Trnsmission Manual

Error Code List
Ergopower- EST37/A
V-928
Order-No.: 5872 993 026
ZF Passau GmbH
Donaustr. 25 - 71
D-94030 Passau
Edition.: 06/2009
Table of contents
Diagnose- and programming ERGOPOWER with

EST-37/A and DPA-05
Data sheet for WG-110 211
Data sheet for WG-260 311
General data sheet for WG-130 310

Description of the fault codes for ERGO-Control EST/37A
Definition of operating modes
Table of fault codes
Measuring of resistance at actuator/sensors and cable
Abbrevation
DIAGNOSE - AND PROGRAMMING

ERGOPOWER with
with EST - 37A and DPA-05
Pentium Laptop least 1,0 GHz

Windows 98.2 / Me or NT
Windows 2000 / or Win XP
Software on CD
Testman Pro + Application
EST-37 ERGOPOWER
WG 110 up to WG 310
5870 220 017
Adaptercable
6008 308 601 = RS 232
6008 207 026 = USB
Programming adapter
DPA - 05
Diagnose - Set
5870 220 703
Adaptercable
6008 207 023
6008 207 024
6029 017 005 EST-37
Diagnosis software on CD-ROM for ERGOPOWER

EST - 37
EST - 37
EST - 37
EST - 37
WG 190/191 WG 260/261
WG 110
WG 130/131
WG 210/211 WG 310/311
WG 115
WG 160/161
Wight : 2.060 kg
Language Versions : ENGLISH / FRANCE / GERMAN / ITALIAN
ASDT
ZF
Passau
G.m.b.H.
2005 / 12
EST-37A
Corporate Division
Off-Road Driveline Technology
and Axle Systems
Data sheet for WG- 110-211

Data of the 3 Inductive transmitter of Engine, turbine and Central gear train:
Resistance: 1050 Ohm ( 10%) at 20 C
Temperature range: -40 C +150 C
Torque limit: 30 Nm
Data for the Hall-Sensor of the Output:

Working range: 2 Hz 5 Khz
Supply voltage: 24V
Data for the Proportional valves:

Resistance: 19 Ohm (10%) at 20C
Current: 100 500 mA
Pressure range: 0,8 bar 8,3 bar
Data for the Lock-up solenoid valve:

Resistance: 60 Ohm 80 Ohm
Current: 0,25 A 0,35 A
Voltage: 24 V
Data for the Lock-up Proportional valve:

Resistance: 10,5 Ohm (10%) at 20C
Current: 0 926 mA
Pressure range: 0 bar 15 bar
EST-37A
Corporate Division
and Axle Systems
Data sheet for WG-260-311

Data of the 3 Inductive transmitter of Engine, turbine and Central gear train:
Resistance: 1050 Ohm ( 10%) at 20 C
Torque limit: 30 Nm
Gap:
Engine- and Turbinetransmitter: 0,5+0,3 mm
Central gear train: 0,30,1 mm
Data for the Hall-Sensor of the Output:

Working range: 2 Hz 5 Khz
Supply voltage: 24V
Gap: 1,0 +0,5 mm
Data for the Proportional valves:

Resistance: 19 Ohm (10%) at 20C
Current: 100 500 mA
Pressure range: 0,8 bar 8,3 bar
Data for the Lock-up solenoid valve:
Resistance: 60 Ohm 80 Ohm
Current: 0,25 A 0,35 A
Voltage: 24 V
Data for the Lock-up Proportional valve:

Resistance: 10,5 Ohm (10%) at 20C
Current: 0 926 mA
Pressure range: 0 bar 15 bar
EST-37A
Corporate Division
and Axle Systems
General data sheet for WG 130 310

Data for temperature sensors:
Sump:
1000 Ohm 1500 Ohm
Retarder:
800 Ohm 1500 Ohm
Data for solenoid valve:
Lock up clutch:
- Resistance:
- Current:
- Voltage:
60 Ohm 80 Ohm
0,25 A 0,35 A
24 V
Data forr:
Control pressure:
Lubrication pressure:
Pressure before the
converter:
16+2 bar
0,2 1,5 bar
130/160: max. 9 bar
190/210: max. 9 bar
260/310: max. 8,5 bar
Pressure behind the :

converter
130/160: max. 3,5 bar

190/210: max. 3,5 bar
260/310: max. 5 bar
Oil-flow from the pump:
130/160: 80 l/min bei n = 2000 min-1

190/210: 105 l/min bei n = 2000 min-1
260/310: 115 l/min bei n = 2000 min-1
Corporate Division
and Axle Systems
EST-37A
1. Description of the fault codes for

ERGO-Control EST-37/A
1.0
Introduction
1.1
Abbreviations
o.c.
s.c.
OP-Mode
TCU
EEC
PTO
open circuit
short circuit
operating mode
transmission control unit
electronic engine controller
power take off
1.2
ZF - Display:
If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows
the fault code, if the gear selector is on neutral position.
If more than one fault is detected, each fault code is shown for about 1 second.
h
left
character
right
character
S
T
O
P
g
(special symbols a-h)
1.3
Display during operation
Symbol
meaning
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
remarks
limp home gear
EST-37A
F or R, no gear
F or R flashing
NN
**
*N
1 bar (special
symbol)
2 bars
3 bars
4 bars
Clutch Cutoff
direction F or R selected while turbine
speed is too high
not neutral, waiting for neutral after
power up or a severe fault
oil temperature too low, no gear
available
oil temperature low, only one gear
available
manual mode 1st gear
6 WG: converter lockup clutch open
Spanner
Fault code
WS
4 WG: Downshift mode activ

at least one fault activ
see faultcode list
warning sump temperature
WT
WE
WV
WL
WO
PN
EE flashing
CAUTION gear will engage if turbine speed drops

to engage a gear, first move shift selector to neutral
position and again to F or R position
warm up engine / transmission
warm up engine / transmission
manual mode 2nd gear

manual mode 3rd gear
manual mode 4th gear and also 5th and
6th gear in 6WG
automatic mode
4 bars and 2
arrows
Bars flashing
WR
Corporate Division
and Axle Systems
difference of engine and turbine speed above a certain

limit and lockup clutch not activated
select neutral to get fault code displayed
changes between actual gear/direction while driving,

in neutral only displayed if no fault is detected
(spanner)
warning retarder temperature
(spanner)
warning torque converter temperature
(spanner)
warning high engine speed
(spanner)
warning high output speed (velocity)
(spanner)
warning high transmission input torque changes between actual gear/direction while driving,
(load)
(spanner)
warning high transmission output torque changes between actual gear/direction while driving,
(load)
(spanner)
direction F or R selected while parking transmission in neutral until parking brake is released
brake engaged
CAUTION: vehicle starts to move after release of
parking brake
no communication with display
checked wiring from TCU to display
EST-37A
1.4
Display during AEB-Mode
symbol
PL
ST
K1..K4,KV,KR
_ and Kx
and Kx
= and Kx
OK
STOP
STOP and Kx
Spanner and Kx
E
E
T
T
FT
FB
FO
FN
FP
STOP
Corporate Division
and Axle Systems
meaning
remarks
AEB - Starter is plugged at the

diagnostic plug
AEB-Starter-button is pressed
calibrating clutch K1..K4, KV or KR
resp.
wait for start, initialization of clutch Kx,
x: 1, 2, 3, 4, V, R
fast fill time determination of clutch Kx
compensating pressure determination of
clutch Kx
calibration for all clutches finished
Transmissions stays in neutral, you have to restart the
TCU (ignition off/on) after removing AEB-Starter
AEB canceled (activation stopped)
TCU (ignition off/on)
AEB stopped, clutch Kx can't be
calibrated
Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, you have to restart the
engine speed too low,
raise engine speed
engine speed too high,
lower engine speed
transmission oil temperature too low,
heat up transmission
transmission oil temperature too high
cool down transmission
transmission temperature not in defined Transmissions stays in neutral, you have to restart the
range during calibration
operating mode not NORMAL or
transmission temperature sensor
defective or storing of Calibrated values
to EEPROM-has failed.
Outputspeed_not_zero
Shift lever not in Neutral position
Parkbrake_not_applied
AEB - Starter was used incorrect or is
defective. Wrong device or wrong cable TCU (ignition off/on)
used
EST-37A
1.5
Corporate Division
and Axle Systems
Display during Inchpedal Calibration
symbol
IP
IP
IP flashing
OK
FN and Stop
FS and Stop
FO and Stop
SL and Stop
SU and Stop
IL and Stop
IU and Stop
TO and Stop
DL and Stop
DU and Stop
FI and Stop
meaning
remarks
push down the pedal slowly until

