Zf ecolife коды ошибок

Коды ошибок тормоза-замедлителя (интардера) ZF. Чтение, стирание. КамАЗ-5490.

Контрольная лампа тормоза-замедлителя загорается при режиме Bremsomat, если тормоз-замедлитель находится в активном режиме, а также при постоянных тормозных ступенях.

После включения зажигания и при установке главного выключателя тормоза-замедлителя в положение “Вкл” система тормоза-замедлителя автоматически проверяет функционирование контрольной лампы.

Контрольная лампа горит 3 секунды.

При наличии дефекта в электрической системе контрольная лампа мигает при включенном тормозе-замедлителе.

Дополнительно к нормальной функции, контрольная индикация тормоза-замедлителя служит для выдачи мигающего кода (номера ошибки).

Выдача мигающего кода и стирание памяти ошибок.

Выдачу мигающего кода (номера ошибки) и стирание памяти ошибок можно включить с помощью рычага тормозных ступеней. Мигающий код показывается контрольной лампой тормоза-замедлителя.

Выдача мигающего кода.

ИНТАРДЕР принцип работы,коды ошибок,данные эксплуатации. #уставшиймонтёр

Пример для 5-ступенчатого рычага тормозных ступеней.

• Выключить зажигание.
• Установить рычаг тормозных ступеней на одну ступень ниже, чем максимальная тормозная ступень, в данном случае положение 4.
• Включить зажигание и дождаться непрерывного горения (3 секунды) или мигания (5 секунд) контрольной лампы тормоза-замедлителя.
• В течение 5 секунд установить рычаг тормозных ступеней на две ступени ниже, чем максимальная тормозная ступень (в данном случае положение 3), и затем снова на одну ступень ниже, чем максимальная тормозная ступень (в данном случае положение 4).
• Подождать выдачу мигающего кода.

Дополнительно к нормальной функции, контрольная лампа тормоза-замедлителя служит для выдачи мигающего кода (номер ошибки).

Если выдача мигающего кода включается рычагом тормозных ступеней, то по окончании контроля лампы или соответственно по истечении 5 секунд включается постоянное мигание (в случае неисправности), которым последовательно выдается записанный в памяти ошибок номер ошибки.

Пример, номер ошибки 23.

Стирание памяти ошибок.

• Выключить зажигание.
• Установить рычаг тормозных ступеней в положение 4 (макс. положение -1).
• Включить зажигание и дождаться непрерывного горения (3 секунды) или мигания (5 секунд) контрольной лампы тормоза-замедлителя.
• В течение 5 секунд установить рычаг тормозных ступеней в положение 3 (макс. положение -2), снова в положение 4 (макс. положение -1), и затем в положение 0.
• Все показываемые мигающим кодом ошибки удаляются для выдачи мигающего кода.

С помощью выдачи мигающего кода могут быть считаны только те ошибки из устройства управления, которые нарушают правильное действие. Ошибки, которые не оказывают влияния на функцию устройства управления, могут быть считаны только с помощью отдельного диагностического прибора.

ZF ECOLIFE

Стирание памяти ошибок с помощью рычага тормозных ступеней делает ошибки, занесенные в память ошибок, невидимыми для выдачи мигающего кода. При помощи отдельного диагностического прибора все ошибки видны до тех пор, пока они не стираются с помощью диагностического прибора.

Мигающий код – перечень ошибок.

Этот перечень ошибок представляет “сжатое обобщение” всех возможных отдельных ошибок. Для оптимального диагноза из памяти ошибок устройства управления ZF (ECU) могут быть считаны виды ошибок, как например, прерывание и/или короткое замыкание. Пожалуйста, обращайтесь по этому вопросу в ближайшую службу сервиса ZF.

Коды ошибок.

Источник: almarka.ru

ZF предлагает новую 6-ступенчатую АКПП EcoLife для автомобилей с пробегом. При разработке данной КПП, которая в первую очередь предназначена для городских автобусов, а также автомобилей специального назначения и рельсовых транспортных средств, прежде всего преследовалась цель

повышения экономичности и создания дополнительных преимуществ для клиентов. Таким образом
данная КПП отлично адаптирована для высокого крутящего момента современных автобусов и может
передавать до 2000 Нм. При этом ZF уже сегодня выполняет будущие нормы токсичности, а также
требования по снижению расхода топлива и выбросов CO2. Благодаря новому гидротрансформатору

КПП EcoLife обладает лучшими разгонными характеристиками при низких оборотах двигателя.
Гаситель крутильных колебаний, интегрированный в гидротрансформатор, обеспечивает плавность

работы и снижает расход топлива при интенсивном движении. Интегрированный ретардер повышенной мощности Citybus оказывает поддержку не только во время торможения, но и вносит свой вклад вместе с теплообменником в улучшение концепции охлаждения EcoLife. Поэтому 6-ступенчатая АКПП может работать даже при температуре в масляном поддоне до 120 градусов – это важно, прежде всего, для дизельных двигателей Евро 5. Благодаря этому также значительно увеличиваются интервалы замены масла и надежность.

Конструкция и принцип действия

Блок управления КПП находится непосредственно на боковой части коробки. Благодаря этому пропадает необходимость использования лишних проводов, а монтаж облегчается ввиду значительного снижения количества разъемов. Блок управления КПП принимает сигналы датчиков из КПП и автомобиля, а также информацию от других блоков управления и направляет исходящие сигналы, с помощью которых управляются исполнительные механизмы коробки передач и автомобиля. Обмен данными с другими блоками управления (управление двигателем, системы контроля динамики движения, приборы, переключатель режимов движения и т.д.) осуществляется по шине CAN.

Источник: autogeriko.com

КПП zf 9s1310 руководство по ремонту

Коробки переключения передач (КПП) немецкой компании ZF Friedrichshafen AG, крупнейшего производителя трансмиссионной автомобильной системы, рулевого управления и подвесок, применялись европейскими автомобильно-строительными фирмами для комплектации зарубежных машин. После создания в 2005 г. в Набережных Челнах совместного российско-немецкого предприятия ООО «ЦФ КАМА» агрегаты стали устанавливать на технику Камского производства.

Завод выпускает разные модели КПП ZF на КамАЗ:

1. Серия ZF 6S700. Простые 6-ступенчатые КПП с малым весом, небольшими габаритами и простой конструкцией.
2. ZF9 — Ecomid 9S1310 TO с 9 ступенями. Широко используются грузовиками средней грузоподъемности: самосвалами КамАЗ-65115 и седельными тягачами 65116, отличаются пониженной передачей, позволяют передвигаться с большими грузами на оптимальной скорости.
3. ZF Ecosplit 16S1820 ТО — ЗФ 16-ступенчатая. Устанавливают на тяжелые машины с двигателями 740.51-320, 740.50-360 мощностью 160-500 л. с.
4. ZF AS Tronic 12S1930 TO — 12-ступенчатая. Применяется редко в тяжеловесах.

Переключение КПП ZF на автомобилях КамАЗ

Для того, чтобы продлить срок эксплуатации КПП, а также снизить расход топлива необходимо использовать наивысшую передачу, а также осуществлять движение при средней скорости вращения коленвала.

