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ZF FRIEDRICHSHAFEN Aktiengesellschaft Benennung: fault codes Nr.: DIN Seite 1 Zusatzbenennung: description of fault codes for Ergo control A4 von 38 Diese technische Unterlage darf weder kopiert 09-10-22 Schwarz noch dritten Personen ohne unsere Erlaubnis 34 mitgeteilt werden. Index Nr. Datum Name K3 ZFN 904 ÄNDERUNGEN Erstellt: Geprüft: Freigegeben : Name: Plank Sieger Abteilung: ACETS TE-AB Datum: 2011-02-21 03-10-01

Film

Description of the fault codes for ERGO-Control EST37

document created for customer "Hyundai construction machineries"

2011-02-21

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

11-02-21

Index of changes: date

TE-AB

index

comment

software version

Seite 2 von 38

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

11-02-21

1 Introduction 1.1 Abbreviations o.c. s.c. OP-Mode TCU EEC PTO

open circuit short circuit operating mode transmission control unit electronic engine controller power take off

1.2 ZF - Display: If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault code, if the gear selector is on neutral position. If more than one fault is detected, each fault code is shown for about 1 second. h

f

e

d

a

b

c

left character

right character

S T O P g

(special symbols a-h)

1.3 Display during operation Symbol meaning

remarks

1F, 1R 2F, 2R 3F, 3R 4F 5F 6F LF, LR F or R, no gear F or R flashing

CAUTION gear will engage if turbine speed drops

NN ** *N 1 bar (special TE-AB

actual gear and direction left digit shows actual gear right digit shows actual direction

limp home gear Clutch Cutoff direction F or R selected while turbine speed is too high not neutral, waiting for neutral after power up or a severe fault oil temperature too low, no gear available oil temperature low, only one gear available manual mode 1st gear

to engage a gear, first move shift selector to neutral position and again to F or R position warm up engine / transmission warm up engine / transmission

Seite 3 von 38

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A symbol) 2 bars 3 bars 4 bars 4 bars and 2 arrows Bars flashing

Spanner Fault code WS

WR

WT

WE

WV

WL

WO

PN

EE flashing

TE-AB

11-02-21

manual mode 2nd gear manual mode 3rd gear manual mode 4th gear and also 5th and 6th gear in 6WG automatic mode 6 WG: converter lockup clutch open 4 WG: Downshift mode activ at least one fault activ see faultcode list warning sump temperature

difference of engine and turbine speed above a certain limit and lockup clutch not activated select neutral to get fault code displayed

changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) warning retarder temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) warning torque converter temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) warning high engine speed changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) warning high output speed (velocity) changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) warning high transmission input torque changes between actual gear/direction while driving, (load) in neutral only displayed if no fault is detected (spanner) warning high transmission output torque changes between actual gear/direction while driving, (load) in neutral only displayed if no fault is detected (spanner) direction F or R selected while parking transmission in neutral until parking brake is released brake engaged CAUTION: vehicle starts to move after release of parking brake no communication with display checked wiring from TCU to display

Seite 4 von 38

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

1.4 Display during AEB-Mode symbol meaning AEB - Starter is plugged at the PL ST K1..K4,KV,KR , KW _ and Kx ≡ and Kx = and Kx

wait for start, initialization of clutch Kx, x: 1, 2, 3, 4, V, R, W fast fill time determination of clutch Kx

OK STOP

AEB canceled (activation stopped)

STOP and Kx

AEB stopped, clutch Kx can't be calibrated Kx couldn't be calibrated, AEB finished

FO

engine speed too low,
raise engine speed engine speed too high,
lower engine speed transmission oil temperature too low,
heat up transmission transmission oil temperature too high
cool down transmission transmission temperature not in defined range during calibration operating mode not NORMAL or transmission temperature sensor defective or storing of Calibrated values to EEPROM-has failed. Outputspeed_not_zero

FN

Shift lever not in Neutral position

FP

Parkbrake_not_applied

STOP

AEB - Starter was used incorrect or is defective. Wrong device or wrong cable used

∆E ∇E ∆T ∇T FT FB

TE-AB

remarks

diagnostic plug AEB-Starter-button is pressed calibrating clutch K1..K4, KV or KR, KW is lockup clutch

compensating pressure determination of clutch Kx calibration for all clutches finished

Spanner and Kx

11-02-21

Transmissions stays in neutral, you have to restart the TCU (ignition off/on) after removing AEB-Starter Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

Seite 5 von 38

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

1.5 Display during Inchpedal Calibration symbol meaning IP ⇓ IP ⇑ IP ⇑ flashing OK FN and Stop FS and Stop FO and Stop SL and Stop SU and Stop IL and Stop IU and Stop TO and Stop DL and Stop DU and Stop FI and Stop

TE-AB

11-02-21

remarks

push down the pedal slowly until endposition is reached and hold this position Release the pedal slowly until endposition is reached A problem occurred, release the pedal slowly until endposition is reached Finished inchpedal calibration successful Shift lever not in Neutral position sensor supply voltage AU1 is out of the specified range Outputspeed is not zero sensor voltage below specified rangel sensor voltage above specified rangel sensor position for released pedal out of specified range sensor position for pressed pedal out of specified range time-out calibration, pedal not moved after calibration start angle between pedalpositions released and pressed to small angle between pedalpositions released and pressed to big sensor signal 1 and 2 don't match together

If the expected enposition could not be reached, release the pedal and try again

Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted Calibration is aborted

Seite 6 von 38

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

11-02-21

2 definition of operating modes NORMAL: There's no failure detected in the transmission-system or the failure has no or slight effects on transmission control. TCU will work without or in special cases with little limitations. (see following table) SUBSTITUTE CLUTCH CONTROL: TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU uses the substitute strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25) LIMP-HOME: The detected failure in the system has strong limitations to transmission control. TCU can engage only one gear in each direction. In some cases only one direction will be possible. TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift the gear selector into neutral position. If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or reverse, the TCU will select the limp-home gear . If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected direction. If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position. TRANSMISSION-SHUTDOWN: TCU has detected a severe failure that disables control of the transmission. TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8. The operator has to slow down the vehicle. The transmission will stay in neutral. TCU-SHUTDOWN: TCU has detected a severe failure that disables control of system. TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake will engage, also all functions are disabled which use ADM 1 to ADM 8. The transmission will stay in neutral.

