Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF lower part of TCU Short circuit to ground at output stage to Y2 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
2
(Valve Splitter)
ZF lower part of TCU Short circuit to ground at output stage to Y3 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
3
(Valve Splitter)
ZF lower part of TCU Short circuit to ground at output stage to Y4 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
4
(Valve Select)
ZF lower part of TCU Short circuit to ground at output stage to Y5 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
5
(Valve Select)
ZF lower part of TCU Short circuit to ground at output stage to Y6 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
6
(Valve Shift)
ZF lower part of TCU Short circuit to ground at output stage to Y7 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
7
(Valve Shift)
ZF lower part of TCU Short circuit to ground at output stage to Y8 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
8
(Valve Range)
ZF lower part of TCU Short circuit to ground at output stage to Y9 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
9
(Valve Range)
ZF lower part of TCU Short circuit to ground at output stage to Y10 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
10
(Main valve)
ZF / Vehicle Relay reverse light, wiring, ZF E- Short circuit to ground at output stage from ZF E- Check for short circuit to ground at plug X36 from pin 14 towards pin 18 or pin 35. Test the function of the relay reverse light, if necessary exchange the ZF E-Modul.
12
manufacturer Modul Modul to relay reverse light
ZF / Vehicle Relay easy start E42, wiring, ZF E- Short circuit to ground at brake pressure check Check for short circuit to ground at plug X36 from pin 15 towards pin 18 or pin 35. Test the function of the relay brake pressure check valve, if necessary exchange the ZF E-Modul.
16
manufacturer Modul valve
ZF lower part of TCU Short circuit to ground at output stage to Y1 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
17
(inertia brake valve)
ZF transmission actuator Short circuit to ground at output stage to Y17 quantify the Ohm coefficient on the 20- pole plug of the clutch actuator between pin 9 and 16, in case coefficient is < 15 Ohm, exchange clutch actuator. ZF No. 0501 212 474
18 clutch actuator (Valve clutch disengage slow)
ZF transmission actuator Short circuit to ground at output stage to Y15 quantify the Ohm coefficient on the 20- pole plug of the clutch actuator between pin 7 and 16, in case coefficient is < 15 Ohm, exchange clutch actuator. ZF No. 0501 212 474
19
clutch actuator (Valve clutch engage slow)
ZF transmission actuator Short circuit to ground at output stage to Y16 quantify the Ohm coefficient on the 20- pole plug of the clutch actuator between pin 12 and 16, in case coefficient is < 15 Ohm, exchange clutch actuator. ZF No. 0501 212 474
20 clutch actuator (Valve clutch disengage fast)
ZF transmission actuator Short circuit to ground at output stage to Y14 quantify the Ohm coefficient on the 20- pole plug of the clutch actuator between pin 8 and 16, in case coefficient is < 15 Ohm, exchange clutch actuator. ZF No. 0501 212 474
21 clutch actuator (Valve clutch engage fast)
ZF / Vehicle transmission actuator, Short circuit to ground at output ADVP or ADVP1 remove plug from transmission output speed sensor, if short circuit is due to the transmitter continuation of the journey is possible with failure No. 99, exchange transmitter, if necessary check
manufacturer transmission output speed sensor, (wakeup control signal for E-module, voltage other components on ADVP 1 (pin 11).
22 E- module, display, warning lamp, supply to display, warning lamp, warning buzzer
buzzer output speed sensor 1)

ZF / Vehicle E- module/ electrical system of Short circuit to ground at output stage to warning wiring, check warning lamp and relay E68. At USA versions check the drive switch.
manufacturer vehicle/ relay E68/ CAN Drive lamp (E- Module)
23 switch (only USA versions)

page 1 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF / Vehicle transmission actuator plug/ short circuit to ground at output SD to display check 20 pole plug/ display plug or electrical system of vehicle
25 manufacturer electrical system of vehicle

Vehicle EDC, CAN wiring CAN message timeout: "Engine configuration" quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error memory of on-board computer.
26 manufacturer

Vehicle vehicle computer CAN signal error "engine configuration message" quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error memory of on-board computer.
manufacturer (engine configuration), messages, current
27 governed speed and steady state engine idling
speed are missing.
ZF Intarder CAN signal error "Actual driveline retarder- quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error memory of Intarder, if necessary
percent torque" signal (ERC1_DR) Intarder ECU exchange Intarder ECU.
28 sends incorrect CAN signal

ZF Intarder CAN signal error "Engine coolant load increase" quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error memory of Intarder, if necessary
29 signal (ERC1 DR), Intarder ECU send incorrect exchange Intarder ECU.
CAN signals
ZF Intarder CAN signal error "Driveline retarder quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error memory of Intarder, if necessary
30 configuration" exchange Intarder ECU.