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

release the pedal and try again
Calibration is aborted
EST-37A
2.
Corporate Division
and Axle Systems
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.
3. Table of fault codes

Fault
Code
(hex)
10
MEANING OF THE FAULT CODE
LOGICAL ERROR AT DIRECTION SELECT SIGNAL 3RD SHIFT

LEVER
TCU detected a wrong signal combination for the

direction
cable from shift lever 3 to TCU is broken
cable is defective and is contacted to battery voltage
or vehicle ground
shift lever is defective
11
LOGICAL ERROR AT GEAR RANGE SIGNAL
TCU detected a wrong signal combination for the gear

range
cable from shift lever to TCU is broken
or vehicle ground
12
13
14
Reaction of the TCU
Possible steps to repair
Remarks
TCU shifts transmission to

neutral if selector activ
OP-Mode: transmission
shutdown if selector activ
check the cables from TCU to shift

lever 3
check signal combinations of shift
lever positions F-N-R
if shift lever is a CAN shift lever
check CAN cable/shifter/device
fault is cleared if TCU

detects a valid neutral signal
for the direction at the shift
lever

neutral
shutdown

lever
lever positions for gear range
failure cannot be detected in

systems with DW2/DW3
shift lever

neutral
shutdown

lever
fault is taken back if TCU

detects a valid signal for the
direction at the shift lever
after selecting neutral, TCU

changes to OP-Mode limp
home
DCO-State
OP-Mode: normal
This fault is reset after

power up of TCU
Possible reason for fault detection
LOGICAL ERROR AT DIRECTION SELECT SIGNAL

direction
or vehicle ground
LOGICAL ERROR AT ENGINE DERATING DEVICE
TCU detected no reaction of engine while derating
device activ
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
-1-
check engine derating device
check the cables from electronic

boxes to status switches
check signals of the status switches

detects a valid signal for the
position

Fault
Code
(hex)
15
LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2. SHIFT

LEVER

direction
cable from shift lever 2 to TCU is broken
or vehicle ground
16
17
18
Reaction of the TCU
Remarks

neutral if selector activ
shutdown if selector activ

lever 2

detects a valid neutral signal
for the direction at the shift
lever
OP-Mode: normal
check the cables from TCU to

feedback axle connection switch
check signals of the feedback axle
connection switch
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
device
specific function no. 1 to TCU
LOGICAL ERROR AT AXLE CONNECTION
feedback axle connection measured by

TCU and output signal axle connection don't fit
axle cant be connected or disconnected due to
mechanical problem
one of the cables from feedback axle connection switch to TCU is broken
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
S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC
FUNCTION NO. 1
looks like a s.c. to battery voltage
internal defect
connector pin is contacted to battery voltage
customer specific
-2-
1)
see chapter 4
1)
see chapter 4

Fault
Code
(hex)
19
1A
1B
1C
1D
Reaction of the TCU
Remarks
customer specific

device
specific function no. 1 device to TCU
device
device
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4

device
device
1)
see chapter 4
1)
see chapter 4
O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 1

looks like a o.c. for this output pin
cable is defective and has no connection to TCU
internal defect
connector has no connection to TCU
internal defect
FUNCTION NO. 2
internal defect
internal defect
customer specific
customer specific
customer specific
customer specific
-3-

Fault
Code
(hex)
1E
1F
21
22
23
Reaction of the TCU
Remarks

internal defect
FUNCTION NO. 3
internal defect
internal defect
S.C. TO BATTERY VOLTAGE AT CLUTCH CUTOFF INPUT
the measured voltage is too high:
clutch cut off sensor has an internal defect
S.C. TO GROUND OR O.C. AT CLUTCH CUTOFF INPUT
the measured voltage is too low:
cable has no connection to TCU
clutch cut off sensor has an internal defect
connector pin is contacted to vehicle ground or is
broken
S.C. TO BATTERY VOLTAGE AT LOAD SENSOR INPUT
customer specific
customer specific
clutch cutoff function is

disabled
OP-Mode: normal

customer specific customer specific
function no. 3 device
device
check the cable from TCU to the
sensor
check the connectors
check the clutch cutoff sensor
clutch cutoff function is

disabled
OP-Mode: normal

sensor
check the clutch cutoff sensor
retarder function is affected

TCU uses default load
OP-Mode: normal

sensor
-4-
1)
see chapter 4
1)
see chapter 4
availability of retarder
depends on default load

Fault
Code
(hex)
Reaction of the TCU
retarder function is affected

TCU uses default load
OP-Mode: normal
check the load sensor sensor

check the assembly tolerances of load
sensor
sensor
check the load sensor sensor
check the assembly tolerances of load
sensor
no reaction,
TCU uses default
temperature
OP-Mode: normal

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

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

sensor
load sensor has an internal defect

24
S.C. TO GROUND OR O.C. AT LOAD SENSOR INPUT
25

load sensor has an internal defect
connector pin is contacted to vehicle ground or is
broken
S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION
SUMP TEMPERATURE SENSOR INPUT
26

temperature sensor has an internal defect
connector pin is contacted to battery voltage or is
broken
S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE
SENSOR INPUT
27
Remarks

S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER /
TORQUECONVERTER TEMPERATURE SENSOR INPUT
broken
-5-
availability of retarder
depends on default load

Fault
Code
(hex)
28
29
S.C. TO GROUND AT RETARDER / TORQUECONVERTER

TEMPERATURE SENSOR INPUT

S.C. TO BATTERY VOLTAGE OR O.C. AT PARKING BRAKE
SENSOR INPUT
2A
2B
2C
Reaction of the TCU
no reaction,
TCU uses default
temperature
OP-Mode: normal

sensor
TCU uses default value

OP-Mode: normal

sensor
check the parking brake sensor

OP-Mode: normal

sensor
check the parking brake sensor
During inching mode: TCU

shifts to neutral
While not inching: no
change
OP-Mode: normal
OP-Mode: normal

sensor
check sensor

sensor has an internal defect
broken
S.C. TO GROUND PARKING BRAKE SENSOR INPUT
INCHSENSOR-SIGNAL MISMATCH
the measured voltage from CCO and CCO2 signal dont
match:
cable is defective
S.C. TO BATTERY VOLTAGE OR O.C. AT DLM TRACTION
ADJUST DASHBOARD DEVICE INPUT
broken
-6-

sensor
check the DLM Traction Adjust
dashboard device
Remarks

Fault
Code
(hex)
2D
2E
2F
31
Reaction of the TCU

OP-Mode: normal

sensor
check the DLM Traction Adjust
dashboard device

OP-Mode: normal

sensor
check the DLM STEERING ANGLE
SENSOR

OP-Mode: normal

sensor
check the DLM STEERING ANGLE
SENSOR
sensor
check the speed sensor
S.C. TO GROUND DLM TRACTION ADJUST DASHBOARD

DEVICE INPUT

S.C. TO BATTERY VOLTAGE OR O.C. AT DLM STEERING
ANGLE SENSOR INPUT
broken
S.C. TO GROUND DLM STEERING ANGLE SENSOR INPUT
S.C. TO BATTERY VOLTAGE OR O.C. AT
ENGINE SPEED INPUT
OP-Mode: substitute clutch

control
TCU measures a voltage higher than 7.00 V at speed

input pin
speed sensor has an internal defect
connector pin is contacted to battery voltage or has
no contact
-7-
Remarks

Fault
Code
(hex)
Reaction of the TCU
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

control

sensor
33
LOGICAL ERROR AT ENGINE SPEED INPUT

control

sensor
check the sensor gap
34
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
sensor gap has the wrong size

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

sensor

control
output speed,
OP-Mode: limp home
control
output speed,
OP-Mode: limp home

sensor
32
TURBINE SPEED INPUT
35
36
Remarks

input pin
no contact
S.C. TO GROUND AT TURBINE SPEED INPUT
at speed input pin
vehicle ground
LOGICAL ERROR AT TURBINE SPEED INPUT
TCU measures a turbine speed over a threshold and at

the next moment the measured speed is zero
-8-

sensor

power up of TCU

power up of TCU

Fault
Code
(hex)
37
38
39

INTERNAL SPEED INPUT

input pin
no contact
S.C. TO GROUND AT INTERNAL SPEED INPUT
at speed input pin
vehicle ground
LOGICAL ERROR AT INTERNAL SPEED INPUT
TCU measures a internal speed over a threshold and at

the next moment the measured speed is zero
3A
Reaction of the TCU

control

sensor

control

sensor

control

sensor
special mode for gear

selection
control
turbine speed,
OP-Mode: limp home

sensor
Remarks

OUTPUT SPEED INPUT

input pin
no contact
-9-

power up of TCU

Fault
Code
(hex)
3B
S.C. TO GROUND AT OUTPUT SPEED INPUT

at speed input pin
vehicle ground
3C
LOGICAL ERROR AT OUTPUT SPEED INPUT
TCU measures a output speed over a threshold and at the

next moment the measured speed is zero
3D
TURBINE SPEED ZERO DOESNT FIT TO OTHER SPEED

