ZF Fault Codes Latest

ZF FRIEDRICHSHAFEN Aktiengesellschaft
Benennung:
fault codes
Nr.:
DIN
Seite 1
Zusatzbenennung:
description of fault codes for Ergo control
A4
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Index
Nr.
Datum
Name
K3 ZFN 904
NDERUNGEN
Erstellt:
Geprft:
Freigegeben :
Name:
Plank
Sieger
Abteilung: ACETS
TE-AB
Datum:
2011-02-21
03-10-01
Film
Description
of the
fault codes
for
ERGO-Control EST37
document created for customer "Hyundai construction machineries"
2011-02-21
ZF Friedrichshafen AG
Faultcodes ERGO-Control EST37A
11-02-21
Index of changes:
date
TE-AB
index
comment
software version
Seite 2 von 38
11-02-21
1 Introduction
1.1 Abbreviations
o.c.
s.c.
OP-Mode
TCU
EEC
PTO
open circuit
short circuit
operating mode
transmission control unit
electronic engine controller
power take off
1.2 ZF - Display:
If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault
code, if the gear selector is on neutral position.
If more than one fault is detected, each fault code is shown for about 1 second.
h
left
character
right
character
S
T
O
P
g
(special symbols a-h)
1.3 Display during operation

Symbol
meaning
remarks
1F, 1R
2F, 2R
3F, 3R
4F
5F
6F
LF, LR
F or R, no gear
F or R flashing
CAUTION gear will engage if turbine speed drops
NN
**
*N
1 bar (special
TE-AB
actual gear and direction

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

Clutch Cutoff
direction F or R selected while turbine
speed is too high
not neutral, waiting for neutral after
power up or a severe fault
oil temperature too low, no gear
available
oil temperature low, only one gear
available
manual mode 1st gear
to engage a gear, first move shift selector to neutral

position and again to F or R position
warm up engine / transmission
warm up engine / transmission
Seite 3 von 38
symbol)
2 bars
3 bars
4 bars
4 bars and 2
arrows
Bars flashing
Spanner
Fault code
WS
WR
WT
WE
WV
WL
WO
PN
EE flashing
TE-AB
11-02-21
manual mode 2nd gear

manual mode 3rd gear
manual mode 4th gear and also 5th and
6th gear in 6WG
automatic mode
6 WG: converter lockup clutch open
4 WG: Downshift mode activ
at least one fault activ
see faultcode list
warning sump temperature
difference of engine and turbine speed above a certain

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

in neutral only displayed if no fault is detected
(spanner)
warning retarder temperature
(spanner)
warning torque converter temperature
(spanner)
warning high engine speed
(spanner)
warning high output speed (velocity)
(spanner)
warning high transmission input torque changes between actual gear/direction while driving,
(load)
(spanner)
warning high transmission output torque changes between actual gear/direction while driving,
(load)
(spanner)
direction F or R selected while parking transmission in neutral until parking brake is released
brake engaged
CAUTION: vehicle starts to move after release of
parking brake
no communication with display
checked wiring from TCU to display
Seite 4 von 38
1.4 Display during AEB-Mode

symbol
meaning
AEB - Starter is plugged at the
PL
ST
K1..K4,KV,KR
, KW
_ and Kx
and Kx
= and Kx
wait for start, initialization of clutch Kx,

x: 1, 2, 3, 4, V, R, W
fast fill time determination of clutch Kx
OK
STOP
AEB canceled (activation stopped)
STOP and Kx
AEB stopped, clutch Kx can't be

calibrated
Kx couldn't be calibrated, AEB finished
FO
engine speed too low,

raise engine speed
engine speed too high,
lower engine speed
transmission oil temperature too low,
heat up transmission
transmission oil temperature too high
cool down transmission
transmission temperature not in defined
range during calibration
operating mode not NORMAL or
transmission temperature sensor
defective or storing of Calibrated values
to EEPROM-has failed.
Outputspeed_not_zero
FN
Shift lever not in Neutral position
FP
Parkbrake_not_applied
STOP
AEB - Starter was used incorrect or is

defective. Wrong device or wrong cable
used
E
E
T
T
FT
FB
TE-AB
remarks
diagnostic plug
AEB-Starter-button is pressed
calibrating clutch K1..K4, KV or KR,
KW is lockup clutch
compensating pressure determination of

clutch Kx
calibration for all clutches finished
Spanner and Kx
11-02-21
Transmissions stays in neutral, you have to restart the