КамАЗ 6520 оснащен коробкой передач зф16. На рисунке изображена схема переключения передач:

Коробка передач имеет синхронизатор, который облегчает переключение. Ряд 3-4 и 5-6 являются нейтральными в схеме «двойное Н». Для того, чтобы выбрать ряд 1-2 или 7-8, необходимо переместить рычаг в направление нужного ряда.

Порядок переключения передач для схемы «налагающаяся Н» будет немного иным. Холостой ход осуществляется в рядах 3-4 и 7-8. Так же, как и в предыдущем случае, переключение на ряд 1-2 и 5-6 осуществляется путем направления рычага в сторону этого ряда. В среднем положении ряда рукоять возвращается в исходное положение. Переключение на ZF 9 происходит таким же путем.

Как правильно переключать

Производителем КПП ZF16 подготовлены рекомендации по эксплуатации. Можно найти множество схем с пояснениями, наглядно показывающими, как правильно переключать.

Начало движения необходимо осуществлять только на 1 передаче. Включать передачи нужно при выключенном сцеплении (педаль нажата до упора). Также важно учитывать, что переключение должно осуществляться при минимальной скорости холостого хода.

Передачи переключаются рычагом в соответствии со схемой. Замедляясь, необходимо переключать передачи в строгой последовательности от 8 до 1. Запрещается при скорости выше 30 км/ч переключаться с высшего диапазона демультипликатора на низший.

Чтобы перейти с ускоряющей передачи на замедляющую в делителе (и наоборот) необходимо поднять/опустить переключатель управления делителем, удерживать 1 секунду и опустить педаль сцепления – передача переключится автоматически.

КПП ZF 16 была создана для тяжелых грузовиков, ведь чем больше дифференциация ступеней, тем меньше нагрузки оказывается на двигатель, автомобиль быстрее разгоняется. Конструкция коробки передач зф 16 с 151 предполагает наличие синхронизатора, что намного упрощает процесс переключения передач, продлевает срок работы двигателя, сцепления и самой КПП.

Устройство и принцип работы КПП от немецкой компании ZF Friedrichshafen AG на машины КамАЗ

Крупнейший производитель трансмиссий для автомобилей немецкая , после создания совместного с предприятия с в 2005 году, стали поставлять коробки переключения передач (КПП) для установки на наши отечественный грузовые автомобили.

Благодаря возможности оптимального выбора передаточного отношения в каждом конкретном случае, при любом скоростном режиме движения автомобиля, коробки передач ZF помогают не только экономить топливо (до 16%), но и улучшают тягово-динамические характеристики двигателей Камаз, повышают их ресурс и раскрывают их потенциал на все 100%.

На Камазы сейчас устанавливают следующие модели КПП от ZF:

ZF Ecomid

Самая распространенная КПП, 9 ступеней, устанавливается на большинство среднетоннажных грузовиков Камаз (такие модели как 65155 и 65116), отличная пониженная передача, оптимальный скоростной режим при транспортировке тяжелых грузов.

КПП Ecomid от ZF представляет собой основной 4-х ступенчатый редуктор, в который интегрирована передача для заднего хода, а также дополнительная пара шестерен для пониженной передачи. На выходе основного редуктора стоит демультипликатор (планетарный редуктор). В итоге получаем: 4 передачи на основном редукторе*2 (передачи на демультипликаторе)+пониженная передача, итого 9 передач для движения вперед и 1 для заднего хода.

ZF Ecosplit

16 ступеней, чаще всего устанавливается на тяжелые автомобили с двигателями Камаз от 320 до 500 л.с. мощности (740.51-320 или 740.50-360). Масса КПП 290 кг.

КПП Ecosplit так же состоит из 4-х ступенчатого основного редуктора с передачей заднего хода и демультипликатором на выходе, но плюс к этому в конструкцию добавлен делитель (промежуточный вал на входе с дополнительной парой шестерен). В итоге передач здесь уже 16: 4 на основном редукторе*2 на демультипликаторе*2 на делителе+2 передачи для заднего хода.

Делитель

Делитель в конструкции нужен для увеличения количества передач в определенном диапазоне движения. Он представляет собой две пары шестерен с разным передаточным отношением, которые установлены на приводе промежуточного вала. Такое решение дает возможность выбирать оптимальную передачи в зависимости от дорожной ситуации и меньше нагружать двигатель. Переключается делитель с помощью воздуха под давлением (пневматический привод).

Демультипликатор

Демультипликатор представляет собой редуктор планетарного типа. На вторичный вал устанавливается его солнечная шестерня, а выходной вал КПП это его водило. При движении в пониженном диапазоне передач демультипликатор повышает крутящий момент, в повышенном диапазоне крутящий момент остается без изменений. Переключение демультипликатора происходит с помощью пневматического привода.

Поиск деталей ZF

• Если Вы знаете номер необходимой запчасти для коробки ЗФ, введите его в строку поиска и нажмите «Найти», чтобы увидеть цену и наличие.
• Если нет номера необходимой запчасти, но известен номер коробки переключения передач (указан на информационной табличке), воспользуйтесь каталогами, чтобы выяснить номер запчасти.
• Вы всегда можете связаться с нами и получить подробную консультацию у наших сотрудников. Они помогут подобрать необходимые запчасти для трансмиссиии помочь купить запчасти на КПП ЗФ.

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Переключение КПП ZF на автомобилях Камаз

Схема переключения КПП ZF Ecomid и Ecosplit на грузовых автомобилях КАМАЗ это так называемая «двойная Н». Т.е. есть пониженный (S) и повышенный (L) диапазон передач. В каждом диапазоне по четыре базовых передачи, которые расширяются за счет делителя и демультипликатора. Возвращение рычага в «нейтраль» после выключения передачи происходит автоматически за счет того, что рычаг прижимается в нейтральное положение пружинными фиксаторами.

Демультипликатор из L диапазона (ряд 3/4) в S (ряд 5/6) и обратно, так же переключается автоматически по средствам подачи воздуха под давлением в рабочий цилиндр. Включить новую передачу можно только после того как будет завершен процесс предыдущего переключения. Задний ход и пониженная передача (С) доступна только в пониженном (S) диапазоне демультипликатора. Включение этих передач идет через небольшое усилие, т.к.

там установлена предохранительная пружина, которая исключает возможность случайного выбора одной из этих передач.

Переключение передач на ZF Ecomid

Переключение передач на ZF Ecosplit

Рекомендации по переключению передач

• Рычаг КПП следует перемещать плавно, без рывков и лишних усилий с разжатой рукой.
• Когда включаете передачу, удерживайте рычаг, пока синхронизатор выполнит переключение.
• Для того, чтобы переключиться с дорожки 3-4 на 5-6 и наоборот, нужно сделать короткий толчок в нужную сторону и потом плавно включить нужную передачу.
• Если автомобиль замедляется, передачи переключать в обратном порядке рекомендуется последовательно или максимум через две ступени.
• Двигаться автомобиль должен всегда при включенной передаче. Особенно это касается движения накатом на спуске.
• При переключении с высшего диапазона на низший скорость должна быть меньше 30 км/ч.
• Заднюю передачу включать только на стоящем автомобиле.

