ZF Transmission EST37 fault codes

August 13, 2018 | Author: Kamiar Delavari | Category: Electrical Connector, Manual Transmission, Transmission (Mechanics), Sensor, Clutch
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Short Description

ZF Transmission EST37 fault codes...

Description

ZF FRIEDRICHSHAFEN Aktiengesellschaft Benennung: fault codes  Nr.: DIN Seite 1 Zusatzbenennung: description of fault codes for Ergo control A4 von 52 Diese technische Unterlage darf weder kopiert 03-03-28 Schwarz noch dritten Personen ohne unsere Erlaubnis 17 mitgeteilt werden. Index N r. Datum Name K3 ZFN 904 ÄNDERUNGEN

Erstellt:  Name:

Schwarz

Abteilung:

TE-AB

Datum:

03-03-28

Geprüft:

Description of the fault codes for  ERGO-Control EST37

Freigegeben :

Film

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

03-05-13

Index of changes: da t e 97-12-12 98-03-18 98-04-02 98-05-04

index

98-05-15 98-05-25 98-07-08 98-07-24 98-09-07 98-10-06 98-10-20

99-02-09

99-08-05 99-09-06 99-11-18 99-12-16 00-01-14 00-01-25

7 8

comment first document based on error.doc dated 97-11-03 corrections adjusted for document automation inserted internal faultcode-numbers, completed reaction of TCU for s.c to Battery at K1..KR  inserted fault code F6 inserted fault code BB, BD .. BF inserted fault code for additional customer specific functions add customer Sisu inserted fault code 15 add description of conditions for taking faults back   overlie fault code 55 for DeviceNet replace retarder request signal with aeb request signal, retarder request was not used inserted internal faultcode-number 173 and 174, add customer Kalmar, add fault code for difflock  add display description remove faults in display description (sz) insert high/low voltage limits for 12V / 24 V devices add fault code for overtemp torqueconverter  change SCT and DCT (sz) several corrections (so)

software version

V826

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

03-05-13

Index of changes: da t e 97-12-12 98-03-18 98-04-02 98-05-04

index

98-05-15 98-05-25 98-07-08 98-07-24 98-09-07 98-10-06 98-10-20

99-02-09

99-08-05 99-09-06 99-11-18 99-12-16 00-01-14 00-01-25

7 8

comment first document based on error.doc dated 97-11-03 corrections adjusted for document automation inserted internal faultcode-numbers, completed reaction of TCU for s.c to Battery at K1..KR  inserted fault code F6 inserted fault code BB, BD .. BF inserted fault code for additional customer specific functions add customer Sisu inserted fault code 15 add description of conditions for taking faults back   overlie fault code 55 for DeviceNet replace retarder request signal with aeb request signal, retarder request was not used inserted internal faultcode-number 173 and 174, add customer Kalmar, add fault code for difflock  add display description remove faults in display description (sz) insert high/low voltage limits for 12V / 24 V devices add fault code for overtemp torqueconverter  change SCT and DCT (sz) several corrections (so)

software version

V826

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

03-05-13

1 Introduction 1.1  Abbreviations 

o.c. s.c. OP-Mode TC U EEC PTO

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

1.2  ZF - Di splay:  play: 

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

S T O

f

e

d

left character 

right character 

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A symbol) 2 bars 3 bars 4 bars

manual mode 2nd gear  manual mode 3rd gear  manual mode 4th gear and also 5 th and 6th gear in 6WG automatic mode

