which have no impact whatsoever on control unit
functions can only be called up using an external
diagnosis unit.
Deleting the error memory with the aid of the brake step
lever makes the errors entered in the error memory
invisible for flash code output. All errors can still be seen
when using an external diagnosis device and remain
visible until deleted using the diagnosis device.
6085 758 102 - 2004-03 23

Flash Code Error List
3.8 Flash Code Error List
NOTE
This error list is a “reduced summary” of all the error memory of the ZF control unit (ECU) for
possible individual errors. Types of errors, such as optimum diagnosis. Please contact your nearest ZF
open circuit and/or short circuit can be called up in Service Center for more details.
Error code Meaning

11 El. defect - accumulator charge valve
12 El. defect - engine brake activation
13 El. defect - Intarder monitoring display activation
14 El. defect - “Reduced power” warning light activation
15 El. defect - brake lights activation
16 El. defect - fault lamp activation
17 El. defect - cruise control deactivation during constant brake step operation
18 El. defect - brake step lever supply
19 El. defect - proportional solenoid (AIP) activation
21 El. defect - prop. solenoid return (ADM1)
23 Proportional solenoid error (control unit / ECU internal)
24 LED lamp activation (brake step lever defect)
25 El. defect - Bremsomat activation, disengagement when Bremsomat is active
6085 758 102 - 2004-03 24

CAN icon in main screen

1 = OK
0 = not on the CAN BUS
D003 D006 D007 D017 (outriggers, left-hand)
D001 D015 (outriggers, right-

hand)
CAN BUS STATE Superstructure CGC

5 = OK (not for ATF360G-6)
127 = not OK D016 (spirit level)
• If power-up of the bus system has been completed correctly, the CAN icon must disappear
• In case a control unit does not log on to the bus, “0” (zero) appears in its place and the CAN ICON appears
on the main screen!
• If “0” appears, first check the fuses
o D001 = 0 fuse: F002
o D003 = 0 fuse: F003
o D006 = 0 fuse: F004
o D007 = 0 fuse: F005
o D017 = 0 fuse: F006
o D015 = 0 fuse: F006
o D016 = 0 fuse: F006
• As second check in case “0” appears, the DCPs provide for interchanging the 55-pin connectors.
o Example: interchange connector D001 and connector D003; if the DCP D001 is faulty, D003 must
be considered as faulty after the interchange.
• The third step consists in checking the wiring:
for power supply, GND and short-circuit, cable break
• 24V must be applied to the following pins:
• D001 = Pin 1/38/9/10/2/20
• D002 = Pin 1
• D003 = Pin 1/38/9/2/20
• D004 = Pin 1
• D005 = Pin 1/38/28/2/20
• D006 = Pin 1
• D007 = Pin 1/38/10/2/20
• D008 = Pin 1
• D017 = Pin 1
• D015 = Pin 1
• D016 = Pin 1
Error code list

• As fourth step, the terminating resistor must be measured:
o the measurement between CAN HIGH and CAN LOW must result in 120 OHM; failing this, the DIP
switches on the CMV and the separate terminating resistor on the spirit level must be checked; or
there is a possibility that the CAN might be interrupted
• If all these efforts remain without success, the control unit in question must be replaced
Error code list

2 Error codes indicated in the CMV colour display
2.1 Error code screen
If this icon appears in the CMV, it signals an active fault which can be read from the selection
menu’s error screen.
Item 5 Item: 4 Item: 7 Item: 8
Item 1: Item 9
Item 2:
Item 3:
o Item 6 Reset lifting of axle

o Should an error have occurred while the axle has been lifted, causing an undefined state, the
function can be reset by pressing the level pushbutton S402 – only in this screen - for 7 seconds.
o Attention: Now the axle will fall down!
o Item 1 Indication of the overall system’s CAN BUS status

o : 5 = OK
o No 5 = CAN problems
o Item 2 ID designation of the various nodes

o ID2=D001 / ID3=D003 / ID4=D006 / ID5=D007 / ID6=D017(Driver) / ID7=D0015 (Rider) /
o ID16 = Inclinometer / OW = Superstructure
o Item 3 Indication of the CAN BUS status of the various nodes
o 0 = not active on CAN bus
o 1 = active on CAN bus
o Item 4: Error Icon = Signals an active fault
Error code list

o Item 5: Error code = simultaneous error description
o Example:
Error code no.: Sensor designation SC := ShortCut

of circuit diagram CB = Cable break
1: S437_SC
2: S437_CB
o
o Item 7 Number of the last current error number in the FIFO!
o Should this number be incremented at intervals of one or two seconds, an active fault is present
It must be taken into consideration that switching the control unit ON and OFF always
generates several faults which, however, are not critical.
This is the reason why there are always any error codes saved in the memory.
o Item 8 Designation of the control units in the circuit diagram

o P020 = CMV + FIFO / D001-D007 = DCP / D015-D017 = CGM / A014 = ADM
o Item 10 The appropriate control system can be selected via the central menu button, and activated via the
button in the right-hand bottom area.
o Item 9 Designation of the various control units for selection of the error memory
o P020 is the FIFO; all errors present on the CAN BUS are recorded
o D001-D017: only the internal faults of the appropriate control unit are recorded
o A014 is the ADM; only the errors which are present at the moment can be read; the error memory
is not visible; if the error is generated before the CAN Bus is active (the first 7s after “ignition ON”),
the error is not recorded and cannot be displayed here. In this case, the Minidiag must be used.
Thus, only P020 needs to be tested in case of an error! If the result suggests a major error in D001
(for example), D001 can be selected to enable a more detailed investigation to be performed.
Error code list

General Information
In case of a steering error:
Prior to ALL actions do following steps:
1. Read out the ERROR MEMORY

at “5-or more–axle” cranes BOTH steering computers
2. Clear the Error memory

at “5-or more–axle” cranes at BOTH steering computers
3. Provoke the error of the steering system to occur again
4. Read out the ERROR MEMORY again

at “5-or more–axle” cranes BOTH steering computers
5. Write these errors down
Only if you follow these 5 steps you will get a detailed information how to fix0
the error!
Rear steering
PIN Table
J1
SLC 018 071 / 040 035 (A503)
J1: 70-pole AMP 1-963484-1
1 SAE5 JPT 24 SAE6 JPT 48 SAE3 JPT

2 5Vext MT-II 25 SAE4 JPT 49 AGND MT-II
3 5VREFext MT-II 26 AGND MT-II 50 AGND MT-II
4 5VREFext MT-II 27 SAE2 MT-II 51 5VREFext MT-II
5 5VREFext MT-II 28 SAE1 MT-II 52 AGND MT-II
6 INK2_A/CLK MT-II 29 INK1_A/CLK MT-II 53 GND MT-II
7 INK2_B/UD MT-II 30 INK1_B/UD MT-II 54 GND MT-II
8 DE9 (INT/C3- MT-II 31 SDE1 MT-II 55 SDE4 MT-II
Signal)
9 DE6 MT-II 32 DE8 (active Low) MT-II 56 CAN2_L MT-II
10 SDE3 MT-II 33 DE5 MT-II 57 CAN2_H MT-II
11 Bootloader MT-II 34 SDE2 MT-II 58 CAN2_L MT-II
12 DA8_LS MT-II 35 DE7 MT-II 59 CAN2_H MT-II
13 DA7_LS MT-II 36 DA8_LS MT-II 60 CAN1_L MT-II
14 POL-(GND) MT-II 37 DA7_LS MT-II 61 CAN1_H MT-II
15 I Sens 4 MT-II 38 POL+ MT-II 62 CAN1_L MT-II
16 I Sens 1 MT-II 39 I Sens 3 MT-II 63 CAN1_H MT-II
17 PWM4 MT-II 40 I Sens 2 MT-II 64 GND (Out) MT-II
18 PWM3 MT-II 41 RS232-TxD MT-II 65 RS232-RxD MT-II
19 PWM1 MT-II 42 PWM2 MT-II 66 SDA2 MT-II
20 SDA6 MT-II 43 SDA4 MT-II 67 SDA1 MT-II
21 SDA5 MT-II 44 SDA3 MT-II 68 +Sensor 2 MT-II
22 L-GND JPT 45 +Sensor 3 MT-II 69 L-GND JPT
23 +UB JPT 46 L-GND JPT 70 +Sensor 1 JPT
47 +UB JPT
Rear steering
J3 J2 J1
SLC 019 049 / 040 030-3 (A502)

J1: 18-pole AMP 9-966140-1
1 2 3 4 5 6 7 8 9
PWM PMW2 DA5 DA6 DA7 Isens Isens DA4 DA3
1 PWM3 PWM4 (LS)
10 11 12 13 14 15 16 17 18
DA2 DA1 L-GND L-GND L-GND L-GND +UB +UB +UB
J2: 21-pole AMP 9-966140-6
1 2 3 4 5 6 7 8 9 10
DE9 DE8 DE7 DE6 DE5 DE4 DE3 DE2 DE1 SCHIR
C3 M
11 12 13 14 15 16 17 18 19 20 21
CANL CANL CANH CANH GND RS23 RS23 DA8 DA8 POL- POL
2-RXD 2-TXD (LS) (LS) (GND) +
J3: 15-pole AMP 9-966140-2
1 2 3 4 5 6 7 8
AGND AE6 AE5 GND AE4 5VEXT AGND AE3
9 10 11 12 13 14 15
5VREF GND AE2 5VEXT AGND AE1 5VREF
Rear steering
Error codes
ERRORS WHICH NORMALLY NEVER APPEAR ARE HATCHED !!!
NOTE: “- check wiring and pins” means:

check wiring AND pins AND plugs AND signal
Location Type of error Error description and solution help

05 Digital- Out 05=DA1,
06 06=DA2,
07 07=DA3,
08 08=DA4,
02 Cable break Cable break at concerning Output
- Check magnetic coils at concerning output (resistance shoult be 15-30OHM)
- Check wiring to the coils (plugs and pins too!!!)
03 Short circuit Short circuit at concerning Output
- short circuit to GND
1. (pull out plus at concerning magnetic coils and check wiring of connection to GND)
2. check magnetic coils at concerning output (resistance shoult be 15-30OHM)
05 Parameterprog Rechnerinterner Konfigurationsfehler
12 > max. Value Rechnerinterner Konfigurationsfehler
13 < min Value Resistance of locking coils is not correct

Check magnetic coils
Check software and parameter Version matching to the type of coils
19 Abweichung Current at one pair of coils is too high or too low
Check magnetic coils at concerning output (resistance shoult be 15-30OHM
20 PWM- Ausgänge 20=PWM1 (Prop. coil Rear Axle coil A),
21 21=PWM2 (Prop. coil Rear Axle coil B),
22 22=PWM3 (Prop. coil Rear Axle coil C),
23 23=PWM4 (Prop. coil Rear Axle coil D)
.....
02 Cable break Cable break at concerning Output
- Check coils at concerning output (resistance shoult be 2-3,5OHM)
- Check wiring to the coils (plugs and pins too!!!):
03 Short circuit Short circuit at concerning Output
- short circuit to GND
1. (pull out plus at concerning coils and check wiring of connection to GND)
2. check magnetic coils at concerning output (resistance should be 2-3,5OHM)
05 Parameterprog Rechnerinterner Konfigurationsfehler
Rear steering