SIGNALS
3E
OUTPUT SPEED ZERO DOESNT FIT TO OTHER

SPEED SIGNALS
40
41
Reaction of the TCU

selection
control
turbine speed,
OP-Mode: limp home
selection
control
turbine speed,
OP-Mode: limp home
-

sensor
Remarks
if transmission is not neutral and the shifting has

finished,
TCU measures outputspeed zero and turbine speed or
internal speed not equal to zero.
FCAN MESSAGE GEAR RANGE SELECT
(ZF_3_IDENT) contains invalid data
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

selection
control
turbine speed,
OP-Mode: limp home
gear range set from 1st to 5th
ignore FWD commands
-10-

sensor
check the sensor signal of output

speed sensor
check the sensor gap of output speed
sensor
sensor
check FWD controller

check wire of CAN-Bus
reconfigure with
TCU Configuration Command
(ID PC)

power up of TCU
not used

power up of TCU

Fault
Code
(hex)
Reaction of the TCU
FMR1 TIMEOUT
Timeout of CAN-message FMR1 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
FMR2 TIMEOUT
Timeout of CAN-message FMR2 from engine controller
EAMODUL1 TIMEOUT
Timeout of CAN-message EAM1 from I/O - controller
TCU operates like jake brake

is off and exhaut brake is
off.
OP-Mode: normal
check engine controller

check cable to engine controller

control

TCU shifts to neutral and

uses substitute gear selector
OP-Mode: normal
check I/O controller

check cable to I/O controller
52
SSM1 TIMEOUT
Timeout of CAN-message SSM1 from SSM
TCU closes Park Brake if

output speed is below 0.5
km/h
OP-Mode: normal
check SSM1 controller

check cable to SSM
52
INSTRUMENT TIMEOUT
Timeout of CAN-message Instrument from Instrument
AEB abouts if active

OP-Mode: normal
check Instrument controller

check cable to Instrument
50
51
52
-11-
Remarks

Fault
Code
(hex)
Reaction of the TCU
no reaction
check ABS controller

check cable to ABS controller
TCU keeps old auto

downshift information and
old manual downshift
information
OP-Mode: normal
check cluster controller

check cable to cluster controller
OP-Mode: normal
check display computer

check cable to display computer

OP-Mode: normal
check OMRON-master

53
54
54
54
55
ABS TIMEOUT
Timeout of CAN-message ABS from ABS - controller
MDU1 TIMEOUT
Timeout of CAN-message MDU1 from cluster controller
DCT1 TIMEOUT
Timeout of CAN-message DCT1 from display computer
GEAR RANGE SELECT TIMEOUT
Timeout of CAN-message Gear Range Select
(ZF_3_IDENT)
FWD Controller is defective
DNS1 TIMEOUT
Timeout of CAN-message DNS1 from OMRON-master
-12-

Remarks

Fault
Code
(hex)
55
55
55
55
Reaction of the TCU
SCT1 TIMEOUT
Timeout of CAN-message SCT1 from steering computer
FLC1 TIMEOUT
Timeout of CAN-message FCL1 from cluster controller
JSS TIMEOUT
Timeout of CAN-message JSS from Joystick Steering
Controller
FRONT WHEEL DRIVE STATUS TIMEOUT
Timeout of CAN-message
Front Wheel Drive Status (V_IDENT_FWD)
FWD Controller is defective
check cable to OMRON-master
OP-Mode: normal
check steering computer

check cable to steering computer
TCU keeps old auto/man

selection, old Clutch cutoff
selection and old Clutch
Cuttoff Setting
OP-Mode: normal

TCU shifts to neutral while

Joystick Steering is active
OP-Mode: normal
check Joystick steering controller

check cable to Joystick steering
controller
-13-

Remarks

Fault
Code
(hex)
Reaction of the TCU
56
ENGINE CONF TIMEOUT

Timeout of CAN-message ENGINE CONF from engine
controller

control

57
EEC1 TIMEOUT
Timeout of CAN-message EEC1 from EEC controller
EEC3 TIMEOUT
CAN wire/connector is defective an has contact to
AEB-REQUEST AND PARKBRAKETEST SIGNALS ON AT

control
check EEC controller

check cable to EEC controller

control

no reaction
check programming of vehicle

controller
no reaction ????

last selection is kept

58
59
THE SAME TIME
CAN signal for AEB-Request and for ParkbrakeTest are

ON at the same time
5A
PARKBRAKE STATUS SIGNAL
CAN signal for parkbrake status is defective

cluster controller is defective
5C
AUTO DOWNSHIFT SIGNAL
CAN signal for automatic downshift is defective

-14-
Remarks

Fault
Code
(hex)
5D
Reaction of the TCU

check cable to ???? controller

check cable to ???? controller
TCU shifts to neutral and

uses informations from
substitute shift lever
OP-Mode: normal
OP-Mode: normal

MANUAL DOWNSHIFT SIGNAL
CAN signal for manual downshift is defective

5E
CCO REQUEST SIGNAL
CAN signal for CCO request is defective

5F
5F
5F
60
61
62
SHIFT LEVER SIGNAL
CAN signal for shift lever is defective

I/O controller is defective
TRANSMISSION NEUTRAL REQUEST SIGNAL
CAN signal for transmission Neutral Request is
defective
steering computer is defective
CAN MESSAGE FRONT WHEEL DRIVE STATUS
(V_IDENT_FWD) CONTAINS INVALID DATA
ADDITIONAL BRAKE STATUS SIGNAL
CAN signal for additional park brake status is defective

AEB REQUEST SIGNAL
CAN signal for AEB request is defective
PTO TORQUE SIGNAL
CAN signal for PTO torque is defective
check steering computer

check cable to steering computer
no reaction
OP-Mode: normal

no reaction
OP-Mode: normal
Last selection is kept

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

-15-
Remarks

Fault
Code
(hex)
63
DRIVING MODE SIGNAL
CAN signal for driving mode is defective

64
STARTING GEAR SIGNAL
CAN signal for starting gear is defective

(illegal starting gear)
65
ENGINGE TORQUE SIGNAL
CAN signal for engine torque is defective

69
REFERENCE ENGINE TORQUE SIGNAL
CAN signal for reference of engine torque is defective

6A
ACTUAL ENGINE TORQUE SIGNAL
CAN signal for actual engine torque is defective

6B
6E
Reaction of the TCU
no reaction,
TCU uses default driving
mode signal
OP-Mode: normal
no reaction,
TCU uses default starting
gear
OP-Mode: normal

NOM FRICTION TORQUE SIGNAL
CAN signal for nominal friction torque is defective

EEC2 TIMEOUT

OP-Mode:substitute clutch
control

control

control

control

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

-16-
Remarks

Fault
Code
(hex)
71
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 too high.
cable / connector is defective and has contact to
battery voltage
regulator has an internal defect
72
73
74
S.C. TO GROUND AT CLUTCH K1

the voltage at K1 valve is too low.
vehicle ground
another regulator output of the TCU
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

battery voltage
75
Reaction of the TCU
Remarks

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

gearbox
check the connectors from TCU to
the gearbox
check the regulator resistance 1)
check internal wire harness of the
gearbox
gearbox
check the connectors from gearbox to
TCU
gearbox
1)
see chapter 4
1)
see chapter 4

gearbox
TCU
gearbox
gearbox
TCU
gearbox
gearbox
TCU
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4


OP-Mode: limp home
pending

OP-Mode: limp home
pending
OP-Mode: limp home
pending
OP-Mode: limp home
pending
-17-