TE-AB

Seite 7 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

11-02-21

3 table of fault codes Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection

10

5001

12

LOGICAL ERROR AT DIRECTION SELECT SIGNAL 3RD SHIFT LEVER

TCU shifts transmission to neutral if selector activ TCU detected a wrong signal combination OP-Mode: transmission for the direction shutdown if selector activ • cable from shift lever 3 to TCU is broken • cable is defective and is contacted to battery voltage or vehicle ground • shift lever is defective

• check the cables from TCU to shift lever fault is cleared if TCU detects a valid neutral signal for the 3 • check signal combinations of shift lever direction at the shift lever positions F-N-R • if shift lever is a CAN shift lever check CAN cable/shifter/device

11

5000

12

LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to TCU detected a wrong signal combination neutral for the gear range OP-Mode: transmission • cable from shift lever to TCU is broken shutdown • cable is defective and is contacted to battery voltage or vehicle ground • shift lever is defective

• check the cables from TCU to shift lever fault is taken back if TCU • check signal combinations of shift lever detects a valid signal for the positions for gear range position

12

5010

12

TCU shifts transmission to neutral TCU detected a wrong signal combination OP-Mode: transmission for the direction shutdown • cable from shift lever to TCU is broken • cable is defective and is contacted to battery voltage or vehicle ground • shift lever is defective

• check the cables from TCU to shift lever fault is taken back if TCU • check signal combinations of shift lever detects a valid signal for the direction at the shift lever positions F-N-R

13

5020

12

LOGICAL ERROR AT ENGINE DERATING DEVICE

•

LOGICAL ERROR AT DIRECTION SELECT SIGNAL

after selecting neutral, TCU changes to OP-Mode limp home

check engine derating device

This fault is reset after power up of TCU

TCU detected no reaction of engine while derating device activ TE-AB

Seite 8 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex) 14

5030

12

MEANING OF THE FAULT CODE

5040

12

16

5050

12

reaction of the TCU

LOGICAL ERROR AT PARKBRAKE STATUS

5110

3

TCU shifts transmission to neutral if selector activ TCU detected a wrong signal combination OP-Mode: transmission for the direction shutdown if selector activ • cable from shift lever 2 to TCU is broken • cable is defective and is contacted to battery voltage or vehicle ground • shift lever is defective LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2. SHIFT LEVER

LOGICAL ERROR AT AXLE CONNECTION

S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION SUMP TEMPERATURE SENSOR INPUT

the measured voltage is too high: • cable is defective and is contacted to TE-AB

remarks

TCU shifts transmission to DCO- • check the cables from electronic boxes State to status switches OP-Mode: normal • check signals of the status switches

• check the cables from TCU to shift lever 2 • check signal combinations of shift lever positions F-N-R

OP-Mode: normal

• check the cables from TCU to feedback axle connection switch • check signals of the feedback axle connection switch

no reaction, TCU uses default temperature OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the temperature sensor

feedback axle connection measured by TCU and output signal axle connection don't fit • axle can’t be connected or disconnected due to mechanical problem • one of the cables from feedback axle connection -switch to TCU is broken 25

possible steps to repair

possible reason for fault detection

Parkbrake-status-signal measured by TCU and parkbrake-status-signal send by CAN don't fit • one of the cables from status-switch to electronic box is broken • one of the status-switches is defective 15

11-02-21

fault is taken back if TCU detects a valid neutral signal for the direction at the shift lever

Seite 9 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection battery voltage • cable has no connection to TCU • temperature sensor has an internal defect • connector pin is contacted to battery voltage or is broken

26

5110

4

S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE SENSOR INPUT

the measured voltage is too low: • cable is defective and is contacted to vehicle ground • temperature sensor has an internal defect • connector pin is contacted to vehicle ground 27

5120

3

S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER / TORQUECONVERTER TEMPERATURE SENSOR INPUT

no reaction, TCU uses default temperature OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the temperature sensor

no reaction, TCU uses default temperature OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the temperature sensor

no reaction, TCU uses default temperature OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the temperature sensor

the measured voltage is too high: • cable is defective and is contacted to battery voltage • cable has no connection to TCU • temperature sensor has an internal defect • connector pin is contacted to battery voltage or is broken 28

5120

4

S.C. TO GROUND AT RETARDER / TORQUECONVERTER TEMPERATURE SENSOR INPUT

the measured voltage is too low: • cable is defective and is contacted to vehicle ground TE-AB

Seite 10 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • temperature sensor has an internal defect • connector pin is contacted to vehicle ground

29

5130

3

S.C. TO BATTERY VOLTAGE OR O.C. AT PARKING BRAKE SENSOR INPUT

TCU uses default value OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the parking brake sensor

TCU uses default value OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the parking brake sensor

the measured voltage is too high: • cable is defective and is contacted to battery voltage • cable has no connection to TCU • sensor has an internal defect • connector pin is contacted to battery voltage or is broken 2A

5130

4

S.C. TO GROUND PARKING BRAKE SENSOR INPUT

the measured voltage is too low: • cable is defective and is contacted to vehicle ground • sensor has an internal defect • connector pin is contacted to vehicle ground 2B

5313

12

2C

5135

3

INCHSENSOR-SIGNAL MISMATCH the measured voltage from CCO and CCO2 signal don’t match: • cable is defective • sensor has an internal defect