30 Power supply
02 Cable break Power signal from Terminal 15 (ignition) is missing.
- check Terminal 15 Voltage
- check wiring of Terminal 15 to the steering computers (including relais and pins)
04 Plausibility Signal from Terminal 15 is not plausible.
The time between „ignition“ und „engine running“ is too short.
- check Terminal 15 of short circuit to signal „ engine running“
10 5V Reference 5V reference Voltage out of range
- check 5V reference outputs (in table “Type” “5V to extern“ or „5V ref”) there has to be
5V at the pins when “ignition” is ON
1. If you have 0V, check for short circuit to GND at this cable
2. If you have 24V at this line, check for short circuit to +Ub at this cable
- check wiring and pins
12 > max. value Max. allowed Voltage has been exeeded!
Ubat > 30V!, check for short circuits to +Ub
13 < min. value Min. allowed Voltage has been fallen short of!
Ubat < 14V!, check for short circuits to GND
31 speed. > 0 Power supply has been switched on at a speed higher than 10 km/h.
Check power supply and pins for loose contacts
31 Parameter
05 Parameterprog Faulty values in Parameterblock, default values are used.
Check parameter values, contact manufacturer
19 Variance Parameter signature is not correct. The signature has to be inserted at P_39.
(abweichung) The system will only work for 5 minutes!
Load correct parameter file to the steering computer.
32 Pressure sensor
02 Cable break No signal from pressure sensor
Check the voltage of the pressure sensor (ignition ON!) The Voltage has to be between
0,5 and 4,5V
26 Pressure rise The pressure signal is not plausible. Check pressure sensor and pressure
(Druckaufbau) supply
The pressure signal has to rise if Loading valve is ON and the steering is not
moved
33 Pressure supply
05 Parameterprog The parametering in P_80 is wrong.
09 level Cable break or oil level too low in steering oil tank.
Check Oil level, signal is connected to GND when oil level is OK
If the outrigger is extended to the max. the switch will open the connection to GND
12 > max. value Max. allowed steering pressure is exeeded!
The pressure is higher than programmed in P_90.
13 < min. value Min. allowed steering pressure has fallen short of!
The pressure is lower than programmed in P_89.
26 Pressure rise The pressure could not be established after start of the system within the
(Druckaufbau) time programmed in P_91.
Check pressure supply, pump, pressure sensor
45 maintenance The pressure filter is bunged up
check oil filter., signal is connected to GND when oil level is OK
Rear steering
34 Battery check
(Ladekontrolle)
02 Cable break Engine speed signal shows a error
Check the engine controller
04 Plausibilität Engine speed signal is shown as not available
06 Timeout Engine speed signal is not available
Check the CAN connection to engine controller
31 speed > 0 Speed signal >0km/h but „engine running“ signal is missing
Check the wiring
35 Accumulator
(Druckspeicher)
04 plausibility The pressure is established too fast.
Check the pressure devolution at pressure establishment, check Accumulator
(Kontrollieren Sie den Druckverlauf beim Druckaufbau. Eventuell sind die Druckspeicher
defekt).
36 Redundant power
supply
02 Cable break The power supply of the steering computers from Terminal 91 (Generator) is
not available although the enginge is running.
Check the fuse „generator“.
04 Plausibility The power supply of the steering computers from Terminal 91 (Generator) is
plausibel.
The signal „Generator“ is active although enginge is NOT running.
Check wiring , pins and the signal „generator“
37 Rigid axle
(Starrachse)
09 value Steering program cannot be selected
Check if rigid axle is lifted, check signal “axle lifted” and wiring.
38 Emergency steering
Pump
04 Plausibility The signal „emcy steering pump“ is active while the vehicle standing idle or
is Inactive while the vehicle is moving.
Check Emergency steering Pump and wiring
39 Offroad Switch
04 Plausibility The signal „ Offroad Switch “ is not noticed from both steering computers
simultaneously.
Check wiring of Offroad switch
Rear steering

40 Angle transmitter
…
49
ATF 65G-4 + 90G-4 ATF 110G-5 + 160G-5 + 220G-5 ATF 360G-6
Steering computer #1 Steering computer #1 Steering computer #1
40 = Angle transmitter Axle 3 path 1 40 = Axle 4 path 1 40 = Axle 4 path 1
42 = Angle transmitter Axle 4 path 1 42 = Axle 6 path 1
49 = Axle 1 path 2
NO Steering computer #2
ATF 50G-3 ATF 110G-5 160G-5 220G-5 ATF 360G-6
42 = Angle transmitter Axle 3 path 1
49 = Axle 2 path 2 49 = Axle 2 path 2
02 Cable break The Voltage signal is in cable break zone.
- check voltage at the input path, it has to be between 0,2V and 4,8V
- check power supply to angle transmitter (! 5-Axle cranes use 5V power supply, the
other ones use 24V power supply!)
- check GND connection at the angle transmitter
- check wiring and pins to steering computer
05 Parameterprog. Parameter P_64 error.
11 5V extern 5V reference/extern Voltage out of range
- check 5V reference outputs (in table “Type” “5V to extern“ or „5V ref”) there has to
be 5V at the pins when “ignition” is ON
1. If you have 0V, check for short circuit to GND at this cable
2. If you have 24V at this line, check for short circuit to +Ub at this cable
17 Sum path 1/2 The sum of the voltages at path 1 and path 2 is not correct.
- check sum of both voltages (the sum has to be 5V ±0,15V Parameter_66)
- check the devolution (Verlauf) of the voltage-sum (steer left and right and watch the
voltages)
- check the connection of the shield of the angle transmitter
- check angle transmitter
18 Difference path 1/2 The calculated angles differ more than the maximum value set in
Parameter P_65 (usually 15%)
- if the angle transmitter has been changed: do the alignment procedure
47 breakdown There are errors at both paths of the angle transmitter.
- check the voltage at the analogue inputs of the steering computer where the angle
transmitter signal comes in
Rear steering
Information about speed signals: The steering computer uses Speed signal #1 as reference value
This is defined in P_72 (62) The speed signal may be ignored after the rear axles are locked (FA031 25 km/h
and up) by setting P_26 from 1 to 101 (NOT at 5 and 6 axle cranes)
52 SPEED 1 Signal coming from
◄ GEAR◄ ABVcontroller◄ wheel-sensor
ATF 50G-3: Signal coming from

◄Tachograph◄distributor gear (Verteilergetriebe)◄pulse generator
02 Cable break The speed signal is shown faulty from CAN.
- check the systems which provide speed signal #1
04 Plausibility The speed signal is shown as not available from CAN.
05 Parameterprog Parameter for speed selection is programmed faulty.
- check Parameter P_16, P_17 und P_72
06 Timeout The speed signal can not be received from CAN.
- check wiring and pins of CAN connection
18 Difference Difference between speed signal #1 and #2 is greater the programmed in
parameter P_73 (usually 5km/h).
One speed signal may be missing!
- check the speed signals (both) by performing a test drive (can be watched
simultaneously in steering control board)
- if one signal is obviously not correct, check the systems which provide this signal
- redo the calibration of the speed signals
- check the wheel diameter (programmed in Parameter_17 (pulse provider) )
53 SPEED 2 Signal coming from
◄Tachograph◄distributor gear (Verteilergetriebe)◄pulse generator
ATF 50G-3: Signal coming from

◄ gear controller◄gear output speed sensor
06 Timeout The speed signal can not be received from CAN.
54 SPEED 3

45 maintenance The speed signal can not be received from CAN.
Rear steering
55 Steering angle 55 = Axle 1, 56 = Axle 2,

56 monitoring 57 = Axle 3, 58 = Axle 4
57 Steering Axle X
58
05 Parameter- One of the parameters of the steering tolerance monitoring is
programming programmed faulty.
19 Difference The adjustment regulation of the axle has been exeeded for a longer time
than programmed in parameter P_97.
The axle could not be correctly positioned.
- check Oil supply
- are the steering forces too high?
- is the axle locked?
30 Invered axle The axle moved in the opposite way than expected to do.
movement - check the proportional valves
- check the devolution (Verlauf) of the voltage-sum (steer left and right and watch the
voltages) -> tolerance too high?(do the values immediately follow the steering
movement?)
37 v1 > v >v2 Warning
Temporary transgression (Überschreitung) of the regulation of the speed
value programmed in parameter P_98 and P_99.
- check the actual steering speed and the hydraulic oil pressure supply
38 v2 > v > v3 Warning
- check the actual steering speed and the hydraulic oil pressure supply.
39 v3 > v > v4 Warning
40 v > v4 Warning
value programmed in parameter P_101.
41 Factor The regulation difference of the axle has been exeeded more than
programmed in parameter P_106. The axle has been deactivated.
- are the steering forces too high?
- check Oil supply
Rear steering
60, alignment angle

… transmitter
71
ATF 65G-4 + 90G-4 ATF 110G-5 160G-5 220G-5 ATF 360G-6
69 = Axle 1 path 2
ATF 50G-3 ATF 110G-5 160G-5 220G-5 ATF 360G-6
69 = Axle 2 path 2 69 = Axle 2 path 2
04 Plausibility Alignment values of the angle transmitter are saved incomplete or wrong
-redo the alignment procedure
42 0° - alignment The saved 0°- Alignment value is out of the tolerance value of 2350mV bis
2650mV.
-redo the alignment procedure of 0°
43 alignment left side The saved left - Alignment value is out of the tolerance
-redo the alignment procedure of the left side, the value has to be less than 2000mV
44 alignment right side The saved right - Alignment value is out of the tolerance
-redo the alignment procedure of the right side, the value has to be more than 3000mV
31 speed. > 0 While doing the alignment procedure a speed higher than 10km/h was
detected.
- check the speed signal
- check the systems which provide speed signal
72 CAN-Terminal
06 Timeout The CAN-connection to the operation panel is lost.
- check wiring and pins and fuses
Rear steering
73 Confirmation (Quittierung)
07 Active Because of a malfunction of a redundant part the system waits for a
acknowledgement-action of the driver to deactivate the shifting-lock
(press MENÜ/ENTER).
- check error codes and solve the problem
74 Software
46 overload The processing time is too high, the system has been overburdend.
- only for start up by Mobilelectronic
75 CAN-connection
12 Too high The CAN messages cannot be handled, there are too many messages
- check CAN messages
76 Angle transmitter for
reference value
04 Plausibility
05 Parameter
06 timeout The signal from the CMV is missing for more than 5 seconds
- check CAN connection from CMV to steering computers
- check CMV
- check Software on SLCs (5-Axles cranes) Software version must be higher or equal
V107
77 Axle configuration
05 Parameterprog. At least one parameter of P_52 to P_55 configurated wrong.
- check configuration of axles
78 Steering suppression
05 Parameterprog. Parameter P_18 is programmed wrong.
- check configuration of steering suppression
79 Steering reducer
05 Parameterprog. Parameter P_70 or P_71 programmed wrong.
- check configuration of steering reducer
80 Global reference value ramp
05 Parameterprog. At least one parameter of P_119 bis P_121 is programmed wrong.
- check configuration of reference value ramp
81 Fuse monitoring
09 level The digital input is not active.
- check redundant fuse (3Ampere) of the error lamp ore wiring
82 Centering unit
02 Cable break The pressure sensor of the centering unit has detected a cable break.
83 Steering program buttons
04 Plausibility The control elements for the steering program selection have not been
actuated correctly. The operating pane no longer accepts commands.
- check the buttons if tone is stuck
- check wiring and pins of the operating panel
05 Parameterprog. Parameter P_112 and P_128 are programmed wrong.
- check values
84 Reduction of steering
Line
05 Parameterprog. Parameter P_70 or P_71 are programmed wrong.
- check values
21 Locking cycle Locking of the axles was not possible after finishing reduction of the
steering line
The steering program “narrow curve” is expected to be finished automatically
Howerver the axle locking was not possible – check locking cylinders
Rear steering
86 Speed limiter
04 Plausibility Vehicle speed is expected to be limited. However, a speed of 30km/h has
been exeeded.
- check speed limiter Relay
87 CAN-Master
06 Timeout The CAN connection from the present controller to the main controller has
been interrupted
- check error codes on Main controller and solve problems there
18 Difference The front axle positions of both steering circuits are differing
- check values of the steering circuits
- redo an alignment procedure at the front axles
47 breakdown The main controller has failed with an error
- check main controller errors and solve problems there
88 CAN-Slave 1
06 Timeout The CAN connection from the present controller to the other controller has
been interrupted
- check error codes on SLAVE controller and solve problems there
18 Differenz The front axle positions of both steering circuits are differing
- check values of the steering circuits
- redo an alignment procedure at the front axles
47 breakdown The slave controller has failed with an error
- check slave controller errors and solve problems there
90, Axle locking 90 = Axle 1, 91 = Axle 2,

91, 92 = Axle 3, 93 = Axle 4,
92, 93
16 Drift The locking position does not match to the aligned 0° value. Current
angle is more than 0°.
- check the angle transmitter of correct fitting in axle
- does the angle value change when the suspension is moving up and down?
19 deviation There is a deviation from the locking position or the retaining is

not possible. The actual value is higher than 0°.
(The allowed deviation is set in parameter P_94)
Notes for the trouble shooting:
The centred axle has moved out of the 0° position or it won´t
reach the 0° position to be locked.
- Check the mechanical coupling of the angle transducer of too much play.
- Check the actual value of the rear axle. The rear axle should not move in a range of
more than 0,5°.
- Are there any axle tensions possible, especiall y when driving through a curve ?
- Does the steering axle alter when the vehicle suspends, is the angle transducer
fixed to the frame?
22 Unlocking cycle Only with mechanical locked axles:
The axle can not be steered even after an unlocking cycle is
done.
- Check the centering switch and the compressed air.
24 Unlock Switch The Signal “ Axle unlocked” is missing for more than 2 seconds.
Check the switch, wiring and pins, and the hydraulic pressure at the switch.
If used, check the hydraulic filter in the return line to the tank
Rear steering
95, Test of the actuator 95 = Axle 1, 96 = Axle 2,

96, steered axle X 97 = Axle 3, 98 = Axle 4
97, 98
32 Check valve open A movement of the axle is possible although the check valves are
closed (currentless).
- Probably the check valves are defective
33 Check valve closed The axle won´t move even if the check valves are opened (turned on).
- Probably the check valves are defective or the required steering forces are too high
34 Circulation valve The circulation valve does not work (closed/opened).
35 Centering function A centering of the axle is not possible.
- Check if the steering forces are too high.
36 Hydraulic retainment The centering part of the cylinder is not lockable hydraulically.
of the centering Maybe the non-return valve at the cylinder is defective
cylinder
100 Digital- Inputs 100 = DE1,
... 101 = DE2,
102 = DE3,
103 = DE4,
104 = DE5,.... 119 = DE20
119 04 Plausibility Internal error at safety input
05 Parameterprog Internal configuration error.
solve error in parameters
12 > max. value Internal configuration error.
120 Analogue Inputs 120 = AE1,
... 121 = AE2,
122 = AE3,
123 = AE4,
124 = AE5, .... 29 = AE10
129 03 Short circuit Short circuit between analogue inputs.
- check wiring of the concerned PINs
04 Plausibility Internal error of a safety input
140 Digitale Inputs via CAN 140 = CAN-DE1, .... 156 = CAN-DE16
... Bus
156 05 Parameterprog Internal configuration error.
160 Digitale Outputs via CAN 160 = CAN-DA1, .... 176 = CAN-DA16
... Bus
176 05 Parameterprog Internal configuration error.
Rear steering
239 Steering computer

1 .. Internal error
4 - change steering computer
5 Parameter error
– Reload parameter with PCS-Software
- if upper solution does not help: change steering computer
6 software error
– flash softwarte again
7 .. Internal error
19 Test of internal safety switch failed
– check digital outputs of short circuit to +24V
20 Internal error
- change steering computer
21 .. Test of digital outputs failed
36 – check digital outputs of short circuit to +24V
41 .. Digital Outputs of expansion board do not switch.
46 Output concerned = error code – 24
61 .. Fault of Digital Inputs of expansion board.
– check digital outputs voltage
95 Expansion board #1 out of order.
– exchange board
99 No supply of safety digital outputs available
– check digital outputs voltage
101 .. Internal error
106 Power supply voltage too high (>31V)
– check voltage
107 Power supply voltage too low (<14V)
– check voltage
108 Internal Temperature too high (> 85°C)
– check temperature
- change steering computer
109 .. Internal error
114 Reference voltage +5Vref out of tolerance
– check voltage
- check sensors for short circuit
115 Reference voltage +5Vext out of tolerance
– check voltage
- check sensors for short circuit
116 Test of internal safety switch failed
Rear steering
121 .. Test of digital outputs failed.