Fault
Code
(hex)
Reaction of the TCU


gearbox
76
vehicle ground
O.C. AT CLUTCH K2
TCU

OP-Mode: limp home
pending
1)
see chapter 4
77

OP-Mode: limp home
pending

gearbox
TCU
gearbox
gearbox
TCU
gearbox
gearbox
TCU
gearbox
1)
see chapter 4
1)
see chapter 4

gearbox
TCU
gearbox
1)
see chapter 4

battery voltage
78
79
Remarks

vehicle ground
O.C. AT CLUTCH K3
TCU

OP-Mode: limp home
pending

OP-Mode: limp home
pending
-18-

Fault
Code
(hex)
Reaction of the TCU

valve
valve
Remarks
7A
S.C. TO BATTERY VOLTAGE AT CONVERTER CLUTCH
no reaction
OP-Mode: normal
7B
S.C. TO GROUND AT CONVERTER CLUTCH
CONVERTER LOCK UP
CLUTCH SOLENOID
CONNECTED AT ADMX:
TCU switch off VPS2

OP-mode: normal
CONVERTER LOCK UP
CLUTCH SOLENOID
CONNECTED AT AIP7:
7C
O.C. AT CONVERTER CLUTCH
7D
S.C. TO GROUND AT
ENGINE DERATING DEVICE

engine derating device has an internal defect
7E
S.C. TO BATTERY VOLTAGE AT

ENGINE DERATING DEVICE
TCU switch off VPS2

OP-mode: normal
no reaction
OP-Mode: normal
engine derating will be on
until TCU power down even
if fault vanishes (loose
connection)
OP-Mode: normal
no reaction
OP-Mode: normal

battery voltage
7F
O.C. AT ENGINE DERATING DEVICE

no reaction
OP-Mode: normal
-19-

valve
engine derating device
check the connectors from engine
derating device to TCU
check the resistance 1) of engine
derating device
check the connectors from backup
alarm device to TCU
check the resistance 1) of backup
alarm device
derating device to TCU
1)
see chapter 4
1)
see chapter 4

Fault
Code
(hex)
81
82

battery voltage

vehicle ground
83
O.C. AT CLUTCH K4

TCU
84
Reaction of the TCU
Remarks
S.C. TO BATTERY VOLTAGE AT CLUTCH KV

the voltage at KV valve is too high.
battery voltage

OP-Mode: limp home
pending
OP-Mode: limp home
pending

OP-Mode: limp home
pending
OP-Mode: limp home
pending
-20-

derating device
gearbox
TCU
gearbox
gearbox
TCU
gearbox

gearbox
TCU
gearbox
gearbox
TCU
gearbox
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4

Fault
Code
(hex)
85
86
87
S.C. TO GROUND AT CLUTCH KV

the voltage at KV valve is too low.
vehicle ground
O.C. AT CLUTCH KV
TCU
S.C. TO BATTERY VOLTAGE AT CLUTCH KR

the voltage at KR valve is too high.
battery voltage
88
Reaction of the TCU
Remarks

OP-Mode: limp home
pending

gearbox
TCU
gearbox
1)
see chapter 4

OP-Mode: limp home
pending

gearbox
TCU
gearbox
gearbox
TCU
gearbox
gearbox
TCU
gearbox
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4
S.C. TO GROUND AT CLUTCH KR

the voltage at KR valve is too low.
vehicle ground

OP-Mode: limp home
pending
OP-Mode: limp home
pending
-21-

Fault
Code
(hex)
89
Reaction of the TCU
Remarks

OP-Mode: limp home
pending

gearbox
TCU
gearbox
valve
check the resistance of valve
1)
see chapter 4
1)
see chapter 4
no reaction
OP-Mode: normal

valve
1)
see chapter 4
no reaction
OP-Mode: normal

valve
1)
see chapter 4
output will be on until TCU

power down even if fault
vanishes (loose connection)
OP-Mode: normal

device
check the resistance of device
1)
see chapter 4
O.C. AT CLUTCH KR

TCU
8A
S.C. TO GROUND AT DLM TRANSVERSAL OUTPUT
8B

device has an internal defect
S.C. TO BATTERY VOLTAGE AT DLM TRANSVERSAL
OUTPUT

OP-Mode: normal

8C
O.C. AT DLM TRANSVERSAL OUTPUT
8D

S.C. TO GROUND AT DLM INDICATOR LAMP OUTPUT
-22-

Fault
Code
(hex)
8E
8F
Reaction of the TCU
Remarks
no reaction
OP-Mode: normal

device
1)
see chapter 4
no reaction
OP-Mode: normal

device
1)
see chapter 4
backup alarm will be on

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

backup alarm device
alarm device to TCU
alarm device
backup alarm device
alarm device to TCU
alarm device
1)
see chapter 4
1)
see chapter 4

backup alarm device
alarm device to TCU
1)
see chapter 4
S.C. TO BATTERY VOLTAGE AT DLM INDICATOR LAMP

OUTPUT

O.C. DLM INDICATOR LAMP OUTPUT
91
S.C. TO GROUND AT RELAY REVERSE WARNING ALARM
92

backup alarm device has an internal defect
S.C. TO BATTERY VOLTAGE AT RELAY REVERSE WARNING
ALARM
93

O.C. AT RELAY REVERSE WARNING ALARM
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
-23-

Fault
Code
(hex)
94
95

S.C. TO GROUND AT RELAY STARTER INTERLOCK
starter interlock relay has an internal defect
S.C. TO BATTERY VOLTAGE AT RELAY STARTER
INTERLOCK
96
97
98
Reaction of the TCU
Remarks

O.C. AT RELAY STARTER INTERLOCK
S.C. TO GROUND AT PARK BRAKE SOLENOID
park brake solenoid has an internal defect
S.C. TO BATTERY VOLTAGE AT PARK BRAKE SOLENOID
connector pin is contacted to battery voltag
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
-24-

alarm device
starter interlock relay
check the connectors from starter
interlock relay to TCU
check the resistance 1) of starter
interlock relay
interlock relay
interlock relay
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
brake solenoid
solenoid to TCU
solenoid
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4

Fault
Code
(hex)
99
O.C. AT PARK BRAKE SOLENOID
9A

S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH
SOLENOID

converter clutch solenoid has an internal defect
9B
O.C. AT CONVERTER LOCK UP CLUTCH SOLENOID
9C

S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP
CLUTCH SOLENOID
9D
Reaction of the TCU
Remarks
no reaction
OP-Mode: normal

brake solenoid
solenoid to TCU
solenoid
converter clutch solenoid
check the connectors from converter
clutch solenoid to TCU
check the resistance 1) of converter
clutch solenoid
1)
see chapter 4
1)
see chapter 4

clutch solenoid
clutch solenoid
1)
see chapter 4
1)
see chapter 4

retarder solenoid
check the connectors from retarder
1)
see chapter 4

S.C. TO GROUND AT RETARDER SOLENOID
CONVERTER LOCK UP
CLUTCH SOLENOID
CONNECTED AT ADMX:
TCU switch off VPS2

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

OP-mode: normal
converter clutch always
open, retarder not available
OP-mode: normal
no reaction
OP-mode: normal
no reaction
OP-mode: normal
-25-

Fault
Code
(hex)
9E
9F
A1

retarder solenoid has an internal defect
O.C. AT RETARDER SOLENOID
S.C. TO BATTERY VOLTAGE AT RETARDER SOLENOID
S.C. TO GROUND AT DIFFLOCK OR AXLE CONNECTION
SOLENOID
A2

difflock solenoid has an internal defect
S.C. TO BATTERY VOLTAGE AT DIFFLOCK OR AXLE
CONNECTION SOLENOID
A3
Reaction of the TCU
Remarks

O.C. AT DIFFLOCK OR AXLE CONNECTION SOLENOID
no reaction
OP-mode: normal
no reaction
OP-mode: normal
no reaction
OP-mode: normal
solenoid to TCU
check the resistance 1) of retarder
solenoid
retarder solenoid
solenoid to TCU
solenoid
retarder solenoid
solenoid to TCU
solenoid
difflock solenoid
check the connectors from difflock
solenoid to TCU
check the resistance 1) of difflock
solenoid
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4
no reaction
OP-mode: normal

difflock solenoid
solenoid to TCU
solenoid
1)
see chapter 4
no reaction
OP-mode: normal

difflock solenoid
solenoid to TCU
1)
see chapter 4
-26-

Fault
Code
(hex)
A4
A5
A6
A7
Reaction of the TCU

S.C. TO GROUND AT WARNING SIGNAL OUTPUT
warning device has an internal defect
O.C. AT WARNING SIGNAL OUTPUT
S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT
no reaction
OP-mode: normal
no reaction
OP-mode: normal
no reaction
OP-mode: normal
customer specific

internal defect
A8
Remarks

FUNCTION NO. 4
customer specific

-27-

solenoid
warning device
check the connectors from warning
device to TCU
check the resistance 1) of warning
device
warning device
device to TCU
device
warning device
device to TCU
device
device
specific function no. 4 device to
TCU
device
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4Fehler!