Обслуживание и ремонт

КамАЗы с автоматическими и механическими коробками ZF должны проходить техническое обслуживание (ТО) в условиях автосервиса, иначе возможны проблемы с гарантией. ТО заключается в замене масла. Периодичность зависит от типа КПП и условий эксплуатации машины. Чаще всего замена ГСМ производится через 45-90 тыс. км пробега, при особо сложных условиях эксплуатации — не реже 1 тыс. рабочих часов.

Что необходимо для продления срока эксплуатации КПП

Для того, чтобы избежать поломки, необходимо следовать рекомендациям по эксплуатации, данным производителем.

Необходимо правильно переключать передачи, в соответствии со схемами (двойная или каскадная Н).

Также важно регулярно проверять уровень трансмиссионного масла, менять его каждые 30 тыс. км пробега. О том, какое масло необходимо для конкретной модели КПП, производители всегда сообщают.

Зимой очень важно прогреть коробку передач, иначе загустевшее масло не сможет достаточно хорошо смазать детали, что приведет к их преждевременному износу.

Начинать движение всегда нужно на 1 передаче, переключение должно осуществляться при выключенном сцеплении.

Также важно своевременное ТО, во время которого проверяются и при необходимости регулируются все элементы трансмиссии.

Контроль уровня

Заправочные объемы указаны на заводской табличке, расположенной сбоку КПП. Перед заполнением емкости сливают отработку, заливают трансмиссионную жидкость через отверстие. Проверка уровня масла осуществляется так: уровень считается правильным при достижении нижней кромки контрольного отверстия или при вытекании материала из него.

Какое масло выбрать

В коробки ZF 9S1310 ТО и ZF 16S151 подходит масло, соответствующее перечню смазочных материалов TE-ML 02. Его можно узнать во всех пунктах ТО компании. Производитель рекомендует использовать масло для трансмиссии ZF-Ecofluid M.

Объем масла в коробке ZF 9 составляет 9 л, на КамАЗ ZF 16 для стандартного монтажа — 11 л, при замене — 8 л.

Неисправности и их устранение

Если включение передач затруднено, причина — неполное выключение сцепления. В данном случае его регулируют и проверяют клапан, к которому подключается делитель. Клапан подключения должен быть всегда чистым и не закрываться. При неправильной настройке устройства возможно разрушение синхронизатора.

При попадании ржавчины, конденсата и других загрязнений из системы ресивера в клапаны и цилиндры КПП самостоятельно отключается. Устанавливают заблаговременно отвод конденсата из пневмоочистителя с водоотделителем, если он отсутствует. Слив выполняют 1 раз в неделю, зимой каждый день.

При самопроизвольном выключении передач в делителе регулируется ход рычага механизма.

К характерным поломкам КПП ZF относится самопроизвольное выключение демультипликатора, посторонние шумы при его включении. Проблема может возникнуть из-за неправильной эксплуатации: переключение передач на S при скорости выше допустимой выходит из строя синхронизатор или его отдельные детали.

Коды ошибок АКПП ZF

Коробка передач-автомат ZF AS-Tronic может сообщать о возникших неисправностях. Для того, чтобы устранить неполадку, достаточно сопоставить код с возможной причиной поломки.

Некоторые коды ошибок SPN:

• 2 – возникло короткое замыкание в переднем делителе (клапан Y2)
• 10 – отсутствует давление воздуха на главный клапан
• 13 – короткое замыкание в цепи подключения КОМ
• 21 – произошло быстрое замыкание сцепления
• 27 – нет сигнала в шину CAN
• 35 – неисправность выхода клапана Y3 (передний делитель)
• 63 – неполадка при отключении КОМ

Цены на основные работы

* — стоимость нормо-часа 1400 руб. * — стоимость работ может меняться в зависимости от типа автомобиля и его технического состояния
В связи с тем, что невозможно предоставить полный прейскурант цен из-за большого объема производимых работ, то предлагаем Вам позвонить по указанному номеру или отправить заявку на диагностику автомобиля через форму обратной связи и расчета стоимости ремонта.

Также обращаем ваше внимание на то, что нормативное время для выполнения конкретной операции принимается из действующей нормативной базы завода изготовителя автомобиля. Для расчета стоимости выполненных работ, необходимо количество нормо-часов (нормативное время выполнения рабочей операции) умножить на стоимость одного нормо-часа.

Записаться на диагностику

Ремонт КПП ZF

Перед началом ремонта необходимо произвести диагностику. Для этого нужно установить код ошибки, соотнести его с видом неисправности и её возможной причиной. В некоторых случаях устранить неисправность можно своими руками, но так как коробка передач представляет собой сложное устройство, ремонт лучше доверить профессионалам.

Для того, чтобы произвести ремонт трансмиссии, необходимо сначала разобрать КПП:

1. Снять узел переключения передач: вывернуть винты М8 из картера переключения, снять картер и уплотнители, демонтировать упорный щиток и пружину
2. Снять фланец крепления подшипника: ослабить винты крепления, снять фланцы и уплотнители
3. Разборка валов и штоков: отвинтить пробки с уплотнителем, вынуть пружины и штифты из картера, удалить винты по периметру картера. Ослабить контргайку на фланце ВОМ. Вытащить игольчатые подшипники, центральный вал управления. Снять вторичный вал и вилки переключения передач.

В процессе можно сделать переборку деталей, заменить уплотнители, укрепить соединения, поменять износившиеся винты. Также необходимо очистить от масляного осадка.

По коду неисправности можно узнать рекомендации по ремонту, например, если произошло короткое замыкание регулятора давления сцепления, то необходимо проверить все кабели и соединения, если где-то зажат кабель или есть разрыв, то этот участок необходимо поменять.

Кроме электроники очень часто случаются неисправности трансмиссии, в частности, ломается синхронизатор. В таких случаях его необходимо менять.

Источник: nomadcar.ru

дон юг авто сервис

ИНСТРУКЦИИ ДЛЯ РЕМОНТА И ЭКСПЛУАТАЦИИ ГРУЗОВОЙ СПЕЦТЕХНИКИ.

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Коды ошибок КПП ZF Meritor ( Freedomline)

Коды ошибок КПП ZF Meritor ( Freedomline)

Коробка передач FreedomLine SAE J1708, Система Управления Коробкой передач
Коробка передач FreedomLine SAE J1939, Система Управления Коробкой передач
Коробка передач SureShift, Система Управления Коробкой передач
Коробка передач ZF FreedomLine (K Line), Коробка передач с электронным контролем