TCU (ignition off/on) after removing AEB-Starter
TCU (ignition off/on)


Seite 5 von 38
1.5 Display during Inchpedal Calibration

symbol
meaning
IP
IP
IP flashing
OK
FN and Stop
FS and Stop
FO and Stop
SL and Stop
SU and Stop
IL and Stop
IU and Stop
TO and Stop
DL and Stop
DU and Stop
FI and Stop
TE-AB
11-02-21
remarks
push down the pedal slowly until

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

release the pedal and try again
Calibration is aborted
Seite 6 von 38
11-02-21
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.
TE-AB
Seite 7 von 38
description of fault codes for ERGO-Control
11-02-21
3 table of fault codes

Fault SPN FMI
Code
(hex)
MEANING OF THE FAULT CODE
reaction of the TCU
possible steps to repair
remarks
possible reason for fault detection
10
5001
12
LOGICAL ERROR AT DIRECTION SELECT

SIGNAL 3RD SHIFT LEVER
TCU shifts transmission to

neutral if selector activ
TCU detected a wrong signal combination OP-Mode: transmission
for the direction
shutdown if selector activ
cable from shift lever 3 to TCU is
broken
cable is defective and is contacted to
battery voltage or vehicle ground
shift lever is defective
check the cables from TCU to shift lever fault is cleared if TCU detects
a valid neutral signal for the
3
check signal combinations of shift lever direction at the shift lever
positions F-N-R
if shift lever is a CAN shift lever check
CAN cable/shifter/device
11
5000
12
LOGICAL ERROR AT GEAR RANGE SIGNAL

TCU detected a wrong signal combination neutral
for the gear range
OP-Mode: transmission
cable from shift lever to TCU is broken shutdown
check the cables from TCU to shift lever

fault is taken back if TCU
check signal combinations of shift lever detects a valid signal for the
positions for gear range
position
12
5010
12

neutral
for the direction
shutdown
cable from shift lever to TCU is broken
check the cables from TCU to shift lever fault is taken back if TCU
check signal combinations of shift lever detects a valid signal for the
direction at the shift lever
positions F-N-R
13
5020
12
LOGICAL ERROR AT ENGINE DERATING

DEVICE

SIGNAL
after selecting neutral, TCU

changes to OP-Mode limp home
check engine derating device
This fault is reset after power

up of TCU
TCU detected no reaction of engine while

derating device activ
TE-AB
Seite 8 von 38
Fault SPN FMI

Code
(hex)
14
5030
12
5040
12
16
5050
12
reaction of the TCU
LOGICAL ERROR AT PARKBRAKE STATUS
5110

neutral if selector activ
for the direction
shutdown if selector activ
cable from shift lever 2 to TCU is
broken
SIGNAL 2. SHIFT LEVER
LOGICAL ERROR AT AXLE CONNECTION
S.C. TO BATTERY VOLTAGE OR O.C. AT

TRANSMISSION SUMP TEMPERATURE
SENSOR INPUT
the measured voltage is too high:

TE-AB
remarks
TCU shifts transmission to DCO- check the cables from electronic boxes
State
to status switches
OP-Mode: normal
check signals of the status switches
check the cables from TCU to shift lever

2
check signal combinations of shift lever
positions F-N-R
OP-Mode: normal
check the cables from TCU to feedback

axle connection switch
check signals of the feedback axle
connection switch
no reaction,
TCU uses default temperature
OP-Mode: normal
check the cable from TCU to the sensor

check the connectors
check the temperature sensor
feedback axle connection measured by

TCU and output signal axle connection
don't fit
axle cant be connected or
disconnected due to mechanical
problem
one of the cables from feedback axle
connection -switch to TCU is broken
25
Parkbrake-status-signal measured by TCU

and parkbrake-status-signal send by CAN
don't fit
one of the cables from status-switch to
electronic box is broken
one of the status-switches is defective
15
11-02-21
fault is taken back if TCU

detects a valid neutral signal
for the direction at the shift
lever
Seite 9 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

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
S.C. TO GROUND AT TRANSMISSION SUMP