Verweisquelle konnte nicht
gefunden werden.
1)
see chapter 4

Fault
Code
(hex)
A9
AA
AB
Reaction of the TCU
Remarks

internal defect
internal defect
internal defect
FUNCTION NO. 5

customer specific
customer specific
customer specific

internal defect
-28-

device
device
TCU
device
1)
see chapter 4
1)
see chapter 4
1)
see chapter 4

Fault
Code
(hex)
AC
AD
Reaction of the TCU
Remarks
customer specific

device
check the cable from TCU to function
6 device
TCU
1)
see chapter 4
1)
see chapter 4

internal defect
customer specific

internal defect
AE
AF

FUNCTION NO. 6

internal defect
internal defect
check the resistance of function 6

device
customer specific

device
1)
see chapter 4
customer specific

device
1)
see chapter 4
-29-

Fault
Code
(hex)
B1
Reaction of the TCU

OP-Mode: limp home
pending
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

OP-Mode: limp home
pending

sensor
sensor
replace clutch

OP-Mode: limp home
pending

sensor
sensor
replace clutch
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
B2
B3

low main pressure
clutch is defective
low main pressure
clutch is defective
-30-
Remarks

Fault
Code
(hex)
B4
B5
B6
Reaction of the TCU

OP-Mode: limp home
pending

sensor
check sensor gap at turbine speed
sensor
check signal at turbine speed sensor
replace clutch

OP-Mode: limp home
pending
check pressure at clutch KV

sensor
sensor
replace clutch

OP-Mode: limp home
pending
check pressure at clutch KR

sensor
sensor
replace clutch
TCU calculated a difference speed at TCU calculates a

differential speed at closed clutch K4. If this calculated
value is out of range, TCU interprets this as slipping
clutch.
low main pressure
wrong signal at turbine speed sensor
clutch is defective
SLIPPAGE AT CLUTCH KV
TCU calculates a differential speed at closed clutch KV.
low pressure at clutch KV
low main pressure
clutch is defective
SLIPPAGE AT CLUTCH KR
TCU calculates a differential speed at closed clutch KR.
low pressure at clutch KR
low main pressure
clutch is defective
-31-
Remarks

Fault
Code
(hex)
B7
OVERTEMP SUMP
TCU measured a temperature in the oil sump that is over

the allowed threshold.
B8
OVERTEMP RETARDER
TCU measured a temperature in the retarder oil that is

over the allowed threshold.
B9
BA
OVERSPEED ENGINE
DIFFERENTIAL PRESSURE OIL FILTER
TCU measured a voltage at differential pressure switch

out of the allowed range
oil filter is polluted
cable/connector is broken or
cable/connector is contacted to battery voltage or
vehicle ground
differential pressure switch is defective
BB
BC
BD
Reaction of the TCU
no reaction
OP-Mode: normal
cool down machine

check oil level
check temperature sensor
TCU disables retarder

OP-Mode: normal
cool down machine

check oil level
-
Remarks
retarder applies if configured

OP-Mode: normal
no reaction
OP-Mode: normal
check pressure at converter lockup

clutch
check sensor gap at engine speed
sensor
sensor
check signal at engine speed sensor
replace clutch
SLIPPAGE AT CONVERTER LOCKUP CLUTCH
TCU calculates a differential speed at closed converter

lockup clutch. If this calculated value is out of range,
TCU interprets this as slipping clutch.
low pressure at converter lockup clutch
low main pressure
wrong signal at engine speed sensor
clutch is defective
OVERSPEED OUTPUT
TCU messures an transmission output speed above the
defined threshold
S.C. TO GROUND AT ENGINE BRKAE SOLENOID
check oil filter

check wiring from TCU to
differential pressure switch
check differential pressure switch
(measure resitance)
No reaction
OP-Mode: normal
no reaction
OP-mode: normal
-32-

engine brake solenoid
1)
see chapter 4

Fault
Code
(hex)
BE
BF

engine brake solenoid has an internal defect
S.C. TO BATTERY VOLTAGE AT ENGINE BRAKE
O.C. AT ENGINE BRAKE

C0
C1
C2
C3
C4
Reaction of the TCU
Remarks
ENGINE TORQUE OR ENGINE POWER OVERLOAD

TCU calculates an engine torque or engine power above
the defined thresholds
TRANSMISSION OUTPUT TORQUE OVERLOAD
TCU calculates an transmission output torque above the
defined threshold
TRANSMISSION INPUT TORQUE OVERLOAD
TCU calculates an transmission input torque above the
defined threshold
OVERTEMP CONVERTER OUTPUT
TCU measured a oil temperature at the converter ouput

that is over the allowed threshold.
S.C. TO GROUND AT JOYSTICK STATUS INDICATOR
no reaction
OP-mode: normal
no reaction
OP-mode: normal
brake solenoid to TCU

brake solenoid
brake solenoid
brake solenoid
OP-Mode: normal
OP-Mode: normal
programmable :No reaction

or shift to neutral
OP-Mode: normal
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
-33-
cool down machine

check oil level
check the cable from TCU to joystick
status indicator
check the connectors from joystick
status indicator to TCU
1)
see chapter 4
1)
see chapter 4

Fault
Code
(hex)
C5
C6
C7
C8
C9
Reaction of the TCU
joystick status indicator has an internal defect

S.C. TO BATTERY VOLTAGE AT JOYSTICK
STATUS INDICATOR
O.C. AT JOYSTICK STATUS INDICATOR
S.C. TO GROUND AT OVERTEMP NEUTRAL
INDICATOR
overtemp status indicator has an internal defect
S.C. TO BATTERY VOLTAGE AT OVERTEMP NEUTRAL
INDICATOR
overtemp status indicator has an internal defect
O.C. AT OVERTEMP NEUTRAL INDICATOR

no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
no reaction
OP-Mode: normal
-34-
check the resistance 1) of joystick

status indicator
status indicator
status indicator
status indicator
status indicator
OVERTEMP NEUTRAL INDICATOR
check the connectors from
OVERTEMP NEUTRAL INDICATOR to
TCU
check the resistance 1) of
TCU
Remarks

Fault
Code
(hex)
Reaction of the TCU

OVETEMP status indicator has an internal defect
CA
CB
D1
ENGINE_RETARDER CONFIG_TIMEOUT
Timeout of CAN-message ENGINE_RETARDER CONFIG
from EEC controller
ERC1 TIMEOUT
Timeout of CAN-message ERC1 from EEC controller
S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR

control

see fault codes no. 21 to 2C
check cables and connectors to

sensors, which are supplied from
AU1
check the power supply at the pin
AU1
(should be appx. 5V)
check cables and connectors to
sensors, which are supplied from
AU1
check the power supply at the pin
AU1 (should be appx. 5V)
check power supply battery
check cables from batteries to TCU
check connectors from batteries to
TCU
TCU measures more than 6V at the pin AU1 (5V sensor

supply)
D3
Remarks
S.C. TO GROUND AT POWER SUPPLY FOR SENSORS

TCU measures less than 4V at the pin AU1 (5V sensor
supply)
see fault codes no. 21 to 2C
LOW VOLTAGE AT BATTERY
shift to neutral
measured voltage at power supply is lower than 10 V

(12V device)
lower than 18 V (24V device)

TCU

control
SENSORS
D2
-35-
fault codes no. 21 to no. 2C

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

may be a reaction of this
fault

Fault
Code
(hex)
D4
D5
D6
D7
D8
Reaction of the TCU
shift to neutral
check power supply battery

check cables from batteries to TCU
check connectors from batteries to
TCU
check fuse
check cables from gearbox to TCU
check connectors from gearbox to
TCU
replace TCU
Remarks
HIGH VOLTAGE AT BATTERY
measured voltage at power supply is higher than 18 V

(12V device)
higher than 32.5 V (24V device)
ERROR AT VALVE POWER SUPPLY VPS1
TCU switched on VPS1 and measured VPS1 is off or
TCU switched off VPS1 and measured VPS1 is still on
cable or connectors are defect and are contacted to
battery voltage
vehicle ground
permanent power supply KL30 missing
TCU has an internal defect
ERROR VALVE POWER SUPPLY VPS2
TCU switched on VPS2 and measured VPS2 is off or
TCU switched off VPS2 and measured VPS2 is still on
battery voltage
vehicle ground
permanent power supply KL30 missing
TCU has an internal defect
S.C. TO GROUND AT DLM LONGITUDINAL OUTPUT
S.C. TO BATTERY VOLTAGE AT DLM
LONGITUDINAL OUTPUT
shift to neutral
shift to neutral
check fuse
check cables from gearbox to TCU
check connectors from gearbox to
TCU
replace TCU