During inching mode: TCU shifts • check the cable from TCU to the sensor to neutral • check the connectors While not inching: no change • check sensor OP-Mode: normal

S.C. TO BATTERY VOLTAGE OR O.C. AT DLM TRACTION ADJUST DASHBOARD DEVICE INPUT

TCU uses default value OP-Mode: normal

the measured voltage is too high: TE-AB

• check the cable from TCU to the sensor • check the connectors • check the DLM Traction Adjust dashboard device Seite 11 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • cable is defective and is contacted to battery voltage • cable has no connection to TCU • sensor has an internal defect • connector pin is contacted to battery voltage or is broken

2D

5135

4

S.C. TO GROUND DLM TRACTION ADJUST DASHBOARD DEVICE INPUT

TCU uses default value OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the DLM Traction Adjust dashboard device

TCU uses default value OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the DLM STEERING ANGLE SENSOR

TCU uses default value OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the DLM STEERING ANGLE SENSOR

the measured voltage is too low: • cable is defective and is contacted to vehicle ground • sensor has an internal defect • connector pin is contacted to vehicle ground 2E

5137

3

S.C. TO BATTERY VOLTAGE OR O.C. AT DLM STEERING ANGLE SENSOR INPUT

the measured voltage is too high: • cable is defective and is contacted to battery voltage • cable has no connection to TCU • sensor has an internal defect • connector pin is contacted to battery voltage or is broken 2F

5137

4

S.C. TO GROUND DLM STEERING ANGLE SENSOR INPUT

the measured voltage is too low: • cable is defective and is contacted to vehicle ground • sensor has an internal defect • connector pin is contacted to vehicle ground

TE-AB

Seite 12 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex) 31

5140

3

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

5140

4

33

5140

12

S.C. TO BATTERY VOLTAGE OR O.C. AT ENGINE SPEED INPUT

OP-Mode: substitute clutch control

• check the cable from TCU to the sensor • check the connectors • check the speed sensor

S.C. TO GROUND AT ENGINE SPEED INPUT TCU measures a voltage less than 0.45V at speed input pin • cable / connector is defective and is contacted to vehicle ground • speed sensor has an internal defect

OP-Mode: substitute clutch control

• check the cable from TCU to the sensor • check the connectors • check the speed sensor

LOGICAL ERROR AT ENGINE SPEED INPUT

OP-Mode: substitute clutch control

• • • •

OP-Mode: substitute clutch control if a failure is existing at output speed, TCU shifts to neutral OP-Mode: limp home

• check the cable from TCU to the sensor • check the connectors • check the speed sensor

TCU measures a engine speed over a threshold and the next moment the measured speed is zero • cable / connector is defective and has bad contact • speed sensor has an internal defect • sensor gap has the wrong size 34

5150

3

S.C. TO BATTERY VOLTAGE OR O.C. AT TURBINE SPEED INPUT

TCU measures a voltage higher than 7.00 V at speed input pin • cable is defective and is contacted to battery voltage • cable has no connection to TCU • speed sensor has an internal defect TE-AB

remarks

possible reason for fault detection

TCU measures a voltage higher than 7.00 V at speed input pin • cable is defective and is contacted to battery voltage • cable has no connection to TCU • speed sensor has an internal defect • connector pin is contacted to battery voltage or has no contact 32

possible steps to repair

check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap

This fault is reset after power up of TCU

Seite 13 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • connector pin is contacted to battery voltage or has no contact

35

5150

4

36

5150

12

S.C. TO GROUND AT TURBINE SPEED INPUT TCU measures a voltage less than 0.45V at speed input pin • cable / connector is defective and is contacted to vehicle ground • speed sensor has an internal defect

OP-Mode: substitute clutch control if a failure is existing at output speed, TCU shifts to neutral OP-Mode: limp home

• check the cable from TCU to the sensor • check the connectors • check the speed sensor

LOGICAL ERROR AT TURBINE SPEED INPUT

OP-Mode: substitute clutch control if a failure is existing at output speed, TCU shifts to neutral OP-Mode: limp home

• • • •

OP-Mode: substitute clutch control

• check the cable from TCU to the sensor • check the connectors • check the speed sensor

S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch TCU measures a voltage less than 0.45V control at speed input pin • cable / connector is defective and is contacted to vehicle ground

• check the cable from TCU to the sensor • check the connectors • check the speed sensor

TCU measures a turbine speed over a threshold and at the next moment the measured speed is zero • cable / connector is defective and has bad contact • speed sensor has an internal defect • sensor gap has the wrong size 37

5160

3

S.C. TO BATTERY VOLTAGE OR O.C. AT INTERNAL SPEED INPUT

TCU measures a voltage higher than 7.00 V at speed input pin • cable is defective and is contacted to battery voltage • cable has no connection to TCU • speed sensor has an internal defect • connector pin is contacted to battery voltage or has no contact 38

TE-AB

5160

4

check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap

This fault is reset after power up of TCU

Seite 14 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • speed sensor has an internal defect

39

5160

12

LOGICAL ERROR AT INTERNAL SPEED INPUT

TCU measures a internal speed over a threshold and at the next moment the measured speed is zero • cable / connector is defective and has bad contact • speed sensor has an internal defect • sensor gap has the wrong size 3A

5170

3

S.C. TO BATTERY VOLTAGE OR O.C. AT OUTPUT SPEED INPUT

TCU measures a voltage higher than 12.5 V at speed input pin • cable is defective and is contacted to battery voltage • cable has no connection to TCU • speed sensor has an internal defect • connector pin is contacted to battery voltage or has no contact 3B