Error 239 121 means: check Digital output DA01
161 .. Error at digital input
– check digital input voltage
201 .. Error at analogue input
– check analogue input voltage
221 .. Error at analogue output
– check analogue output voltage
Rear steering
Priority table
Check the errors with the higher priority first
Priority table
Location Priority 123456789
005 – 008 9 1111111111
020 – 023 8 111111111
030 4 1111
031 2 11
032 3 111
033 3 111
034 3 111
035 3 111
036 3 111
037 3 111
038 7 11111111
039 5 11111
040 – 049 8 111111111
052 7 11111111
053 7 11111111
055 – 058 6 1111111
072 6 1111111
073 2 11
076 3 111
081 3 111
082 3 111
083 3 111
084 3 111
086 3 111
087 4 1111
088 4 1111
090 – 093 3 111
095 – 098 3 111
100 – 119 4 1111
120 – 129 4 1111
239 8 111111111
Rear steering
Other Components ABS-D 5.
have to take into account the wide mum voltages of the sensor. For this
range of voltages. purpose it is necessary to turn the
wheel at a consistently slow speed,
WABCO recommends to measure and the size of the pole wheel must
these components and the resist- be known.
ance of the sensor insulation at least
while the vehicle is being manufac- The output voltage of the sensor de-
tured (cab, axles). pends on the clearance and the size
of the pole wheel. The monitoring fa-
By turning only one wheel and read- cility integrated in the ECU takes
ing out the wheel speed, the proper into account any excessive clear-
allocation of sensors can be ance in combination with small pole
checked. wheel sizes. In production, the
clearance between the sensor and
Any run-out deviation of the pole the pole wheel should be set proper-
wheel and the clearance between ly.
sensor and pole wheel can be com- WABCO offers different types of
puted by reading out the analogue equipment for testing after final as-
values of the minimum and maxi- sembly.
5.4.4 Flash code To activate the flash code, the warn- If an error is perceived, or if the lamp
ing lamp or the ASR lamp has to be is grounded for longer than 6.3 sec-
grounded for a certain time by push- onds, the flash code is ended. If the
ing a button. The type of lamp used flash code is stimulated (via the
depends on the type of ECU or the warning lamp) for longer than 15
parameters set for it. The length of seconds, a warning lamp defect
time the push-button is held down might be perceived.
determines the mode. After releas-
ing that push-button, the lamp is on Testing equipment that grounds
for another 0.5 second to confirm all dashboard lamps activates the
that the push-button has been rec- flash code. ABS ECUs for such
ognized and that the ECU has ac- vehicles usually inhibit the flash
cepted stimulation of the flash code. code.
Electronic Control Unit = ECU.
1 23
5. ABS-D Other Components
Diagnostic mode: In order to activate the diagnostic held down for between 0.5 and 3.0
mode, the push-button has to be seconds.
FC: error code // 1 to 8 // switched off and then on again, or

a: first part; b: second part the vehicle has to move off (speed
see flash code list, page 27 measured on more than one axle).
FC1 is repeated continuously if the
error was detected after the ECU If no current fault is detected, the
was switched on. last fault detected is the first one to
If an error is detected during the ”ig- be flashed out. Any subsequent indi-
nition on” phase (current error), this cations may not show the errors in
is flashed out. If several errors were the order in which they occurred.
detected within that phase, only the The flash cycle ends when the last
last one is flashed out. To end the one of the errors stored has been
flash code, the ignition has to be flashed out.
FC: error code // 1 to 8 // see flash code list, page 27

a: first part; b: second part
Flash code timing:
5.4.4.1System mode: The system mode is activated if the has to move off (speed measured on
deleting errors push-button was pressed for be- more than one axle).
tween 3 and 6.3 seconds. All errors The system code (a number) shows
stored:
stored are deleted only if there is the system expected by the ECU
currently no error. To end the flash and should be used to verify that the
code, the ignition has to be switched right ECU version is being used.
off and then on again, or the vehicle
24 1
After activating the system mode, > 0.5 sec [ASR(ATC) reduces
ASR (ATC) is inhibited to prevent the engine torque for 10 sec.].
ASR (ATC) errors being detected on
the roller dynamometer and to per- 2. A recognized ASR (ATC) or re-
mit higher differences in the speeds tarder system can be reset
of the driving and steering axles. If (reconfiguration) by pressing the
an ECU is used which provides for push-button three times > 0.5
stimulation of the flash code via the sec. (the absence of components
warning lamp, the ASR (ATC) lamp is confirmed). Reconfiguration is
comes on to show that ASR (ATC) confirmed by four brief flashing
has been inhibited. pulses.
Two seconds after the system mode No current error:

has been activated, other functions DELETION OF ALL ER-
are possible: RORS STORED
1. ASR (ATC) engine control can Deletion is confirmed by 8 brief

be tested by pressing the push- flashing pulses; this is followed by
button twice for the system code being flashed out.
Current error: ”DELETION OF ALL ER-

like ”no current error”, RORS STORED” is not
possible.
Systems:
1 X 6S/6M (6x2 ASR) 6 X 4S/3M (VAR rear)
2 X 4S/4M 7 X 4S/2M (VAR both)
3 X 4S/3M (MAR/VAR front)
4 X 6S/4M
5 X 6S/6M (6x4 ASR)
1 25
5.4.4.2 Functional testing of After pressing the push-button two actuations must be shorter than 3
engine control more times, the ABS/ASR ECU seconds.
causes the engine to idle for 10 sec- The 10 seconds begin 3 seconds af-
onds. The push-button has to be ac- ter the last actuation. At the same
tuated twice for longer than 0.5 time, the system code is being
seconds, and the interval between flashed out.
5.4.4.3 Reconfiguration q The ECU changes its basic set- monitoring feature cannot be used
ting (without ASR/ATC) to ABS/ on a vehicle that does not contain
ASR(ATC) if a differential brake these components. Diagnostic
valve and engine control have equipment or the flash code can be
been detected. used for reconfiguration.
q Once an SAE J1939 (CAN) inter-

To prevent unintentional reconfigu-
face has been detected without
ration, this function must be con-
a differential brake valve, this in-
firmed by pressing the push-button
terface is monitored as an ex-
three times, as described above for
tended ABS component.
functional testing of engine control.
Before the system code is flashed
q Once a sustained-action brake
out, 4 brief flash pulses confirm that
relay (DBR outlet) has been de-
the parameters are being changed.
tected or a retarder message re-
ceived from the SAE J1939
interface (irrespective of param- The length of the ASR/ATC filament
eter setting), this is also stored test shows whether the configura-
and monitored. tion includes ASR/ATC: no ASR/
ATC - 1.5 sec., with ASR/ATC 3 sec.
Unless it has been subject to recon- (similar to warning lamp).
figuration, an ECU with an extended
26 1
Roller dynamometer function: In order to prevent hazardous situa-
tions caused by brake force after ig-
On some roller dynamometers it is nition off/on, ASR/ATC is inhibited
necessary to inhibit ASR/ATC to as long as there is such a difference
permit higher differences in the in speeds after switching on the igni-
speeds between the driving axle and tion. If this is the case, the ASR/ATC
the steering axle. By activating the lamp will be on.
system mode, ASR/ATC is inhibited.
If the flash code via the warning On vehicles without ASR/ATC, the
lamp is used, the ASR/ATC lamp detection of some errors is inhibited.
comes on to indicate that ASR/ATC
has been inhibited.
5.4.4.4Flash code list First part of error code Second part of error code
(FC. a) (FC. b)
1 NO ERROR 1 NO ERROR
2 ABS MODULATOR 1 FRONT RIGHT
3 SENSOR CLEARANCE 2 FRONT LEFT
4 SENSOR short circuit/ 3 REAR RIGHT
interrupt
5 SENSOR defective / tyre size 4 REAR LEFT
6 SENSOR POLE WHEEL 5 3rd AXLE RIGHT
6 3rd AXLE LEFT
7 SYSTEM FUNCTION 1 DATA CONNECTION
2 ASR VALVE
3 SUSTAINED ACTION BRAKE
RELAY
4 WARNING LAMP
5 ASR CONFIGURATION
6 ASR PROP/DIF LOCK/
STOP VALVE
8 ECU 1 UNDERVOLTAGE
2 EXCESS VOLTAGE
3 INTERNAL DEFECT
4 CONFIGURATION ERROR
5 GROUND CONNECTION
1 27
Error code Repairinstructions
2.n Check modulator cable. Inlet (IV) or outlet (OV) or joint cable is continuously or
temporarily disconnected to shorted to ground or plus.
3.n Amplitude of sensor signal is too low. Check wheel bearing clearance, wheel
wobble, push sensor in further. Check sensor wiring and plug-in connections for
intermittent contact. Another possible cause: gear was engaged on slippery road
surface causing a driving wheel to slip for 16 seconds.
4.n Check sensor cable. Interrupt, short to plus or ground or between cables IG/IGM
has been detected.
5.n Check sensor cables and plugs for intermittent contact. Check pole wheel for any
damage. Check if cables of two sensors have been confused.
Tyres or number of teeth on pole wheel are different.
6-n Check pole wheel for any damage, missing teeth. Check for wobble. Check
using WABCO Sensor Probe. Replace pole wheel as required.
If clearance errors have also been stored, adjust the clearance (pushing in the
sensor).
7 -1 ECU with PROP: Check cable and speedometer signal. C3/B7 signal
calibration,
check tyre sizes.
gear lever shows ”neutral” or has been manipulated.
Electronic engine control: check interface wiring or other ECUs.
High slip / dynamometer? One axle was much faster than others?
7 -2 Check cable. Output interrupt or shorted to ground or battery voltage.