TEMPERATURE SENSOR INPUT
the measured voltage is too low:

vehicle ground
defect
connector pin is contacted to vehicle
ground
27
5120

RETARDER / TORQUECONVERTER
TEMPERATURE SENSOR INPUT
no reaction,
OP-Mode: normal

no reaction,
OP-Mode: normal

no reaction,
OP-Mode: normal


battery voltage
defect
28
5120
S.C. TO GROUND AT RETARDER /

TORQUECONVERTER TEMPERATURE
SENSOR INPUT

vehicle ground
TE-AB
Seite 10 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

defect
ground
29
5130

PARKING BRAKE SENSOR INPUT
TCU uses default value

OP-Mode: normal

check the parking brake sensor

OP-Mode: normal

check the parking brake sensor

battery voltage
sensor has an internal defect
2A
5130
S.C. TO GROUND PARKING BRAKE SENSOR

INPUT

vehicle ground
ground
2B
5313
12
2C
5135
INCHSENSOR-SIGNAL MISMATCH
the measured voltage from CCO and
CCO2 signal dont match:
cable is defective
During inching mode: TCU shifts check the cable from TCU to the sensor
to neutral
While not inching: no change
check sensor
OP-Mode: normal

DLM TRACTION ADJUST DASHBOARD
DEVICE INPUT

OP-Mode: normal

TE-AB

check the DLM Traction Adjust
dashboard device
Seite 11 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

battery voltage
2D
5135
S.C. TO GROUND DLM TRACTION ADJUST

DASHBOARD DEVICE INPUT

OP-Mode: normal

check the DLM Traction Adjust
dashboard device

OP-Mode: normal

check the DLM STEERING ANGLE
SENSOR

OP-Mode: normal

check the DLM STEERING ANGLE
SENSOR

vehicle ground
ground
2E
5137

DLM STEERING ANGLE SENSOR INPUT

battery voltage
2F
5137
S.C. TO GROUND DLM STEERING ANGLE

SENSOR INPUT

vehicle ground
ground
TE-AB
Seite 12 von 38
Fault SPN FMI

Code
(hex)
31
5140
11-02-21
reaction of the TCU
5140
33
5140
12

ENGINE SPEED INPUT
OP-Mode: substitute clutch

control

check the speed sensor
S.C. TO GROUND AT ENGINE SPEED INPUT

TCU measures a voltage less than 0.45V
at speed input pin
cable / connector is defective and is
contacted to vehicle ground
speed sensor has an internal defect

control

LOGICAL ERROR AT ENGINE SPEED INPUT

control

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

TCU measures a engine speed over a

threshold and the next moment the
measured speed is zero
cable / connector is defective and has
bad contact
sensor gap has the wrong size
34
5150

TURBINE SPEED INPUT
TCU measures a voltage higher than 7.00

V at speed input pin
battery voltage
TE-AB
remarks

battery voltage
voltage or has no contact
32

check the sensor gap

up of TCU
Seite 13 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

35
5150
36
5150
12
S.C. TO GROUND AT TURBINE SPEED INPUT

at speed input pin

control
speed,
OP-Mode: limp home

LOGICAL ERROR AT TURBINE SPEED INPUT

control
speed,
OP-Mode: limp home

control

S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch

control
at speed input pin

TCU measures a turbine speed over a

threshold and at the next moment the
bad contact
37
5160

INTERNAL SPEED INPUT

battery voltage
38
TE-AB
5160


up of TCU
Seite 14 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

39
5160
12
LOGICAL ERROR AT INTERNAL SPEED INPUT
TCU measures a internal speed over a

bad contact
3A
5170

OUTPUT SPEED INPUT

battery voltage
3B
5170
3C
5170
12
S.C. TO GROUND AT OUTPUT SPEED INPUT

at speed input pin
LOGICAL ERROR AT OUTPUT SPEED INPUT
TCU measures a output speed over a

bad contact
TE-AB

control
special mode for gear selection

control
if a failure is existing at turbine
speed,
OP-Mode: limp home


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




up of TCU

up of TCU
Seite 15 von 38
Fault SPN FMI

Code
(hex)
3E
5180
11-02-21
reaction of the TCU
remarks

up of TCU

OP-Mode: limp home
OUTPUT SPEED ZERO DOESNT FIT TO

OTHER SPEED SIGNALS

control
speed,
OP-Mode: limp home
check the sensor signal of output speed

sensor
check the sensor gap of output speed
sensor
if transmission is not neutral and the

shifting has finished,
TCU measures outputspeed zero and
turbine speed or internal speed not equal
to zero.
54
5260
DCT1 TIMEOUT
Timeout of CAN-message DCT1 from
display computer
interference on CAN-Bus
CAN wire/connector is broken
CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
OP-Mode: normal
check display computer

check wire of CAN-Bus
check cable to display computer
55
5270
JSS TIMEOUT
Timeout of CAN-message JSS from
Joystick Steering Controller
battery voltage
TCU shifts to neutral while