5170

4

3C

5170

12

S.C. TO GROUND AT OUTPUT SPEED INPUT TCU measures a voltage less than 1.00V at speed input pin • cable / connector is defective and is contacted to vehicle ground • speed sensor has an internal defect LOGICAL ERROR AT OUTPUT SPEED INPUT

TCU measures a output speed over a threshold and at the next moment the measured speed is zero • cable / connector is defective and has bad contact TE-AB

OP-Mode: substitute clutch control

• • • •

special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral OP-Mode: limp home

• check the cable from TCU to the sensor • check the connectors • check the speed sensor

special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral OP-Mode: limp home special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral

• check the cable from TCU to the sensor • check the connectors • check the speed sensor

• • • •

check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap

check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap

This fault is reset after power up of TCU

This fault is reset after power up of TCU

Seite 15 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

3E

5180

2

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

This fault is reset after power up of TCU

possible reason for fault detection • speed sensor has an internal defect • sensor gap has the wrong size

OP-Mode: limp home

OUTPUT SPEED ZERO DOESN’T FIT TO OTHER SPEED SIGNALS

special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral OP-Mode: limp home

• check the sensor signal of output speed sensor • check the sensor gap of output speed sensor • check the cable from TCU to the sensor

if transmission is not neutral and the shifting has finished, TCU measures outputspeed zero and turbine speed or internal speed not equal to zero. • speed sensor has an internal defect • sensor gap has the wrong size 54

5260

9

DCT1 TIMEOUT Timeout of CAN-message DCT1 from display computer • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to vehicle ground or battery voltage

OP-Mode: normal

• check display computer • check wire of CAN-Bus • check cable to display computer

55

5270

9

JSS TIMEOUT Timeout of CAN-message JSS from Joystick Steering Controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to vehicle ground or battery voltage

TCU shifts to neutral while Joystick Steering is active OP-Mode: normal

• check Joystick steering controller • check wire of CAN-Bus • check cable to Joystick steering controller

56

5280

9

ENGINE CONF TIMEOUT Timeout of CAN-message ENGINE CONF from engine controller • interference on CAN-Bus

OP-Mode: substitute clutch control

• check engine controller • check wire of CAN-Bus • check cable to engine controller

TE-AB

Seite 16 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • CAN wire/connector is broken • CAN wire/connector is defective and has contact to vehicle ground or battery voltage

57

5290

9

EEC1 TIMEOUT Timeout of CAN-message EEC1 from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to vehicle ground or battery voltage

OP-Mode: substitute clutch control

• check EEC controller • check wire of CAN-Bus • check cable to EEC controller

58

5300

9

EEC3 TIMEOUT Timeout of CAN-message EEC3 from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective an has contact to vehicle ground or battery voltage

OP-Mode: substitute clutch control

• check EEC controller • check wire of CAN-Bus • check cable to EEC controller

59

5310

2

no reaction

• check programming of vehicle controller

61

5390

2

AEB-REQUEST AND PARKBRAKETEST SIGNALS ON AT THE SAME TIME CAN signal for AEB-Request and for ParkbrakeTest are ON at the same time AEB REQUEST SIGNAL CAN signal for AEB request is defective • I/O controller is defective • interference on CAN-Bus

no reaction OP-Mode: normal Last selection is kept

• check I/O controller • check wire of CAN-Bus • check cable to I/O controller

65

5430

2

ENGINGE TORQUE SIGNAL

OP-Mode:substitute clutch control

• check engine controller • check wire of CAN-Bus • check cable to engine controller

CAN signal for engine torque is defective • engine controller is defective TE-AB

Seite 17 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • interference on CAN-Bus

69

5440

2

REFERENCE ENGINE TORQUE SIGNAL

CAN signal for reference of engine torque is defective • engine controller is defective • interference on CAN-Bus 6A

5450

2

ACTUAL ENGINE TORQUE SIGNAL

CAN signal for actual engine torque is defective • engine controller is defective • interference on CAN-Bus 6B

5460

2

NOM FRICTION TORQUE SIGNAL

CAN signal for nominal friction torque is defective • engine controller is defective • interference on CAN-Bus

OP-Mode:substitute clutch control

• check engine controller • check wire of CAN-Bus • check cable to engine controller

OP-Mode:substitute clutch control

• check engine controller • check wire of CAN-Bus • check cable to engine controller

OP-Mode:substitute clutch control

• check engine controller • check wire of CAN-Bus • check cable to engine controller

6E

5470

2

EEC2 TIMEOUT Timeout of CAN-message EEC2 from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to vehicle ground or battery voltage

no reaction, TCU uses default signal accelerator pedal in idle position OP-Mode: normal

• check EEC controller • check wire of CAN-Bus • check cable to EEC controller

71

5480

3

S.C. TO BATTERY VOLTAGE AT CLUTCH K1

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from TCU to the gearbox • check the regulator resistance 1) • check internal wire harness of the

the measured resistance value of the valve is out of limit, the voltage at K1 valve is too high. • cable / connector is defective and has contact to battery voltage TE-AB

1)

see chapter 4

Seite 18 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

5480

4

S.C. TO GROUND AT CLUTCH K1

the measured resistance value of the valve is out of limit, the voltage at K1 valve is too low. • cable / connector is defective and has contact to vehicle ground • cable / connector is defective and has contact to another regulator output of the TCU • regulator has an internal defect 73

5480

5

O.C. AT CLUTCH K1

the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to TCU • regulator has an internal defect 74

5490

3

S.C. TO BATTERY VOLTAGE AT CLUTCH K2

the measured resistance value of the valve is out of limit, the voltage at K2 valve is too high. • cable / connector is defective and has contact to battery voltage • regulator has an internal defect 75

5490

4

S.C. TO GROUND AT CLUTCH K2

the measured resistance value of the valve is out of limit, the voltage at K2 valve is too low. • cable / connector is defective and has contact to vehicle ground • cable / connector is defective and has TE-AB

remarks

possible reason for fault detection gearbox

• regulator has an internal defect 72

possible steps to repair

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox • check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