Vehicle On board computer (FR), CAN CAN signal error "Actual engine retarder - quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error memory of on-board computer.
31 manufacturer signal or connection percent torque" signal (ERC1_ER)

Vehicle On board computer (FR), CAN CAN signal error "Engine retarder configuration" quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error memory of on-board computer.
32 manufacturer signal or connection

Vehicle On board computer (FR), CAN CAN message timeout: "Engine configuration" quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error memory of on-board computer.
33 manufacturer signal or connection

ZF lower part of TCU Interruption at output stage to Y2 (Valve Splitter) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
34

ZF lower part of TCU Interruption at output stage to Y3 (Valve Splitter) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
35
ZF lower part of TCU Interruption at output stage to Y4 (Valve Select) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
36
ZF lower part of TCU Interruption at output stage to Y5 (Valve Select) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
37
ZF lower part of TCU Interruption at output stage to Y6 (Valve Shift) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
38

ZF lower part of TCU Interruption at output stage to Y7 (Valve Shift) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
39

ZF lower part of TCU Interruption at output stage to Y8 (Valve Range) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
40

page 2 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF lower part of TCU Interruption at output stage to Y9 (Valve Range) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
41
ZF lower part of TCU Interruption at output stage to Y10 (Main valve) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
42
ZF / Vehicle E-Modul, relay E13 Interruption at output stage to relay reverse light Disconnect plug X36 and relay E13, check from E-Modul pin 14 towards the relay base and from the relay base towards the ground for interrupion; check relay E13, if necessary exchange
44
manufacturer E13 the relay; check E-Modul, if necessary exchange the E-Modul.
ZF / Vehicle E-Modul, relay E42 Interruption at output stage to brake pressure Disconnect plug X36 and relay E42, check from E-Modul pin 15 towards the relay base and from the relay base towards the ground for interrupion; check relay E42, if necessary exchange
48
manufacturer check valve the relay; check E-Modul, if necessary exchange the E-Modul.
ZF lower part of TCU Interruption at output stage to Y1 (inertia brake according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
49
valve)
ZF transmission actuator Interruption at output stage valve Y17 (clutch test the 20 pole clutch actuator plug between pin 9 and 16 for interruption ( Ohm coefficient approx. 16 Ω), if okay exchange transmission actuator / if not okay exchange clutch actuator
50
clutch actuator disengage slow)
ZF transmission actuator Interruption at output stage valve Y15 (clutch test the 20 pole clutch actuator plug between pin 7and 16 for interruption ( Ohm coefficient approx. 16 Ω), if okay exchange transmission actuator / if not okay exchange clutch actuator
51
clutch actuator engage slow)
ZF transmission actuator Interruption at output stage valve Y16 (clutch test the 20 pole clutch actuator plug between pin 12 and 17 for interruption ( Ohm coefficient approx. 16 Ω), if okay exchange transmission actuator / if not okay exchange clutch actuator
52
clutch actuator disengage fast)
ZF transmission actuator Interruption at output stage to large Y14 (clutch test the 20 pole clutch actuator plug between pin 8 and 17 for interruption ( Ohm coefficient approx. 16 Ω), if okay exchange transmission actuator / if not okay exchange clutch actuator
53
clutch actuator engage fast)
ZF / Vehicle output speed sensor transmission/ interruption at output ADVP or ADVP1 (voltage remove 35 pole E- module plug and measure voltage between pin 2 and 18 (ought to be 24 V); if voltage okay exchange E- module otherwise check more components, which are attached
manufacturer main wiring transmission/ supply to output speed sensor transmission, E- between pin 2 (E- module) and pin 11 (ADVP), exchange them if necessary; measure voltage at the transmissionsided output speed sensor plug between pin 1 and 2 (ought to be 24 V) if
electrical system of vehicle/ CAN module, display, warning lamp etc.) voltage okay change sensor, if voltage not okay test transmission main wiring pin 18 to 1or 6 to 2 for interruption.
54 drive switch (only USA version)

ZF / Vehicle E- module/ electrical system of Interruption at output stage to warning lamp (E- Disconnect E-modul plug X36, ignition on and quantify voltage between pin 16 and pin 35, < 24V exchange E-modul. if o.k. check wiring at plug X36 pin 16 and relay E68, if necessary repair
manufacturer vehicle/ relay E68/ Drive switch module) or exchange the wire, if o.k. check the relay E68, if necessary exchange the relay.
55 (only USA versions)

ZF transmission actuator Short circuit to positive at output stage to Y2 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
66 (Valve Splitter)
ZF transmission actuator Short circuit to positive at output stage to Y3 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
67 (Valve Splitter)
ZF transmission actuator Short circuit to positive at output stage to Y4 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
68 (Valve Select)
ZF transmission actuator Short circuit to positive at output stage to Y5 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
69 (Valve Select)
ZF transmission actuator Short circuit to positive at output stage to Y6 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
70 (Valve Shift)
ZF transmission actuator Short circuit to positive at output stage to Y7 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
71 (Valve Shift)
ZF transmission actuator Short circuit to positive at output stage to Y8 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
72 (Valve range low)

