6WG Failure Codes

ZF FRIEDRICHSHAFEN Aktiengesellschaft
Benennung: fault codes Nr.: DIN Seite 1

Zusatzbenennung: description of fault codes for Ergo control A4 von 53
Diese technische Unterlage darf weder kopiert 03-05-13 Schwarz
noch dritten Personen ohne unsere Erlaubnis 22
mitgeteilt werden. Index Nr. Datum Name Film
K3 ZFN 904 ÄNDERUNGEN
Erstellt: Geprüft: Freigegeben :
Name: Burkhart Sieger Burkhart
Abteilung: AC-ET1 TE-AB AC-ET1
Datum: 2005-01-31 03-10-01 05-01-31
Description
of the
fault codes
for
ERGO-Control EST37
document created for customer "6WG mit CAN J1939" jjjj-04-tt

ZF Friedrichshafen AG 05-01-31
Faultcodes ERGO-Control EST37A
Index of changes:
date index comment software version
TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 2 von 37

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.
left right
h f e d character character
S
T
O
P
a b c g
(special symbols a-h)
1.3 Display during operation

Symbol meaning remarks
1F, 1R actual gear and direction
2F, 2R left digit shows actual gear
3F, 3R right digit shows actual direction
4F
5F
6F
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing direction F or R selected while turbine CAUTION gear will engage if turbine speed drops
speed is too high
NN not neutral, waiting for neutral after to engage a gear, first move shift selector to neutral
power up or a severe fault position and again to F or R position
** oil temperature too low, no gear warm up engine / transmission
available
*N oil temperature low, only one gear warm up engine / transmission
available
1 bar (special manual mode 1st gear
symbol)

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 automatic mode
arrows
Bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed above a certain
limit and lockup clutch not activated
4 WG: Downshift mode activ
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
WT warning torque converter temperature changes between actual gear/direction while driving, in
WE warning high engine speed changes between actual gear/direction while driving, in
WV warning high output speed (velocity) changes between actual gear/direction while driving, in
WL warning high transmission input torque changes between actual gear/direction while driving, in
(load) neutral only displayed if no fault is detected (spanner)
PN 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
EE flashing no communication with display checked wiring from TCU to display

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 Transmissions stays in neutral, you have to restart the
calibrated TCU (ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, you have to restart the
∆E engine speed too low,
Ö raise engine speed
∇E engine speed too high,
Ö lower engine speed
∆T transmission oil temperature too low,
Ö heat up transmission
∇T transmission oil temperature too high
Ö cool down transmission
FT transmission temperature not in defined Transmissions stays in neutral, you have to restart the
range during calibration TCU (ignition off/on)
FB operating mode not NORMAL or Transmissions stays in neutral, you have to restart the
transmission temperature sensor TCU (ignition off/on)
defective or storing of Calibrated values
to EEPROM-has failed.
FO Outputspeed_not_zero Transmissions stays in neutral, you have to restart the
FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the
FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart the
STOP AEB - Starter was used incorrect or is Transmissions stays in neutral, you have to restart the
defective. Wrong device or wrong cable TCU (ignition off/on)
used

1.5 Display during Inchpedal Calibration

symbol meaning remarks
push down the pedal slowly until
IP ⇓ endposition is reached and hold this
position
Release the pedal slowly until
IP ⇑ endposition is reached
A problem occurred, release the pedal If the expected enposition could not be reached, release
IP ⇑ flashing slowly until endposition is reached the pedal and try again
OK Finished inchpedal calibration
successful
FN and Stop Shift lever not in Neutral position Calibration is aborted
FS and Stop sensor supply voltage AU1 is out of Calibration is aborted
the specified range
FO and Stop Outputspeed is not zero Calibration is aborted
SL and Stop sensor voltage below specified Calibration is aborted
rangel
SU and Stop sensor voltage above specified Calibration is aborted
rangel
IL and Stop sensor position for released pedal Calibration is aborted
out of specified range
IU and Stop sensor position for pressed pedal out Calibration is aborted
of specified range
TO and Stop time-out calibration, pedal not moved Calibration is aborted
after calibration start
DL and Stop angle between pedalpositions Calibration is aborted
released and pressed to small
DU and Stop angle between pedalpositions Calibration is aborted
released and pressed to big
FI and Stop sensor signal 1 and 2 don't match Calibration is aborted
together