OP-Mode: normal

valve
1)
see chapter 4
no reaction
OP-Mode: normal

valve
1)
see chapter 4
-36-

Fault
Code
(hex)
D9
E1

O.C. AT DLM LONGITUDINAL OUTPUT
OPEN CIRCUIT AT DIRECTION SELECT
SIGNALS
E2
E3
E4
Reaction of the TCU
Remarks
no reaction
OP-Mode: normal

valve
1)

neutral
shutdown

lever

neutral
shutdown

lever
no reaction
OP-Mode: normal

display
check the connectors at the display
change display
no reaction
OP-Mode: normal

display
check the connectors at the display
change display
TCU detected a o.c signals for the direction

OPEN CIRCUIT AT DIRECTION SELECT
SIGNALS OF SHIFTER 2
TCU detected a o.c signals for the direction
S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT
TCU sends data to the display and measures allways a
high voltage level on the connector
cable or connectors are defective and are contacted
to battery voltage
display has an internal defect
S.C. TO GROUND AT DISPLAY OUTPUT
TCU sends data to the display and measures allways a
high voltage level on the connector
cable or connectors are defective and are contacted
to vehicle ground
display has an internal defect
-37-
see chapter 4

Fault
Code
(hex)
E5
E6
F1
F2
Reaction of the TCU
TCU select parameter set

with ID0
OP-Mode: Limp Home
check display controller

check cable to display controller
DISPID1_TIMEOUT
Timeout of CAN-message DISPID1 from display
controller
ILLEGAL ID REQUEST VIA CAN
GENERAL EEPROM FAULT
TCU can't read non volantile memoy
TCU is defective
CONFIGURATION LOST
TCU has lost the correct configuration and can't control

the transmission.
interference during saving data on non volatile
memory
TCU is brand new or from another vehicle
transmission stay neutral

no reaction
OP-Mode: normal
replace TCU

Reprogramm the correct

configuration for the vehicle (e.g.
with cluster controller,...)
F2
FWD CONFIGURATION LOST

TCU has lost the FWD configuration.
memory
TCU is brand new or from another vehicle
reconfigure with
TCU Configuration Command
(ID PC)
F3
APPLICATION ERROR

replace TCU !!
shift to neutral
OP-Mode: limp home
The external controller has to cancel

the request
something of this application is wrong
F4
Remarks
LIMP HOME REQUEST
no fault! indicates that another computer requested limp

home via CAN
-38-
Often shown together with

Fault code F2
This fault occurs only if an

test engineer did something
wrong in the application of
the vehicle

Fault
Code
(hex)
F5
F6
Reaction of the TCU
Remarks

check clutch
TCU shows also the affected

clutch on the Display
default values = 0 for AEB

offsets used
OP-Mode: normal
no Inchmode available
CLUTCH FAILURE
AEB was not able to adjust clutch filling parameters

One of the AEB-Values is out of limit
CLUTCH ADJUSTMENT DATA LOST OR INCHPEDAL
CALIBRATION DATA LOST
TCU was not able to read correct clutch adjustment
parameters
memory
TCU is brand new
-39-
execute AEB
4.
Measuring of resistance at actuator/sensors and cable
4.1
actuator:
1
open circuit:
short cut to ground:
short cut to battery:
4.2
R12 R1G R2G

R12 R;
R1G 0, R2G R or R1G R, R2G 0
R12 R;
R1G 0, R2G R or R1G R, R2G 0
(for s.c. to ground, G is connected to vehicle ground)

(for s.c. to battery, G is connected to battery voltage)
cable:
UBat
P (power supply)
TCU
Actuator /
1
Sensor
C (chassis)
Gnd
open circuit:
short cut to ground:
short cut to battery:
R12 R1P R1C R2P R2C

R12 0;
R1C R2C 0,
R12 0,
R1C R2C ,
R1P R2P
R1P R2P 0
Abkrzung
abbrevation
ABS
Englisch
Franzsisch
Spanisch
Italienisch
Anti-Blockier-System
Deutsch
anti-block system
Systme antiblocage des rouses
Sistema antibloqueo de frenos
Sistema antibloccaggio delle
Ausgang Digital 24 V
digital output 24 V (output digital)
Sortie numrique 24 V
Salida digital 24 V
Uscita digitale 24 V
(ABS)
AD
ADM
ADS
ADVP
AIP
ripte (ABS)
Ausgang Digital Masse
digital output ground/earth
Sortie numrique masse
Salida digital masa
Uscita digitale massa
Ausgang Digitale schellschaltend
digital output fast switching
Sortie numrique connexion rapide
Salida digital conexin rida
Uscita digitale connessione rapida
Ausgang Digital Versorgung Plus
digital output power supply
Sortie numrique alimentation plus
Salida digital alimentacin positivo
Uscita digitale alimentazione positivo
Ausgang Strom Proportional
power output proportional (+)
Sortie courant proportionnel
Salida de corriente electroimn
Uscita corrente proporzionale
proporcional
alpha_fp
ASR
Gaspedalstellung (Wert in %)
accelerator pedal position
Position pdale acclraleur
Posicin pedal acelerador
(value in %)
(valeur en %)
(valor en %)
Posizione pedale acceleratore