page 3 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF transmission actuator Short circuit to positive at output stage to Y9 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
73
(Valve range high)
ZF transmission actuator Short circuit to positive at output stage to Y10 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
74
(Main valve)
ZF / Vehicle ZF E-modul, relay E13, wiring Short circuit to positive at output stage E-modul to Disconnect and check relay E13, if necessary exchange the relay; if o.k. disconnect E-modul plug X36 and check pin 14 toward ground for short circuit, if necessary repair or exchange the
76
manufacturer relay reverse light wire, if o.k. exchange the E-modul.
ZF / Vehicle ZF E-modul, relay E42, wiring Short circuit to positive at output stage to brake Disconnect and check relay E42, if necessary exchange the relay; if o.k. disconnect E-modul plug X36 and check pin 15 toward ground for short circuit, if necessary repair or exchange the
80
manufacturer pressure check valve wire, if o.k. exchange the E-modul.
ZF transmission actuator Short circuit to positive at output stage to Y1 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
81 (inertia brake valve)
ZF clutch actuator/ upper part of TCU Short circuit to positive at output stage to valve test the 20 pole transmission actuator plug to the clutch actuator between pin 9/11/15/10/7/8/12 and pin 18 (ADVP 24V plus) for short circuit, if there is a short circuit exchange clutch actuator
82 Y17 (clutch disengage slow) ZF No. 0501 212 474. If there is no short circuit then exchange upper part of TCU ZF No. 6009 298 004 with vehicle specific programming.

ZF clutch actuator Short circuit to positive at output stage to valve test the 20 pole transmission actuator plug to the clutch actuator between pin 9/11/15/10/7/8/12 and pin 18 (ADVP 24V plus) for short circuit, if there is a short circuit exchange clutch actuator
83 Y15 (clutch engage slow) ZF No. 0501 212 474. If there is no short circuit then exchange upper part of TCU ZF No. 6009 298 004 with vehicle specific programming.

ZF clutch actuator Short circuit to positive at output stage to valve test the 20 pole transmission actuator plug to the clutch actuator between pin 9/11/15/10/7/8/12 and pin 18 (ADVP 24V plus) for short circuit, if there is a short circuit exchange clutch actuator
84 Y16 (clutch disengage fast) ZF No. 0501 212 474. If there is no short circuit then exchange upper part of TCU ZF No. 6009 298 004 with vehicle specific programming.

ZF clutch actuator Short circuit to positive at output stage to valve test the 20 pole transmission actuator plug to the clutch actuator between pin 9/11/15/10/7/8/12 and pin 18 (ADVP 24V plus) for short circuit, if there is a short circuit exchange clutch actuator
85 Y14 (clutch engage fast) ZF No. 0501 212 474. If there is no short circuit then exchange upper part of TCU ZF No. 6009 298 004 with vehicle specific programming.

ZF / Vehicle output speed sensor transmission/ short circuit to positive at output ADVP or ADVP1 remove 35 pole E- module plug and measure voltage between pin 2 and 18 (ought to be 24 V); if voltage okay exchange E- module otherwise check more components, which are attached
manufacturer main wiring transmission/ (voltage supply to output speed sensor between pin 2 (E- module) and pin 11 (ADVP), (for USA versions check also pin 14 at the drive switch), exchange them if necessary; measure voltage at the transmissionsided output speed
electrical system of vehicle/ CAN transmission, E- module, display, warning lamp sensor plug between pin 1 and 2 (ought to be 24 V) if voltage okay change sensor, if voltage not okay test transmission main wiring pin 18 to pin 1 or pin 6 to pin 2 for interruption.
86 drive switch (only USA version) etc.)

ZF / Vehicle E- module/ electrical system of Short circuit to positive at output stage to warning Europe: Disconnect E-modul plug X36 and relay E68. Measure at E-modul pin 16 and at the relay base for short circuit to positive (terminal 15). USA: Disconnect plug at CAN drive switch
manufacturer vehicle/ relay E68/ CAN drive lamp ( E- module) A2 and relay E68. Measure at plug A2 pin 4 and at the relay base for short circuit to positive (terminal 15); if okay check relay E68 and exchange if necessary. (At USA version can happen
87 switch (only USA versions) that the CAN drive switch A2 is defect -> check, if necessary exchange the drive switch).

ZF / Vehicle clutch actuator/ electrical system Short circuit to positive at output SD to display Europe: Disconnect the plug at display A5. Check the display socket plug pin1 for short circuit against pin 2. Not okay exchange the display. If okay disconnect plug X1a, check from pin 9
manufacturer of vehicle towards pin 1/4/5/11 for short circuit. If there is an short circuit, check or exchange the vehicle sided wiring harness; if the harness okay, exchange upper part of TCU 6009 298 004. USA:
Disconnect the plug at drive switch A2. Check the socket plug pin 12 (CAN-H) and pin 11 (CAN-L) against pin 14 (VP) for short circuit. If there is an short circuit, exchange drive switch. If no
89 short circuit, diconnect plug X1a, check pin 3 (CAN-H) and pin 6 (CAN-L) towards pin 1/4/5/11 for short circuit. If short circuit, check the vehicle sided wiring harness, if necessary exchange
harness. If no short circuit, exchange upper part of TCU 6009 298 004.