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

check cable to Joystick steering
controller
56
5280
ENGINE CONF TIMEOUT

Timeout of CAN-message ENGINE
CONF from engine controller

control
check engine controller

check cable to engine controller
TE-AB
Seite 16 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

battery voltage
57
5290
EEC1 TIMEOUT
Timeout of CAN-message EEC1 from
EEC controller
battery voltage

control
check EEC controller

check cable to EEC controller
58
5300
EEC3 TIMEOUT
EEC controller
CAN wire/connector is defective an
battery voltage

control

59
5310
no reaction
check programming of vehicle controller
61
5390
AEB-REQUEST AND PARKBRAKETEST

SIGNALS ON AT THE SAME TIME
CAN signal for AEB-Request and for
ParkbrakeTest are ON at the same time
AEB REQUEST SIGNAL
CAN signal for AEB request is defective
I/O controller is defective
no reaction
OP-Mode: normal
Last selection is kept
check I/O controller

check cable to I/O controller
65
5430
ENGINGE TORQUE SIGNAL
OP-Mode:substitute clutch
control

CAN signal for engine torque is defective

engine controller is defective
TE-AB
Seite 17 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

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

is defective
6A
5450
ACTUAL ENGINE TORQUE SIGNAL
CAN signal for actual engine torque is

defective
6B
5460
NOM FRICTION TORQUE SIGNAL
CAN signal for nominal friction torque is

defective
control

control

control

6E
5470
EEC2 TIMEOUT
EEC controller
battery voltage
no reaction,
TCU uses default signal
accelerator pedal in idle position
OP-Mode: normal

71
5480
S.C. TO BATTERY VOLTAGE AT CLUTCH K1

OP-Mode: limp home
if failure at another clutch is
pending
OP-Mode: TCU shutdown
check the cable from TCU to the

gearbox
check the connectors from TCU to the
gearbox
check the regulator resistance 1)
check internal wire harness of the
the measured resistance value of the valve

is out of limit, the voltage at K1 valve is
too high.
contact to battery voltage
TE-AB
1)
see chapter 4
Seite 18 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
5480
S.C. TO GROUND AT CLUTCH K1

too low.
contact to vehicle ground
contact to another regulator output of
the TCU
regulator has an internal defect
73
5480
O.C. AT CLUTCH K1

is out of limit.
no contact to TCU
74
5490

too high.
75
5490

too low.
TE-AB
remarks

gearbox

72

OP-Mode: limp home
pending

gearbox
check the connectors from gearbox to
TCU
gearbox
1)
see chapter 4

OP-Mode: limp home
pending

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

gearbox
TCU
gearbox
1)
see chapter 4

OP-Mode: limp home
pending

OP-Mode: limp home
pending
Seite 19 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

the TCU
76
5490
O.C. AT CLUTCH K2

is out of limit.
no contact to TCU
77
5500

too high.
78
5500

too low.
the TCU
79
5500
O.C. AT CLUTCH K3

is out of limit.
no contact to TCU
TE-AB

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

OP-Mode: limp home
pending

gearbox
TCU
gearbox
1)
see chapter 4

OP-Mode: limp home
pending

gearbox
TCU
1)
see chapter 4

OP-Mode: limp home
pending
OP-Mode: limp home
pending
Seite 20 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

7A
5540
S.C. TO BATTERY VOLTAGE AT CONVERTER

CLUTCH
no reaction
OP-Mode: normal
7B
5540
S.C. TO GROUND AT CONVERTER CLUTCH
CONVERTER LOCK UP CLUTCH

SOLENOID CONNECTED AT
ADMX:

gearbox
check the cable from TCU to the valve
TCU switch off VPS2

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

OP-mode: normal
7C
5540
O.C. AT CONVERTER CLUTCH
81
5510

too high.
82
5510

too low.
the TCU
TE-AB
no reaction
OP-Mode: normal
OP-Mode: limp home
pending

gearbox
TCU
gearbox

OP-Mode: limp home
pending

gearbox
TCU
gearbox
1)
see chapter 4
1)
see chapter 4
Seite 21 von 38
Fault SPN FMI