4 bars and 2 arrows Bars Bars flas flash hing ing

6 WG WG: co converte erterr lo lockup cl clutc utch op open

Spanner Fault code WS

4 WG: Downshift mode activ at least one fault activ see faultcode list warning sump temperature

WR

WT

WE

PN

EE flashing

03-05-13

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

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

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

03-05-13

1.4  Di splay duri ng AEB-M ode  ode 

symbol

meaning

PL

AEB - Starter is plugged at the diagnostic plug AEB-Starter-button is pressed

remarks

ST K1..K4,KV,KR  calibrating clutch K1..K4, KV or KR   _ and Kx ≡ and

Kx = and Kx OK  STOP STOP and Kx Spanner and Kx ∆ E ∇ E ∆ T

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 calibr calibrati ation on for all clutch clutches es finish finished ed Transm Transmiss ission ionss stay stayss in in neut neutral ral,, you you have have to to rest restart art the TCU (ignition off/on) after removing AEB-Starter  AEB AEB canc cancel eled ed (ac (acti tiva vati tion on sto stopp pped ed)) Tran Transm smis issi sion onss stays stays in in neut neutra ral, l, you you hav havee to res resta tart rt the the TCU (ignition off/on) AEB stopped, clutch Kx can't be Transmissions stays in neutral, you have to restart the calibrated TCU (ignition off/on) Kx couldn't couldn't be calibrate calibrated, d, AEB finished finished Transmissio Transmissions ns stays in neutral, neutral, you have have to restart the TCU (ignition off/on) engine speed too low, ð raise engine speed engine speed too high, ð lower engine speed transmission oil temperature too low, ð heat up transmission

ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A

03-05-13

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

ZF Friedrichshafen AG description of fault codes for ERGO-Control

97-09-18

3 table of fault codes Fault SPN FMI Int. Code Code (hex) (dec) 11

5000

12

48

MEANING OF THE FAULT CODE

LOGICAL ERROR AT GEAR RANGE SIGNAL

TCU detected a wrong signal combination for the gear range • cable from shift lever to TCU is broken • cable is defective and is contacted to battery voltage or vehicle ground  •  shift lever is defective 12

5010

12

46

LOGICAL ERROR AT DIRECTION SELECT SIGNAL

TCU detected a wrong signal combination for the direction • cable from shift lever to TCU is broken • cable is defective and is contacted to battery voltage or vehicle ground  •  shift lever is defective 13

5020

12

95

LOGICAL ERROR AT E NGINE DERATING

DEVICE TCU detected no reaction of engine while derating device activ

14

5030

TE-AB

12

169

reaction of the TCU

possible steps to repair

remarks

possible reason for fault detection TCU shifts transmission to neutral OP-Mode: transmission shutdown



TCU shifts transmission to neutral OP-Mode: transmission shutdown



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



TCU shifts transmission to DCOParkbrake-status-signal measured by TCU State and parkbrake-status-signal send by CAN OP-Mode: normal don't fit • one of the cables from status-switch to electronic box is broken LOGICAL ERROR AT PARKBRAKE STATUS

J:\DATNBANK\EST37\FEHLERLI\Fc_37_V912.doc





• •

costu mer

failure cannot be detected in check the cables from TCU to shift systems with DW2/DW3 lever  check signal combinations of shift lever  shift lever   positions for gear range fault is taken back if TCU detects a valid signal for the  position

all

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

all

check engine derating device

This fault is reset after power  all up of TCU

Case

check the cables from electronic boxes to status switches check signals of the status switches

Seite 7 von 52

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Int. Code Code (hex) (dec)

MEANING OF THE FAULT CODE

5040

12

176

LOGICAL ERROR AT DIRECTION SELECT

TCU detected a wrong signal combination for the direction • cable from shift lever 2 to TCU is broken • cable is defective and is contacted to battery voltage or vehicle ground  •  shift lever is defective 5050

12

178

LOGICAL ERROR AT AXLE CONNECTION

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



OP-Mode: normal



feedback axle connection measured by TCU and output signal axle connection don't fit • axle can’t be connected or  disconnected due to mechanical   problem • one of the cables from feedback axle connection -switch to TCU is broken 17

5060

4

148

possible steps to repair

S.C. TO GROUND AT CUSTOMER SPECIFIC





customer specific

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 



FUNCTION NO .

TE-AB

remarks

costu mer

one of the status-switches is defective

SIGNAL 2. SHIFT LEVER 

16

reaction of the TCU

possible reason for fault detection •

15

97-09-18

J:\DATNBANK\EST37\FEHLERLI\Fc_37_V912.doc

• •

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

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

all

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

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

all case

1)

 see chapter 4

Seite 8 von 52

ZFunkt ion1

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Int. Code Code (hex) (dec) 18

5060

3

150

MEANING OF THE FAULT CODE

97-09-18

reaction of the TCU

possible steps to repair

S.C. TO BATTERY VOLTAGE AT CUSTOMER 

customer specific

1 TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • customer specific function no. 1 device has an internal defect  • connector pin is contacted to battery voltage



SPECIFIC FUNCTION NO.