ZF upper part of TCU Communication error between controller 1 and disconnect main electric current supply or ignition, if error is still existent undertake programming again, if necessary exchange upper part of TCU ZF No. 6009 298 004 vehicle specific
90 controller 2 (ECU failure) programming must be installed.

page 4 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

Vehicle EBS, Vehicle CAN CAN message timeout: "brake message" check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
91
manufacturer
Vehicle ABS brake control CAN error on "ABS active" signal (EBC1) check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
92 manufacturer
Vehicle ABS brake control CAN error on "ASR engine control active" signal check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
93
manufacturer (EBC1)
Vehicle ASR (anti slip control), CAN error on "ASR brake control active signal" check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
94 vehicle CAN
manufacturer
Vehicle Tacho, vehicle CAN, on- board CAN error on "Cruise control active" signal check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
95 manufacturer computer (CCVS)
Vehicle Tacho, on- board computer CAN error on "Cruise control set speed" (CCVS) check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
96 manufacturer
Vehicle on- board computer CAN error on "Engine speed" signal (EEC1) check engine speed sensor or signal flux to on- board computer
97 manufacturer
ZF lower part of TCU ZF signal error on transmission input speed according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
98
signal
ZF output speed sensor/ electrical ZF signal error on output speed signal 1 transmission with Intarder: exchange of transmission output speed sensor ZF No. 0501 210 855; check 24 V voltage supply at the output speed sensor plug between pin 18 and pin 6. Test
99 system of transmission signal flux between pin 11 at the 20 pole plug of the transmission main wiring and pin 4 at the output speed sensor plug for passing.

ZF / Vehicle ABS brake control / output speed CAN error on output speed signal 2 check CAN signal "speed of rear axle". Signal checkup from vehicle CAN to transmission actuator; transmission with Intarder: exchange of transmission output speed sensor ZF No. 0501 210
manufacturer sensor / ECU 855; check 24 V voltage supply at the output speed sensor plug between pin 18 and pin 6. Test signal flux between pin 11 at the 20 pole plug of the transmission main wiring and pin 4 at the
100 output speed sensor plug for good connection.

ZF / Vehicle output speed sensor / electrical Error on both output speed signals: ZF signal check CAN signal "speed of rear axle". Signal checkup from vehicle CAN to transmission actuator; transmission with Intarder: exchange of transmission output speed sensor ZF No. 0501 210
manufacturer system of transmission / ABS error "output speed signal 1" and CAN signal 855; check 24 V voltage supply at the output speed sensor plug between pin 18 and pin 6. Test signal flux between pin 11 at the 20 pole plug of the transmission main wiring and pin 4 at the
101 brake control error "output speed signal 2" output speed sensor plug for good connection.

ZF output speed sensor/ electrical Plausibility error between transmission input check CAN signal "speed of rear axle". Signal checkup from vehicle CAN to transmission actuator; transmission with Intarder: exchange of transmission output speed sensor ZF No. 0501 210
system of transmission / speed and output speed 855; check 24 V voltage supply at the output speed sensor plug between pin 18 and pin 6. Test signal flux between pin 11 at the 20 pole plug of the transmission main wiring and pin 4 at the
102 transmission actuator output speed sensor plug for good connection. As the case may be input speed error, sensor problem (lower part of TCU) or value fault (upper part of TCU)

Vehicle ABS / EBS, on-board computer, CAN error on "CCVS wheel-based vehicle speed" check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
103 manufacturer vehicle CAN signal
Vehicle electrical system of vehicle High voltage (Vehicle electrical system voltage check vehicle supply voltage, ought to be 19,5 - 29,5V, check battery power and ignition voltage.
104 manufacturer too high)
Vehicle electrical system of vehicle Low voltage (Vehicle electrical system voltage too check vehicle supply voltage, ought to be 19,5 - 29,5V, check battery power and ignition voltage.
105
manufacturer low)
ZF transmission actuator Stabilised voltage supply at output AU (clutch loosen the 20 pole transmission actuator plug, measure voltage between pin 15 and 20 (ought to be 4,6 - 5,8V), if okay exchange clutch actuator ZF No. 0501 212 474, if not okay exchange
107 sensor supply) out of valid range upper part of TCU ZF No. 6009 298 004 with suitable vehicle specific programming

page 5 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF / Vehicle speed range selector / electrical Error in selector lever or tip lever Loosen 35 pole plug at the E- module !
manufacturer system of vehicle selector lever position:
good connection between pin 17 and between R N D
pin 29: good no no
pin 11: no good no
pin 8 : no no good

tip lever position:

108 good connection between pin 17 and between reset position manual/ upshift downshift
automatic
pin 7 : good good no no
pin 25: no good no no
pin 26: no no no good
pin 28: no no good no