ECU with SAE J1922 or SAE J1939: Check other ECUs. No communication via
interface.
7 -4 Check cable and bulb. Was flash code button pushed down for longer than
16 sec?
7 -5 Check cable and parameters. A differential brake valve has been detected but no
engine control feature. If ”ASR self-learning” is inhibited, engine control feature
CAN, PWM, PROP has been detected.
8 -1 Check voltage supply and fuses. Supply voltage is too low at times.
8 -2 Check generator and battery. Supply voltage was too high for longer than 5 sec.
8 -3 Replace the ABS (ASR) ECU if the error occurs repeatedly.
8 -4 Wrong ECU or wrong parameter settings on the ECU.
8 -5 Check ECU ground wiring and shared valve lines IV/OV.
28 1
7. ABS-D Circuit Schematic 841 801 277 0
32
Circuit Schematic 841 801 278 0 ABS-D 7.
33
DaimlerChrysler Powersystems Engines
Brief overview
Displaying / deleting error codes Page 32
Programming accelerator pedal Page 16
Modifying individual parameters Page 18
minidiag2 Creating/modifying/saving parameter blocks Page 36

Version C 4
Diagnostics and parameterization device

Operating instructions
Transferring data from PC to minidiag 2 Page 54
Issue B/v 2.48
II
Key Overview minidiag 2/Connector view
Confirm Delete new and 1 Display with main menu

not yet confirmed
selection/entry entries 2 Keypad
Confirm Minus 1
selection/entry
Move cursor Comma/Decimal

or display field up- point
wards
Move cursor Switch to

or display field letter input 2
downwards
Back to Enter numbers

previous menu Setting display
contrast and
Scroll forward brightness
through value dis-
play (e. g. parameter
values)
Scroll back through Keys currently
value display (e. g. unassigned
parameter values)
minidiag 2
Browse up Reserved
through display
Browse down Text search aid

through display
Connector view
Help feature
2 25-pin connectors for connecting to

diagnostic socket or PC incl. power supply.
1 and 3 are no longer required.
III IV
35583_Minidiag_engl 18.04.2002 9:09 Uhr Seite 1
minidiag2
minidiag2
minidiag2 is a DaimlerChrysler Powersystems
diagnostic and parameter setting aid. It can be
used separately or to complement Star Diagnose®
products.
minidiag2 is available in three versions:
Version A = successor unit for “minidiag1” with

diagnostics texts.
Part no.: 0001530918
Version B = incl. PC program for transferring
description files and parameter blocks.
Part no.: 0001531018
Version C = with authorization to influence statutory
speed restrictions. In this case, the
statutory regulations as under ECE-R 89,
Part I, Section 5.1.2.2 are to be observed.
Part no.: 0001531118
35583_Minidiag_engl 18.04.2002 9:09 Uhr Seite A3
Table of contents
1. Safety 5
1.1. Symbols 5
1.2. General 5
1.3. Proper and intended usage 5
1.4. Personnel requirements 5
Printed in Germany 1.5. Conversions and modifications to minidiag2 5
Subject to changes in technical details for control 1.6. Organizational measures 5
modules and engines compared with details 1.7. Mercedes-Benz OEM Parts 6
and illustrations contained in previous operating 1.8. Operating conditions 6
instructions. 2. General 7
No reprinting, copying or translating, including 3. Connection 7
as excerpts, without express written permission. 3.1. Connecting to diagnostic socket 7
3.2. Connecting to PC 8
Technical status: 4. 3. 2002 4. Operation 9
4.1. minidiag2 information 9
4.2. Adapting display configurations 10
DaimlerChrysler AG
4.3. Software/hardware versions 11
Powersystems
4.4. PC communication 12
70567 Stuttgart 4.5. ECU search routine 13
Germany 4.5.1. KWP 2000 13
4.5.2. J 1587 13
4.5.3. Free running 13
4.6. Displaying ECU information 15
4.7. Programming accelerator pedal 16
4.8. Set parameters 18
4.8.1. Individual parameter setting 18
4.8.2. Data block parameter setting 21
4.8.3. Saving modified parameter blocks 24
4.9. Displaying actual values 26
4.9.1. Displaying analog measurement values 26
4.9.2. Displaying binary measured values 28
4.10. Displaying/deleting fault code memory 30
4.10.1. Displaying fault code memory 30
4.10.2. Deleting fault code memory 32
5. minidiag2 assistant 34
5.1. minidiag2 assistant tasks 34
5.2. Installation 34
5.3. Creating/modifying/saving parameter blocks 36
5.3.1. Creating parameter block 36
5.3.2. Modifying parameter block 40
5.3.3. Saving minidiag2 parameters to PC 44
5.4. Saving to or loading data carrier 48
5.4.1. Saving to data carrier 48
5.4.2. Loading from data carrier 51
5.5. Transferring files to minidiag2 54
3
Safety
1.Safety
1.1. Symbols 1.3. Proper and intended usage
The following notes are marked with different The minidiag2 diagnostics device is solely in-
symbols. tended for the contractually defined application
!
purpose. Any other use, or one in addition to
this, is not deemed to be proper and intended
Risk of injury! usage.
This symbol is used for all safety notes, DaimlerChrysler cannot be held responsible for
which if ignored may result in immediate any consequential damage resulting from
danger of injury or death. such action. The previous minidiag2 operating
instructions are to be adhered to.
1.4. Personnel requirements
! This symbol is used for all safety notes,

which if ignored result primarily in
a risk of material and functional damage.
All notes which serve to ease both

understanding and working with the
Parameter settings may only be performed by
relevantly trained or DaimlerChrysler trained
personnel as well as skilled personnel in
DaimlerChrysler authorized workshops.
1.5. Conversions and modifications

to minidiag2
minidiag2 are highlighted in blue. Arbitrary modifications to minidiag2 may
compromise the functionality and safety of the
1.2. General device. DaimlerChrysler cannot be held
!
responsible for any damage resulting from
such action.
Danger of accident and death!
The minidiag2 diagnostics device can be 1.6. Organizational measures
used to influence safety-relevant con- The operating instructions should be handed
figurations on the engine and vehicle over along with the minidiag2 diagnostic
(e. g. accelerator pedal analysis, control device to the personnel assigned to operate it
for engine brake etc.). and should be kept close at hand.
Improper editing of parameters may signi- The operating instructions are to be augmented
ficantly affect the characteristics of the by the generally valid, country-specific, statu-
engine or vehicle. This in turn may cause tory and miscellaneous regulations pertaining
damage to people and property. to accident prevention and environmental
protection.
5
Safety General Connection
2. General 3. Connection
1.7. Mercedes-Benz OEM parts The operating temperature range lies between The minidiag2 diagnostics device enables 3.1. Connection to diagnostic socket
Mercedes-Benz OEM Parts are subject to the 0 °C and 50 °C. Deviating temperatures the following operations to be performed on
most stringent of quality inspections and serve
to guarantee the best possible functionality,
safety and value retention. Each component is
specifically designed, manufactured, selected
and approved for DaimlerChrysler.
For this reason, we cannot accept any responsibility

may compromise the functionality of the
electronic components.
The device is to be kept dry. If fluid pene-
trates the inside of the device, the electronic
circuits will be corroded – this can then
lead to a malfunctioning of the device.
Mercedes-Benz ecu:
programming of accelerator pedal
(see page 16),

parameter setting (see page 18),
reading out actual values (see page 26),
reading out/deleting fault code memory

!

The ignition must be switched off
when connecting!
Use an appropriate cable

(see illustration).
for consequential damage as a result of using The device may not be opened. The warranty (see page 30).
parts and accessories which do not comply with is rendered null and void if the device is
such requirements. In Germany and in several opened. Improper treatment may result in All ECUs are subject to constant advanced de-
other countries specific components such as, for damage occurring. velopment. Please appreciate that for this rea-
example, safety parts are only approved for in- Do not drop, push or hit the device. Such son we reserve the right to make alterations.
stallation and conversion when they correspond action could break the sensitive PCBs within Therefore, all details, illustrations and specifi-
with valid statutory regulations. the device. This could cause the device to cations contained in these operating instruc-
This precondition is always fulfilled by malfunction. tions cannot be called on to press claims.
Mercedes-Benz OEM parts. Do not use aggressive chemicals, solutions or
In those instances where other parts are used powerful cleaning agents to clean the mini-
that have not been tested and approved by diag2. Use a soft cloth dampened with a mild Cable for diagnostics socket connection.
DaimlerChrysler this may – even where in indi- soap solution only to wipe down the device.
vidual cases an inspection or authorization The device is designed as a diagnostic unit Left: counter connector for connection to 25-pin
exists – lead to an inability to assess or guarantee and is not intended for continuous operation. socket on minidiag2 (see cover page IV).
such parts in spite of current market monitoring. Warranty claims will not be accepted for any Right: counter connector for connection to
Warranty claims may therefore be unilaterally faults which are the consequence of improper diagnostics socket.
restricted by DaimlerChrysler. operation, faulty or negligent treatment or
handling. minidiag2
1.8. Operating conditions
1 minidiag2 info
!
Observe the following list of Faulty devices are to be returned to the 2 ecu search routine Note:
operating conditions in order address below within the warranty period 3 PC communication The F2 (darker)
to avoid any damage to the and F3 (brighter)
(6 months as from DaimlerChrysler date
keys can be used
device and components. of dispatch): to adjust the con-
The device may not be stored or operated DaimlerChrysler AG F2/F3 trast directly
in locations that exhibit a high degree Powersystems
of exposure to dust or high air humidity.
Switch on ignition.
SVA Department
Storage temperature may not be in excess
minidiag2 switches on automatically
70567 Stuttgart
of 80 °C.
Main menu appears
Germany
6 7
Connection Operation
4. Operation
3.2. Connection to PC 4.1. minidiag2 information
Display device’s serial number and software
When connected to a PC, the minidiag2 version:
requires a voltage supply (12 V...24 V/
as of 800 mA). To this end an external Connect minidiag2 (see page 7)
minidiag2
power supply should be connected to the Main menu appears
1 minidiag2 info
corresponding connector (see cover Cursor at “minidiag2 info”
2 ecu search routine
page IV). 3 PC communication
The minidiag2 is connected to the PC’s

RS 232 serial interface F2/F3
Use an appropriate cable
(see illustration) system information
1 release info
Cursor at “release info”
2 sw/hw version
3 display
Cable for connection to PC.
9-pin: counter connector for connection

to PC’s RS 232 serial interface.
25-pin: counter connector for connection
release info
February 2002

Description of device configuration displayed
Back to main menu
to 25-pin minidiag2 connector
(see cover page IV).
minidiag2
1 minidiag2 info
3 PC communication
F2/F3
minidiag2 switches on automatically after

being connected
Main menu appears
8 9
Operation Operation
4.2. Adapting display configurations 4.3. Software/hardware versions

minidiag2 minidiag2
Configuration of display contrast and Cursor on “minidiag2 info”
1 minidiag2 info 1 minidiag2 info
brightness.
2 ecu search routine 2 ecu search routine
In the main menu set the cursor to
3 PC communication 3 PC communication
“minidiag2 info”
F2/F3
system information
1 release info
Cursor on display system information
1 release info
Cursor on “sw/hw version”
(sw/hwversions).
sw = software
2 sw/hw version 2 sw/hw version
3 display 3 display hw = hardware
display settings
1 contrast
Move the cursor to the corresponding
position to adjust the display’s contrast and
brightness
A code:
minidiag2 info
0001531018
A code:
Ser.-Nr (Ser. no.):
OSSW-version:
= Mercedes-Benz part number
= serial number
= operating system version
2 back light serial nr: 2210
OSSW-Ver.: 01.02.02 software: = user software version
software: 02.46.00 date: = latest update
date: 20.02.02
contrast
F2 = stronger
The function keys and Back to main menu:
F3 = weaker
press << to escape enable the contrast to be gradually adjusted;
go back with:
back light After selecting back light the brightness can

F2 = lighter be adjusted in the same manner; go back to
F3 = darker the main menu using:
press << to escape 3x
10 11
Operation Operation
4.4. PC communication 4.5. ECU search routine

minidiag2
In order to be capable of transferring data from Connect minidiag2 (see page 7).
1 minidiag2 info
the PC to the minidiag2, the diagnostics device Main menu appears.
must be configured accordingly: 3 PC communication
Cursor on “ecu search routine”
Connect minidiag2 to PC (see page 8).

minidiag2 Main menu appears F2/F3

1 minidiag2 info Cursor on “PC communication”
2 ecu search routine 4.5.1. KWP 2000
ecu detection
3 PC communication For Actros, Atego, Axor, IMO etc./CAN,
1 KWP 2000
K-line, Deployment: international (ISO 14230)
2 J1587
F2/F3 3 Free running
RS 232 remote operation

Data transfer using PC software
start “minidiag2 assistant” (see page 54 cf.)
minidiag2 is ready to accept data from PC
or:
4.5.2. J1587
Back to main menu: ecu detection
Including for Freightliner corporation, diag.
1 KWP 2000
bus/deployment: NAFTA States (SAE J 1708
2 J1587
3 Free running physical layer/J 1587 protocol)
minidiag2
1 minidiag2 info
or:
4.5.3. Free running
2 ecu search routine ecu detection
3 PC communication For “LK” und “SK” trucks, K-line/deployment:
1 KWP 2000
international (ISO 9141)
2 J1587
F2/F3 3 Free running
12 13
Operation Operation
ecu list
1 ADM text fault
A list of connected ecu is displayed. ecu list
1 ADM text fault
4.6. Displaying ecu information
Run ecu search routine (see page 13)
Cursor on required ecu (e. g. PLD)

2 PLD text fault Alongside the abbreviations for the ecu the 2 PLD text fault
3 FMR no text fault suffixes are also listed: 3 FMR no text fault
text fault = description file loaded into
minidiag2 for the respective ecu.

no text fault = description file not loaded into
minidiag2 for the respective ecu. Cursor on “system info”
PLD function
1 diagnosis
2 set parameters
3 routines
4 password routines
If a ecu description file is not loaded in 5 system info

the minidiag2, then no explanatory text for
fault codes, measured values etc. will be ecu information appears:
made available. Parameter settings and PLD sysinfo
A code = Mercedes-Benz
specific diagnostic routines cannot be per- A code: A0004467440
part number
formed for this ecu. engine number:
065535 00126075 Engine number = 14-digit figure
The loading of description files and para- DiagVer = diagnostics version
diag ver: 6
meter blocks with the aid of the “minidi- Pin: 3 Pin = connection pin on
ag2 assistant” PC program (see Chapter B_PLD_SW_V56_NEU minidiag2
5.5., “Transferring files to minidiag2, B_PLD_SW_V 56_NEU = description file name
page 54).
Description files in accordance with
the ecu information (see page 15) can be
requested from DaimlerChrysler.
14 15
Operation Operation
4.7. Programming accelerator pedal