Code
(hex)
83
5510
5520
O.C. AT CLUTCH K4
S.C. TO BATTERY VOLTAGE AT CLUTCH KV

is out of limit, the voltage at KV valve is
too high.
85
5520
S.C. TO GROUND AT CLUTCH KV

is out of limit, the voltage at KV valve is
too low.
the TCU
86
5520
O.C. AT CLUTCH KV

is out of limit.
no contact to TCU
TE-AB
reaction of the TCU
remarks

is out of limit.
no contact to TCU
84
11-02-21

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

OP-Mode: limp home
pending

gearbox
TCU
gearbox
1)
see chapter 4

OP-Mode: limp home
pending

gearbox
TCU
gearbox
1)
see chapter 4

OP-Mode: limp home
pending
OP-Mode: limp home
pending
Seite 22 von 38
Fault SPN FMI

Code
(hex)
87
5530
5530
S.C. TO BATTERY VOLTAGE AT CLUTCH KR
S.C. TO GROUND AT CLUTCH KR

is out of limit, the voltage at KR valve is
too low.
the TCU
89
5530
O.C. AT CLUTCH KR

is out of limit.
no contact to TCU
8A
5535
S.C. TO GROUND AT DLM TRANSVERSAL

OUTPUT
TCU detected a wrong voltage at the

output pin, that looks like a s.c. to vehicle
ground
vehicle ground
device has an internal defect
TE-AB
reaction of the TCU
remarks

is out of limit, the voltage at KR valve is
too high.
88
11-02-21

OP-Mode: limp home
pending

gearbox
TCU
gearbox
1)
see chapter 4

OP-Mode: limp home
pending

gearbox
TCU
gearbox
1)
see chapter 4

OP-Mode: limp home
pending

gearbox
TCU
gearbox
check the resistance of valve
1)
see chapter 4
1)
see chapter 4
output will be on until TCU

power down even if fault
vanishes (loose connection)
OP-Mode: normal
Seite 23 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

ground
8B
5535
S.C. TO BATTERY VOLTAGE AT DLM

TRANSVERSAL OUTPUT
no reaction
OP-Mode: normal

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

1)
see chapter 4

OP-Mode: normal
check the cable from TCU to the device

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

1)
see chapter 4

output pin, that looks like a s.c. to battery
voltage
battery voltage
voltage
8C
5535
O.C. AT DLM TRANSVERSAL OUTPUT

output pin, that looks like a o.c. for this
output pin
cable is defective and has no
connection to TCU
connector has no connection to TCU
8D
5536
S.C. TO GROUND AT DLM INDICATOR

LAMP OUTPUT

ground
vehicle ground
ground
8E
TE-AB
5536

INDICATOR LAMP OUTPUT
Seite 24 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
5536
O.C. DLM INDICATOR LAMP OUTPUT
no reaction
OP-Mode: normal

1)
see chapter 4
backup alarm will be on until

TCU power down even if fault
OP-Mode: normal
check the cable from TCU to the backup

alarm device
check the connectors from backup alarm
device to TCU
check the resistance 1) of backup alarm
device
1)
see chapter 4
no reaction
OP-Mode: normal

alarm device
device to TCU
1)
see chapter 4

output pin
connection to TCU
91
5560
S.C. TO GROUND AT RELAY REVERSE

WARNING ALARM

ground
vehicle ground
backup alarm device has an internal
defect
ground
92
5560
S.C. TO BATTERY VOLTAGE AT RELAY

REVERSE WARNING ALARM

TE-AB
remarks

voltage
battery voltage
voltage
8F
Seite 25 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
5560
O.C. AT RELAY REVERSE WARNING ALARM

output pin
connection to TCU
defect
94
5570

device
S.C. TO GROUND AT RELAY STARTER

INTERLOCK
no reaction
OP-Mode: normal

alarm device
device to TCU
device
1)
see chapter 4
no reaction
OP-Mode: normal
check the cable from TCU to the starter

interlock relay
check the connectors from starter
interlock relay to TCU
check the resistance 1) of starter
interlock relay
1)
see chapter 4
no reaction
OP-Mode: normal

interlock relay
1)
see chapter 4

ground
vehicle ground
starter interlock relay has an internal
defect
ground
95
5570
S.C. TO BATTERY VOLTAGE AT RELAY

STARTER INTERLOCK

voltage
TE-AB
remarks

voltage
battery voltage
defect
voltage
93
Seite 26 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
5570
O.C. AT RELAY STARTER INTERLOCK

output pin
connection to TCU
defect
A4
5620
interlock relay
S.C. TO GROUND AT WARNING SIGNAL