ZF / Vehicle E- module/ electrical system of ZF CAN timeout Exchange E- module, check ZF CAN wiring, check good connection between 35 pole E- module plug and 20 pole transmission actuator plug. Pin 20 CAN H (E- module) to pin 3 (
110 manufacturer vehicle transmission actuator 3) / pin 3 CAN-L (E- module) to pin 6 (transmission actuator 3)

Vehicle Tacho, vehicle CAN CAN message timeout: "TIME / DATE" Check tacho, if necessary exchange tacho; tacho okay, check CAN lines: measure at plug X1a pin 8 (CAN-H) towards pin 12 (CAN-L) and if necessary at Europe versions pin 14 (CAN-H+)
111 manufacturer towards pin 13 (CAN-L+). Ought to be 60 Ω.
Vehicle Tacho, vehicle CAN CAN error on "TIME / DATE" signal Check tacho, if necessary exchange tacho; tacho okay, check CAN lines: measure at plug X1a pin 8 (CAN-H) towards pin 12 (CAN-L) and if necessary at Europe versions pin 14 (CAN-H+)
112 manufacturer towards pin 13 (CAN-L+). Ought to be 60 Ω.
ZF / Vehicle EST42, on-board computer, CAN CAN message timeout: "Driveline retarder In case of errors in the EST42 proceed as described in the degraded mode list; If there are several CAN errors, check the CAN lines: measure at plug X1a pin 8 (CAN-H) towards pin 12
113 manufacturer wiring configuration" (CAN-L) and if necessary at Europe versions pin 14 (CAN-H+) towards pin 13 (CAN-L+). Ought to be 60 Ω; check on-board computers, if necessary exchange them.

ZF / Vehicle transmission / clutch clutch engaged unintentionally in standstill, gear check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be 119mm (Europe) or 145mm
manufacturer engaged (USA));check disengagement and lubrication of contact areas declutching bearing/ release fork, lubricate if necessary; check configuration of pressure plate/ driving disc according to
114 customer's specification.

ZF transmission / clutch Error in clutch self - adjustment process Is declutching bearing engaged? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be
119mm (Europe) or 145mm (USA)) ; check configuration of pressure plate/ driving disc according to customer's specification. Check spigot bearing within the fly- wheel; if error occurs
117 immediately after ignition is activated, exchange upper part of TCU ZF No. 6009 298 004.

ZF transmission / clutch clutch does not disengage Is declutching bearing engaged? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be
119mm (Europe) or 145mm (USA)); check configuration of pressure plate/ driving disc according to customer's specification. Check spigot bearing within the fly- wheel; if error occurs
118 immediately after ignition is activated, exchange upper part of TCU ZF No. 6009 298 004.

ZF transmission / clutch clutch does not engage/ does not transmit engine Is declutching bearing engaged? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be
torque 119mm (Europe) or 145mm (USA)); check configuration of pressure plate/ driving disc according to customer's specification. Check spigot bearing within the fly- wheel; if error occurs
119 immediately after ignition is activated, exchange upper part of TCU ZF No. 6009 298 004.

page 6 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF clutch actuator Mechanical failure of small disengagement clutch Is declutching bearing engaged? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be
120 valve Y17 119mm (Europe) or 145mm (USA)); exchange upper part of TCU if necessary ZF No. 6009 298 004.

ZF clutch actuator Mechanical failure of large disengagement clutch Is declutching bearing engaged? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be
121 valve Y16 119mm (Europe) or 145mm (USA)); exchange upper part of TCU if necessary ZF No. 6009 298 004.

ZF clutch actuator Mechanical failure of small engagement clutch Is declutching bearing engaged? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be
122 valve Y15 119mm (Europe) or 145mm (USA)); exchange upper part of TCU if necessary ZF No. 6009 298 004.

ZF clutch actuator Mechanical failure of large engagement clutch Is declutching bearing engaged? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be
123 valve Y14 119mm (Europe) or 145mm (USA)); exchange upper part of TCU if necessary ZF No. 6009 298 004.

ZF clutch actuator Error on clutch travel signal Is declutching bearing engaged? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 474; check length of tappet (ought to be
119mm (Europe) or 145mm (USA)) ; check configuration of pressure plate/ driving disc according to customer's specification. Check spigot bearing within the fly- wheel; check counting disc
124 for close fit and normal function (demounting of transmission actuator is necessary); if error occurs immediately after ignition is activated, exchange upper part of TCU ZF No. 6009 298 004.