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
3 table of fault codes
Fault SPN FMI MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
11 5000 12 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to neutral • check the cables from TCU to shift lever failure cannot be detected in
TCU detected a wrong signal combination OP-Mode: transmission shutdown • check signal combinations of shift lever systems with DW2/DW3 shift
for the gear range positions for gear range lever
• cable from shift lever to TCU is fault is taken back if TCU
broken detects a valid signal for the
• cable is defective and is contacted to position
battery voltage or vehicle ground
• shift lever is defective
12 5010 12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to neutral • check the cables from TCU to shift lever fault is taken back if TCU
SIGNAL OP-Mode: transmission shutdown • check signal combinations of shift lever detects a valid signal for the
TCU detected a wrong signal combination positions F-N-R direction at the shift lever
for the direction
• cable from shift lever to TCU is
broken
• cable is defective and is contacted to
13 5020 12 LOGICAL ERROR AT ENGINE DERATING after selecting neutral, TCU • check engine derating device This fault is reset after power
DEVICE changes to OP-Mode limp home up of TCU
TCU detected no reaction of engine while
derating device activ
15 5040 12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to neutral • check the cables from TCU to shift lever fault is taken back if TCU
SIGNAL 2. SHIFT LEVER if selector activ 2 detects a valid neutral signal
TCU detected a wrong signal combination OP-Mode: transmission shutdown • check signal combinations of shift lever for the direction at the shift
for the direction if selector activ positions F-N-R lever
• cable from shift lever 2 to TCU is
broken

(hex)
16 5050 12 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal • check the cables from TCU to feedback
feedback axle connection measured by axle connection switch
TCU and output signal axle connection • check signals of the feedback axle
don't fit connection switch
• axle can’t be connected or
disconnected due to mechanical
problem
• one of the cables from feedback axle
connection -switch to TCU is broken
25 5110 3 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, • check the cable from TCU to the sensor
TRANSMISSION SUMP TEMPERATURE SENSOR TCU uses default temperature • check the connectors
INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too high:
battery voltage
• cable has no connection to TCU
• temperature sensor has an internal
defect
• connector pin is contacted to battery
voltage or is broken
26 5110 4 S.C. TO GROUND AT TRANSMISSION SUMP no reaction, • check the cable from TCU to the sensor
TEMPERATURE SENSOR INPUT TCU uses default temperature • check the connectors
the measured voltage is too low: OP-Mode: normal • check the temperature sensor
vehicle ground
defect
• connector pin is contacted to vehicle
ground

(hex)
27 5120 3 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, • check the cable from TCU to the sensor
RETARDER / TORQUECONVERTER TCU uses default temperature • check the connectors
TEMPERATURE SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too high:
battery voltage
defect
28 5120 4 S.C. TO GROUND AT RETARDER / no reaction, • check the cable from TCU to the sensor
TORQUECONVERTER TEMPERATURE SENSOR TCU uses default temperature • check the connectors
INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too low:
vehicle ground
defect
ground
29 5130 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TCU uses default value • check the cable from TCU to the sensor
PARKING BRAKE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the parking brake sensor
battery voltage
• sensor has an internal defect
2A 5130 4 S.C. TO GROUND PARKING BRAKE SENSOR TCU uses default value • check the cable from TCU to the sensor
INPUT OP-Mode: normal • check the connectors

(hex)
the measured voltage is too low: • check the parking brake sensor
vehicle ground
ground
2B 5313 12 INCHSENSOR-SIGNAL MISMATCH During inching mode: TCU shifts • check the cable from TCU to the sensor
the measured voltage from CCO and CCO2 to neutral • check the connectors
signal don’t match: While not inching: no change • check sensor
• cable is defective OP-Mode: normal
2C 5135 3 S.C. TO BATTERY VOLTAGE OR O.C. AT DLM TCU uses default value • check the cable from TCU to the sensor
TRACTION ADJUST DASHBOARD DEVICE OP-Mode: normal • check the connectors
INPUT • check the DLM Traction Adjust
the measured voltage is too high: dashboard device
battery voltage
2D 5135 4 S.C. TO GROUND DLM TRACTION ADJUST TCU uses default value • check the cable from TCU to the sensor
DASHBOARD DEVICE INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the DLM Traction Adjust
• cable is defective and is contacted to dashboard device
vehicle ground
ground
2E 5137 3 S.C. TO BATTERY VOLTAGE OR O.C. AT DLM TCU uses default value • check the cable from TCU to the sensor

(hex)
STEERING ANGLE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the DLM STEERING ANGLE
• cable is defective and is contacted to SENSOR
battery voltage
2F 5137 4 S.C. TO GROUND DLM STEERING ANGLE TCU uses default value • check the cable from TCU to the sensor
SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the DLM STEERING ANGLE
• cable is defective and is contacted to SENSOR
vehicle ground
ground
31 5140 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the sensor
ENGINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 V • check the speed sensor
at speed input pin
battery voltage
• speed sensor has an internal defect
voltage or has no contact
32 5140 4 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
TCU measures a voltage less than 0.45V at control • check the connectors
speed input pin • check the speed sensor
• cable / connector is defective and is
contacted to vehicle ground