Accelerator pedal contacts (idle throttle, full throt-
tle) are not assigned any constant signal values.
ADM routine1
adjust routine running ...
Wait for next display
For this reason, it is necessary to perform a one-

time programming of the accelerator pedal on the
vehicle ecu.
This procedure enters the accelerator pedal contacts
ecu list
1 ADM text fault
in the ecu’s permanent memory. When an accelera-
tor pedal or ecu is exchanged the programming
routine has to be repeated.
ADM
“ + - - A“
routine1
Press accelerator pedal to floor and hold there
for approx. 5 seconds, until next display ap-
pears
The accelerator pedal must be in the idle position push down acc. pedal !
Cursor on vehicle ecu (e. g. ADM or FMR)
ADM
1 diagnosis
function
Cursor on “routines” ADM routine1
“+ - - +“ limiting stops
Press “OK” for temporary storage of the
signal values
2 set parameters detected !
3 routines press OK to store,
4 system info press << to escape
ADM routine list

01 acc. pedal adjust.
Cursor on “acc. pedal adjust.” ADM
ADM OK !
routine1
Continue routine with “OK”
02 set param. on default adjustment routine

03 oil level lamp successful
04 engine stop lamp press OK to continue
05 fault lamp
06 grid heater lamp
ADM routine1
if initial start-up, ecu or acc.
ADM
6
To permanently store the accelerator pedal
signal values, turn off the ignition for
6 seconds
pedal change. turn ignition off for 6s
(press OK to continue) After switching off the ignition a count-
down appears. Switch on ignition again after
16 17
Operation Operation
4.8. Set parameters

The minidiag2 diagnostic device can be used
to perform two types of parameter settings:
ADM pargroup 2
1 idle single step

Parameters of selected parameter group
displayed
Cursor on required parameter
2 idle ramp rate
individual parameter settings (e. g. “3 max. adjusted idle”)
3 max. adjusted idle
data bolcks parameter settings
4 max. speed inc./dec.
In addition to this, edited parameter data can 5 transmission type
be stored from the ecu back into the minidiag2 6 ABS/ATC type
ecu list
1 ADM text fault
(see page 24), in order to load them back into
the PC from the minidiag2 at a later stage (see
page 44)
ADM
850
par 2/3
rpm
Displayed value of selected parameter:
Par 2/3 = parameter 3 of group 2
850 rpm = current value
2 FMR text fault. maximum adjusted idle
3 PLD no text fault Default = presetting/default value
4.8.1. Individual parameter settings speed default: 850
max: 4000 max = maximum value
Individual parameter setting values are
min: 0 min = minimum value
modified.

Run ecu serach routine (see page 13)
Cursor on desired ecu (e. g. ADM) Enter new value.

ADM function ADM par 2/3
If an incorrect entry is made it can be
1 diagnosis 1000 rpm
Functions of selected ecu appear deleted by pressing the “clear” key
2 set parameters maximum adjusted idle
3 routines Cursor on “set parameters”
speed default: 850
4 system info max: 4000
min: 0
ADM parameter
1 read/write ecu
Cursor on “read/write ecu parameters”

parameters
2 select parameter set
3 store modified parameter
set
ADM
01 CAN
pargroup

The ecu parameter groups are displayed
Cursor on required parameter group
(e.g. “02 config. vehicle”)
02 config. vehicle
03 common limiters
04 limiters LIMO/1
05 limiters KLIMA
07 configuration PTO
18 19
Operation Operation
ADM
1000
par 2/3
rpm
4.8.2. Data blocks parameter setting
A created parameter block is sent to a ecu. Thus
all the ecu’s parameter values are modified at the
maximum adjusted idle 3x same time, according to the parameter block.
speed default: 850 Create parameter block using “minidiag2
max: 4000
min: 0 assistant” PC program (see page 36)
Transfer parameter block to minidiag2 using
ADM
6
After completing the parameter setting, turn off
the ignition for 6 seconds. Only then will the
modified parameters be permanently stored
“minidiag2 assistant” PC program (see page 54)
turn ignition off for 6s

in the ecu
After switching off the ignition a countdown
is displayed. Switch on again after the 6 seconds

have elapsed
ADM parameter
Communication with the ecu is restarted ecu list
1 read/write ecu 1 ADM text fault
parameters 2 PLD text fault
2 select parameter set If several parameters have to be modi- 3 FMR no text fault
3 store modified parameter fied, first of all modify all the parame-
set ters and then turn off the ignition for

6 seconds.
Functions of selected ecu are displayed
PLD function
!
Cursor on “set parameters”
Parameter setting should not be 1 diagnosis
performed with the engine running! 2 set parameters
3 routines
4 password routines
5 system info
PLD parameter
1 read/write ecu
Cursor on “select parameter set”
parameters
set
20 21
Operation Operation
PLD
1 Müller
par/customer
Cursor on desired customer (e. g. “Müller”)
PLD parameter
1 read/write ecu
Communication with the ecu is restarted
2 Mayer parameters
set
! Parameter setting must not be
performed with the engine running.
PLD
1 application 1
parameter
Cursor on required application 1
(e. g. “application1”)
2 application 2
PLD
flashing active:
parameter
The selected ecu (PLD) is then set in accor-
dance with the parameter block (data record)
“application1”. Each parameter group trans-
engine identification
ferred is displayed
PLD
1 application 1
parameter
The selected ecu (PLD) is then set in accor-
dance with the parameter block (data record)
“application1”
2 application 2
2x
PLD
6
After completing the parameter setting, turn
off the ignition for 6 seconds. Only then are
the modified parameters permanently stored
turn ignition off for 6s
in the ecu
is displayed. Switch on again after the 6 sec-
onds have elapsed
22 23
Operation Operation
4.8.3. Saving modified parameter blocks Enter “parameter set name” or accept
PLD store param.
(ecu to minidiag2) automatically generated name (Acquired 1)
Acquired1
Parameter data can be stored from the ecu back
to the minidiag2. enter parameter set name
press OK to continue
press << to escape
ecu list
1 ADM text fault

PLD
reading:
store param.
Parameter groups are read in and displayed
2 PLD text fault engine identification

3 FMR no text fault
PLD
1 diagnosis
function

The selected ecu functions are then displayed
Cursor on “set parameters”
PLD parameter
1 read/write ecu
The parameter block is read out/stored
by the selected ecu (PLD)
2 set parameters parameters
3 routines 2 select parameter set
4 password routines 3 store modified parameter
5 system info set
PLD parameter
1 read/write ecu
Cursor on “store mofified parameter set” The modified parameter block can now
be saved by the minidiag2 to the PC
(see Chapter 5.3.3., “Save parameter
parameters from minidiag2 to PC”, page 44).
set
PLD
Noname
store param.
Enter or select customer name (if available)
or accept automatically generated name
(Noname) ! Parameter setting must not be
performed with the engine running.
enter customer name
press OK to continue
press << to escape
24 25
Operation Operation
4.9. Displaying actual values
4.9.1. Displaying analog measured values

PLD
01
list ana
engine torque demand

A list of the analog measured values is displayed.
Cursor on required analog measured value
(e. g. “01 engine torque”)
02 max. moment. torque
03 actual torque
04 injection time
05 internal value
06 actual speed demand
ecu list
1 PLD text fault
Cursor on required ecu (e. g. PLD) PLD
500 Nm
ana1
The value of the selected analog measured
value, attendant physical unit and an explana-
tory text are displayed
2 ADM text fault engine torque demand from
FR or PSM
the value is with not operated
acc. pedal zero, at idle negati- Scroll down through display
ve and with operated acc.
PLD
1 diagnosis
function

Cursor on “diagnosis”
PLD
500 Nm
ana1

2 set parameters pedal positive.
3 routines The benchmark figures
4 password routines depend on the type.
5 system info max: 5000
min: – 5000
PLD diagnosis
1 show actual values
Cursor on “show actual values”
Display next analog measured value
2 show fault code memory

Display previous analog measured value
PLD actual values

1 show analog values
Cursor on “show analog values”
2 show binary values
26 27
Operation Operation
ecu list
1 PLD text fault
4.9.2. Displaying binary measured values

PLD
1100
bin 2/1
no
The current status “not requested”
and explanation (lower text) of binary
measured value are displayed.
2 ADM text fault warning buzzer
0: warning buzzer not Cursor is positioned on selected binary
activated measured value.
1: warning buzzer
activated
PLD
1 diagnosis
function

Display next binary measured value
2 set parameters
3 routines Display previous binary measured value
4 password routines
5 system info
PLD diagnosis
Cursor on “show actual values”
PLD actual values

1 show analog values
Cursor on “show binary values”
2 show binary values
PLD
2/1 warning buzzer
list bin
The list of binary measured values are
displayed:
e. g. 2/1 = binary measured value 1 of group 2
2/2 stop lamp
2/3 CAN-status low Cursor on required binary measured value
2/4 CAN-status high (e. g. “2/1 warning buzzer”)
3/1 status term. 15 MR
3/2 status term. 15 FR
28 29
Operation Operation
4.10. Displaying/deleting fault code memory
4.10.1. Displaying fault code memory

PLD
1 actual fault code
fcm
Cursor on required fault group (e. g. “actual
fault code”)
2 stored fault code
3 delete fault code memory
ecu list
1 PLD text fault
PLD
1 20309
act. fault code

The fault codes of the selected fault group are
displayed
Cursor on required fault code (e. g. 20309)
2 ADM text fault 2 10409
3 FMR no text fault 3 11515
4 11615
PLD
1 diagnosis
function

20309
act. fault code 1
0 h.
The selected fault code, attendant description
(consisting of fault names and explanations/
remedies) as well as the status of the operating
2 set parameters crankshaft sensor
3 routines hours counter are displayed
interruption
4 password routines
5 system info Display next fault code
PLD diagnosis
Cursor on “show fault code memory”
Display previous fault code
The operating hours counter indicates

the number of operating hours that have

elapsed since the last fault code occur-
actual faul codes = actually valid (not yet cleared) rence. The counter can count to a maxi-
PLD fcm
fault codes. mum of 255 hours; after reaching this
1 actual fault code
These cannot be deleted maximum value it will stop counting.
2 stored fault code
3 delete fault code memory stored faul codes = not actually (possibly already
cleared) fault codes. These
can be – if required – deleted.
30 31
Operation minidiag2 assistant
4.10.2. Deleting fault code memory Depending upon the state of the fault code
ecu list
Run ecu search routine (see page 13) memory, one of the two following messages is
1 ADM text fault Cursor on required ecu (e. g. PLD) then shown on the display:
2 PLD text fault
3 FMR no text fault
No more actual (not yet cleared) fault codes
PLD fcm
in memory The entire fault code memory has
no more fault codes found
been deleted
PLD
1 diagnosis
function

2 set parameters
3 routines
4 password routines or:
5 system info
PLD diagnosis
Cursor on “show fault code memory”
PLD fcm
more actual fault codes in
The fault code memory contains current
(not yet cleared) faults.
2 show fault code memory memory
Current (not yet cleared) faults cannot

be deleted.
PLD
1 actual fault code
fcm
Cursor on “delete fault code memory” After completing work on the fault code mem-
ory, turn off the ignition for 6 seconds. Only
then will the modified faults be permanently
2 stored fault code
3 delete fault code memory deleted from the ecu.
is displayed. Switch on again after the 6 sec-

onds have elapsed.
The ecu fault code memory is deleted
PLD fcm
Wait for next display
fault code memory
deleting ...
32 33
minidiag2 assistant minidiag2 assistant
5.minidiag2 assistant
5.1. minidiag2 assistant tasks 5.2. Installation Step 3:
Creation or modifying of parameter blocks The minidiag2 assistant software is available via: select a target drive
for parameter setting of ecu’s (see page 36 ) the Internet by e-mail or (local hard drive, usually “C:”)
Saving or loading parameter blocks and on data carrier (diskettes/CD-ROM) for the installation and confirm by pressing
description files (see page 48 ) the “Copy” button.
Transferring parameter blocks and description In order for the minidiag2 assistant software The minidiag2 assistant will then automatically
files to the minidiag2, so that the ecus can be to be used, it must be installed on your PC. create the “Minidiag” directory on the hard drive.
set the parameters accordingly (see page 54 ) The system requirements for this are as follows: The Setup window appears with a progress
Microsoft ® Windows ™ 3.1 or higher bar, followed by a message window on the
main memory (RAM) of at least 8 MB successful installation.
selection of target drive
free hard disk capacity of at least 10 MB
Step 1:
e-mail: (Internet)
Save the files attached to an e-mail into a directory
on the hard drive.
Diskettes/CD-ROM:
Insert installation diskette/CD-ROM into drive.
installation progress display

Step 2:
With the aid of a file manager (e. g. MS Explorer)
or the command path select the “SETUP.EXE”
file and run it.
Following this a window appears to allow

selection of the target drive (see next page).
message window following successful installation
Step 4:
click on “OK”, after which the installation
procedure is concluded.
34 35
5.3. Creating/modifying/saving
parameter block
5.3.1. Creating parameter block