1)

see chapter 4

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

Seite 19 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection contact to another regulator output of the TCU • regulator has an internal defect

76

5490

5

O.C. AT CLUTCH K2

the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to TCU • regulator has an internal defect 77

5500

3

S.C. TO BATTERY VOLTAGE AT CLUTCH K3

the measured resistance value of the valve is out of limit, the voltage at K3 valve is too high. • cable / connector is defective and has contact to battery voltage • regulator has an internal defect 78

5500

4

S.C. TO GROUND AT CLUTCH K3

the measured resistance value of the valve is out of limit, the voltage at K3 valve is too low. • cable / connector is defective and has contact to vehicle ground • cable / connector is defective and has contact to another regulator output of the TCU • regulator has an internal defect 79

5500

5

O.C. AT CLUTCH K3

the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to TCU TE-AB

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox • check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1)

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

Seite 20 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • regulator has an internal defect

OP-Mode: TCU shutdown

7A

5540

3

S.C. TO BATTERY VOLTAGE AT CONVERTER CLUTCH

no reaction OP-Mode: normal

7B

5540

4

S.C. TO GROUND AT CONVERTER CLUTCH

CONVERTER LOCK UP CLUTCH SOLENOID CONNECTED AT ADMX:

• check internal wire harness of the gearbox • check the cable from TCU to the valve • check the regulator resistance 1) • check the cable from TCU to the valve • check the regulator resistance 1)

TCU switch off VPS2 OP-mode: normal CONVERTER LOCK UP CLUTCH SOLENOID CONNECTED AT AIP7:

TCU switch off VPS2 OP-mode: normal 7C

5540

5

O.C. AT CONVERTER CLUTCH

81

5510

3

S.C. TO BATTERY VOLTAGE AT CLUTCH K4

the measured resistance value of the valve is out of limit, the voltage at K4 valve is too high. • cable / connector is defective and has contact to battery voltage • regulator has an internal defect 82

5510

4

S.C. TO GROUND AT CLUTCH K4

the measured resistance value of the valve is out of limit, the voltage at K4 valve is too low. • cable / connector is defective and has contact to vehicle ground • cable / connector is defective and has contact to another regulator output of the TCU • regulator has an internal defect TE-AB

no reaction OP-Mode: normal TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the valve • check the regulator resistance 1) • check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

1)

see chapter 4

Seite 21 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex) 83

5510

5

MEANING OF THE FAULT CODE

5520

3

O.C. AT CLUTCH K4

S.C. TO BATTERY VOLTAGE AT CLUTCH KV

the measured resistance value of the valve is out of limit, the voltage at KV valve is too high. • cable / connector is defective and has contact to battery voltage • regulator has an internal defect 85

5520

4

S.C. TO GROUND AT CLUTCH KV

the measured resistance value of the valve is out of limit, the voltage at KV valve is too low. • cable / connector is defective and has contact to vehicle ground • cable / connector is defective and has contact to another regulator output of the TCU • regulator has an internal defect 86

5520

5

O.C. AT CLUTCH KV

the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to TCU • regulator has an internal defect

TE-AB

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection

the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to TCU • regulator has an internal defect 84

11-02-21

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox • check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

Seite 22 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex) 87

5530

3

MEANING OF THE FAULT CODE

5530

4

S.C. TO BATTERY VOLTAGE AT CLUTCH KR

S.C. TO GROUND AT CLUTCH KR

the measured resistance value of the valve is out of limit, the voltage at KR valve is too low. • cable / connector is defective and has contact to vehicle ground • cable / connector is defective and has contact to another regulator output of the TCU • regulator has an internal defect 89

5530

5

O.C. AT CLUTCH KR

the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to TCU • regulator has an internal defect 8A

5535

4

S.C. TO GROUND AT DLM TRANSVERSAL OUTPUT

TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • device has an internal defect • connector pin is contacted to vehicle TE-AB

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection

the measured resistance value of the valve is out of limit, the voltage at KR valve is too high. • cable / connector is defective and has contact to battery voltage • regulator has an internal defect 88

11-02-21

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox

1)

see chapter 4

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox • check the connectors from gearbox to TCU • check the regulator resistance 1) • check internal wire harness of the gearbox • check the cable from TCU to the valve • check the connectors • check the resistance of valve

1)

see chapter 4

1)

see chapter 4

output will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal

Seite 23 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection ground

8B

5535

3

S.C. TO BATTERY VOLTAGE AT DLM TRANSVERSAL OUTPUT

no reaction OP-Mode: normal

• check the cable from TCU to the valve • check the connectors • check the resistance of valve

1)

see chapter 4

no reaction OP-Mode: normal

• check the cable from TCU to the valve • check the connectors • check the resistance of valve

1)

see chapter 4

output will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal

• check the cable from TCU to the device • check the connectors • check the resistance of device

1)

see chapter 4

no reaction OP-Mode: normal

• check the cable from TCU to the device • check the connectors

1)

see chapter 4

TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • device has an internal defect • connector pin is contacted to battery voltage 8C

5535

5

O.C. AT DLM TRANSVERSAL OUTPUT

TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • device has an internal defect • connector has no connection to TCU 8D

5536

4

S.C. TO GROUND AT DLM INDICATOR LAMP OUTPUT

TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • device has an internal defect • connector pin is contacted to vehicle ground 8E

TE-AB

5536

3

S.C. TO BATTERY VOLTAGE AT DLM INDICATOR LAMP OUTPUT

Seite 24 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

5536

5

O.C. DLM INDICATOR LAMP OUTPUT

• check the resistance of device

no reaction OP-Mode: normal

• check the cable from TCU to the device • check the connectors • check the resistance of device

