ZF Transmission EST37 fault codes
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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