(hex)
33 5140 12 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power
TCU measures a engine speed over a control • check the connectors up of TCU
threshold and the next moment the • check the speed sensor
measured speed is zero • check the sensor gap
• cable / connector is defective and has
bad contact
• sensor gap has the wrong size
TURBINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 V if a failure is existing at output • check the speed sensor
at speed input pin speed,
• cable is defective and is contacted to TCU shifts to neutral
battery voltage OP-Mode: limp home
35 5150 4 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
speed input pin if a failure is existing at output • check the speed sensor
• cable / connector is defective and is speed,
contacted to vehicle ground TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
36 5150 12 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power
TCU measures a turbine speed over a control • check the connectors up of TCU
threshold and at the next moment the if a failure is existing at output • check the speed sensor
measured speed is zero speed, • check the sensor gap
• cable / connector is defective and has TCU shifts to neutral
bad contact OP-Mode: limp home

(hex)
INTERNAL SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 V • check the speed sensor
at speed input pin
battery voltage
38 5160 4 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor
speed input pin • check the speed sensor
• cable / connector is defective and is
39 5160 12 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power
TCU measures a internal speed over a control • check the connectors up of TCU
threshold and at the next moment the • check the speed sensor
measured speed is zero • check the sensor gap
bad contact
3A 5170 3 S.C. TO BATTERY VOLTAGE OR O.C. AT special mode for gear selection • check the cable from TCU to the sensor
OUTPUT SPEED INPUT OP-Mode: substitute clutch • check the connectors
TCU measures a voltage higher than 12.5 V control • check the speed sensor
at speed input pin if a failure is existing at turbine
• cable is defective and is contacted to speed,
battery voltage TCU shifts to neutral

(hex)
• cable has no connection to TCU OP-Mode: limp home
3B 5170 4 S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear selection • check the cable from TCU to the sensor
TCU measures a voltage less than 1.00V at OP-Mode: substitute clutch • check the connectors
speed input pin control • check the speed sensor
• cable / connector is defective and is if a failure is existing at turbine
contacted to vehicle ground speed,
• speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
3C 5170 12 LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear selection • check the cable from TCU to the sensor This fault is reset after power
TCU measures a output speed over a OP-Mode: substitute clutch • check the connectors up of TCU
threshold and at the next moment the control • check the speed sensor
measured speed is zero if a failure is existing at turbine • check the sensor gap
• cable / connector is defective and has speed,
bad contact TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
3E 5180 2 OUTPUT SPEED ZERO DOESN’T FIT TO OTHER special mode for gear selection • check the sensor signal of output speed This fault is reset after power
SPEED SIGNALS OP-Mode: substitute clutch sensor up of TCU
if transmission is not neutral and the control • check the sensor gap of output speed
shifting has finished, if a failure is existing at turbine sensor
TCU measures outputspeed zero and speed, • check the cable from TCU to the sensor
turbine speed or internal speed not equal to TCU shifts to neutral
zero. OP-Mode: limp home
56 5280 9 ENGINE CONF TIMEOUT OP-Mode: substitute clutch • check engine controller
Timeout of CAN-message ENGINE CONF control • check wire of CAN-Bus
from engine controller • check cable to engine controller
• interference on CAN-Bus

(hex)
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
57 5290 9 EEC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller

Timeout of CAN-message EEC1 from EEC control • check wire of CAN-Bus
controller • check cable to EEC controller
battery voltage
58 5300 9 EEC3 TIMEOUT OP-Mode: substitute clutch • check EEC controller

Timeout of CAN-message EEC3 from EEC control • check wire of CAN-Bus
• CAN wire/connector is defective an
battery voltage
65 5430 2 ENGINGE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller

CAN signal for engine torque is defective control • check wire of CAN-Bus
• engine controller is defective • check cable to engine controller
69 5440 2 REFERENCE ENGINE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for reference of engine torque control • check wire of CAN-Bus
is defective • check cable to engine controller
• engine controller is defective
6A 5450 2 ACTUAL ENGINE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller

(hex)
CAN signal for actual engine torque is control • check wire of CAN-Bus
defective • check cable to engine controller
6B 5460 2 NOM FRICTION TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for nominal friction torque is control • check wire of CAN-Bus
defective • check cable to engine controller
6E 5470 2 EEC2 TIMEOUT no reaction, • check EEC controller