Step 1:
run minidia2 assistant using the
“Mdiagass.exe” in the “Minidiag”
directory on the PC.
“parameter assistant” window
Step 3:
go to the “parameter set” menu and
click on the “new” option.
Next window: “new parameter set”.
start window
Step 2:
click on “parameter assistant”.
The “parameter assistant” window appears.
36 37
“new parameter set” window “parameter data” window
Step 12:
If “default” is clicked, the parameter
Step 4: Step 8: click on the parameter group to be displayed
values for all the groups are reset to
in the “ecu” field click on the required ecu, enter new customer names or click on existing or modified (highlighted in green).
the original values.
for which a parameter block is to be created. customer names in the “customer” field. Step 13:
Step 5: Step 9: enter the required value of each parameter in
click on the required ecu version in the “diag- enter the new parameter block name in the the “actual” field (highlighted in red). Step 14:
nosis version” field. Read out ecu version using “parameter set” field. actual = set value of a parameter. to save the created or modified parameter
minidiag2 (see page 15). Step 10: default = presetting or default value of block go to the “parameter set” menu and
Step 6: comments can be entered in the parameter (not changeable). click on “save”.
click on the required description file “comments” field. min = minimum value of parameter
in the “description file” field. Step 11: (not changeable).
Step 7: click on “select”. max = maximum value of parameter
click on the required language in the Next window: “parameter data”. (not changeable).
“language” field. demension = parameter unit (not changeable).
38 39
5.3.2. Modify parameter block

Step 1: run minidiag2 assistant using the “Mdi-
agass.exe” file in the “Minidiag” directory on
the PC.
The start window appears.
“parameter assistant” window
Step 3:
go to the “parameter set” menu
and click on the “open” option.
The “parameter selection” window
is opened.
start window
Step 2:
click on “parameter assistant”.
The “parameter assistant” window is opened.
40 41
“parameter selection” window

“parameter data” window
Step 4: Step 8:
click on the required ecu, for which the param- click on the appropriate customer name in the
eter block is to be modified, in the “ecu” field. “customer” field.
Step 5: Step 9:
click on the corresponding ecu version in the click on the appropriate parameter set
Step 11:
“diagnosis version” field. to be modified in the “parameter set” field.
click on the parameter group to be modified
Step 6:
(highlighted in green).
click on the corresponding description file in Click on “delete parameter set”
Step 12:
the “description file” field. to delete the selected parameter block.
click on the required value of the respective
Step 7:
parameter in the “actual” input field
click on the corresponding language in the Step 10:
(highlighted in red).
“language” field. click on “Select”.
For more details see page 39.
The “parameter data” window appears.
Step 13:
to save the modified parameter block go to
the “parameter set” menu and click on
the “save” option.
42 43
5.3.3. Saving parameters from

minidiag2 to PC
Step 1:
run the minidiag2 assistant using the
“Mdiagass.exe” file in the “Minidiag”
“logistic assistant” window
Step 3:
click on “parameter from minidiag2”.
2 additional windows open containing infor-
mation on the parameter block from the ecu
start window (see following page).
Step 2:
click on “logistic assistant”.
The “logistic assistant” window is opened.
44 45
“information on parameter block from

ecu” window
“parameter selection” window
Step 4:
after confirming by clicking on “OK”, the Step 5:
parameter block is copied to the PC and the checking new parameter block from
procedure is thus concluded. Notes on ecu in the parameter assistant.
checking this can be found on the following See Chapter 5.3.2.
page under “Step 5”. Modifying parameter block (open).
46 47
5.4. Saving to or loading from data carrier
5.4.1. Saving to data carrier

Step 1: run the minidiag2 assistant using the
“Mdiagass.exe” file in the “Minidiag” directory
on the PC.
The start window appears.
Step 3:
click on “store on data carrier”.
Next window: “store on data carrier”.
start window
Step 2: click on “logistic assistant”.

The “logistic assistant” window is opened.
48 49
Step 4: click on selected target drive and 5.4.2. Loading from data carrier
In the customer version, the selection
make selection. Loading minidiag2 files from diskette
can only be opened to a limited extent!
or hard drive.
Non-available applications are hidden
Step 1: run the minidiag2 assistant using
from view. See “store on data carrier”
the “Mdiagass.exe” file in the “Minidiag”
window.
The start window appears:
Step 5:
click on “copy”.
After clicking on “copy” the selected

data on the data carrier is saved in the
“store on data carrier” window “Md0.pac” file.
The “setup.exe” file can be used to
install the PC program (minidiag2 assis-
tant) onto another drive or PC.
When saving onto 3 1/2 " disks it

may – for capacity reasons – be neces-
sary to insert another data carrier
into the drive; this is indicated by the
following window:
progress bar for saving onto data carrier
By inserting a new disk and clicking on

“OK” the saving procedure is continued
normally, and its success indicated by the
following window:
please insert new disk
Step 6: start window

click on “OK” to confirm the successful
save message. Step 2: Click on “logistic assistant”.
data has been successfully saved With this the saving procedure is concluded. Next window: “logistic assistant”
50 51
Step 4:
click on the appropriate drive in the
“source file” field.
Step 5:
click on the appropriate drive in the
“target file” field.
Step 6:
click on “copy”. The progress bar and
then a successful load message window
are displayed:
“download from data carrier” window
When saving onto 3 1/2 " disks it

may – for capacity reasons – be
necessary to insert another data
carrier into the drive; this is
progress bar window indicated by the following window:
By inserting a new disk and pressing the OK

button the saving procedure is continued
normally, and its ultimate success indicated
by the following window:
new disk required
Step 3:
click “download from data carrier”.
Window for selecting drives appears
(next page).
Step 7:
data has been successfully saved click on “OK”; the loading procedure
is thus concluded.
52 53
minidiag2 assistant minidiag 2 assistant
5.5. Transferring files to minidiag2 Step 2:

Step 1: run minidiag2 assistant on PC.
connect minidiag2 to the PC (connecting cable, The start window appears:
see page 8) and then set up the voltage supply.
The minidiag2 display now adopts one of three
possible states:
a) main menu is displayed:

minidiag2
Cursor on “3 PC communication”,
1 minidiag2 info
confirm by pressing “OK”
3 PC communication
F2/F3
RS232 remote operation

The device is ready for communication.
Continue with Step 2
b) Communication mode
RS232 remote operation
W: no system... The data are not completely loaded and
the minidiag2 is then automatically set
to communication mode.
start window
Step 3:
c) empty display
run logistic assistant.
The operating system has not been fully
loaded or overwritten, and must therefore
be transferred again.
54 55
Step 7:
click on the “parameter files on minidiag2”
button in “logistic assistant”. The “updating”
window is displayed.
“updating” window
The minidiag2 operating program is

compared with the PC operating program
and updated.
The entire data memory in the minidiag2

is deleted.
All parameter blocks and description files
are transferred to the minidiag2. With this
“logistic assistant” window the data transfer process is completed.
Step 8: confirm the following message

Step 4: by clicking on “OK”:
click on “communication settings”.
New window: “COM settings”
Step 5:
click on interface (“COM Port”),
to which the minidiag2 is connected.
successful data transfer message
The baud rate cannot be changed!
“COM settings” window

Step 6: The minidiag2 display then shows the main
click on “OK”. The “logistic assistant” menu and is ready for other applications.
window is displayed again.
56 57
Notes Notes
58 59
Issue B/v 2.48
ZF diagnosis tool
Description and menu layout
1
ZF diagnosis tool
Table of contents
Page
Description and menu layout ............................................................................................................................... 1
Table of contents.................................................................................................................................................... 2
Preface .................................................................................................................................................................... 3
Important work safety information..................................................................................................................... 4
Operation................................................................................................................................................................ 5
Function table ........................................................................................................................................................ 6
TestmanPro Directory Structure......................................................................................................................... 9
Screenshot ............................................................................................................................................................ 10
DPA DriversTestmanPro.................................................................................................................................... 12
TestmanPro DPA Drivers Programming and Updating................................................................................. 13
Inserting and starting PDF files......................................................................................................................... 14
Troubleshooting in the Event of Faulty Communication ............................................................................... 16
2
ZF diagnosis tool
Preface
This documentation has been developed for specialist staff who have been trained by ZF Friedrichshafen AG to undertake
maintenance and repair work on ZF products.
The document makes reference to a volume production ZF product in accordance with the state of development on
the date of issue.
However, due to continuing technical development of the assembly in question, repair work might require work practices
and adjustment or test data other than that specified here.
We therefore recommend that work done on your ZF product is carried out only by supervisors and fitters who have had
their practical and theoretical knowledge updated on a regular basis at our after-sales service training center.
ZF FRIEDRICHSHAFEN AG
Commercial Vehicles/Special Transmissions Division
Service Plant 2
Tel.: 00 49 75 41 77-0 Fax: 00 49 75 41 77-5726
Service points equipped by ZF Friedrichshafen AG all over the world offer you:
1. Continuously well-trained staff
2. Specified equipment, e.g. specialized tools
3. Genuine ZF spares, to our latest specifications - All work performed in these service points is carried out can
conscientiously and with care.
Warranty:
Repair work carried out at ZF service points is covered by warranty in accordance with the prevailing contractual
conditions.
Damage resulting from work caused by non-ZF personnel in an improper and professional manner, together with follow-on
costs caused by such work, is excluded from the contractual liability agreement. This also applies where genuine ZF spares
have not been used.
3
ZF diagnosis tool
Important work safety information
Companies which repair ZF assemblies are responsible for their own work safety.
To avoid injury to personnel and damage to products, all safety regulations and legal requirements
which apply to repair and maintenance work must be observed.
Before starting work, repair staff must familiarize themselves with these regulations.
Personnel required to carry out repairs on these ZF products must receive appropriate training in advance.
It is the responsibility of each company to ensure that their repair staff is properly trained.
The following safety instructions appear in this manual:
NOTE:
Refers to special processes, techniques, methods, information etc.
CAUTION:
This is used when incorrect, unprofessional working practices could damage the product.
DANGER!
This is used when lack of care could lead to personal injury or damage to property.
4
ZF diagnosis tool
Operation
Testman Pro can be operated using the mouse or keypad.
§ When using the mouse, you simply have to select the button shown on the sensitive
surface and activate this by clicking with the left-hand mouse key.
§ When using the keypad, the buttons can be operated using various keypad commands.
The meaning of the symbols is shown in the following table:
§ 8 Can only be operated with the mouse
§ 87 Can be operated with mouse and keypad (e.g. press the ENTER key).
Note:
The keypad designations may vary depending on language and keypad manufacturer!
5
ZF diagnosis tool
Function table
Button Description Can be operated with:
OK, confirmation of a function or end of a

display (e.g. test device) 87
Abort
8
Help screen, additional information is displayed
8
Print out a screen page
87 +
Back to previous page

87
System functions
87 Multiplication
button
6
ZF diagnosis tool
Function table
Page up a screen page.

87
Page down a screen page.
87
Increase or decrease a page section (e.g.
circuit diagrams) 8
Increase screen content.
8
Reduce screen content.
8
Menu selection
(e.g. diagnosis). 87
7
ZF diagnosis tool
Function table
With the next 2 functions, you can use the keyboard to proceed in small steps by holding down
each key briefly, or in large steps by holding the key down for longer. When using the mouse,
you can only proceed in small steps.
Settings can be changed to the left.
(e.g. using key 1). 87
Settings can be changed to the right.
(e.g. using key f). 87
8
ZF diagnosis tool
TestmanPro Directory Structure
TestmanPro Target folder for individual application files,
main directory Variable index lists, license, and various
(files must not be applications which TestmanPro requires.
moved). Target directory for
PDF documentation
Project folder comprises the individual

ASTronic2
applications.
Target directory for vehicle
technical data and Target
statistics memory files. ASTronic2directory for
Ecomat target directory for vehicle
HEX programming files.
technical d,ata.
Ecomat target
directory for BIN
Intarder EST42/48 programming files.
Target directory for
vehicle technical data. Intarder EST42/48
Target directory for
WSK target directory for vehicle
EOL programming files.
technical data.
WSK EST41/61
Target directory, EOL
ASTronic2
programming files.
Test rig protocols.
Basic Data Logger
directory
Target directory for registered and saved
Data Logger files.
Basic directory for
statistics diagram tool
and storage for Recommended directory for
statistics file .sta. statistic diagram files saved. Currently not needed.
Basic Flash data for DPA05. Files must not be moved.

Basic Flash data for DPA05. Files must not
be moved.
Screenshot tool, refer to next page for description.