1)

see chapter 4

backup alarm will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal

• check the cable from TCU to the backup alarm device • check the connectors from backup alarm device to TCU • check the resistance 1) of backup alarm device

1)

see chapter 4

no reaction OP-Mode: normal

• check the cable from TCU to the backup alarm device • check the connectors from backup alarm device to TCU

1)

see chapter 4

TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • device has an internal defect • connector has no connection to TCU 91

5560

4

S.C. TO GROUND AT RELAY REVERSE WARNING ALARM

TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • backup alarm device has an internal defect • connector pin is contacted to vehicle ground 92

5560

3

S.C. TO BATTERY VOLTAGE AT RELAY REVERSE WARNING ALARM

TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery TE-AB

remarks

possible reason for fault detection TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • device has an internal defect • connector pin is contacted to battery voltage

8F

possible steps to repair

Seite 25 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

5560

5

O.C. AT RELAY REVERSE WARNING ALARM

TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • backup alarm device has an internal defect • connector has no connection to TCU 94

5570

4

• check the resistance 1) of backup alarm device

S.C. TO GROUND AT RELAY STARTER INTERLOCK

no reaction OP-Mode: normal

• check the cable from TCU to the backup alarm device • check the connectors from backup alarm device to TCU • check the resistance 1) of backup alarm device

1)

see chapter 4

no reaction OP-Mode: normal

• check the cable from TCU to the starter interlock relay • check the connectors from starter interlock relay to TCU • check the resistance 1) of starter interlock relay

1)

see chapter 4

no reaction OP-Mode: normal

• check the cable from TCU to the starter interlock relay • check the connectors from starter interlock relay to TCU • check the resistance 1) of starter

1)

see chapter 4

TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • starter interlock relay has an internal defect • connector pin is contacted to vehicle ground 95

5570

3

S.C. TO BATTERY VOLTAGE AT RELAY STARTER INTERLOCK

TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage TE-AB

remarks

possible reason for fault detection voltage • cable is defective and is contacted to battery voltage • backup alarm device has an internal defect • connector pin is contacted to battery voltage

93

possible steps to repair

Seite 26 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

5570

5

O.C. AT RELAY STARTER INTERLOCK

TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • starter interlock relay has an internal defect • connector has no connection to TCU A4

5620

4

interlock relay

S.C. TO GROUND AT WARNING SIGNAL OUTPUT

no reaction OP-Mode: normal

• check the cable from TCU to the starter interlock relay • check the connectors from starter interlock relay to TCU • check the resistance 1) of starter interlock relay

1)

see chapter 4

no reaction OP-mode: normal

• check the cable from TCU to the warning device • check the connectors from warning device to TCU • check the resistance 1) of warning device

1)

see chapter 4

no reaction OP-mode: normal

• check the cable from TCU to the warning device • check the connectors from warning device to TCU • check the resistance 1) of warning device

1)

see chapter 4

TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • warning device has an internal defect • connector pin is contacted to vehicle ground A5

5620

5

O.C. AT WARNING SIGNAL OUTPUT

TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • warning device has an internal defect TE-AB

remarks

possible reason for fault detection • cable is defective and is contacted to battery voltage • starter interlock relay has an internal defect • connector pin is contacted to battery voltage

96

possible steps to repair

Seite 27 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • connector has no connection to TCU

A6

5620

3

S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT

no reaction OP-mode: normal

• check the cable from TCU to the warning device • check the connectors from warning device to TCU • check the resistance 1) of warning device

TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • warning device has an internal defect • connector pin is contacted to battery voltage B1

5660

2

SLIPPAGE AT CLUTCH K1 TCU calculates a differential speed at closed clutch K1. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch K1 • low main pressure • wrong signal at internal speed sensor • wrong signal at output speed sensor • wrong size of the sensor gap • clutch is defective

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check pressure at clutch K1 • check main pressure in the system • check sensor gap at internal speed sensor • check sensor gap at output speed sensor • check signal at internal speed sensor • check signal at output speed sensor • replace clutch

B2

5665

2

SLIPPAGE AT CLUTCH K2 TCU calculates a differential speed at closed clutch K2. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch K2 • low main pressure • wrong signal at internal speed sensor • wrong signal at output speed sensor • wrong size of the sensor gap

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check pressure at clutch K2 • check main pressure in the system • check sensor gap at internal speed sensor • check sensor gap at output speed sensor • check signal at internal speed sensor • check signal at output speed sensor • replace clutch

TE-AB

1)

see chapter 4

Seite 28 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • clutch is defective

B3

5670

2

SLIPPAGE AT CLUTCH K3 TCU calculates a differential speed at closed clutch K3. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch K3 • low main pressure • wrong signal at internal speed sensor • wrong signal at output speed sensor • wrong size of the sensor gap • clutch is defective

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check pressure at clutch K3 • check main pressure in the system • check sensor gap at internal speed sensor • check sensor gap at output speed sensor • check signal at internal speed sensor • check signal at output speed sensor • replace clutch

B4

5675

2

SLIPPAGE AT CLUTCH K4 TCU calculated a difference speed at TCU calculates a differential speed at closed clutch K4. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch K4 • low main pressure • wrong signal at internal speed sensor • wrong signal at turbine speed sensor • wrong size of the sensor gap • clutch is defective

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check pressure at clutch K4 • check main pressure in the system • check sensor gap at internal speed sensor • check sensor gap at turbine speed sensor • check signal at internal speed sensor • check signal at turbine speed sensor • replace clutch

B5

5680

2

SLIPPAGE AT CLUTCH KV TCU calculates a differential speed at closed clutch KV. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch KV • low main pressure • wrong signal at internal speed sensor

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check pressure at clutch KV • check main pressure in the system • check sensor gap at internal speed sensor • check sensor gap at turbine speed sensor • check signal at internal speed sensor • check signal at turbine speed sensor • replace clutch