OUTPUT
no reaction
OP-Mode: normal

interlock relay
interlock relay
1)
see chapter 4
no reaction
OP-mode: normal

warning device
check the connectors from warning
device to TCU
check the resistance 1) of warning device
1)
see chapter 4
no reaction
OP-mode: normal

warning device
device to TCU
1)
see chapter 4

ground
vehicle ground
warning device has an internal defect
ground
A5
5620
O.C. AT WARNING SIGNAL OUTPUT

output pin
connection to TCU
TE-AB
remarks

battery voltage
defect
voltage
96
Seite 27 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

A6
5620
S.C. TO BATTERY VOLTAGE AT WARNING

SIGNAL OUTPUT
no reaction
OP-mode: normal

warning device
device to TCU

voltage
battery voltage
voltage
B1
5660
SLIPPAGE AT CLUTCH K1
TCU calculates a differential speed at
closed clutch K1. If this calculated value is
out of range, TCU interprets this as
slipping clutch.
low pressure at clutch K1
low main pressure
wrong signal at internal speed sensor
wrong signal at output speed sensor
wrong size of the sensor gap
clutch is defective

OP-Mode: limp home
pending
check pressure at clutch K1

check main pressure in the system
check sensor gap at internal speed
sensor
check sensor gap at output speed sensor
check signal at internal speed sensor
check signal at output speed sensor
replace clutch
B2
5665
slipping clutch.
low main pressure

OP-Mode: limp home
pending

sensor
replace clutch
TE-AB
1)
see chapter 4
Seite 28 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

clutch is defective
B3
5670
slipping clutch.
low main pressure
clutch is defective

OP-Mode: limp home
pending

sensor
replace clutch
B4
5675
TCU calculated a difference speed at TCU
calculates a differential speed at closed
clutch K4. If this calculated value is out of
range, TCU interprets this as slipping
clutch.
low main pressure
wrong signal at turbine speed sensor
clutch is defective

OP-Mode: limp home
pending

sensor
check sensor gap at turbine speed sensor
check signal at turbine speed sensor
replace clutch
B5
5680
SLIPPAGE AT CLUTCH KV
closed clutch KV. If this calculated value
is out of range, TCU interprets this as
slipping clutch.
low pressure at clutch KV
low main pressure

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

sensor
replace clutch
TE-AB
Seite 29 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

clutch is defective
B6
5685
B7
5700
SLIPPAGE AT CLUTCH KR
closed clutch KR. If this calculated value
is out of range, TCU interprets this as
slipping clutch.
low pressure at clutch KR
low main pressure
clutch is defective

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

sensor
replace clutch
OVERTEMP SUMP
no reaction
OP-Mode: normal
cool down machine

check oil level
check temperature sensor
TCU measured a temperature in the oil

sump that is over the allowed threshold.
BA
5730
DIFFERENTIAL PRESSURE OIL FILTER

no reaction
TCU measured a voltage at differential
OP-Mode: normal
pressure switch out of the allowed range
oil filter is polluted
cable/connector is broken or
cable/connector is contacted to battery
voltage or vehicle ground
differential pressure switch is defective
BC
5745
15
C0
5751
OVERSPEED OUTPUT
No reaction
TCU messures an transmission output
OP-Mode: normal
speed above the defined threshold
ENGINE TORQUE OR ENGINE POWER
OP-Mode: normal
OVERLOAD
TCU calculates an engine torque or engine
TE-AB
check oil filter

check wiring from TCU to differential
pressure switch
check differential pressure switch
(measure resitance)
Seite 30 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

power above the defined thresholds
C1
5752
TRANSMISSION OUTPUT TORQUE
OP-Mode: normal
OVERLOAD
C2
5755
15
C3
5760
TCU calculates an transmission output

torque above the defined threshold
TRANSMISSION INPUT TORQUE OVERLOAD
TCU calculates an transmission input
torque above the defined threshold
OVERTEMP CONVERTER OUTPUT
TCU measured a oil temperature at the

converter ouput that is over the allowed
threshold.
C4
5770
S.C. TO GROUND AT JOYSTICK STATUS
INDICATOR
ground
vehicle ground
joystick status indicator has an
internal defect
ground
C5
5770
S.C. TO BATTERY VOLTAGE AT JOYSTICK
STATUS INDICATOR
voltage
battery voltage
internal defect
TE-AB
programmable :No reaction or