19

5060

5

149

O.C. AT CUSTOMER SPECIFIC FUNCTION NO .

• •

customer specific

1 TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU  • customer specific function no. 1 device has an internal defect  • connector has no connection to TCU  1A

5070

4

151

S.C. TO GROUND AT CUSTOMER SPECIFIC

• • •

customer specific

2 TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground  • customer specific function no. 2 device has an internal defect  • connector pin is contacted to vehicle  ground 



FUNCTION NO .

TE-AB

remarks

possible reason for fault detection

J:\DATNBANK\EST37\FEHLERLI\Fc_37_V912.doc

• •

costu mer

check the cable from TCU to customer  specific function no. 1 device check the connectors from customer  specific function no. 1 to TCU check the resistance of customer  specific function no. 1 device

1)

ZFunkt ion1

check the cable from TCU to customer  specific function no. 1 device check the connectors from customer  specific function no. 1 device to TCU check the resistance of customer  specific function no. 1 device

1)

ZFunkt ion1

check the cable from TCU to customer  specific function no. 2 device check the connectors from customer  specific function no. 2 device to TCU check the resistance of customer  specific function no. 2 device

1)

ZFunkt ion2

 see chapter 4

 see chapter 4

 see chapter 4

Seite 9 von 52

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Int. Code Code (hex) (dec) 1B

5070

3

153

MEANING OF THE FAULT CODE

97-09-18

reaction of the TCU

possible steps to repair

S.C. TO BATTERY VOLTAGE AT CUSTOMER 

customer specific

2 TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • customer specific function no. 2 device has an internal defect  • connector pin is contacted to battery voltage



SPECIFIC FUNCTION NO.

1C

5070

5

152

O.C. AT CUSTOMER SPECIFIC FUNCTION NO .

• •

customer specific

2 TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU  • customer specific function no. 2 device has an internal defect  • connector has no connection to TCU  1D

5080

4

154

S.C. TO GROUND AT CUSTOMER SPECIFIC

• • •

customer specific

3 TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground  • customer specific function no. 3 device has an internal defect  • connector pin is contacted to vehicle  ground 



FUNCTION NO .

TE-AB

remarks

possible reason for fault detection

J:\DATNBANK\EST37\FEHLERLI\Fc_37_V912.doc

• •

costu mer

check the cable from TCU to customer  specific function no. 2 device check the connectors from customer  specific function no. 2 device to TCU check the resistance of customer  specific function no. 2 device

1)

ZFunkt ion2

check the cable from TCU to customer  specific function no. 2 device check the connectors from customer  specific function no. 2 device to TCU check the resistance of customer  specific function no. 2 device

1)

ZFunkt ion2

check the cable from TCU to customer  specific function no. 3 device check the connectors from customer  specific function no. 3 device to TCU check the resistance of customer  specific function no. 3 device

1)

ZFunkt ion3

 see chapter 4

 see chapter 4

 see chapter 4

Seite 10 von 52

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Int. Code Code (hex) (dec) 1E

5080

3

156

MEANING OF THE FAULT CODE

97-09-18

reaction of the TCU

possible steps to repair

S.C. TO BATTERY VOLTAGE AT CUSTOMER 

customer specific

3 TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • customer specific function no. 3 device has an internal defect  • connector pin is contacted to battery voltage



SPECIFIC FUNCTION NO.

1F

5080

5

155

O.C. AT CUSTOMER SPECIFIC FUNCTION NO .