Timeout of CAN-message EEC2 from EEC TCU uses default signal • check wire of CAN-Bus
controller accelerator pedal in idle position • check cable to EEC controller
• interference on CAN-Bus OP-Mode: normal
battery voltage
1)
71 5480 3 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4
the measured resistance value of the valve OP-Mode: limp home • check the connectors from TCU to the
is out of limit, the voltage at K1 valve is if failure at another clutch is gearbox
too high. pending • check the regulator resistance 1)
• cable / connector is defective and has TCU shifts to neutral • check internal wire harness of the
contact to battery voltage OP-Mode: TCU shutdown gearbox
• regulator has an internal defect
1)
72 5480 4 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4
the measured resistance value of the valve OP-Mode: limp home • check the connectors from gearbox to
is out of limit, the voltage at K1 valve is if failure at another clutch is TCU
too low. pending • check the regulator resistance 1)
contact to vehicle ground OP-Mode: TCU shutdown gearbox

(hex)
contact to another regulator output of
the TCU
1)
73 5480 5 O.C. AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4
is out of limit. if failure at another clutch is TCU
• cable / connector is defective and has pending • check the regulator resistance 1)
no contact to TCU TCU shifts to neutral • check internal wire harness of the
• regulator has an internal defect OP-Mode: TCU shutdown gearbox
1)
1)
the TCU
1)
OP-Mode: TCU shutdown

(hex)
• regulator has an internal defect gearbox
1)
1)
the TCU
1)
1)

(hex)
1)
the TCU
1)
1)
84 5520 3 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4
is out of limit, the voltage at KV valve is if failure at another clutch is TCU
1)
85 5520 4 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4
is out of limit, the voltage at KV valve is if failure at another clutch is TCU

(hex)
the TCU
1)
86 5520 5 O.C. AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4
1)
87 5530 3 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4
is out of limit, the voltage at KR valve is if failure at another clutch is TCU
1)
88 5530 4 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4
is out of limit, the voltage at KR valve is if failure at another clutch is TCU
the TCU
1)
89 5530 5 O.C. AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the gearbox see chapter 4

(hex)
1)
8A 5535 4 S.C. TO GROUND AT DLM TRANSVERSAL output will be on until TCU • check the cable from TCU to the valve see chapter 4
OUTPUT power down even if fault • check the connectors
TCU detected a wrong voltage at the output vanishes (loose connection) • check the resistance of valve
pin, that looks like a s.c. to vehicle ground OP-Mode: normal
vehicle ground
• device has an internal defect
ground
1)
8B 5535 3 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the valve see chapter 4
TRANSVERSAL OUTPUT OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the output • check the resistance of valve
pin, that looks like a s.c. to battery voltage
battery voltage
voltage
1)
8E 5536 3 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the device see chapter 4
INDICATOR LAMP OUTPUT OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the output • check the resistance of device
battery voltage
voltage
1)
8F 5536 5 O.C. DLM INDICATOR LAMP OUTPUT no reaction • check the cable from TCU to the device see chapter 4
OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the output • check the resistance of device
pin, that looks like a o.c. for this output pin

(hex)
• cable is defective and has no
connection to TCU
• connector has no connection to TCU
1)
93 5560 5 O.C. AT RELAY REVERSE WARNING ALARM no reaction • check the cable from TCU to the backup see chapter 4
TCU detected a wrong voltage at the output OP-Mode: normal alarm device
pin, that looks like a o.c. for this output pin • check the connectors from backup alarm
• cable is defective and has no device to TCU
connection to TCU • check the resistance 1) of backup alarm
• backup alarm device has an internal device
defect
1)
94 5570 4 S.C. TO GROUND AT RELAY STARTER no reaction • check the cable from TCU to the starter see chapter 4
INTERLOCK OP-Mode: normal interlock relay
TCU detected a wrong voltage at the output • check the connectors from starter
pin, that looks like a s.c. to vehicle ground interlock relay to TCU
• cable is defective and is contacted to • check the resistance 1) of starter interlock
vehicle ground relay
• starter interlock relay has an internal
defect
ground
1)
95 5570 3 S.C. TO BATTERY VOLTAGE AT RELAY no reaction • check the cable from TCU to the starter see chapter 4
STARTER INTERLOCK OP-Mode: normal interlock relay
TCU detected a wrong voltage at the output • check the connectors from starter
pin, that looks like a s.c. to battery voltage interlock relay to TCU
• cable is defective and is contacted to • check the resistance 1) of starter interlock
battery voltage relay
• starter interlock relay has an internal
defect
voltage