ZF upper part of TCU Error on pressure sensor signal internal voltage problem at the pressure sensor inside the transmission actuator, according to frequency of occurence exchange upper part of TCU ZF No. 6009 298 004.
126

ZF upper part of TCU Error on ECU temperature sensor signal internal voltage problem at the temperature sensor inside the transmission actuator, according to frequency of occurence exchange upper part of TCU ZF No. 6009 298 004.
127

ZF lower part of TCU No shift sensor signal (Short circuit to positive) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
129

ZF transmission actuator No shift sensor signal (Short circuit to ground) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
130

131 ZF transmission actuator No shift sensor signal (Interruption) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
ZF transmission actuator / Self adjustment error of shift sensor check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm); piston rod of main
transmission transmission not engaged after exchange of transmission actuator; check end position value (end position_gears_even/uneven) 530- 580/80- 120. The error is situated in the main
132 transmission if the values lie outside this range. If error occurs sporadically exchange lower part of TCU ZF No. 6009 298 006

ZF transmission actuator No gate select sensor signal (short circuit to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
133 positive)
ZF transmission actuator No gate select sensor signal (short circuit to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
134
ground)
ZF transmission actuator No gate select sensor signal (interruption) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
135

ZF transmission actuator, Gate select sensor self adjustment error check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm); check end position value:
transmission (Anschlag_gasse_1/2 is:10/12 gear transmission gate R/1) ought to be 70-120 (end position_gate_3/4 is: 10/12 gear transmission gate 2/3) ought to be 500-580; The error is situated in the
136 main transmission if the values lie outside this range. If error occurs sporadically exchange lower part of TCU ZF No. 6009 298 006

page 7 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF transmission actuator No range change group (GP) sensor signal (short according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
137 circuit to positive)
ZF transmission actuator No range change group (GP) sensor signal (short according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
138
circuit to ground)
ZF transmission actuator No range change group (GP) sensor signal according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
139 (interruption)

ZF transmission actuator / Self adjustment error of range change group check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm); check end position value: (end
transmission sensor in position fast position_GPS) ought to be:490-590; (end position_GPL) ought to be:80-130. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically
140 exchange lower part of TCU ZF No. 6009 298 006

ZF transmission actuator No splitter group (GV) sensor signal (Short circuit according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
141 to positive)
ZF transmission actuator No splitter group (GV) sensor signal (Short circuit according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
142
to ground)
ZF transmission actuator No splitter group (GV) sensor signal (interruption) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006
143
ZF transmission actuator / Splitter group (GV) sensor self adjustment error check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm); check end position value: (end
transmission position_GVS) ought to be:500-620; (end position_GVL) ought to be:70-140. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically
144
exchange lower part of TCU ZF No. 6009 298 006

ZF transmission Range change group (GP) disengagement error shift up to gear 8; check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm); check
sensor travel signal, record Meßwert_Neu_GP, the measured value should not drift or show signal disturbances after GP shifting. If error occurs sporadically exchange lower part of TCU ZF
145 No. 6009 298 006. If the measured values are okay there is presumably a damage in the main transmission.

ZF transmission Changeover error during range change group carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal
(GP) shifting diameter (9mm); check end position value: (Anschlag_GPS) ought to be 490-590; (Anschlag_GPL) ought to be 80-130. Drive up to gear 8: record Meßwert_Neu_GP, the measured value
146 should not drift or show signal disturbances after GP shifting. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically exchange lower part
of TCU ZF No. 6009 298 006.

ZF transmission Range change group (GP) does not engage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal
diameter (9mm); check end position value: (Anschlag_GPS) ought to be 490-590; (Anschlag_GPL) ought to be 80-130. Drive up to gear 8: record Meßwert_Neu_GP, the measured value
147 should not drift or show signal disturbances after GP shifting. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically exchange lower part
of TCU ZF No. 6009 298 006.

ZF transmission Splitter (GV) does not disengage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal
diameter (9mm); check end position value: (Anschlag_GVS) ought to be 500-620; (Anschlag_GVL) ought to be 70-140. Drive up to gear 5: record Meßwert_Neu_GV, the measured value
148 should not drift or show signal disturbances after GV shifting. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically exchange lower part
of TCU ZF No. 6009 298 006.

page 8 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF transmission, e.g. boring in GV Change over error during splitter shifting carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal
synchronizer ring for take up of diameter (9mm); check end position value: (Anschlag_GVS) ought to be 500-620; (Anschlag_GVL) ought to be 70-140. Drive up to gear 5: record Meßwert_Neu_GV, the measured value
149 the 3 arresting pins is too big should not drift or show signal disturbances after GV shifting. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically exchange lower part
of TCU ZF No. 6009 298 006.

ZF transmission Splitter (GV) does not engage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal
diameter (9mm); check end position value: (Anschlag_GVS) ought to be 500-620; (Anschlag_GVL) ought to be 70-140. Drive up to gear 5: record Meßwert_Neu_GV, the measured value
150 should not drift or show signal disturbances after GV shifting. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically exchange lower part
of TCU ZF No. 6009 298 006.

ZF transmission Selector cylinder does not disengage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal
diameter (9mm); check end position value: (Anschlag_Gasse1/2) ought to be 70-120; (Anschlag_Gasse3/4) ought to be 500-580). Drive up to gear 4: record Meßwert_Neu_GA, after
151 selection the measured value should not drift or show signal disturbances. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically
exchange lower part of TCU ZF No. 6009 298 006.