• •

customer specific

3 TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU  • customer specific function no. 3 device has an internal defect  • connector has no connection to TCU  21

5090

3

32

S.C. TO BATTERY VOLTAGE AT CLUTCH CUTOFF INPUT

5090 TE-AB

4

29

S.C. TO GROUND OR O .C. AT CLUTCH

• • •

clutch cutoff function is disabled OP-Mode: normal

the measured voltage is too high: • cable is defective and is contacted to battery voltage • clutch cut off sensor has an internal  defect  • connector pin is contacted to battery voltage 22

remarks

possible reason for fault detection

clutch cutoff function is disabled

J:\DATNBANK\EST37\FEHLERLI\Fc_37_V912.doc

costu mer

check the cable from TCU to customer  specific customer specific function no. 3 device check the connectors from customer  specific function no. 3 device to TCU check the resistance of customer  specific function no. 3 device

1)

ZFunkt ion3

check the cable from TCU to customer  specific function no. 3 device check the connectors from customer  specific function no. 3 device to TCU check the resistance of customer  specific function no. 3 device

1)

ZFunkt ion3

 see chapter 4

 see chapter 4

John Deere



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



check the cable from TCU to the sensor 

John

• •

Seite 11 von 52

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Int. Code Code (hex) (dec)

MEANING OF THE FAULT CODE

97-09-18

reaction of the TCU

CUTOFF INPUT

OP-Mode: normal

the measured voltage is too low: • cable is defective and is contacted to vehicle ground  • cable has no connection to TCU  • clutch cut off sensor has an internal  defect  • connector pin is contacted to vehicle  ground or is broken 23

5100

3

69

S.C. TO BATTERY VOLTAGE AT LOAD SENSOR INPUT

the measured voltage is too high: • cable is defective and is contacted to battery voltage • load sensor has an internal defect  • connector pin is contacted to battery voltage 24

5100

4

70

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

the measured voltage is too low: • cable is defective and is contacted to vehicle ground  • cable has no connection to TCU  • load sensor has an internal defect  • connector pin is contacted to vehicle  ground or is broken 25

5110

3

33

possible steps to repair

remarks

possible reason for fault detection

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

• •

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

• • • •

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

• • • •

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

• • •

Deere

check the connectors check the clutch cutoff sensor 

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

availability of retarder  depends on default load

ohne CAN

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

availability of retarder  depends on default load

ohne CAN

all, Sisu

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

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

J:\DATNBANK\EST37\FEHLERLI\Fc_37_V912.doc

costu mer

Seite 12 von 52

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Int. Code Code (hex) (dec)

MEANING OF THE FAULT CODE

• •

5110

4

30

S.C. TO GROUND AT TRANSMISSION SUMP

the measured voltage is too low: • cable is defective and is contacted to vehicle ground  • temperature sensor has an internal  defect  • connector pin is contacted to vehicle  ground  5120

3

76

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

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

5120

4

74

S.C. TO GROUND AT RETARDER  TEMPERATURE SENSOR INPUT

the measured voltage is too low: • cable is defective and is contacted to vehicle ground  • temperature sensor has an internal  TE-AB

possible steps to repair

remarks

costu mer

battery voltage cable has no connection to TCU  temperature sensor has an internal  defect  connector pin is contacted to battery voltage or is broken

TEMPERATURE SENSOR INPUT

27

reaction of the TCU

possible reason for fault detection •

26

97-09-18

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



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



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



J:\DATNBANK\EST37\FEHLERLI\Fc_37_V912.doc

• •

• •

• •

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

all, Sisu

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

6WG

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

6WG

Seite 13 von 52

ZF Friedrichshafen AG description of fault codes for ERGO-Control

Fault SPN FMI Int. Code Code (hex) (dec)

MEANING OF THE FAULT CODE

5130

3

31

5130

4

28

S.C. TO BATTERY VOLTAGE OR O .C. AT

S.C. TO GROUND

PARKING BRAKE SENSOR 

INPUT

TCU uses default value OP-Mode: normal

31

5313

5140

12

3

135

38



TCU uses default value OP-Mode: normal

• • •

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

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



S.C. TO BATTERY VOLTAGE OR O .C. AT

OP-Mode: substitute clutch control



ENGINE SPEED INPUT

TCU measures a voltage higher than 7.00 V at speed input pin TE-AB

• •

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

possible steps to repair

remarks

costu mer

defect  connector pin is contacted to vehicle  ground 

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

reaction of the TCU

possible reason for fault detection •

29

97-09-18

J:\DATNBANK\EST37\FEHLERLI\Fc_37_V912.doc

• •

• •

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

all

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

all

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

all

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

all, Sisu

Seite 14 von 52

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