Источник: remontgruzovik.ru

Error code list

Ergopower- EST37/A Z F P a s s a u G m b h

D o n a u s t r a ß e 2 5 — 7 1 D — 9 4 0 3 4 P a s s a u

Diagnose — Set5870 220 703

ASDT ZF Passau G.m.b.H.ZF Passau G.m.b.H. 2004 / 11

DIAGNOSE — UND PROGRAMMIERUNGEST 37 ERGOPOWER mit LAPTOP und DPA-05

DIAGNOSE — UND PROGRAMMIERUNGEST 37 ERGOPOWER mit LAPTOP und DPA-05

Zulässiges BetriebssystemWindows 95 / 98 / Me oder NTWindows 2000 / Win XP

Adapterkabel 6008 308 601 = RS 2326008 207 026 = USB

Software Testman Pro undGetriebe ApplikationERGOPOWER 5870 220 017

auf CD

Programmieradapter DPA — 05

Diagnose Software auf CD-ROM für ERGOPOWER

EST — 37 WG 130/131WG 160/161

Enthaltene Sprachversionen : DEUTSCH / ENGLISH / FRANCAI`S / ITALIANO

EST — 37 WG 190/191WG 210/211

EST — 37 WG 260/261WG 310/311

EST — 37 WG 110WG 115

Adapterkabel 6008 207 0236008 207 0246029 017 005 ZFP

Ducu..CorelPerspektivdarst5870AB200220017

Pentium Laptop min. 1,0 GHz

Gewicht : 2,060 kg

16

17

18

p23033

p23033

ZF Friedrichshafen AG 03-05-13 Faultcodes ERGO-Control EST37A

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1 Introduction

1.1 Abbreviations

o.c. open circuit s.c. short circuit OP-Mode operating mode TCU transmission control unit EEC electronic engine controller PTO power take off

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

STOP

h f e d

a b c g

(special symbols a-h)

le f tcharacter

rightcharacter

1.3 Display during operation

Symbol meaning remarks 1F, 1R 2F, 2R 3F, 3R 4F 5F 6F LF, LR

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

F or R, no gear Clutch Cutoff F or R flashing direction F or R selected while turbine

speed is too high CAUTION gear will engage if turbine speed drops

NN not neutral, waiting for neutral after power up or a severe fault

to engage a gear, first move shift selector to neutral position and again to F or R position

** oil temperature too low, no gear available

warm up engine / transmission

*N oil temperature low, only one gear available

warm up engine / transmission

ZF Friedrichshafen AG 03-05-13 Faultcodes ERGO-Control EST37A

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1 bar (special symbol)

manual mode 1st gear

2 bars manual mode 2nd gear 3 bars manual mode 3rd gear 4 bars manual mode 4th gear and also 5th and 6th

gear in 6WG

4 bars and 2 arrows automatic mode Bars flashing 6 WG: converter lockup clutch open

4 WG: Downshift mode activ

difference of engine and turbine speed above a certain limit and lockup clutch not activated

Spanner at least one fault activ select neutral to get fault code displayed Fault code see faultcode list WS warning sump temperature changes between actual gear/direction while driving, in

neutral only displayed if no fault is detected (spanner) WR warning retarder temperature changes between actual gear/direction while driving, in

neutral only displayed if no fault is detected (spanner) WT warning torque converter temperature changes between actual gear/direction while driving, in

neutral only displayed if no fault is detected (spanner) WE warning high engine speed changes between actual gear/direction while driving, in

neutral only displayed if no fault is detected (spanner) PN direction F or R selected while parking

brake engaged transmission in neutral until parking brake is released CAUTION: vehicle starts to move after release of parking brake

EE flashing no communication with display checked wiring from TCU to display

AEB Clutch Calibration instructions Before starting the AEB following instructions must be followed. Parking Brake must be “on” Gear selector lever in “ Neutral” Transmission sump temperature between “ 70 – 90 ° Celsius” Engine Idle speed between 650 – 1100 rpm – if to low increase engine speed with gas pedal and keep RPM. Correct Oil Level – check Dip stick Vehicle must be on flat surfice level. Please make shure that safety instructions are followed and no persons next to the vehicle! When connecting AEB Starter symbol “ PL” will show up on display. To start AEB please push red botton at least 3 seconds till “ K1” show up on display after that release the button “ AEB” will continiue itself. Finally if clutches could be calibrated “ OK “ will show up on display! Switch off ignition, for at least 5 seconds. Any Errors appear during AEB procedure please read the Error code book 5872 993 025 German 5872 993 026 englisch copyright Hermann Wagner ASI

ZF Friedrichshafen AG 03-05-13 Faultcodes ERGO-Control EST37A

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1.4 Display during AEB-Mode

symbol meaning remarks PL AEB — Starter is plugged at the

diagnostic plug

ST AEB-Starter-button is pressed

K1..K4,KV,KR calibrating clutch K1..K4, KV or KR resp.

_ and Kx wait for start, initialization of clutch Kx, x: 1, 2, 3, 4, V, R

≡ and Kx fast fill time determination of clutch Kx

= and Kx compensating pressure determination of clutch Kx

OK calibration for all clutches finished Transmissions stays in neutral, you have to restart the TCU (ignition off/on) after removing AEB-Starter

STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

STOP and Kx AEB stopped, clutch Kx can’t be calibrated

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

Spanner and Kx Kx couldn’t be calibrated, AEB finished Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

∆ E engine speed too low, ð raise engine speed

∇ E engine speed too high, ð lower engine speed

∆ T transmission oil temperature too low, ð heat up transmission

∇ T transmission oil temperature too high ð cool down transmission

FT transmission temperature not in defined range during calibration

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

FB operating mode not NORMAL or transmission temperature sensor defective or storing of Calibrated values to EEPROM-has failed.

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

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

FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

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

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

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

ZF Friedrichshafen AG 03-05-13 Faultcodes ERGO-Control EST37A

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2 definition of operating modes

NORMAL:

There’s no failure detected in the transmission-system or the failure has no or slight effects on

transmission control. TCU will work without or in special cases with little limitations. (see following

table)

SUBSTITUTE CLUTCH CONTROL:

TCU can’t change the gears or the direction under the control of the normal clutch modulation. TCU

uses the substitute strategy for clutch control. All modulations are only time controlled. (Comparable

with EST 25)

LIMP-HOME:

The detected failure in the system has strong limitations to transmission control. TCU can engage only

one gear in each direction. In some cases only one direction will be possible.

TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator

must shift the gear selector into neutral position.

If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into

forward or reverse, the TCU will select the limp-home gear .

If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home

gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the

selected direction.

If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator

has to slow down the vehicle and must shift the gear selector into neutral position.

TRANSMISSION-SHUTDOWN:

TCU has detected a severe failure that disables control of the transmission.

TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).

Transmission shifts to Neutral. The park brake will operate normally, also the other functions which

use ADM 1 to ADM 8.

The operator has to slow down the vehicle. The transmission will stay in neutral.

TCU-SHUTDOWN:

TCU has detected a severe failure that disables control of system.

TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park

brake will engage, also all functions are disabled which use ADM 1 to ADM 8.

The transmission will stay in neutral.