Files should not be moved.
USB driver for DPA05. Files must not be
moved.
9
ZF diagnosis tool
Screenshot
The Screenshot tool provides a simple means of turning screenshots into graphics files, or for
printing them out.
When a graphics file is generated, there is an entirely free choice for naming the image and selecting
a target directory.
Whenever Testman is loaded or updated, the Screenshot tool is automatically set up in the Autorun
directory, i.e. you will therefore find this application on the task bar beside the system clock
whenever you boot your computer.
When you press the Print button, a .jpg image is created and saved automatically.
When you press the Print button together with the Shift function, the screen image is only printed
(i.e. it is not saved).
Whenever you select the icon using the right-hand mouse button, you can select the appropriate file
name and target directory in the Options function. You can also select any of the following functions:
Create Image File; Print Screen (Screen Dump); Minimize Application and Close Application.
10
ZF diagnosis tool
Screenshot
Select target directory
Select any file prefix
Save screen contents Print screenshot

as a graphics file (*.jpg)
Minimize application Close application
11
ZF diagnosis tool
DPA DriversTestmanPro
PC driver
TestmanPro in conjunction with DPA04 / 05 can be
checked and/or updated using a dialog window. DPA04i driver
The following description illustrates the individual
functions.
USB driver
After starting the TestmanPro, you can verify the new
drivers by clicking on the ZF symbol in your task bar When required,
you can select
(DPA04/05 must be powered at correct operating your COM port
voltage): here.
On request, you
can extend the
time until the
timeout here (for
PCs with smaller
working
capacities this
Important: may be necessary
so to avoid a
Please consult the documentation accompanying this preliminary
software to check the latest version status! ..abortion of
communication).
12
ZF diagnosis tool
TestmanPro DPA Drivers Programming and Updating

After the installation, the PC and DPA version must be available in the system as shown in the figure (refer to page 12). If that is not
the case, then the DPA04/05 must be re-programmed as follows:
Note to DPA05:
· With DPA05 the DPA cannot be programmed via the USB port. However, this is only true for complete programming, not for
DPA05 updates.
However, this is not usually required because updating is usually sufficient. Nevertheless, if complete programming does prove
necessary (complete loss of data), this can be performed using the COM interface.
If the computer does not have a COM interface, a standard USB -> COM adapter needs to be used (not in the ZF scope of supply,
please source from a specialist provider).
· If the system detects a missing USB driver or one which has not been updated, please follow the instructions provided by the
software (driver for Windows / DPA05 available in the GDS3000\usb_driver).
Note to DPA04:
· The DPA04i can only be programmed if the computer has a COM 1 or a COM2. If this is not the case, the entire GDS3000\
dpaload_uni directory can be copied onto another computer and the DPA can then be programmed from that other computer. This
also needs to be taken into consideration if the DPA is connected up via a USB->COM adapter (not in the ZF scope of supply,
please obtain from a specialist provider).
Complete programming:
1. Connect the DPA04/05 to the COM interface of your PC.
2. Connect the DPA04/05 to a 24 V power source.
3. Click on Load DPA.
USB Update (only DPA05):
1. Connect the DPA05 to the USB interface of your PC.
2. Connect the DPA05 to a 24 V power source.
3. Click on UpdateDPA05.
13
ZF diagnosis tool
Inserting and starting PDF files

Testman Pro not only allows for communication between laptop and control unit but is
also a source of information for various pieces of documentation such as manuals, repair
manuals and lists of lubricants.
These files are also supplied depending on the application in question. Furthermore, up
to 5 individual links to PDF files can be created and can be started via the Testman Pro
menu.
The links can be created in a configuration file.
The configuration files are created in the ..\GDS3000\apps\pdf directory for each
application during installation.
The file name always consists of the ‘docu_‘ prefix as well as a project abbreviation
(e.g. docu_as2.txt).
In order to create PDF links, the first line in the relevant project-dependent configuration
file must be adapted accordingly (see next page).
14
ZF diagnosis tool
Description of the first data line of the configuration file
n;Name1;pdf/file name1;....;Name4;pdf/file name4;
n -> Number of documents (max. 4)

NameX -> Button text in Testman Pro
File nameX -> File name of PDF file (always with ’pdf/...‘)
Important information:
- A maximum of 4 individual PDF documents can be linked

- PDF files must ALWAYS be linked with - 'pdf/...'!!!
IMPORTANT: use slash(/) and NOT backslash (\)
- Data must be available in the 1st line
- Lines MUST always end with a semicolon
Example:
2;system manual;pdf/sys_manual.pdf;adjustment data;pdf/adjust_data .pdf;
15
ZF diagnosis tool
Troubleshooting in the Event of Faulty Communication

Possible for
Possible cause Remedy DPA:
03 04 05
Cable connections are not OK. Check that all cables are correctly connected X X X
and check that all cables and connectors are
undamaged.
Wrong ISO connecting cable. Check ISO connecting cable. X X X
ZFF 0501 211 103
ZFP 6029 017 005
Incorrect setting for COM port (interface). Set and check COM port (interface) X X
(refer to pages 12-13)
DPA is not recognized by the PC. Check connection. X X
Check DPA operating voltage.
If necessary, reprogram the DPA
(refer to pages 12-13)
Incorrect address code. As standard, TestmanPro uses the correct X X X
address code but you may still need to change
the address code on some old control units.
16
ZF diagnosis tool
Troubleshooting in the Event of Faulty Communication

Possible for
Possible cause Remedy DPA:
03 04 05
Control unit detects voltage supply at UPRG switch on DPA must be in OFF position X X X
EUPR input. during normal diagnosis and there should be no
electrical power supply to the EUPR input on the
control unit.
L line excited (ISO mode). Check L line on control unit. During diagnosis X X X
process, K line should not be connected to an
electrical power source.
Check that DPA is correctly connected. X X X

Check vehicle current supply (Terminal 30).
Green UBATT lamp off.
Switch on ignition if necessary (Terminal15).
Check ground connection.
DPA04 may have lost its programming. X
Green UBATT lamp flashing.
Reprogram the DPA.
DPA05 may have lost its programming. X
Green LED OK lamp not flashing.
Reprogram the DPA.
Check with specialist provider that the adapter
you have just purchased is working properly.
USB->COM adapter is not working correctly.
Ensure that cable is kept short (as short as
possible)!
17
WABCO
Operating Instructions
WABCO Compact Tester
446 300 410 0
Operating Instructions
for WABCO
Compact Tester
446 300 410 0
October 1999 Edition
© Copyright WABCO 1999
WABCO
Fahrzeugbremsen
A Division of
WABCO Standard GmbH
The right of amendment is reserved.

Table of Contents Page
1. Connecting the Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Error Search (<ERROR> button) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Error Delete (<CLEAR> button) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Display System (<SYSTEM> button) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Testing Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Testing Retarder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Allocation Testing - without control pressure - . . . . . . . . . . . . . . . . . 8
5.4 Allocation Testing - with control pressure - . . . . . . . . . . . . . . . . . . . . 9
5.5 Allocation of Pulse Programmes. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.6 Schematic Procedure for Functional Test. . . . . . . . . . . . . . . . . . . . 13
6. Resetting the System (Reconfiguration) . . . . . . . . . . . . . . . . . . . . . . . . 14
7. Summary 15
8. Sticker on Back Panel 17
2
WABCO Compact Tester
446 300 410 0
After the great success of Compact This new device can be used to both
Tester 446 300 400 0 for Trailer ABS display and delete any errors stored,
systems of the Vario-C and Vario Com- and to display the system configuration
pact ABS (VCS) types, WABCO has of the control units. In addition, it allows
now developed an equally easy-to-use functional testing of the ABS system.
device for testing the motor vehicle’s The Compact Tester is also used for the
ABS-C2/C3 systems and ABS-D: reconfiguration of an ABS-D.
1. Connecting the Tester
• Push nine-pole plug of the WABCO The Tester's display will be illuminated
diagnostic cable (e.g. 446 300 401 0) immediately (display: ”888“). After ap-
into the appropriate socket on the prox. 1 second, the Tester tries to es-
Compact Tester. tablish the diagnostic connection with
the ECU. At the same time, the display
• Push plug on the vehicle side of the
begins to flash. Once the connection
diagnostic cable into the diagnostic
has been successfully established, the
socket on the vehicle.
type of system identified will be dis-
• Switch on ignition played:
Time: Display: Comments:

0 - 1 sec ABS
1 - 2 sec ASR only if D-version is being used and ASR has
been identified
after 1 sec c-v C-version with v limiter
after 1 sec or d-v D-version with v limiter
after 2 sec
c stands for ’C-version‘,

d stands for ’D-version‘ and
v stands for an active speed limiting device. If the ECU does not use the v limiter,
”–“ will appear on the display.
Please note:
The Compact Tester cannot be used for testing ABS ECUs of the C1 generation.
If a C1 ECU is connected, the CT display will show: ”ECU“.
3
Description of front panel pictographs:
clearance defect
pole wheel defect
sensor defective signal
wrong tyre size
parted cable
wrong cable connection
short to UBatt
short to earth
modulator short / 1)
time error 2)
slip error
overvoltage
DIF valve undervoltage
retarder defect: relay or switch position
engine con- defective component (ECU)
trol / interface ABS warning lamp
ECU 1)
/ outside source of energy /
shorted coil
2) (cut-in, actuating and
activating times)
If the Compact Tester is unable to iden- baud rate identified on the Compact
tify the ECU connected, the display will Tester. This means that ABS ECUs with
show ”ECU“. any transmission rates can be connect-
ed to the Compact Tester.
When establishing the diagnostic con-
nection, the baud rate is checked auto- The following functions can be initiated
matically. The programme sets the by pushing the appropriate buttons:
4
2. Error Search
(<ERROR> button)
After pushing the <ERROR> button, On the front panel of the Compact Test-
both the current (RAM) and the histori- er, the errors are decoded with the help
cal (EEPROM) error memories are read of pictographs. Groups of errors which
out. These are shown as follows: are related are marked with a horizontal
bar (sensor, modulator or ECU). Differ-
1st digit 2nd digit 3rd digit ent combinations of error path and error
error path error type frequency type may occur.
Examples:
Display: Meaning:
411 speed sensor wheel D, excessive clearance, has occurred once
862 modulator wheel B, short to UBatt, has occurred twice
H59 retarder, parted cable, has occurred 9 or more times
Error Allocation on Housing Sticker
The following different error types and error paths are shown on the hous-
ing:
consec. no. error path consec. no. error type

1 wheel A (L2) 1 clearance defect
2 wheel B (L1) 2 pole wheel defect
3 wheel C (A1) 3 defective signal
sensor
4 wheel D (A2) 4 wrong tyre
5 wheel E (Z2) 5 parted cable
6 wheel F (Z1) 6 wrong cable connection
7 wheel A 7 short UBatt
8 wheel B 8 short earth
9 wheel C 9 short / outside energy source
modulator
10 (A) wheel D / shorted coil
11 (C) wheel E 10 (A) time error
12 (E) wheel F 11 (C) slip error
13 (F) DIF valve 12 (E) overvoltage
14 (H) retarder 13 (F) undervoltage
15 (P) engine control / 14 (H) defective relay, switch
interface position
16 (L) ECU 15 (P) defective component
16 (L) ABS warning lamp
5
Whilst the ECU’s error memory is being searched and sorted by the Tester, a line
moves back and forth on the display.
activating
error search By continuing to push the <ERROR> button, each subse-
<ERROR> quent error will be displayed. Pushing any other button will
end the error search.
displaying
currently existing First any currently existing errors (RAM) are displayed.
errors
display When all currently existing errors have been displayed, ‘old’
‘old’ will appear.
displaying errors This is followed by all not currently existing errors

NOT currently
existing (EEPROM) being displayed.
When the last error has been displayed, the type of ECU
end of error
search,display identified by the Tester will once again be shown (‘ABS’)
‘ABS’
On the back panel of the Tester, another sticker shows additional pictographs.
3. Error Delete (<CLEAR> button) 4. Display System (<SYSTEM>

By pushing the <CLEAR> button (for
button)
more than 0.5 sec), the whole of the er-
ror memory in the ECU is deleted (RAM By pushing the <SYSTEM> button, the
+ EEPROM). However, this is done only system identified by the ECU can be
provided there is no currently existing displayed.
error! To delete the whole of the error If ABS-C is being used, it is merely pos-
memory, the ignition needs to be sible to ascertain whether a 4-channel
switched off and then on again. After or a 6-channel system is in place.
this, the display once again shows the
type of ECU identified (‘ABS’). The following will be displayed:
1st digit 2nd digit 3rd digit

for 4-channel ABS-C2/C3 4 - -
for 6-channel ABS-C2/C3 6 - -
Example:
Display: Meaning:
6-- 6-channel ABS
6
If an ABS-D ECU is connected, the system used will be shown as follows:
1st digit 2nd digit 3rd digit
no. of sensors no. of modulators no. of modulators
if 1M at front if 1M at rear (if nS-3M)
system display
4S2M 4 - 2
4S3M-V 4 3 -
4S3M-H 4 - 3
6S3M 6 3 -
4S3+1M 4 3 1
4S4M 4 - 4
4S4Mx4 4 4 -
6S3+1M 6 3 1
6S4Mx4 6 4 -
6S4+1M 6 4 1
6S6M 6 - 6
6S6Mx4 6 6 -
Summary of Error Paths: Summary of Error Types:
earth switch diag. 1 (D) modulator B, C, E sensor resistance (C)
earth switch diag. 2 (D) modulator A, D, F parted cable (C)
parted cable
interrupt (D)
DIF valve diag. 1 (C)
interrupt IV/OV (D)
DIF valve diag. 2 (C) DIF valve
DIF valve (D) frequency (C)
slip error
slip (D)
MOT el. (C)
MOT pn. (C) clearance (D)
clearance error
engine control (C) intermittent contact (C/D)
C3 signal (C/D) engine control / interface

cut-in time (D)
electr. engine interface (D)
actuating time (D) time error
prop. valve (D)
activating time (D)
CAN/SAE interface (D)
outside energy source (C)
short
ECU computer (D) short (D)
EEPROM (D)
internal defect (C) all MOT el defects (C)
overvoltage (C/D) ECU rattling (D)

frequency too high (D) defective signal
undervoltage (C)
abnormal signal (D)
valve relay diag. 1 (C)
pulse width frequency
valve relay diag. 2 (C)
defective (D)
(C) error of ABS-C2/C3 time-out (D)