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

check oil level
check temperature sensor
no reaction
OP-Mode: normal
check the cable from TCU to joystick

status indicator
check the connectors from joystick
status indicator to TCU
check the resistance 1) of joystick status
indicator
no reaction
OP-Mode: normal

status indicator
indicator
Seite 31 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

voltage
C6
5770
O.C. AT JOYSTICK STATUS
INDICATOR
output pin
connection to TCU
internal defect
C7
5780
S.C. TO GROUND AT OVERTEMP

NEUTRAL INDICATOR
no reaction
OP-Mode: normal

status indicator
indicator
no reaction
OP-Mode: normal
check the cable from TCU to

OVERTEMP NEUTRAL INDICATOR
check the connectors from OVERTEMP
NEUTRAL INDICATOR to TCU
check the resistance 1) of OVERTEMP
NEUTRAL INDICATOR
no reaction
OP-Mode: normal

NEUTRAL INDICATOR

ground
vehicle ground
overtemp status indicator has an
internal defect
ground
C8
5780
S.C. TO BATTERY VOLTAGE AT

voltage
battery voltage
overtemp status indicator has an
internal defect
TE-AB
Seite 32 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

voltage
C9
5780
O.C. AT OVERTEMP NEUTRAL
INDICATOR
output pin
connection to TCU
OVETEMP status indicator has an
internal defect
no reaction
OP-Mode: normal

NEUTRAL INDICATOR
CA
5790
ENGINE_RETARDER CONFIG_TIMEOUT
Timeout of CAN-message
ENGINE_RETARDER CONFIG from EEC
controller
battery voltage

control

CB
5800
ERC1 TIMEOUT
Timeout of CAN-message ERC1 from
EEC controller
battery voltage

control

D1
5810
S.C. TO BATTERY VOLTAGE AT POWER

SUPPLY FOR SENSORS
see fault codes no. 21 to 2C
check cables and connectors to sensors,

which are supplied from AU1
check the power supply at the pin AU1
TCU measures more than 6V at the pin

TE-AB
fault codes no. 21 to no. 2C

may be a reaction of this fault
Seite 33 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU

AU1 (5V sensor supply)
D2
5810
S.C. TO GROUND AT POWER SUPPLY FOR

SENSORS
(should be appx. 5V)

see fault codes no. 21 to 2C
TCU measures less than 4V at the pin

AU1 (5V sensor supply)
D3
5820
D4
5820
D5
5830
D6
5840
TE-AB
remarks
check cables and connectors to sensors,

which are supplied from AU1
check the power supply at the pin AU1
(should be appx. 5V)
LOW VOLTAGE AT BATTERY

shift to neutral
measured voltage at power supply is lower OP-Mode: TCU shutdown
than 10 V (12V device)
lower than 18 V (24V device)
HIGH VOLTAGE AT BATTERY
shift to neutral
measured voltage at power supply is
higher than 18 V (12V device)
higher than 32.5 V (24V device)
ERROR AT VALVE POWER SUPPLY VPS1
shift to neutral
TCU switched on VPS1 and measured
VPS1 is off or TCU switched off VPS1
and measured VPS1 is still on
cable or connectors are defect and are
contacted to battery voltage
permanent power supply KL30 missing
TCU has an internal defect
check power supply battery

check cables from batteries to TCU
check connectors from batteries to TCU
check fuse
check cables from gearbox to TCU
check connectors from gearbox to TCU
replace TCU
ERROR VALVE POWER SUPPLY VPS2

shift to neutral
TCU switched on VPS2 and measured
VPS2 is off or TCU switched off VPS2
and measured VPS2 is still on
contacted to battery voltage
permanent power supply KL30 missing
check fuse
check cables from gearbox to TCU
check connectors from gearbox to TCU
replace TCU
fault codes no. 21 to no. 2C

may be a reaction of this fault
check power supply battery

check cables from batteries to TCU
check connectors from batteries to TCU
Seite 34 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
remarks

TCU has an internal defect
D7
5545
S.C. TO GROUND AT DLM LONGITUDINAL

OUTPUT

ground
vehicle ground
ground
D8
5545

LONGITUDINAL OUTPUT

OP-Mode: normal

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

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

1)
see chapter 4
no reaction
OP-Mode: normal
check the cable from TCU to the display

check the connectors at the display

voltage
battery voltage
voltage
D9
5545
O.C. AT DLM LONGITUDINAL OUTPUT

output pin
connection to TCU
E3
TE-AB
5860
S.C. TO BATTERY VOLTAGE AT DISPLAY

OUTPUT
Seite 35 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU

TCU sends data to the display and
measures allways a high voltage level on
the connector
cable or connectors are defective and
are contacted to battery voltage
display has an internal defect
change display
E4
5860
S.C. TO GROUND AT DISPLAY OUTPUT