(hex)
1)
96 5570 5 O.C. AT RELAY STARTER INTERLOCK no reaction • check the cable from TCU to the starter see chapter 4
TCU detected a wrong voltage at the output OP-Mode: normal interlock relay
pin, that looks like a o.c. for this output pin • check the connectors from starter
• cable is defective and has no interlock relay to TCU
connection to TCU • check the resistance 1) of starter interlock
• starter interlock relay has an internal relay
defect
1)
9A 5590 4 S.C. TO GROUND AT CONVERTER LOCK UP no reaction • check the cable from TCU to the see chapter 4
CLUTCH SOLENOID OP-mode: normal converter clutch solenoid
TCU detected a wrong voltage at the output • check the connectors from converter
pin, that looks like a s.c. to vehicle ground clutch solenoid to TCU
• cable is defective and is contacted to • check the resistance 1) of converter clutch
vehicle ground solenoid
• converter clutch solenoid has an
internal defect
ground
1)
9B 5590 3 O.C. AT CONVERTER LOCK UP CLUTCH converter clutch always open, • check the cable from TCU to the see chapter 4
SOLENOID retarder not available converter clutch solenoid
TCU detected a wrong voltage at the output OP-mode: normal • check the connectors from converter
pin, that looks like a o.c. for this output pin clutch solenoid to TCU
• cable is defective and has no • check the resistance 1) of converter clutch
connection to TCU solenoid
internal defect
1)
9C 5590 5 S.C. TO BATTERY VOLTAGE AT CONVERTER no reaction • check the cable from TCU to the see chapter 4
LOCK UP CLUTCH SOLENOID OP-mode: normal converter clutch solenoid
TCU detected a wrong voltage at the output • check the connectors from converter
pin, that looks like a s.c. to battery voltage clutch solenoid to TCU

(hex)
• cable is defective and is contacted to • check the resistance 1) of converter clutch
battery voltage solenoid
internal defect
voltage
1)
9D 5600 4 S.C. TO GROUND AT RETARDER SOLENOID no reaction • check the cable from TCU to the retarder see chapter 4
TCU detected a wrong voltage at the output OP-mode: normal solenoid
pin, that looks like a s.c. to vehicle ground • check the connectors from retarder
• cable is defective and is contacted to solenoid to TCU
vehicle ground • check the resistance 1) of retarder
• retarder solenoid has an internal solenoid
defect
ground
1)
9E 5600 3 O.C. AT RETARDER SOLENOID no reaction • check the cable from TCU to the retarder see chapter 4
TCU detected a wrong voltage at the output OP-mode: normal solenoid
pin, that looks like a o.c. for this output pin • check the connectors from retarder
• cable is defective and has no solenoid to TCU
connection to TCU • check the resistance 1) of retarder
• retarder solenoid has an internal solenoid
defect
1)
9F 5600 5 S.C. TO BATTERY VOLTAGE AT RETARDER no reaction • check the cable from TCU to the retarder see chapter 4
SOLENOID OP-mode: normal solenoid
TCU detected a wrong voltage at the output • check the connectors from retarder
pin, that looks like a s.c. to battery voltage solenoid to TCU
• cable is defective and is contacted to • check the resistance 1) of retarder
• retarder solenoid has an internal
defect

(hex)
voltage
1)
A1 5610 4 S.C. TO GROUND AT DIFFLOCK OR AXLE no reaction • check the cable from TCU to the difflock see chapter 4
CONNECTION SOLENOID OP-mode: normal solenoid
TCU detected a wrong voltage at the output • check the connectors from difflock
pin, that looks like a s.c. to vehicle ground solenoid to TCU
• cable is defective and is contacted to • check the resistance 1) of difflock
• difflock solenoid has an internal
defect
ground
1)
A2 5610 3 S.C. TO BATTERY VOLTAGE AT DIFFLOCK OR no reaction • check the cable from TCU to the difflock see chapter 4
AXLE CONNECTION SOLENOID OP-mode: normal solenoid
• cable is defective and is contacted to • check the resistance 1) of difflock
defect
voltage
1)
A3 5610 5 O.C. AT DIFFLOCK OR AXLE CONNECTION no reaction • check the cable from TCU to the difflock see chapter 4
SOLENOID OP-mode: normal solenoid
pin, that looks like a o.c. for this output pin solenoid to TCU
• cable is defective and has no • check the resistance 1) of difflock
connection to TCU solenoid
defect
1)
A4 5620 4 S.C. TO GROUND AT WARNING SIGNAL no reaction • check the cable from TCU to the warning see chapter 4
OUTPUT OP-mode: normal

(hex)
TCU detected a wrong voltage at the output device
pin, that looks like a s.c. to vehicle ground • check the connectors from warning
• cable is defective and is contacted to device to TCU
vehicle ground • check the resistance 1) of warning device
• warning device has an internal defect
ground
1)
A5 5620 5 O.C. AT WARNING SIGNAL OUTPUT no reaction • check the cable from TCU to the warning see chapter 4
TCU detected a wrong voltage at the output OP-mode: normal device
pin, that looks like a o.c. for this output pin • check the connectors from warning
• cable is defective and has no device to TCU
connection to TCU • check the resistance 1) of warning device
1)
A6 5620 3 S.C. TO BATTERY VOLTAGE AT WARNING no reaction • check the cable from TCU to the warning see chapter 4
SIGNAL OUTPUT OP-mode: normal device
TCU detected a wrong voltage at the output • check the connectors from warning
pin, that looks like a s.c. to battery voltage device to TCU
• cable is defective and is contacted to • check the resistance 1) of warning device
battery voltage
voltage
B1 5660 2 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral • check pressure at clutch K1

TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
closed clutch K1. If this calculated value is if failure at another clutch is • check sensor gap at internal speed sensor
out of range, TCU interprets this as pending • check sensor gap at output speed sensor
slipping clutch. TCU shifts to neutral • check signal at internal speed sensor
• low pressure at clutch K1 OP-Mode: TCU shutdown
• check signal at output speed sensor
• low main pressure • replace clutch
• wrong signal at internal speed sensor
• wrong signal at output speed sensor

(hex)
• wrong size of the sensor gap
• clutch is defective

• low main pressure
• replace clutch


TCU calculated a difference speed at TCU OP-Mode: limp home • check main pressure in the system
calculates a differential speed at closed if failure at another clutch is • check sensor gap at internal speed sensor
clutch K4. If this calculated value is out of pending • check sensor gap at turbine speed sensor
range, TCU interprets this as slipping TCU shifts to neutral • check signal at internal speed sensor
clutch. OP-Mode: TCU shutdown
• check signal at turbine speed sensor
• low pressure at clutch K4
• replace clutch

(hex)
• wrong signal at turbine speed sensor
B5 5680 2 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV

closed clutch KV. If this calculated value if failure at another clutch is • check sensor gap at internal speed sensor
is out of range, TCU interprets this as pending • check sensor gap at turbine speed sensor
• low pressure at clutch KV OP-Mode: TCU shutdown
B6 5685 2 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR

closed clutch KR. If this calculated value if failure at another clutch is • check sensor gap at internal speed sensor
is out of range, TCU interprets this as pending • check sensor gap at turbine speed sensor
• low pressure at clutch KR OP-Mode: TCU shutdown
B7 5700 0 OVERTEMP SUMP no reaction • cool down machine

TCU measured a temperature in the oil OP-Mode: normal • check oil level
sump that is over the allowed threshold. • check temperature sensor
B8 5710 0 OVERTEMP RETARDER TCU disables retarder • cool down machine

TCU measured a temperature in the OP-Mode: normal • check oil level

(hex)
retarder oil that is over the allowed • check temperature sensor
threshold.
B9 5720 0 OVERSPEED ENGINE retarder applies if configured -

OP-Mode: normal
BA 5730 0 DIFFERENTIAL PRESSURE OIL FILTER no reaction • check oil filter
TCU measured a voltage at differential OP-Mode: normal • check wiring from TCU to differential
pressure switch out of the allowed range pressure switch
• oil filter is polluted • check differential pressure switch
• cable/connector is broken or (measure resitance)
cable/connector is contacted to
• differential pressure switch is
defective
BB 5740 2 SLIPPAGE AT CONVERTER LOCKUP CLUTCH • check pressure at converter lockup clutch
TCU calculates a differential speed at • check main pressure in the system
closed converter lockup clutch. If this • check sensor gap at engine speed sensor
calculated value is out of range, TCU • check sensor gap at turbine speed sensor
interprets this as slipping clutch. • check signal at engine speed sensor
• low pressure at converter lockup • check signal at turbine speed sensor
clutch
• replace clutch
• wrong signal at engine speed sensor
BC 5745 15 OVERSPEED OUTPUT No reaction

TCU messures an transmission output OP-Mode: normal
speed above the defined threshold
1)
BD 5750 4 S.C. TO GROUND AT ENGINE BRKAE no reaction • check the cable from TCU to the engine see chapter 4
SOLENOID OP-mode: normal brake solenoid
TCU detected a wrong voltage at the output • check the connectors from engine brake
pin, that looks like a s.c. to vehicle ground solenoid to TCU

(hex)
• cable is defective and is contacted to • check the resistance 1) of engine brake
• engine brake solenoid has an internal
defect
ground
1)
BE 5750 3 S.C. TO BATTERY VOLTAGE AT ENGINE no reaction • check the cable from TCU to the engine see chapter 4
BRAKE OP-mode: normal brake solenoid
TCU detected a wrong voltage at the output • check the connectors from engine brake
• cable is defective and is contacted to • check the resistance 1) of engine brake
• engine brake solenoid has an internal
defect
voltage
1)
BF 5750 5 O.C. AT ENGINE BRAKE no reaction • check the cable from TCU to the engine see chapter 4
TCU detected a wrong voltage at the output OP-mode: normal brake solenoid
pin, that looks like a o.c. for this output pin • check the connectors from engine brake
• cable is defective and has no solenoid to TCU
connection to TCU • check the resistance 1) of engine brake
• engine brake solenoid has an internal solenoid
defect
C2 5755 15 TRANSMISSION INPUT TORQUE OVERLOAD programmable :No reaction or