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 7 von 53

3 table of fault codes

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

11 5000 12 48 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU detected a wrong signal combination for the gear range • cable from shift lever to TCU is broken • cable is defective and is contacted to

battery voltage or vehicle ground • shift lever is defective

TCU shifts transmission to neutral OP-Mode: transmission shutdown

• check the cables from TCU to shift lever • check signal combinations of shift lever

positions for gear range

failure cannot be detected in systems with DW2/DW3 shift lever

fault is taken back if TCU detects a valid signal for the position

all

12 5010 12 46 LOGICAL ERROR AT DIRECTION SELECT SIGNAL TCU detected a wrong signal combination for the direction • cable from shift lever to TCU is broken • cable is defective and is contacted to

battery voltage or vehicle ground • shift lever is defective

TCU shifts transmission to neutral OP-Mode: transmission shutdown

• check the cables from TCU to shift lever • check signal combinations of shift lever

positions F-N-R

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

all

13 5020 12 95 LOGICAL ERROR AT ENGINE DERATING DEVICE TCU detected no reaction of engine while derating device activ

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

• check engine derating device This fault is reset after power up of TCU

all

14 5030 12 169 LOGICAL ERROR AT PARKBRAKE STATUS 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

TCU shifts transmission to DCO-State OP-Mode: normal

• check the cables from electronic boxes to status switches

• check signals of the status switches

Case

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 8 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

15 5040 12 176 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2. SHIFT LEVER TCU detected a wrong signal combination for the direction • 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

TCU shifts transmission to neutral if selector activ OP-Mode: transmission shutdown if selector activ

• check the cables from TCU to shift lever 2

• check signal combinations of shift lever positions F-N-R

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

all case

16 5050 12 178 LOGICAL ERROR AT AXLE CONNECTION 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

OP-Mode: normal • check the cables from TCU to feedback axle connection switch

• check signals of the feedback axle connection switch

all

17 5060 4 148 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 1 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 • customer specific function no. 1 device

has an internal defect • connector pin is contacted to vehicle

ground

customer specific • check the cable from TCU to customer specific function no. 1 device

• check the connectors from customer specific function no. 1 to TCU

• check the resistance of customer specific function no. 1 device

1) see chapter 4 Z-Funktion1

18 5060 3 150 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION NO. 1 TCU detected a wrong voltage at the

customer specific • check the cable from TCU to customer specific function no. 1 device

• check the connectors from customer

1) see chapter 4 Z-Funktion1

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 9 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to

battery voltage • customer specific function no. 1 device

has an internal defect • connector pin is contacted to battery

voltage

specific function no. 1 to TCU • check the resistance of customer

specific function no. 1 device

19 5060 5 149 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 1 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 • customer specific function no. 1 device

has an internal defect • connector has no connection to TCU

customer specific • check the cable from TCU to customer specific function no. 1 device

• check the connectors from customer specific function no. 1 device to TCU

• check the resistance of customer specific function no. 1 device

1) see chapter 4 Z-Funktion1

1A 5070 4 151 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 2 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 • customer specific function no. 2 device

has an internal defect • connector pin is contacted to vehicle

ground

customer specific • check the cable from TCU to customer specific function no. 2 device

• check the connectors from customer specific function no. 2 device to TCU

• check the resistance of customer specific function no. 2 device

1) see chapter 4 Z-Funktion2

1B 5070 3 153 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION NO. 2 TCU detected a wrong voltage at the

customer specific • check the cable from TCU to customer specific function no. 2 device

• check the connectors from customer

1) see chapter 4 Z-Funktion2

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 10 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to

battery voltage • customer specific function no. 2 device

has an internal defect • connector pin is contacted to battery

voltage

specific function no. 2 device to TCU • check the resistance of customer

specific function no. 2 device

1C 5070 5 152 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 2 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 • customer specific function no. 2 device

has an internal defect • connector has no connection to TCU

customer specific • check the cable from TCU to customer specific function no. 2 device

• check the connectors from customer specific function no. 2 device to TCU

• check the resistance of customer specific function no. 2 device

1) see chapter 4 Z-Funktion2

1D 5080 4 154 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 3 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 • customer specific function no. 3 device

has an internal defect • connector pin is contacted to vehicle

ground

customer specific • check the cable from TCU to customer specific function no. 3 device

• check the connectors from customer specific function no. 3 device to TCU

• check the resistance of customer specific function no. 3 device

1) see chapter 4 Z-Funktion3

1E 5080 3 156 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION NO. 3 TCU detected a wrong voltage at the

customer specific • check the cable from TCU to customer specific customer specific function no. 3 device

1) see chapter 4 Z-Funktion3

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 11 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to

battery voltage • customer specific function no. 3

device has an internal defect • connector pin is contacted to battery

voltage

• check the connectors from customer specific function no. 3 device to TCU

• check the resistance of customer specific function no. 3 device

1F 5080 5 155 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 3 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 • customer specific function no. 3

device has an internal defect • connector has no connection to TCU

customer specific • check the cable from TCU to customer specific function no. 3 device

• check the connectors from customer specific function no. 3 device to TCU

• check the resistance of customer specific function no. 3 device

1) see chapter 4 Z-Funktion3

21 5090 3 32 S.C. TO BATTERY VOLTAGE AT CLUTCH CUTOFF INPUT the measured voltage is too high: • cable is defective and is contacted to

battery voltage • clutch cut off sensor has an internal

defect • connector pin is contacted to battery

voltage

clutch cutoff function is disabled OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the clutch cutoff sensor

John Deere

22 5090 4 29 S.C. TO GROUND OR O.C. AT CLUTCH CUTOFF INPUT the measured voltage is too low: • cable is defective and is contacted to

clutch cutoff function is disabled OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the clutch cutoff sensor

John Deere

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 12 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

vehicle ground • cable has no connection to TCU • clutch cut off sensor has an internal

defect • connector pin is contacted to vehicle

ground or is broken

23 5100 3 69 S.C. TO BATTERY VOLTAGE AT LOAD SENSOR INPUT the measured voltage is too high: • cable is defective and is contacted to

battery voltage • load sensor has an internal defect • connector pin is contacted to battery

voltage

retarder function is affected TCU uses default load OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the load sensor sensor • check the assembly tolerances of load

sensor

availability of retarder depends on default load

ohne CAN

24 5100 4 70 S.C. TO GROUND OR O.C. AT LOAD SENSOR INPUT the measured voltage is too low: • cable is defective and is contacted to

vehicle ground • cable has no connection to TCU • load sensor has an internal defect • connector pin is contacted to vehicle

ground or is broken

retarder function is affected TCU uses default load OP-Mode: normal

• check the cable from TCU to the sensor • check the connectors • check the load sensor sensor • check the assembly tolerances of load

sensor

availability of retarder depends on default load

ohne CAN

25 5110 3 33 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

battery voltage • cable has no connection to TCU • temperature sensor has an internal

defect

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

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

all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 13 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• connector pin is contacted to battery voltage or is broken

26 5110 4 30 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

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

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

all, Sisu

27 5120 3 76 S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER TEMPERATURE SENSOR INPUT 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

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

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

6WG

28 5120 4 74 S.C. TO GROUND AT RETARDER 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

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

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

6WG

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 14 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

29 5130 3 31 S.C. TO BATTERY VOLTAGE OR O.C. AT PARKING BRAKE 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

TCU uses default value OP-Mode: normal

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

all

2A 5130 4 28 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

TCU uses default value OP-Mode: normal

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

all

2B 5313 12 135 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 to neutral While not inching: no change OP-Mode: normal

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

all

31 5140 3 38 S.C. TO BATTERY VOLTAGE OR O.C. AT ENGINE 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

OP-Mode: substitute clutch control

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

all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 15 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• connector pin is contacted to battery voltage or has no contact

32 5140 4 34 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

all, Sisu

33 5140 12 42 LOGICAL ERROR AT ENGINE SPEED INPUT 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

OP-Mode: substitute clutch control

• 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

all, Sisu

34 5150 3 39 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 • connector pin is contacted to battery

voltage or has no contact

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

all, Sisu

35 5150 4 35 S.C. TO GROUND AT TURBINE SPEED INPUT TCU measures a voltage less than 0.45V at speed input pin