TE-AB

Seite 29 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • wrong signal at turbine speed sensor • wrong size of the sensor gap • clutch is defective

B6

5685

2

B7

5700

0

SLIPPAGE AT CLUTCH KR TCU calculates a differential speed at closed clutch KR. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch KR • low main pressure • wrong signal at internal speed sensor • wrong signal at turbine speed sensor • wrong size of the sensor gap • clutch is defective

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check pressure at clutch KR • check main pressure in the system • check sensor gap at internal speed sensor • check sensor gap at turbine speed sensor • check signal at internal speed sensor • check signal at turbine speed sensor • replace clutch

OVERTEMP SUMP

no reaction OP-Mode: normal

• cool down machine • check oil level • check temperature sensor

TCU measured a temperature in the oil sump that is over the allowed threshold. BA

5730

0

DIFFERENTIAL PRESSURE OIL FILTER no reaction TCU measured a voltage at differential OP-Mode: normal pressure switch out of the allowed range • oil filter is polluted • cable/connector is broken or cable/connector is contacted to battery voltage or vehicle ground • differential pressure switch is defective

BC

5745

15

C0

5751

0

OVERSPEED OUTPUT No reaction TCU messures an transmission output OP-Mode: normal speed above the defined threshold ENGINE TORQUE OR ENGINE POWER OP-Mode: normal OVERLOAD TCU calculates an engine torque or engine

TE-AB

• check oil filter • check wiring from TCU to differential pressure switch • check differential pressure switch (measure resitance)

Seite 30 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection power above the defined thresholds

C1

5752

0

TRANSMISSION OUTPUT TORQUE

OP-Mode: normal

OVERLOAD

C2

5755

15

C3

5760

0

TCU calculates an transmission output torque above the defined threshold TRANSMISSION INPUT TORQUE OVERLOAD TCU calculates an transmission input torque above the defined threshold OVERTEMP CONVERTER OUTPUT

TCU measured a oil temperature at the converter ouput that is over the allowed threshold. C4

5770

4

S.C. TO GROUND AT JOYSTICK STATUS

INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • joystick status indicator has an internal defect • connector pin is contacted to vehicle ground C5

5770

3

S.C. TO BATTERY VOLTAGE AT JOYSTICK

STATUS INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • joystick status indicator has an internal defect • connector pin is contacted to battery TE-AB

programmable :No reaction or shift to neutral OP-Mode: normal no reaction OP-Mode: normal

• cool down machine • check oil level • check temperature sensor

no reaction OP-Mode: normal

• check the cable from TCU to joystick status indicator • check the connectors from joystick status indicator to TCU • check the resistance 1) of joystick status indicator

no reaction OP-Mode: normal

• check the cable from TCU to joystick status indicator • check the connectors from joystick status indicator to TCU • check the resistance 1) of joystick status indicator

Seite 31 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection voltage

C6

5770

5

O.C. AT JOYSTICK STATUS

INDICATOR TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • joystick status indicator has an internal defect • connector has no connection to TCU C7

5780

4

S.C. TO GROUND AT OVERTEMP NEUTRAL INDICATOR

no reaction OP-Mode: normal

• check the cable from TCU to joystick status indicator • check the connectors from joystick status indicator to TCU • check the resistance 1) of joystick status indicator

no reaction OP-Mode: normal

• check the cable from TCU to OVERTEMP NEUTRAL INDICATOR • check the connectors from OVERTEMP NEUTRAL INDICATOR to TCU • check the resistance 1) of OVERTEMP NEUTRAL INDICATOR

no reaction OP-Mode: normal

• check the cable from TCU to OVERTEMP NEUTRAL INDICATOR • check the connectors from OVERTEMP NEUTRAL INDICATOR to TCU • check the resistance 1) of OVERTEMP NEUTRAL INDICATOR

TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • overtemp status indicator has an internal defect • connector pin is contacted to vehicle ground C8

5780

3

S.C. TO BATTERY VOLTAGE AT

OVERTEMP NEUTRAL INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • overtemp status indicator has an internal defect • connector pin is contacted to battery TE-AB

Seite 32 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection voltage

C9

5780

5

O.C. AT OVERTEMP NEUTRAL

INDICATOR TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • OVETEMP status indicator has an internal defect • connector has no connection to TCU

no reaction OP-Mode: normal

• check the cable from TCU to OVERTEMP NEUTRAL INDICATOR • check the connectors from OVERTEMP NEUTRAL INDICATOR to TCU • check the resistance 1) of OVERTEMP NEUTRAL INDICATOR

CA

5790

9

ENGINE_RETARDER CONFIG_TIMEOUT Timeout of CAN-message ENGINE_RETARDER CONFIG from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective an has contact to vehicle ground or battery voltage

OP-Mode: substitute clutch control

• check EEC controller • check wire of CAN-Bus • check cable to EEC controller

CB

5800

9

ERC1 TIMEOUT Timeout of CAN-message ERC1 from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective an has contact to vehicle ground or battery voltage

OP-Mode: substitute clutch control

• check EEC controller • check wire of CAN-Bus • check cable to EEC controller

D1

5810

3

S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS

see fault codes no. 21 to 2C

• check cables and connectors to sensors, which are supplied from AU1 • check the power supply at the pin AU1

TCU measures more than 6V at the pin TE-AB

fault codes no. 21 to no. 2C may be a reaction of this fault

Seite 33 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

possible reason for fault detection AU1 (5V sensor supply)

D2

5810

4

S.C. TO GROUND AT POWER SUPPLY FOR SENSORS

(should be appx. 5V) see fault codes no. 21 to 2C

TCU measures less than 4V at the pin AU1 (5V sensor supply) D3

5820

4

D4

5820

3

D5

5830

2

D6

5840

2

TE-AB

remarks

• check cables and connectors to sensors, which are supplied from AU1 • check the power supply at the pin AU1 (should be appx. 5V)