TCU calculates an transmission output shift to neutral
torque above the defined threshold OP-Mode: normal
C4 5770 4 S.C. TO GROUND AT JOYSTICK STATUS no reaction • check the cable from TCU to joystick
INDICATOR OP-Mode: normal status indicator
TCU detected a wrong voltage at the output • check the connectors from joystick status
pin, that looks like a s.c. to vehicle ground indicator to TCU
• cable is defective and is contacted to • check the resistance 1) of joystick status

(hex)
vehicle ground indicator
• joystick status indicator has an
internal defect
ground
C5 5770 3 S.C. TO BATTERY VOLTAGE AT JOYSTICK no reaction • check the cable from TCU to joystick
STATUS INDICATOR OP-Mode: normal status indicator
TCU detected a wrong voltage at the output • check the connectors from joystick status
pin, that looks like a s.c. to battery voltage indicator to TCU
• cable is defective and is contacted to • check the resistance 1) of joystick status
battery voltage indicator
• joystick status indicator has an
internal defect
voltage
C6 5770 5 O.C. AT JOYSTICK STATUS INDICATOR no reaction • check the cable from TCU to joystick
TCU detected a wrong voltage at the output OP-Mode: normal status indicator
pin, that looks like a o.c. for this output pin • check the connectors from joystick status
• cable is defective and has no indicator to TCU
connection to TCU • check the resistance 1) of joystick status
• joystick status indicator has an indicator
internal defect
CA 5790 9 ENGINE_RETARDER CONFIG_TIMEOUT OP-Mode: substitute clutch • check EEC controller

Timeout of CAN-message control • check wire of CAN-Bus
ENGINE_RETARDER CONFIG from EEC • check cable to EEC controller
controller
battery voltage

(hex)
CB 5800 9 ERC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller

Timeout of CAN-message ERC1 from EEC control • check wire of CAN-Bus
battery voltage
D1 5810 3 S.C. TO BATTERY VOLTAGE AT POWER see fault codes no. 21 to 2C • check cables and connectors to sensors, fault codes no. 21 to no. 2C
SUPPLY FOR SENSORS which are supplied from AU1 may be a reaction of this fault
TCU measures more than 6V at the pin • check the power supply at the pin AU1
AU1 (5V sensor supply) (should be appx. 5V)
D2 5810 4 S.C. TO GROUND AT POWER SUPPLY FOR see fault codes no. 21 to 2C • check cables and connectors to sensors, fault codes no. 21 to no. 2C
SENSORS which are supplied from AU1 may be a reaction of this fault
TCU measures less than 4V at the pin AU1 • check the power supply at the pin AU1
(5V sensor supply) (should be appx. 5V)
D3 5820 4 LOW VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is lower OP-Mode: TCU shutdown • check cables from batteries to TCU
than 10 V (12V device) • check connectors from batteries to TCU
lower than 18 V (24V device)
D4 5820 3 HIGH VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is higher OP-Mode: TCU shutdown • check cables from batteries to TCU
than 18 V (12V device) • check connectors from batteries to TCU
higher than 32.5 V (24V device)
D5 5830 2 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral • check fuse
TCU switched on VPS1 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 and • check connectors from gearbox to TCU
measured VPS1 is still on • replace TCU
• cable or connectors are defect and are
contacted to battery voltage

(hex)
• permanent power supply KL30 missing
• TCU has an internal defect
D6 5840 2 ERROR VALVE POWER SUPPLY VPS2 shift to neutral • check fuse
TCU switched on VPS2 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 and • check connectors from gearbox to TCU
measured VPS2 is still on • replace TCU
contacted to battery voltage
• permanent power supply KL30 missing
• TCU has an internal defect
1)
D7 5545 4 S.C. TO GROUND AT DLM LONGITUDINAL output will be on until TCU • check the cable from TCU to the valve see chapter 4
OUTPUT power down even if fault • check the connectors
TCU detected a wrong voltage at the output vanishes (loose connection) • check the resistance of valve
pin, that looks like a s.c. to vehicle ground OP-Mode: normal
vehicle ground
ground
1)
D8 5545 3 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the valve see chapter 4
LONGITUDINAL OUTPUT OP-Mode: normal • check the connectors
TCU detected a wrong voltage at the output • check the resistance of valve
battery voltage
voltage