OP-Mode: substitute clutch control if a failure is existing at output speed,

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

all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 16 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• cable / connector is defective and is contacted to vehicle ground

• speed sensor has an internal defect

TCU shifts to neutral OP-Mode: limp home

36 5150 12 43 LOGICAL ERROR AT TURBINE SPEED INPUT 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

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 • check the sensor gap

This fault is reset after power up of TCU

all, Sisu

37 5160 3 40 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

OP-Mode: substitute clutch control

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

all, Sisu

38 5160 4 36 S.C. TO GROUND AT INTERNAL 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

all, Sisu

39 5160 12 44 LOGICAL ERROR AT INTERNAL SPEED INPUT

OP-Mode: substitute clutch control

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

This fault is reset after power up of TCU

all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 17 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

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

• check the speed sensor • check the sensor gap

3A 5170 3 41 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

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

all, Sisu

3B 5170 4 37 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

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

all, Sisu

3C 5170 12 45 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 • speed sensor has an internal defect

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 • check the sensor gap

This fault is reset after power up of TCU

all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 18 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• sensor gap has the wrong size

3D 71 TURBINE SPEED ZERO DOESN’T FIT TO OTHER SPEED SIGNALS

— — not used

3E 5180 2 72 OUTPUT SPEED ZERO DOESN’T FIT TO OTHER SPEED SIGNALS 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

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

This fault is reset after power up of TCU

all, Sisu

40 5190 2 146 GEAR RANGE RESTRICTION SIGNAL CAN signal for gear range restriction is defective • cluster controller is defective • interference on CAN-Bus

no gear range restriction • check cluster controller • check wire of CAN-Bus • check cable to cluster controller

Case

40 5200 2 146 FCAN MESSAGE ‘GEAR RANGE SELECT (ZF_3_IDENT)’ contains invalid data

gear range set from 1st to 5th • check FWD controller • check wire of CAN-Bus

O&K

41 5210 2 147 DECLUTCH MODULATION SELECTION SIGNAL

— — not used Case

41 5210 2 147 TCU RECEIVES MESSAGES ‘GEAR RANGE SELECT (ZF_3_IDENT)’ AND ‘FRONT WHEEL DRIVE STATUS’ (V_IDENT_FWD) ALTHOUGH CONFIGURATION STATES THAT FWD CONTROLLER IS NOT INSTALLED

ignore FWD commands • reconfigure with TCU Configuration Command (ID PC)

O&K

50 5220 9 99 FMR1 TIMEOUT Timeout of CAN-message FMR1 from

TCU operates like jake brake is off and exhaut brake is off.

• check engine controller • check wire of CAN-Bus

IES

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 19 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

engine controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and

has contact to vehicle ground or battery voltage

• engine controller is defective

OP-Mode: normal • check cable to engine controller

51 5230 9 100 FMR2 TIMEOUT Timeout of CAN-message FMR2 from engine controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and

has contact to vehicle ground or battery voltage

• engine controller is defective

OP-Mode: substitute clutch control

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

IES

52 5240 9 101 EAMODUL1 TIMEOUT Timeout of CAN-message EAM1 from I/O — 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 and uses substitute gear selector OP-Mode: normal

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

Liebherr

53 5250 9 102 ABS TIMEOUT Timeout of CAN-message ABS from ABS — 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 • check ABS controller • check wire of CAN-Bus • check cable to ABS controller

IES

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 20 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

54 5260 9 103 MDU1 TIMEOUT Timeout of CAN-message MDU1 from cluster 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 keeps old auto downshift information and old manual downshift information OP-Mode: normal

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

John Deere

54 5260 9 103 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

JCB, Kalmar

54 5260 9 103 GEAR RANGE SELECT TIMEOUT Timeout of CAN-message ‘Gear Range Select (ZF_3_IDENT)’ • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and

has contact to vehicle ground or battery voltage

• FWD Controller is defective

gear range set from 1st to 5th • check wire of CAN-Bus • check FWD controller

O&K

55 5270 9 177 DNS1 TIMEOUT Timeout of CAN-message DNS1 from OMRON-master • interference on CAN-Bus • CAN wire/connector is broken

TCU shifts to neutral OP-Mode: normal

• check OMRON-master • check wire of CAN-Bus • check cable to OMRON-master

Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 21 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• CAN wire/connector is defective and has contact to vehicle ground or battery voltage

55 5270 9 177 SCT1 TIMEOUT

Timeout of CAN-message SCT1 from steering 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 steering computer • check wire of CAN-Bus • check cable to steering computer

Kalmar

55 5270 9 177 FLC1 TIMEOUT Timeout of CAN-message FCL1 from cluster 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 keeps old auto/man selection, old Clutch cutoff selection and old Clutch Cuttoff Setting OP-Mode: normal

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

John Deere

55 5270 9 177 FRONT WHEEL DRIVE STATUS TIMEOUT Timeout of CAN-message ‘Front Wheel Drive Status (V_IDENT_FWD)’ • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and

has contact to vehicle ground or battery voltage

• FWD Controller is defective

TCU shifts to neutral • check wire of CAN-Bus • check FWD controller

O&K

56 5280 9 105 ENGINE CONF TIMEOUT Timeout of CAN-message ENGINE CONF

OP-Mode: substitute clutch control

• check engine controller • check wire of CAN-Bus

J1939

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 22 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

from engine controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and

has contact to vehicle ground or battery voltage

• check cable to engine controller

57 5290 9 106 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

J1939

58 5300 9 107 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

J1939

59 5310 2 108 TEST MODE SIGNAL CAN signal for test mode status is defective • cluster controller is defective • interference on CAN-Bus

Testmode is aborted, if activ • check cluster controller • check wire of CAN-Bus • check cable to cluster controller

Case

5A 5320 2 109 PARKBRAKE STATUS SIGNAL CAN signal for parkbrake status is defective • cluster controller is defective

no reaction ???? • check cluster controller • check wire of CAN-Bus • check cable to cluster controller

Case, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 23 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• interference on CAN-Bus

5B 5330 2 110 SHIFT QUALITY SEL SIGNAL CAN signal for shift qualtiy selection is defective • cluster controller is defective • interference on CAN-Bus

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

Not used Case

5C 5340 2 111 AUTO DOWNSHIFT SIGNAL CAN signal for automatic downshift is defective • cluster controller is defective • interference on CAN-Bus

last selection is kept • check cluster controller • check wire of CAN-Bus • check cable to cluster controller

John Deere

5D 5350 2 112 MANUAL DOWNSHIFT SIGNAL CAN signal for manual downshift is defective • cluster controller is defective • interference on CAN-Bus

last selection is kept • check cluster controller • check wire of CAN-Bus • check cable to ???? controller

John Deere

5E 5360 2 113 CCO REQUEST SIGNAL CAN signal for CCO request is defective • cluster controller is defective • interference on CAN-Bus

last selection is kept • check cluster controller • check wire of CAN-Bus • check cable to ???? controller

John Deere

5F 5370 2 114 SHIFT LEVER SIGNAL CAN signal for shift lever is defective • I/O controller is defective • interference on CAN-Bus