TCU sends data to the display and
measures allways a high voltage level on
the connector
cable or connectors are defective and
are contacted to vehicle ground
display has an internal defect
no reaction
OP-Mode: normal
check the cable from TCU to the display

check the connectors at the display
change display
F1
5890
GENERAL EEPROM FAULT

TCU can't read non volantile memoy
TCU is defective
no reaction
OP-Mode: normal
replace TCU
F2
5900
13
F3
5910
13
CONFIGURATION LOST
transmission stay neutral
TCU has lost the correct configuration and OP-Mode: TCU shutdown
can't control the transmission.
interference during saving data on non
volatile memory
TCU is brand new or from another
vehicle
APPLICATION ERROR
something of this application is wrong
F5
5930
CLUTCH FAILURE
AEB was not able to adjust clutch filling

parameters
One of the AEB-Values is out of limit
TE-AB
remarks
often shown together with

fault code F2
Reprogramm the correct configuration

for the vehicle (e.g. with cluster
controller,...)

replace TCU !!

check clutch
This fault occurs only if an

test engineer did something
wrong in the application of
the vehicle
TCU shows also the affected
clutch on the Display
Seite 36 von 38
Fault SPN FMI

Code
(hex)
11-02-21
reaction of the TCU
F6
5930
13
CLUTCH ADJUSTMENT DATA LOST OR

INCHPEDAL CALIBRATION DATA LOST
TCU was not able to read correct clutch
adjustment parameters
interference during saving data on non
volatile memory
TCU is brand new
default values = 0 for AEB

offsets used
OP-Mode: normal
no Inchmode available
execute AEB
F7
5940
11
SUBSTITUTE CLUTCH CONTROL

transmission input torque wrong
engine retarder torque wrong
speed signal(s) defective
OP-Mode : substitute clutch

control
check engine retarder torque

check speed sensors
TE-AB
remarks
Seite 37 von 38
11-02-21
4 measuring of resistance at actuator/sensors and cable

4.1 actuator:
1
open circuit:
short cut to ground:
short cut to battery:
R12 R1G R2G

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

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

R12 0;
R1C R2C 0,
R12 0,
R1C R2C ,
R1P R2P
R1P R2P 0
Seite 38 von 38

ZF Fault Codes Latest

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How does the TCU display faults?

How does the TCU display faults?

ZF FRIEDRICHSHAFEN Aktiengesellschaft

document created for customer "Hyundai construction machineries"

(special symbols a-h)

1.3 Display during operation

CAUTION gear will engage if turbine speed drops

actual gear and direction

limp home gear

to engage a gear, first move shift selector to neutral

manual mode 2nd gear

difference of engine and turbine speed above a certain

changes between actual gear/direction while driving,

1.4 Display during AEB-Mode

wait for start, initialization of clutch Kx,

AEB canceled (activation stopped)

AEB stopped, clutch Kx can't be

engine speed too low,

Shift lever not in Neutral position

AEB - Starter was used incorrect or is

compensating pressure determination of

Transmissions stays in neutral, you have to restart the

Transmissions stays in neutral, you have to restart the

Transmissions stays in neutral, you have to restart the

1.5 Display during Inchpedal Calibration

push down the pedal slowly until

If the expected enposition could not be reached,

2 definition of operating modes

3 table of fault codes

MEANING OF THE FAULT CODE

reaction of the TCU

possible steps to repair

possible reason for fault detection

LOGICAL ERROR AT DIRECTION SELECT

TCU shifts transmission to

LOGICAL ERROR AT GEAR RANGE SIGNAL

check the cables from TCU to shift lever

TCU shifts transmission to

LOGICAL ERROR AT ENGINE DERATING

LOGICAL ERROR AT DIRECTION SELECT

after selecting neutral, TCU

check engine derating device

This fault is reset after power

TCU detected no reaction of engine while

Fault SPN FMI

MEANING OF THE FAULT CODE

reaction of the TCU

LOGICAL ERROR AT PARKBRAKE STATUS

TCU shifts transmission to

LOGICAL ERROR AT AXLE CONNECTION

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

the measured voltage is too high:

check the cables from TCU to shift lever

check the cables from TCU to feedback

check the cable from TCU to the sensor

feedback axle connection measured by