(hex)
E3 5860 3 S.C. TO BATTERY VOLTAGE AT DISPLAY no reaction • check the cable from TCU to the display
OUTPUT OP-Mode: normal • check the connectors at the display
TCU sends data to the display and • change display
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
E4 5860 4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction • check the cable from TCU to the display
TCU sends data to the display and OP-Mode: normal • check the connectors at the display
measures allways a high voltage level on • change display
the connector
• cable or connectors are defective and
are contacted to vehicle ground
• display has an internal defect
F1 5890 2 GENERAL EEPROM FAULT no reaction • replace TCU often shown together with
TCU can't read non volantile memoy OP-Mode: normal fault code F2
• TCU is defective
F3 5910 13 APPLICATION ERROR transmission stay neutral • replace TCU !! This fault occurs only if an
something of this application is wrong OP-Mode: TCU shutdown test engineer did something
wrong in the application of the
vehicle
F5 5930 7 CLUTCH FAILURE transmission stay neutral • check clutch TCU shows also the affected
AEB was not able to adjust clutch filling OP-Mode: TCU shutdown clutch on the Display
parameters
• One of the AEB-Values is out of limit
F6 5930 13 CLUTCH ADJUSTMENT DATA LOST OR default values = 0 for AEB • execute AEB
INCHPEDAL CALIBRATION DATA LOST offsets used
TCU was not able to read correct clutch OP-Mode: normal
adjustment parameters no Inchmode available
• interference during saving data on
non volatile memory

(hex)
• TCU is brand new

4 measuring of resistance at actuator/sensors and cable
4.1 actuator:
1
2
G
open circuit: R12 ≈ R1G ≈ R2G ≈ ∞

short cut to ground: R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 (for s.c. to ground, G is connected to vehicle ground)
short cut to battery: R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 (for s.c. to battery, G is connected to battery voltage)
4.2 cable:
UBat
P (power supply)
TCU
Actuator /
1 2
Sensor
C (chassis)
Gnd
open circuit: R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞

short cut to ground: R12 ≈ 0; R1C ≈ R2C ≈ 0, R1P ≈ R2P ≈ ∞
short cut to battery: R12 ≈ 0, R1C ≈ R2C ≈ ∞, R1P ≈ R2P ≈ 0

6WG Failure Codes

Uploaded by

Copyright:

Available Formats

6WG Failure Codes

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

6WG Failure Codes

Uploaded by

Copyright:

Available Formats

ZF FRIEDRICHSHAFEN Aktiengesellschaft

Benennung: fault codes Nr.: DIN Seite 1

document created for customer "6WG mit CAN J1939" jjjj-04-tt

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 2 von 37

o.c. open circuit

(special symbols a-h)

1.3 Display during operation

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 3 von 37

2 bars manual mode 2nd gear

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 4 von 37

1.4 Display during AEB-Mode

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 5 von 37

1.5 Display during Inchpedal Calibration

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 6 von 37

2 definition of operating modes

SUBSTITUTE CLUTCH CONTROL:

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 7 von 37

3 table of fault codes

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 8 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 9 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 10 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 11 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 12 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 13 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 14 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 15 von 37

57 5290 9 EEC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller

58 5300 9 EEC3 TIMEOUT OP-Mode: substitute clutch • check EEC controller

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

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 16 von 37

6E 5470 2 EEC2 TIMEOUT no reaction, • check EEC controller

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 17 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 18 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 19 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 20 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 21 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 22 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 23 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 24 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 25 von 37

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 26 von 37

B1 5660 2 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral • check pressure at clutch K1

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 27 von 37

B2 5665 2 SLIPPAGE AT CLUTCH K2 TCU shifts to neutral • check pressure at clutch K2

B3 5670 2 SLIPPAGE AT CLUTCH K3 TCU shifts to neutral • check pressure at clutch K3

B4 5675 2 SLIPPAGE AT CLUTCH K4 TCU shifts to neutral • check pressure at clutch K4

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 28 von 37

B5 5680 2 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV

B6 5685 2 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR

B7 5700 0 OVERTEMP SUMP no reaction • cool down machine

B8 5710 0 OVERTEMP RETARDER TCU disables retarder • cool down machine

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 29 von 37

B9 5720 0 OVERSPEED ENGINE retarder applies if configured -

BC 5745 15 OVERSPEED OUTPUT No reaction

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 30 von 37

C2 5755 15 TRANSMISSION INPUT TORQUE OVERLOAD programmable :No reaction or

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 31 von 37

CA 5790 9 ENGINE_RETARDER CONFIG_TIMEOUT OP-Mode: substitute clutch • check EEC controller

TE-AB C:\WINDOWS\TEMP\6WG_CANJ19391.DOC Seite 32 von 37