ZF transmission change over error during gate selection carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal
procedure diameter (9mm); check end position value: (Anschlag_Gasse1/2) ought to be 70-120; (Anschlag_Gasse3/4) ought to be 500-580). Drive up to gear 4: record Meßwert_Neu_GA, after
152 selection the measured value should not drift or show signal disturbances. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically
exchange lower part of TCU ZF No. 6009 298 006.

153 ZF transmission selector cylinder does not engage as failure 152 before
ZF transmission Main transmission gear does not disengage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal
diameter (9mm); check clutch disengagement behaviour; check end position value: (Anschlag_Gaenge_gerade) ought to be 530-580; (Anschlag_Gaenge ungerade) ought to be 80-120.
Drive up to gear 6: record Meßwert_Neu_GE, after shifting the measured value should not drift or show signal disturbances. The error is situated in the main transmission if the values lie
154 outside this range. If error occurs sporadically exchange lower part of TCU ZF No. 6009 298 006.

155 ZF transmission Main transmission gear does not engage as failure 154 before
156 ZF transmission wrong gear shifting in main transmission as failure 154 before
ZF transmission actuator/ Gate select sensor signal (main transmission) test drive up to gear 4, record Meßwert_Neu_GA, after shifting the measured value should not drift or show signal disturbances. The error is situated in the main transmission if the values lie
157 transmission leaves engaged position outside this range. If error occurs sporadically exchange lower part of TCU ZF No. 6009 298 006.

ZF transmission actuator/ shift sensor signal (main transmission) leaves test drive up to gear 4, record Meßwert_Neu_GA, after shifting the measured value should not drift or show signal disturbances. The error is situated in the main transmission if the values lie
158 transmission engaged position during driving outside this range. If error occurs sporadically exchange lower part of TCU ZF No. 6009 298 006.

ZF transmission actuator/ range- change group sensor signal leaves test drive up to gear 12, record Meßwert_Neu_GP, after shifting the measured value should not drift or show signal disturbances. The error is situated in the main transmission if the values lie
159 transmission engaged position during driving outside this range. If error occurs sporadically exchange lower part of TCU ZF No. 6009 298 006.

ZF transmission actuator/ Splitter sensor signal leaves engaged position test drive up to gear 12, record Meßwert_Neu_GV, after shifting the measured value should not drift or show signal disturbances. The error is situated in the main transmission if the values lie
160 transmission during driving outside this range. If error occurs sporadically exchange lower part of TCU ZF No. 6009 298 006.

page 9 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF / Vehicle ZF E-Modul, switch E48, brake Additional brake switch for easy start function Check switch E48, if necessary exchange the switch; if the switch okay, disconnect plug X36 and measure pin 6 to other signal-guiding lines for short circuit; if okay exchange E-Modul; If the
161 manufacturer system, wiring supplies permanent signal or brake release not error still occour, let the vehicle manufacturer check the easy start system and / or the brake system.
completely
ZF / Vehicle ZF E-Modul, switch E48, relay Easy start system not available Check switch E48 and relay E42; if okay check the wiring to the switch E48 and relay E42; if okay exchange E-Modul; If the error still occour, let the vehicle manufacturer check the easy start
162 manufacturer E42, brake system, wiring system and / or the brake system.

Vehicle vehicle engine does not react on torque intervention error in on- board computer, check exhaust brake, it gets possibly stuck, check signal of foot brake switch, it gets possibly stuck
163
manufacturer (increasing engine speed)
Vehicle on- board computer error on "Drivers demand engine percent torque" error in on- board computer, check accelerator pedal Alpha_FP and z_kd; ought to be 0-100% then kickdown signal; plug connection accelerator pedal; test cruise control for function
164 manufacturer (EEC 1)
Vehicle accelerator pedal, EDC, vehicle CAN error on "Accelerator pedal position" signal If several CAN errors pending, check CAN lines: ought to be 60 Ω; if okay check EDC and / or accelerator pedal and change if necessary.
165 manufacturer CAN
Vehicle on- board computer permanent idle signal check accelerator pedal Low idle signal, ought to be: depression >4%+/- 2%, error in on- board computer, check check accelerator pedal Alpha_FP and z_kd; ought to be 0-100% then
166 manufacturer kickdown signal; plug connection accelerator pedal; test cruise control for function

Vehicle on- board computer error on "Percent load at current speed" signal error is set when engine is ongoing, failure No. 27 when engine is off! Error in on- board computer, check accelerator pedal Alpha_FP and z_kd; ought to be 0-100% then kickdown signal;
167 manufacturer (EEC2) plug connection accelerator pedal; test cruise control for function

Vehicle on- board computer error on "AP low idle switch" or never active "idle check accelerator pedal Low idle signal, ought to be: depression >4%+/- 2%, error in on- board computer, check accelerator pedal Alpha_FP and z_kd; ought to be 0-100% then kickdown
168 manufacturer signal" signal; plug connection accelerator pedal; test cruise control for function

ZF transmission actuator Cut- off relay in ECU does not switch off according to frequency of occurence, exchange upper part of TCU ZF No. 6009 298 005 with suitable vehicle specific programming
169