(valore in %)
Antriebs-Schlupf-Regelung
anti-slip control
Systme dantipatinage (ASR)
Control antipatinaje ruedas
Sistema antislittamento (ASR)
Ausgang Spannung (5V Referenz)
vollage output (5V reference)
Sortie tension (5V - rfrence)
Salida de tensin (5V referencia)
CAN Botschaft
CAN message
Message CAN
Mensaje CAN
Messaggio CAN
Bordrechner Driveline retarder
On-board Computer - driveline
Calculateur de bord - chaine
Ordenador de a bordo - Accionam
Computer di bordo - catena
retarder
cinmatique ralentisseur
retardador
cinematica rallentatore
Bordnetz
vehicle power circult
Rseau de bord
Red de a bordo
Rete di bordo
Bremssteurgert
brake control unit
Module de contrle du freinage
Unidad de control frenos
Module di controllo della frentura
Bremsstufenhebel
brake step level
Slecteur de freinage crans
Palanca de frenado por escalones
Selettore dei gradi di frenatua
motrices
AU
aux_stat_zbr
BC-DR
BN
BSG
BSH
Buka
CAN
Buchsenkasten
terminal tester
Bollier douilles
Caja de bornes
Cassetta delle prese
Controller-Area-Network
Controller Area Network (CAN)
Controller-Area-Network (rseau
Controller Area Network (CAN)
Controller-Area-Network (rete
Datenleitung
CAN-bus data network
Ligne donnes
Linea de datos CAN
Linca dati
CAN Full - High
CAN Full - High
CAN Full - High
CAN Full - High
CAN Full - High
CAN Full - Low
CAN Full - Low
CAN Full - Low
CAN Full - Low
CAN Full - Low
Tempomat
cruise control
Tempomat (rgulateur de vitesse)
Tempomat (control autom.
Tempomat (regolatore della velocta)
Tempomat/Fahrzeuggeschwin-
cruise control/vehicle speed
Tempomat/vitesse vhicule
Tempomat/Velocidad del vehiculo
Tempomat/velocit veicolo
instrument panel
Planche de bord
Tablero de instrumentos
Cruscotto portastrumenti
muliplexe)
CAN-Bus
CANF-H
CANF-L
CC
Usicta tensione (5V - riferimento)
interscambio dati CAN)
velocidad)
CCVS
digkeit
DIP
DM
EBC
EBS
EBZ
ECO
ECU
ED
EDC
EDM
Instrumententafel
Diagnose Botschaft
Diagnosis Message
Diagnostique message
Mensaje de diagnosis
Diagnosi messaggio
Elektronische Brems-Steuerung
Electronic Brake Controller
Contrleur electronique de freinage
Control electrnico de frenos
Controllore elettronico della frenatrua
Elektronisches Brems-System
Electronic Brake System
Systme de freinage lectronique
Sistema electrnico de frenado
Sistema di freanature elettronico
Einbauzeichnung
installation drawing
Plan dencombrement
Plano de instalaction
Disegno di installazione
Motor Konfiguration
engine configuration
Configuration du moleur
Configruacin del motor
Configurazione del motore
Elektronisches Steuergert
Electronic control unit (ECU)
Unit de commande lectronique
Unidad electrnica de control
Unit di comando elettronico (UCE)
(Getriebsbesteuerung)
(Transmission control)
(UCE) (calculateur de boite)
(ECU) ( control caja cambies)
(calcolatore cambio)
Eingang Digital 24 V +
Digital input 24 V +
Entre numerique 24 V +
Entrada digital 24 V +
Entrata digitale 24 V +
Elektronische Dieselregelung
Electronic diesel control (EDC)
Gestion lectronique pour moteurs
Regulacin electrnica diesel
Pompa iniezione electronica (EDC)
(Motorelektronik)
(engine electronics)
Diesel
(EDC) (unidad electr. del motor)
Eingang Digital Masse
Digital input ground/earth
Entre numerique masse
Entrada digital masa
Entrata digitale massa
Abkrzung
abbrevation
EEC
EF
EM 1
EMC
EMV
EOL
Ed_Paramele
Deutsch
Motorelektronik
Englisch
Franzsisch
Spanisch
Italienisch
Electronice Engine Controller
Calculateur moteur
Unidad electrnica de control motor
Centralina elettronica del motore
Eingang Frequenz
Frequency input
Entre frquence
Entrada frecuencia
Entrafa frequenze
Elektronik-Modul 1 (Schnittstelle
electronic-modul 1 (interface level/
Module lectronique 1 (interface
Mdulo electrnico 1 (interfaz
Modulo elettronico 1 (interfaccia
Fahrschalter/Bordnetz ASTRONIC)
vehicle circuit -> ASTRONIC
slecteur de marche/rseau de
selector marchas/red be a bordo
selettore di marcia/rette di bordo
bord ASTRONIC)
ASTRONIC
ASTRONIC
Elektromagnetische Vertrglichkeit
electro-magnetic compatibility
Compatibilit lectromagntique
Compatibilidad electromagntica
Campatibilit elettromagnetica
Elektromagnetische Vertrglichkeit
electro-magnetic compatibility
Compatibilit lectromagntique
Compatibilidad electromagntica
Campatibilit elettromagnetica
Bandende
End-of-Line (EOL)
Fin de ligne
Final de la linea
End of line
End of line (Eintrag Fahrzeugpara-
End of line (entry of vehicle
Fin de ligne (entre paramtres
Final de la linea (registro parmetro
End of line (entrata parametri veicolo
meter wie z. B. Hinterachsber-
parameter e. g. rear axle ratio)
vhicule comme p. ex. Rapport
vehiculo p. ej.: relacin eje trasero
come p. es. Rapporto al ponte)
setzung)
EPS
ER
ERC 1_DR
ESG
pont arrire
Elektro-Pneumatische-Schaltung
Electro-pneumatic-shifting unit
Commande lectro-pneumatique
Unidad de cambio electroneumtico
Comando elettropneumatico
Retarder-Steuergert
Electronic Retarder Controller
Boilier de commande ralentisseur
Unidad electrnica del retardador
Centralina elettronica del rallentatore
CAN Botschaft
CAN message
Message CAN
Mensaje CAN
Messaggio CAN
Elektronisches Steuergert
electronic control unit
Unit di comando elettronica (UCE)
Elektronische Steuerung
electronic control
Commande lectronique
Comando elettronic
Elektronische Getriebe-Steuerung
Electronic Transmission Control
Unidad electrnica control caja de
Unit di comando elettronica del
(ETC)
de boite
cambios
cambio
(UCE)
EST
ETC
SPN
STVZO
Fehlerpfad
Error path (suspect number)
Trafet anomalie
Via del fallo
Percorso errore
Straen-Verkehrs-Zulassungs-
German road transport code
Prescriptions dhomologation des
Cdigo de Circulactin alemana
Norme dmmissione alla circolazine
Ordnung
SW
TC1_FT
TCO
TCO
TCU
vhicules
dei veicoli
Software
software
Logiciel
Software
Software
CAN Botschaft
CAN message
Message CAN
Mensaje CAN
Messaggio CAN
Getriebe-Konfiguration
transmission configuration
Configuration boile
Configuracin de la caja de cambios
Configurazione cambio
Tachograph
Tachograph
Tachygraphe
Tacgrafo
Tachigrafo
Getriebe-Steuerung
Transmission Control Unit
Calculateur de boite de vitesses
Unidad de control de la caja de
Centralina cambio
cambios
TKI
TSC
Technische Kundeninformation
Technical customer information
Informations clients techniques
Informacin tcnica para clients
Informazioni clienti tecniche
Drehmoment-/Geschwindigkeit-
torque/speed control
Rgulateur couple/vitesse
Regulador par/velocidad
Regolatore coppia/velocit
TSC
Drehmoment-/Geschwindigkeit-
torque/speed control
Contrle couple/vitesse
Control par/velocidad
Controllo coppia/velocit
engine control unit (ECU)
Unidad de control del motor
Centralina motore
Regler
Kontrolle
UPEC
Motor-Steuergert
del motor
v_cc_set
Valeo
VD
VECU
VM
von Tempomat gesetzte Sollge-
cruise control set requested
Vitesse thorique charge par le
velocidad terica ajustada por el
Velocit teorica impstate dal
schwindigkeit
speed
rgulateur de vitesse
Tempomat
regolatore della velocit
Kupplungshersteller-Firma
clutch manufacturer
Fabricant embrayage
Fabricante del embrague
Costruttore frizione
Fahrzeug Laufleistung
vehicle mileage
Kilomtrage vhicule
Kilometraje del vehiculo
Percorrenza veicolo
Fahrzeugrechner
Vehicle control unit
Calculateur vhicule
Ordenador del vehiculo
Centralina veicolo
Versorgung Masse
Supply ground
Alimentation masse
Alimentacin masa
Alimentazione massa
Abkrzung
abbrevation
VMG
VMHF
VOE
Deutsch
Englisch
Franzsisch
Spanisch
Italienisch
Supply ground to sensors
Alimentation masse pour capteurs
Alimentacin masa para sensores
Alimentazione massa per trasdultori
Versorgung Masse fr CAN
Supply ground to CAN
Alimentation masse pour CAN
Alimentacin masa para CAN
Alimentazione massa per CAN
Vor-Ort-Elektronik
integrated electronic transmission
Unit lectronique embarque
Centralina elettronica integrata
Versorgung Masse fr Sensoren
control
VPE
VPI
WSI
WT
z_Fbr
z_kd
z_low_idie
z_ret_rck
instalada
Versorgung Plus - Klemme 30
supply plus terminal 30
Alimentation + borne 30
Alimentacin positivo - borne 30
Alimentazione positivo - morsetto 30
Versorgung Plus - Klemme 15
supply plus terminal 15
Alimentation + borne 15
Alimentacin positivo - borne 15
Alimentazione positivo - morsetto 15
Raddrehzahlinformation
Wheel speed information
information rgime roues
informacin revoluc. De rueda
Informazione regime ruote
(CAN Botschaft)
(CAN message)
(message CAN)
(mensaje-CAN)
(message CAN)
Wrmetauscher
Heat exchanger
Echangeur thermique
Intercambiador de calor
Scambiatore di catore
Signal Fubremse
foot brake signal
Signal frein pied
Senal freno de pie
Segnale freno a piede
Signal Kick-Down
kickdown signal
Signal kick-down
Senal kick-down
Segnale kick-down
Signal Leerlaufschalter
idling switch signal
Signal contacteur point mort
Senal interruptor de ralenti
Segnale interruttore di folle
Rckschaltanforderung vom
intarder down-shifting request
Requte rtrogradage Intarder
Requerimiento de reduccin de
Richiesta scalata da Intarder
Intader
ETP
EU
FFR
FMI
FMR
FR
Fzg
GP
marcha desde el Intarder
Motortemperatur
Engine temperature
Temprature moteur
Temperatura del motor
Temperatura motore
Analog-Eingang Spannung
Analog input voltage
Entre alnalogique tension
Tensin analgica de entrada
Entrata analogica tensione
Fahrzeugfhrungsrechner
Vehicle Controller
Calculateur de gestion du vhicule
Centralina di gestione del veicolo
Fehlerart
Failure Mode Identifier
Type danomalie
Tipe de fallo
Tipo di anomalia
Fahrzeug-Motor-Regulierung
vehicle engine regulation
Rgulation vhicule-moteur
Regulacin del motor del vehiculo
Regolazione veicolo-motore
Fahrzeug-Rechner
Vehicle Control Unit
Calculateur vhicule
Centralina veicolo
Fahrzeug
vehicle
Vhicule
Vehiculo
Veicolo
Bereichsgruppe (Planetengruppe9
planetary group
Group-relais (groupe picycloidal)
Grupo planetario
Selettore di gamma
Getriebe-Steller
transmission actuator
Actionneur le la boite da vitesses
Unidad de mando de la caja de
(gruppo epicicloidate)
GS
Attuatore del cambio
cambios
GV
HG
HRVD
i. O.
i_HA
IES
IKL
Ink
ISMA
Split-Gruppe (Vorschalt-Gruppe)
splitter group
Doubleur de gamma (relais avant)
Grupo multiplicador
Haupt-Getriebe
main transmission
Boite de base
Caja de camblos principal
Splitter (gruppo epicicloidale a monte)