LOW VOLTAGE AT BATTERY shift to neutral measured voltage at power supply is lower OP-Mode: TCU shutdown than 10 V (12V device) lower than 18 V (24V device) HIGH VOLTAGE AT BATTERY shift to neutral measured voltage at power supply is OP-Mode: TCU shutdown higher than 18 V (12V device) higher than 32.5 V (24V device) ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral TCU switched on VPS1 and measured OP-Mode: TCU shutdown VPS1 is off or TCU switched off VPS1 and measured VPS1 is still on • cable or connectors are defect and are contacted to battery voltage • cable or connectors are defect and are contacted to vehicle ground • permanent power supply KL30 missing • TCU has an internal defect

• check power supply battery • check cables from batteries to TCU • check connectors from batteries to TCU

• • • •

check fuse check cables from gearbox to TCU check connectors from gearbox to TCU replace TCU

ERROR VALVE POWER SUPPLY VPS2 shift to neutral TCU switched on VPS2 and measured OP-Mode: TCU shutdown VPS2 is off or TCU switched off VPS2 and measured VPS2 is still on • cable or connectors are defect and are contacted to battery voltage • cable or connectors are defect and are contacted to vehicle ground • permanent power supply KL30 missing

• • • •

check fuse check cables from gearbox to TCU check connectors from gearbox to TCU replace TCU

fault codes no. 21 to no. 2C may be a reaction of this fault

• check power supply battery • check cables from batteries to TCU • check connectors from batteries to TCU

Seite 34 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection • TCU has an internal defect

D7

5545

4

S.C. TO GROUND AT DLM LONGITUDINAL OUTPUT

TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • device has an internal defect • connector pin is contacted to vehicle ground D8

5545

3

S.C. TO BATTERY VOLTAGE AT DLM LONGITUDINAL OUTPUT

output will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal

• check the cable from TCU to the valve • check the connectors • check the resistance of valve

1)

see chapter 4

no reaction OP-Mode: normal

• check the cable from TCU to the valve • check the connectors • check the resistance of valve

1)

see chapter 4

no reaction OP-Mode: normal

• check the cable from TCU to the valve • check the connectors • check the resistance of valve

1)

see chapter 4

no reaction OP-Mode: normal

• check the cable from TCU to the display • check the connectors at the display

TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • device has an internal defect • connector pin is contacted to battery voltage D9

5545

5

O.C. AT DLM LONGITUDINAL OUTPUT

TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • device has an internal defect • connector has no connection to TCU E3

TE-AB

5860

3

S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT

Seite 35 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

possible reason for fault detection TCU sends data to the display and measures allways a high voltage level on the connector • cable or connectors are defective and are contacted to battery voltage • display has an internal defect

• change display

E4

5860

4

S.C. TO GROUND AT DISPLAY OUTPUT TCU sends data to the display and measures allways a high voltage level on the connector • cable or connectors are defective and are contacted to vehicle ground • display has an internal defect

no reaction OP-Mode: normal

• check the cable from TCU to the display • check the connectors at the display • change display

F1

5890

2

GENERAL EEPROM FAULT TCU can't read non volantile memoy • TCU is defective

no reaction OP-Mode: normal

• replace TCU

F2

5900

13

F3

5910

13

CONFIGURATION LOST transmission stay neutral TCU has lost the correct configuration and OP-Mode: TCU shutdown can't control the transmission. • interference during saving data on non volatile memory • TCU is brand new or from another vehicle APPLICATION ERROR

something of this application is wrong

F5

5930

7

CLUTCH FAILURE

AEB was not able to adjust clutch filling parameters • One of the AEB-Values is out of limit TE-AB

remarks

often shown together with fault code F2

• Reprogramm the correct configuration for the vehicle (e.g. with cluster controller,...)

transmission stay neutral OP-Mode: TCU shutdown

• replace TCU !!

transmission stay neutral OP-Mode: TCU shutdown

• check clutch

This fault occurs only if an test engineer did something wrong in the application of the vehicle TCU shows also the affected clutch on the Display

Seite 36 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Code (hex)

MEANING OF THE FAULT CODE

11-02-21

reaction of the TCU

possible steps to repair

possible reason for fault detection

F6

5930

13

CLUTCH ADJUSTMENT DATA LOST OR INCHPEDAL CALIBRATION DATA LOST TCU was not able to read correct clutch adjustment parameters • interference during saving data on non volatile memory • TCU is brand new

default values = 0 for AEB offsets used OP-Mode: normal no Inchmode available

• execute AEB

F7

5940

11

SUBSTITUTE CLUTCH CONTROL • transmission input torque wrong • engine retarder torque wrong • speed signal(s) defective

OP-Mode : substitute clutch control

• check engine retarder torque • check speed sensors

TE-AB

remarks

Seite 37 von 38

ZF Friedrichshafen AG description of fault codes for ERGO-Control

11-02-21

4 measuring of resistance at actuator/sensors and cable 4.1 actuator: 1

R

2

G

open circuit: short cut to ground: short cut to battery:

R12 ≈ R1G ≈ R2G ≈ ∞ R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0

(for s.c. to ground, G is connected to vehicle ground) (for s.c. to battery, G is connected to battery voltage)

4.2 cable: UBat

P (power supply) TCU Actuator / 1

2

Sensor

C (chassis)

Gnd

open circuit: short cut to ground: short cut to battery:

TE-AB

R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞ R12 ≈ 0; R1C ≈ R2C ≈ 0, R12 ≈ 0, R1C ≈ R2C ≈ ∞,

R1P ≈ R2P ≈ ∞ R1P ≈ R2P ≈ 0

Seite 38 von 38