ZF / Vehicle transmission actuator/ electrical no voltage supply at pin 30 or cut - off relay in check voltage supply at transmission actuator between pin 4/5 to pin 16 or 17, ought to be : 20-24V, if voltage < 18,0 V,check chassis side electrical connection and power supply, if voltage is
170 manufacturer system of vehicle ECU does not switch on okay exchange upper part of TCU ZF No. 6009 298 004 with suitable vehicle specific programming

Vehicle on- board computer, vehicle CAN error on "Actual engine percent torque" signal necessary for ISMA, check on-board computer, electrical CAN connections
171 manufacturer
Vehicle on- board computer, brake error on "Brake switch" signal (CCVS) check brake pressure switch z_fbr, switch on/ switch off pressure point and behaviour, if there is no foot brake signal when foot brake is used, ISMA calculates like ascent because of the
173 manufacturer pressure switch retarding and shifts into gear 1 when vehicle is in standstill
Vehicle on- board computer, kick-down error on "Kickdown switch" signal defined switching point: Kickdown z_kd > 97% accelerator pedal, kickdown switch and kickdown function can be integrated in the accelerator pedal or can take place ,by a seperate pressure
174 manufacturer switch switch, pay attention to pressure point and adjustment.
Vehicle electrical system of vehicle error on "Ignition lock" signal (key 15) check voltage supply at transmission actuator, check fuse, ought to be 10A fuse; between pin 1 to pin 16 or 17, ought to be : 20-24V, if voltage < 18,0 V, check chassis side electrical
175 manufacturer connection and power supply, if voltage is okay exchange upper part of TCU ZF No. 6009 298 004, vehicle specific programming must be installed.

ZF / Vehicle transmission actuator/ vehicle system- CAN Busoff error check CAN connections, ought to be 60Ω; check maximum allowable length of CAN line: 3m, if all resistances and CAN connections are okay exchange upper part of TCU ZF No. 6009 298
177 manufacturer CAN 004, vehicle specific programming must be installed.
ZF / Vehicle transmission actuator/ vehicle CAN Errorwarning check CAN connections, ought to be 60Ω; check maximum allowable length of CAN line: 3m, if all resistances and CAN connections are okay exchange upper part of TCU ZF No. 6009 298
178 manufacturer CAN 004, vehicle specific programming must be installed.

page 10 von 11 created by: MKS-IR, Stoll

 Fault code and repair instruction AS-Tronic for VAN HOOL with Softwareversion V31_13e2 status:2004-07-30

responsibility
ZF-failure No.

cause of failure/
fault description repair instruction
component

ZF / Vehicle transmission actuator/ vehicle CAN queue overrun check CAN connections, ought to be 60Ω; check maximum allowable length of CAN line: 3m, take off all CAN paticipants one after another until failure No. 179 is not active any more,
179 manufacturer CAN exchange defective control unit, if all resistances and CAN connections are okay exchange upper part of TCU ZF No. 6009 298 004 with suitable vehicle specific programming

ZF transmission actuator ECU fault - wrong interrupt disconnect main electric current supply or ignition, if error is still existent undertake programming again, if necessary exchange upper part of TCU ZF No. 6009 298 004 vehicle specific
188 programming must be installed.

189 ZF transmission actuator ECU fault - stack watch as failure 188 before
ZF transmission actuator EOL EEPROM parameter out of valid range as failure 188 before
190

ZF transmission actuator EOL EEPROM parameter chechsum error as failure 188 before
191

192 ZF transmission actuator ECU fault - EEPROM access failure as failure 188 before
ZF transmission actuator ECU temperature too high failure is set when ECU temperature > 125°C, gear oil > 130°C ,oil cooler defective, too little, too much oil, wrong type of oil, turbo charger defective or leaking, exhaust pipe system above
193 the transmission actuator is mounted too close or is leaking ( insulation defective)

Vehicle ABS brake control both sources for front axle speed not available front axle speed sensor /ABS/EBS CAN signal, check plug and wiring; check ZF output speed sensor signal, exchange it if necessary
194
manufacturer
Vehicle ABS brake control error on "Front axle speed" signal (WSI) front axle speed sensor /ABS/EBS CAN signal, check plug and wiring
197
manufacturer
Vehicle ABS brake control / ASR CAN error on "Relative wheel speed" signal front axle speed sensor /ABS/EBS CAN signal, check plug and wiring
198 manufacturer anti slip control, vehicle
CAN
Vehicle ABS brake control / ASR CAN message timeout: "Wheel speed front axle speed sensor /ABS/EBS CAN signal, check plug and wiring
199 manufacturer anti slip control, vehicle information" (WSI)
CAN
ZF transmission actuator Application- Error database for CAN- disconnect main electric current supply or ignition, if error is still existent undertake programming again, if necessary exchange upper part of TCU ZF No. 6009 298 004 vehicle specific
227 communication programming must be installed.

page 11 von 11 created by: MKS-IR, Stoll