(D) error of ABS-D
valve relay does not
All error types or error paths not shown in the above dia- disconnect (C) switch position
grams are clear, i.e. the error path is identical top the
gear switch (D)
symbol on the housing.
7
5 Functional Testing dress its idling speed. The display will
show the remaining actuation time in
After the initial installation of the ABS seconds. If no ASR is identified, the first
system or any modifications done to digit of the display shows a dash in
that system, the proper pneumatic and place of a zero.
electrical allocations of the components
must be checked. This menu item ABS-C: The Compact Tester is unable
should be addressed only if no error to determine whether engine control is
currently exists. in place, and if so, what type. For this
reason, all options are checked: Initially,
The functional test is activated by push- the proportional valve is addressed for
ing the following buttons: 10 seconds (display: ‘020’ ... ‘011’). If
such a valve has been installed, the en-
• Push <SYSTEM> button and re- gine should address its idle speed in
lease. spite of the accelerator being pushed
down. This is followed by the PWM in-
• System used (e.g. ‘4 - 2’) is dis-
terface being addressed for 10 seconds
played.
(display: ‘010’ ... ‘000’). If such an inter-
• Push <CLEAR> button for more face has been installed, again the en-
than 2 seconds. gine speed should remain constant
After 2 seconds, ‘SYS’ appears on the even when the accelerator is pushed
display. down. However, the speed which the
If the warning lamp was on, it will go off engine finally adjusts to depends on the
before the <CLEAR> button is released. type of interface fitted.
The ASR lamp (if any) will then come on
for 1 sec. Pushing the <CLEAR> button for longer
than 0.5 seconds causes the next test
Pushing the <CLEAR> button for longer step to be addressed. If any other but-
than 0.5 second causes the next test ton is pushed for longer than 0.5 sec-
step to be addressed. If any other but- onds, the functional test is aborted and
ton is pushed for longer than 0.5 sec- the type of ECU identified appears on
ond, the functional test is aborted and the display (‘ABS’).
the type of ECU identified appears on
the display (‘ABS’). 5.2 Testing Retarder Control
When the <CLEAR> button is pushed
5.1 Testing Engine Control again for longer than 0.5 second, the re-
ABS-D: ABS-D: For 10 seconds, the tarder is inactive for 5 seconds (display:
Compact Tester transmits the request ‘005’ ... ‘000’). Depending on the type of
for idle operation. This is done to test retarder used, the effect of this will vary.
engine control for ASR and any v-limit- For more information, please refer to
er. During that time, the accelerator is the test instructions for the appropriate
pushed down. The engine should ad- retarder. If no retarder is identified, the
8
first digit of the display shows a dash in If the ECU detects a speed on more
place of a zero. than one wheel, the display will show
‘---’. In this case, the functional test can-
5.3 Allocation Testing - without not be initiated as the Compact Tester
control pressure - would not know which modulator to ad-
After testing retarder control, one wheel dress. A speed of more than 4 k.p.h.
can be turned without the <CLEAR> must have been measured to allow the
button being pushed again. The display modulators to be actuated. When the
then shows the current speed of the wheel which had previously been turned
wheel being turned in k.p.h. This is done is once again stationary, the appropriate
in full figures modulator is actuated:
(e.g. wheel speed measured for wheel
A = 5.6 k.p.h. Ã display: ‘A05’).
4 k.p.h.
wheel speed
modulator
actuation pressure hold
decrease pulse
Pulse Programme 1: Commissioning cycle of right-hand wheels B, D and E if applica-

ble (if 6M ECU is being used) with control pressure
4 k.p.h.
wheel speed
modulator
actuation pressure hold
pulse
decrease
Pulse Programme 2: Commissioning cycle of left-hand wheels A, C and F if applicable

(if 6M ECU is being used) with control pressure
The sensor/modulator allocation is DIF valve which may have been in-
checked by determining that the correct stalled is actuated during the pulse pro-
sensor/modulator have been paired by gramme. If ABS-D is being used, this
way of listening or feeling (touching). happens during the whole of the pro-
The functional test is aborted by push- gramme run; with ABS-C only during
ing any button. This is followed by the the holding phase.
type of ECU identified being displayed.
After successful functional testing, the
If wheels C or E are being turned, any system is operable.
9
5.4 Allocation Testing - with con-
trol pressure -
4 k.p.h.
wheel speed
modulator
actuation pressure
decrease hold pulse
control pressure
Pulse Programme 1: Commissioning cycle of right-hand wheels B, D and E if applica-

ble (if 6M ECU is being used) with control pressure
4 k.p.h.
wheel speed
modulator
actuation pressure
decrease hold pulse
control pressure
Pulse Programme 2: Commissioning cycle of left-hand wheels A, C and F if applicable

(if 6M ECU is being used) with control pressure
In order to check all electrical/pneumatic • Solenoid actuation begins, wheel be-

allocations of sensors/modulators, a ing turned is evacuated and that
supply of compressed air is needed. wheel can now be turned for approx.
3 seconds.
Requirement: • If the wheel cannot be turned after
• brake cylinders pressureless having been evacuated, the sensor/
• otherwise similar to allocation testing modulator allocation is wrong.
- without control pressure - • To facilitate differentiation between
wheels A, C and F, they are not fully
evacuated at once but are pulsed
Testing: (testing without any auxiliary equip-
• Turn wheel (v > 4 k.p.h.). ment).
• Actuate brakes.
10
In certain types of system, one modula- PLEASE NOTE: If a type ABS-C ECU
tor acts on several wheels. Combining is used, diagnosis cannot be applied to
two sensors which are allocated to one determine how many modulators have
modulator can be achieved by axles or been installed. For this reason, the
by sides. The table in Section 5.5 shows Compact Tester assumes that for each
the allocations. sensor one modulator has been con-
nected, and this is actuated accordingly.
After turning the wheels with sensors on This means that if the configuration con-
the left-hand side, evacuation is tains fewer modulators than sensors,
achieved briefly 5 times; wheels on the the Tester will attempt to actuate a mod-
right-hand side with sensors are evacu- ulator which does not actually exist. In
ated once and for an extended period. this case, of course the course of pres-
Any wrong allocation of the A1/Z1 or A2/ sure cannot be measured on the corre-
Z2 sensors in 6S-3M systems cannot be sponding wheel by way of the pulse
detected by means of the pulse pro- programme.
gramme; however, it can be detected
from the display of the Compact Tester.
11
5.5 Allocation of Pulse Programmes pending on the ECU configuration and
The allocation of pulse programmes de- the wheel being turned is as follows:
ECU wheel being modulator being pulse programme

configuration turned actuated no.
4S2M A A 2 (5 x briefly)
1M front B A 1 (once prolonged)
1M rear C C 2
D C 1
4S3M A A 2
1M front B A 1
C C 2
D D 1
4S3M A A 2
1M rear B B 1
C C 2
D C 1
4S4M A A 2
B B 1
C C 2
D D 1
6S3M A A 2
B A 1
C C 2
D D 1
E D 1
F C 2
6S4M A A 2
B B 1
C C 2
D D 1
E D 1
F C 2
6S5M A A 2
B B 1
C C 2
D D 1
E F 1
F F 2
6S6M A A 2
B B 1
C C 2
D D 1
E E 1
F F 2
12
Some of the ECU configurations in the complete the picture. Other systems
Table are not available for purchase. which may be feasible in theory have
They have merely been included to not been listed.
5.6 Schematic Procedure for

Functional Test
initiating the
functional test
warning lamp
off
release <CLEAR>
warning lamp
on
ASR lamp on
for 1 sec.
testing
<CLEAR> <ERROR> or <SYSTEM>
engine control
time end
waiting for
<CLEAR> wheel turn <ERROR> or <SYSTEM>
or button
wheel turn
testing retarder time end
control or <CLEAR>
<ERROR>
or
<SYSTEM> testing sensors
/ modulators
any button
END
13
6. Resetting the System
(Reconfiguration)
The ABS system can be made to once The display is deleted and after a short
again recognize the components con- delay the type of ECU identified will ap-
nected to it (ASR, engine control). The pear again. The reconfiguration process
new status is stored in the parameters is now complete. Now the ignition
of the ECU. This function is available should be switched off and on again,
only for ABS-D systems. and then the menu item ‘error search’
selected.
The reconfiguration is activated by
pushing the following buttons: If for any reason the control unit does
not support the reconfiguration proce-
• Push <SYSTEM> button and re- dure, the display will show ‘---’ immedi-
lease. ately after the <SYSTEM> button has
• System (e.g. ‘4 - 2’) is being dis- been pushed for the second time. In this
played. case, no reconfiguration can be per-
formed.
• Push <SYSTEM> button for longer
than 2 seconds.
14
7. Summary
button display function comments
display: error path, error type

ERROR 861 error indication
and error frequency
CLEAR Clr deleting the error memory hold button for 0.5 sec.
requirement: no currently
existing error
SYSTEM (4-4) system display e.g.: 4S / 4M

(6-4) 6S / 4M
special functions: (please follow sequence!)
1. SYSTEM (4-2) Push button and release

SYS Hold button for 2 sec.
2. CLEAR functional test
Commissioning cycle starts.
1. SYSTEM (4-2) Push button and release

Push button for 2 sec.
resetting the system
2. SYSTEM Reconfiguration is being
(reconfiguration)
performed.
15
16
8. Sticker on Pack Panel
display when ‘ignition on’
ECU type
no error detected
system variant
axle identification
17

Grúa Tadano Faun ATF 130 G5

Uploaded by

Document Information

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

Grúa Tadano Faun ATF 130 G5

Uploaded by

Copyright:

Available Formats

Simple troubleshooting D1-1.

(For other causes, see the position "N".

Electrical equipment section.)

The key-operated switch is at an Set the key-operated switch to

The injection system and the turbo Get it checked in a specialist

(The temperature gauge shows ejector.

over 100 °C).

The pressure relief valve of the Check the functioning of the

Porous cooling water hoses. Replace all cooling water hoses.

Fill the remaining volume of cooling

Keep the following in mind before reading the error codes:

▪ Stopping the mobile crane

▪ Stopping the engine

▪ The gear lever in the neutral position

▪ Engage the parking brake

▪ Switch on the battery main switch

– Apply the service brake

– Move the jogging lever to the left

Error codes are displayed on the gearbox display.

Fault Possible cause Rectification

The solenoid valve is defective. Replace the valve.

The change-over valve is in the Set the change-over valve to the

Incorrect oil types. Follow the oil recommendation and

Differential locks, axles and drive

Fault Possible cause Rectification

The solenoid valve is defective. Replace the solenoid valve.

Incorrect oil types. Follow the oil recommendation and

Balancing plates on propeller Replace the propeller shafts.

Propeller shafts are deflected. Replace the propeller shafts.

Chassis hydraulic system - general

Fault Possible cause Rectification

Hydraulic pump is sucking air. Stop the hydraulic pump

The hydraulic pump bracket is Tighten the screws.

The suction pipe is leaky Tighten the screw couplings,

The pump pressure is incorrect. Check the pressure at the test

Worn-out or damaged hydraulic Replace the hydraulic cylinders.

Fault Possible cause Rectification

The oil viscosity is incorrect. Fill in the prescribed oil depending

Fault Possible cause Rectification

The fuse is defective. Replace the fuse.

The suspension block is defective. Replace the valve block.

The lock pin in the superstructure Check the pin.

The proximity switch is defective. Replace the proximity switch.

The leveling valve is defective Replace the valve.

Check the solenoid valve on the Replace the solenoid valve.

Leveling valves are leaky or Replace the valve.

Fault Possible cause Rectification

Cylinder is defective. Replace the cylinder.

The hydraulic accumulator is Check the pre-charging pressure

DANGER! Before checking the

Check the pressure through the

The suspension system has an air Bleed by lowering the vehicle

Hydraulic hoses are porous. Replace the hydraulic hoses.

Set the pre-charging pressure or

Solenoid valves in the valve block Replace the solenoid valves.

Inclination adjustment and leveling

Fault Possible cause Rectification

The leveling valve is defective. Replace the valve.

The valve block is defective or the Replace the valve block.

The suspension cylinder is leaky or Check the leak tightness of

Outrigger hydraulic system

Fault Possible cause Rectification

The outrigger electronic system is Get the error corrected in a

The fuse is defective. Replace the fuse.