TCU shifts to neutral and uses informations from substitute shift lever OP-Mode: normal

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

Liebherr, Sisu

5F 5370 2 179 TRANSMISSION NEUTRAL REQUEST SIGNAL CAN signal for transmission Neutral Request is defective

OP-Mode: normal • check steering computer • check wire of CAN-Bus • check cable to steering computer

Kalmar

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 24 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• steering computer is defective • interference on CAN-Bus

5F 5370 2 179 CAN MESSAGE ‘ FRONT WHEEL DRIVE STATUS (V_IDENT_FWD)’ CONTAINS INVALID DATA

TCU shifts to neutral • check FWD controller O&K

60 5380 2 115 ADDITIONAL BRAKE STATUS SIGNAL CAN signal for additional park brake status is defective • I/O controller is defective • interference on CAN-Bus

no reaction OP-Mode: normal

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

Liebherr

61 5390 2 116 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

Liebherr, Sisu, John Deere

62 5400 2 117 PTO TORQUE SIGNAL CAN signal for PTO torque is defective • I/O controller is defective • interference on CAN-Bus

no reaction, TCU uses default PTO torque signal OP-Mode: normal

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

Liebherr

63 5410 2 118 DRIVING MODE SIGNAL CAN signal for driving mode is defective • I/O controller is defective • interference on CAN-Bus

no reaction, TCU uses default driving mode signal OP-Mode: normal

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

Liebherr

64 5420 2 119 STARTING GEAR SIGNAL CAN signal for starting gear is defective • I/O controller is defective

(illegal starting gear) • interference on CAN-Bus

no reaction, TCU uses default starting gear OP-Mode: normal

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

Liebherr

65 5430 2 120 ENGINGE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller IES,

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 25 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

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

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

J1939

69 5440 2 124 REFERENCE ENGINE TORQUE SIGNAL CAN signal for reference of engine 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

J1939

6A 5450 2 125 ACTUAL ENGINE TORQUE SIGNAL CAN signal for actual engine 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

J1939

6B 5460 2 126 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

J1939

6E 5470 2 144 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

J1939

71 5480 3 22 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 the measured resistance value of the valve is out of limit, the voltage at K1 valve is

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

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

gearbox • check the regulator resistance 1)

1) see chapter 4 all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 26 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

too high. • cable / connector is defective and has

contact to battery voltage • regulator has an internal defect

TCU shifts to neutral OP-Mode: TCU shutdown

• check internal wire harness of the gearbox

72 5480 4 10 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

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 all, Sisu

73 5480 5 16 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

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 all, Sisu

74 5490 3 23 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

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 all, Sisu

75 5490 4 11 S.C. TO GROUND AT CLUTCH K2 the measured resistance value of the valve is out of limit, the voltage at K2 valve is

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

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

TCU

1) see chapter 4 all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

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

pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the regulator resistance 1) • check internal wire harness of the

gearbox

76 5490 5 17 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

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 all, Sisu

77 5500 3 24 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

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 all, Sisu

78 5500 4 12 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

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 all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 28 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

79 5500 5 18 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 • regulator has an internal defect

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 all, Sisu

7A 5540 3 78 S.C. TO BATTERY VOLTAGE AT CONVERTER CLUTCH

— — not used

7B 5540 4 79 S.C. TO GROUND AT CONVERTER CLUTCH

— — not used

7C 5540 5 80 O.C. AT CONVERTER CLUTCH

— — not used

7D 5550 4 166 S.C. TO GROUND AT ENGINE DERATING DEVICE • cable is defective and is contacted to

vehicle ground • engine derating device has an

internal defect • connector pin is contacted to vehicle

ground

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

• check the cable from TCU to the engine derating device

• check the connectors from engine derating device to TCU

• check the resistance 1) of engine derating device

1) see chapter 4 SHI Proto T10

7E 5550 3 168 S.C. TO BATTERY VOLTAGE AT ENGINE DERATING DEVICE • cable / connector is defective and is

contacted to battery voltage • engine derating device has an

internal defect

no reaction OP-Mode: normal

• check the cable from TCU to the engine derating device

• check the connectors from backup alarm device to TCU

• check the resistance 1) of backup alarm device

SHI Proto T10

7F 5550 5 167 O.C. AT ENGINE DERATING DEVICE TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin

no reaction OP-Mode: normal

• check the cable from TCU to the engine derating device

• check the connectors from engine derating device to TCU

1) see chapter 4 SHI Proto T10

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• cable is defective and has no connection to TCU

• engine derating device has an internal defect

• connector has no connection to TCU

• check the resistance 1) of engine derating device

81 5510 3 25 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

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 all

82 5510 4 13 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

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 all

83 5510 5 19 O.C. AT CLUTCH K4 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

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 all

84 5520 3 26 S.C. TO BATTERY VOLTAGE AT CLUTCH KV

TCU shifts to neutral OP-Mode: limp home

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

1) see chapter 4 all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

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

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

TCU • check the regulator resistance 1) • check internal wire harness of the

gearbox

85 5520 4 14 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

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 all, Sisu

86 5520 5 20 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

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 all, Sisu

87 5530 3 27 S.C. TO BATTERY VOLTAGE AT CLUTCH KR 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

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 all, Sisu

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 31 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

88 5530 4 15 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

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 all, Sisu

89 5530 5 21 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

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 all, Sisu

91 5560 4 1 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

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 all

92 5560 3 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

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 all

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

voltage • cable is defective and is contacted to

battery voltage • backup alarm device has an internal

defect • connector pin is contacted to battery

voltage

• check the resistance 1) of backup alarm device

93 5560 5 2 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

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 all

94 5570 4 4 S.C. TO GROUND AT RELAY STARTER INTERLOCK 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

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

95 5570 3 6 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

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

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• cable is defective and is contacted to battery voltage

• starter interlock relay has an internal defect

• connector pin is contacted to battery voltage

interlock relay

96 5570 5 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

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

97 5580 4 7 S.C. TO GROUND AT PARK BRAKE SOLENOID 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 • park brake solenoid has an internal

defect • connector pin is contacted to vehicle

ground

no reaction OP-Mode: normal

• check the cable from TCU to the park brake solenoid

• check the connectors from park brake solenoid to TCU

• check the resistance 1) of park brake solenoid

1) see chapter 4 John Deere

98 5580 3 9 S.C. TO BATTERY VOLTAGE AT PARK BRAKE SOLENOID 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

no reaction optional: (some customers) TCU shifts to neutral caused by park brake feed back OP-Mode: normal

• check the cable from TCU to the park brake solenoid

• check the connectors from park brake solenoid to TCU

• check the resistance 1) of park brake solenoid

1) see chapter 4 John Deere

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

battery voltage • park brake solenoid has an internal

defect • connector pin is contacted to battery

voltage

99 5580 5 8 O.C. AT PARK BRAKE SOLENOID 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 • park brake solenoid has an internal

defect • connector has no connection to TCU

no reaction optional: (some customers) TCU shifts to neutral caused by park brake feed back OP-Mode: normal