Cambio base
Fahrzeug Laufleistung
Vehicle performance (mileage)
Kilomtrage vhicule
Kilometraje principal
Pervorrenza veicolo
in Ordnung
OK
ok
correcto
ok
Hinterachsenbersetzung
rear axle ratio
Rapport de pont
Relacin del eje trasero
Rapporto al ponte
Integriertes Elektronik-System
integrated electronic system
Systme lectronigue intgr
Sistema electrnico intergrado
Sistema elettronico integrato
Intarder-Kontrollleuchte
Intarder pilot lamp
Tmoin anomalie Intarder
Lmpare de control del Intarder
Spia anomalia Intarder
Inkrement
incremental (step)
incrment
incremento
incremento
Intelligentes Schalt Management
intelligent shift management
Gestion intelligente de change-
Gestin inteligente dei mando
Gestione intelligente del cambio
(Automatik-Modus)
(automatic mode)
ment de vitesses (mode
(Modo automtico)
marcia (modalit automatica)
automatique)
IT
K1
KB
KBE
Intarder
Intarder
Intarder
Intarder
Intarder
Konstante 1
constant ratio 1
Constante 1
Pareja pinones en toma constante 1
Constante 1
Kernbchse
core bush
Douille centrale
Casquillo central
Boccola central
Kupplungsbettigungseinheit
clutch actuation system
Unit dactionnement de
Unidad de accionamiento del
Unit di azionamento della frizione
lembrayage
embrague
Abkrzung
abbrevation
Kitas
K-Line
KS
Deutsch
aktiver Abtriebsdrehzahlgeber fr
Englisch
Franzsisch
Spanisch
Italienisch
active output speed sensor for
Capteur actif de rgime de sortie
Sensor activo revoluc salida
Trasduttore attivo del regime di
Tacho
speedo
pour tachymtre
para velocimetro
uscita per tachimetro
Kommunikationsleitung
communication circuit
Ligne de communication
Cable de comunicacin
Linea di comunicazione
Kupplungssteller
clutch actuator
Actionneur dembrayage
Unidad de accionamiento del
Attuatore della frizione
embrague
LL
LR
m_dd_edc
m_mbr
m_mot_akt
m_sekret
MB
MBr
MUX
MUX
n. d.
n_mot
n_sek
Leerlauf
idie
Ralentie
Ralenti
Folle
Leitrechner
vehicle guide controller
Calculateur vhicule
Ordenador principal del vehiculo
Centrallna veicolo
Berechnete Einspritzmenge von
Caculated EDC injection rate
Quantit dinjection calcule par
Cant. Combustiblelyectada por el
Quanti diniezione calcolata dallÈdc
EDC (Fahrerwunsch
(drivers request)
lEDC (souhait conducteur)
EDC (deseo del conductor)
(richiesta autista)
aktuelles Motorbremsmoment
current engine brake torgue
Couple frein moteur momentan
Par actual del freno-motor
Coppia freno motore momentanea
Aktuell eingespritze Menge der
current injection quantity for
Quantit momentane injecte
Cant. Actual de combustible in-
Quantit momentanea iniettata
EDC
EDC engine
par lEDC
yectada del EDC
dallÈDC
Sekundrretarderbremsmoment
Secondary retarder brake torque
Couple de freinage du ralentisseur
Par de frenado del retardador
Coppia di frentura del rallentatore
aus der CAN-Botschaft ERC1 vom
form CAN message ERC1 taken
(Driveline Retarder)
from Intarder (Driveline Retarder)
secondaire du message CAN ERC1 secundario desde el mensaje-CAN
secondario da messaggio CAN ERZ 1
de lÌntarder (chaine cinmatique
ERC1 bel Intarder (Driveline
proventiente dallIntarder
Retarder)
Retarder)
(catena cinematica Retarder)
Motorbremse
Enigine brake
Frein moteur
Freno-motor
Freno motore
Motorbremse
Enigine brake
Frein moteur
Freno-motor
Freno motore
Muliplex-Signal
muliplex signal
Signal muliplex
Senal muliplex
Segnale multiplex
Muliplex-System
Muliplex system (channel)
Systme muliplex
Sistema muliplex
Sistema multiplex
nicht definiert
not defined
non dfini
no definido
non definio
Drehzahl Motor
engine speed
Rgime moteur
Revoluciones del motor
Regime motore
Drehzahl Antriebswelle Getriebe
transmission output shaft speed
Rgime arbre de sortie de la boite
Revoluciones eje entrada caja de
Regime albero duscita del cambio
cambio
NA
OEM
PTO
RCO
REC
RL
s. n. v.
SA
SDDK
Nebenabtrieb
power-take-off
Prise de mouvement
Toma de fuerza
Presa di forza
Fahrzeughersteller
original equipment manufacturer
Constructeur vhicule
Fabricante del vehiculo
Costruttore veicolo
Nebenabtrieb
power-take-off
Prise de mouvement
Toma de fuerza
Presa di forza
Retarder Konfigurationretarder
retarder configuration
Configuration du ralentisseur
Configuracin dei retardador
Configurazione del rallentatore
Retarder Konfiguration
retarder configuration
Configuration ralentisseur
Configuracin dei retardador
Configurazione del rallentatore
Rckwrtsgang-Langsam
reverse gear low
Marche-amre lente
Marcha alrs corta
Reformarcia lenta
Signal nich verfgbar
Signal not available
Signal non disponible
Senal no est dispnible
Segnate non dispoibile
Absender
Source Address
Emetteur
Remitente
Emittente
Schnittstelle Digital-Diagnose
Interface Digital-Diagnosis K-line
interface diagnostic numrique
Interfaz cable-K diagnosis digital
Interfaccia diagnosi digitale linea K
K.-Leitung
ligne K

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Error Code List

Order-No.: 5872 993 026

Diagnose- and programming ERGOPOWER with

Data sheet for WG-110 211

Data sheet for WG-260 311

General data sheet for WG-130 310

Definition of operating modes

Table of fault codes

Measuring of resistance at actuator/sensors and cable

DIAGNOSE - AND PROGRAMMING

Pentium Laptop least 1,0 GHz

Diagnosis software on CD-ROM for ERGOPOWER

Language Versions : ENGLISH / FRANCE / GERMAN / ITALIAN

Data sheet for WG- 110-211

Data for the Hall-Sensor of the Output:

Data for the Proportional valves:

Data for the Lock-up solenoid valve:

Data for the Lock-up Proportional valve:

Data sheet for WG-260-311

Data for the Hall-Sensor of the Output:

Data for the Proportional valves:

Data for the Lock-up Proportional valve:

General data sheet for WG 130 310

Pressure behind the :

130/160: max. 3,5 bar

Oil-flow from the pump:

130/160: 80 l/min bei n = 2000 min-1

1. Description of the fault codes for

(special symbols a-h)

Display during operation

actual gear and direction

limp home gear

6 WG: converter lockup clutch open

4 WG: Downshift mode activ

CAUTION gear will engage if turbine speed drops

manual mode 2nd gear

difference of engine and turbine speed above a certain

changes between actual gear/direction while driving,

Display during AEB-Mode

AEB - Starter is plugged at the

Display during Inchpedal Calibration

push down the pedal slowly until

If the expected enposition could not be reached,

Definition of operating modes

SUBSTITUTE CLUTCH CONTROL:

3. Table of fault codes

MEANING OF THE FAULT CODE

LOGICAL ERROR AT DIRECTION SELECT SIGNAL 3RD SHIFT

TCU detected a wrong signal combination for the

LOGICAL ERROR AT GEAR RANGE SIGNAL

TCU detected a wrong signal combination for the gear

Reaction of the TCU

Possible steps to repair

TCU shifts transmission to

check the cables from TCU to shift

fault is cleared if TCU

TCU shifts transmission to

check the cables from TCU to shift

failure cannot be detected in

TCU shifts transmission to

check the cables from TCU to shift

fault is taken back if TCU

after selecting neutral, TCU

This fault is reset after