• check the cable from TCU to the park brake solenoid

• check the connectors from park brake solenoid to TCU

• check the resistance 1) of park brake solenoid

1) see chapter 4 John Deere

9A 5590 4 66 S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH SOLENOID 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 • converter clutch solenoid has an

internal defect • connector pin is contacted to vehicle

ground

no reaction OP-mode: normal

• check the cable from TCU to the converter clutch solenoid

• check the connectors from converter clutch solenoid to TCU

• check the resistance 1) of converter clutch solenoid

1) see chapter 4 6WG

9B 5590 3 67 O.C. AT CONVERTER LOCK UP CLUTCH SOLENOID 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

converter clutch always open, retarder not available OP-mode: normal

• check the cable from TCU to the converter clutch solenoid

• check the connectors from converter clutch solenoid to TCU

• check the resistance 1) of converter clutch solenoid

1) see chapter 4 6WG

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• converter clutch solenoid has an internal defect

• connector has no connection to TCU

9C 5590 5 68 S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP CLUTCH SOLENOID 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 • converter clutch solenoid has an

internal defect • connector pin is contacted to battery

voltage

no reaction OP-mode: normal

• check the cable from TCU to the converter clutch solenoid

• check the connectors from converter clutch solenoid to TCU

• check the resistance 1) of converter clutch solenoid

1) see chapter 4 6WG

9D 5600 4 81 S.C. TO GROUND AT RETARDER SOLENOID 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 • retarder solenoid has an internal

defect • connector pin is contacted to vehicle

ground

no reaction OP-mode: normal

• check the cable from TCU to the retarder solenoid

• check the connectors from retarder solenoid to TCU

• check the resistance 1) of retarder solenoid

1) see chapter 4 6WG

9E 5600 3 82 O.C. AT RETARDER SOLENOID 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 • retarder solenoid has an internal

defect

no reaction OP-mode: normal

• check the cable from TCU to the retarder solenoid

• check the connectors from retarder solenoid to TCU

• check the resistance 1) of retarder solenoid

1) see chapter 4 6WG

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 36 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

• connector has no connection to TCU

9F 5600 5 83 S.C. TO BATTERY VOLTAGE AT RETARDER SOLENOID 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 • retarder solenoid has an internal

defect • connector pin is contacted to battery

voltage

no reaction OP-mode: normal

• check the cable from TCU to the retarder solenoid

• check the connectors from retarder solenoid to TCU

• check the resistance 1) of retarder solenoid

1) see chapter 4 6WG

A1 5610 4 84 S.C. TO GROUND AT DIFFLOCK OR AXLE CONNECTION SOLENOID 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 • difflock solenoid has an internal

defect • connector pin is contacted to vehicle

ground

no reaction OP-mode: normal

• check the cable from TCU to the difflock solenoid

• check the connectors from difflock solenoid to TCU

• check the resistance 1) of difflock solenoid

1) see chapter 4 6WG

A2 5610 3 85 S.C. TO BATTERY VOLTAGE AT DIFFLOCK OR AXLE CONNECTION SOLENOID 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 • difflock solenoid has an internal

no reaction OP-mode: normal

• check the cable from TCU to the difflock solenoid

• check the connectors from difflock solenoid to TCU

• check the resistance 1) of difflock solenoid

1) see chapter 4 6WG

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

defect • connector pin is contacted to battery

voltage

A3 5610 5 86 O.C. AT DIFFLOCK OR AXLE CONNECTION SOLENOID 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 • difflock solenoid has an internal

defect • connector has no connection to TCU

no reaction OP-mode: normal

• check the cable from TCU to the difflock solenoid

• check the connectors from difflock solenoid to TCU

• check the resistance 1) of difflock solenoid

1) see chapter 4 6WG

A4 5620 4 96 S.C. TO GROUND AT WARNING SIGNAL 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 • warning device has an internal defect • connector pin is contacted to vehicle

ground

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 6WG

A5 5620 5 97 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 • connector has no connection to TCU

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 6WG

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 38 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

A6 5620 3 98 S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT 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

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 6WG

A7 5630 4 157 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 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 • customer specific function no. 4 device

has an internal defect • connector pin is contacted to vehicle

ground

customer specific • check the cable from TCU to customer specific function no. 4 device

• check the connectors from customer specific function no. 4 device to TCU

• check the resistance of customer specific function no. 4 device

1) see chapter 4 Z-Funktion4

A8 5630 3 159 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION NO. 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 • customer specific function no. 4 device

has an internal defect • connector pin is contacted to battery

voltage

customer specific • check the cable from TCU to customer specific function no. 4 device

• check the connectors from customer specific function no. 4 device to TCU

• check the resistance of customer specific function no. 4 device

1) see chapter 4 Z-Funktion4

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

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Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

A9 5630 5 158 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 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 • customer specific function no. 4 device

has an internal defect • connector has no connection to TCU

customer specific • check the cable from TCU to customer specific function no. 4 device

• check the connectors from customer specific function no. 4 device to TCU

• check the resistance of customer specific function no. 4 device

1) see chapter 4 Z-Funktion4

AA 5640 4 160 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 5 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 • customer specific function no. 5 device

has an internal defect • connector pin is contacted to vehicle

ground

customer specific • check the cable from TCU to customer specific function no. 5 device

• check the connectors from customer specific function no. 5 device to TCU

• check the resistance of customer specific function no. 5 device

1) see chapter 4 Z-Funktion5

AB 5640 3 162 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION NO. 5 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 • customer specific function no. 5 device

has an internal defect • connector pin is contacted to battery

voltage

customer specific • check the cable from TCU to customer specific function no. 5 device

• check the connectors from customer specific function no. 5 device to TCU

• check the resistance of customer specific function no. 5 device

1) see chapter 4 Z-Funktion5

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 40 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

AC 5640 5 161 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 5 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 • customer specific function no. 5 device

has an internal defect • connector has no connection to TCU

customer specific • check the cable from TCU to customer specific function no. 5 device

• check the connectors from customer specific function no. 5 device to TCU

• check the resistance of customer specific function no. 5 device

1) see chapter 4 Z-Funktion5

AD 5650 4 163 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 6 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 • customer specific function no. 6 device

has an internal defect • connector pin is contacted to vehicle

ground

customer specific • check the cable from TCU to function 6 device

• check the connectors from customer specific function no. 6 device to TCU

• check the resistance of function 6 device

1) see chapter 4 Z-Funktion6

AE 5650 3 165 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION NO. 6 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 • customer specific function no. 6 device

has an internal defect • connector pin is contacted to battery

voltage

customer specific • check the cable from TCU to customer specific function no. 6 device

• check the connectors from customer specific function no. 6 device to TCU

• check the resistance of customer specific function no. 6 device

1) see chapter 4 Z-Funktion6

ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18

TE-AB N:AsttElektrikneuFc_37_V912.doc Seite 41 von 53

Fault Code (hex)

SPN FMI Int. Code (dec)

MEANING OF THE FAULT CODE possible reason for fault detection

reaction of the TCU possible steps to repair remarks costumer

AF 5650 5 164 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 6 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 • customer specific function no. 6 device

has an internal defect • connector has no connection to TCU

customer specific • check the cable from TCU to customer specific function no. 6 device

• check the connectors from customer specific function no. 6 device to TCU

• check the resistance of customer specific function no. 6 device

1) see chapter 4 Z-Funktion6

B1 5660 2 60 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

all, Sisu

B2 5665 2 61 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 • 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 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