Error Code ZF 422zx
Error Code ZF 422zx
Ergopower- EST37/A
V-939
ZF Friedrichshafen AG
ZF Services
Donaustr. 71
D - 94034 Passau
Abbrevation
DIAGNOSTIC with Laptop and DPA-05
Software on CD
Testman Pro + applications for
EST-37A / EST-65 / EST-117
EST-64
5870 220 017
Adaptercable
6008 308 601 = RS 232
6008 207 026 = USB
Diagnostic - Set
Programming adapter
DPA - 05 5870 220 713
Adaptercable
6029 017 005 EST-37
2011 / 06
EST-37A
@Current: 0 @ 926 mA
@Pressure range: 0 bar @ 15 bar
1
EST-37A
@Current: 0 @ 926 mA
@Pressure range: 0 bar @ 15 bar
2
EST-37A
@ Sump:
Data for temperature sensors:
1000 Ohm ĺ 1500 Ohm
@ Retarder: 800 Ohm ĺ 1500 Ohm
@ Lock – up clutch:
Data for solenoid valve:
- Resistance: 60 Ohm ĺ 80 Ohm
- Current: 0,25 A ĺ 0,35 A
- Voltage: 24 V
Data forr:
3
EST-37A
1.0 Introduction
1.1 Abbreviations
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
1
EST-37A
2
EST-37A
{ and Kx
x: 1, 2, 3, 4, V, R
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
TCU (ignition off/on)
3
EST-37A
IP
push down the pedal slowly until
endposition is reached and hold this
position
IP
Release the pedal slowly until
endposition is reached
IP flashing
A problem occurred, release the pedal If the expected enposition could not be reached,
slowly until endposition is reached release 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 the Calibration is aborted
specified range
FO and Stop Outputspeed is not zero Calibration is aborted
SL and Stop sensor voltage below specified rangel Calibration is aborted
SU and Stop sensor voltage above specified rangel Calibration is aborted
IL and Stop sensor position for released pedal out of Calibration is aborted
specified range
IU and Stop sensor position for pressed pedal out of Calibration is aborted
specified range
TO and Stop time-out calibration, pedal not moved Calibration is aborted
after calibration start
DL and Stop angle between pedalpositions released Calibration is aborted
and pressed to small
DU and Stop angle between pedalpositions released Calibration is aborted
and pressed to big
FI and Stop sensor signal 1 and 2 don't match Calibration is aborted
together
4
EST-37A
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)
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.
5
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)
10 5001 12 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 3RD SHIFT TCU shifts transmission to neutral x check the cables from TCU fault is cleared if
LEVER if selector activ to shift lever 3 TCU detects a
TCU detected a wrong signal combination for the direction OP-Mode: transmission shutdown x check signal combinations valid neutral
x cable from shift lever 3 to TCU is broken if selector activ of shift lever positions F-N- signal for the
x cable is defective and is contacted to battery voltage or R direction at the
vehicle ground x if shift lever is a CAN shift shift lever
x shift lever is defective lever check CAN
cable/shifter/device
11 5000 12 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to neutral x check the cables from TCU failure cannot be
TCU detected a wrong signal combination for the gear range OP-Mode: transmission shutdown to shift lever detected in
x cable from shift lever to TCU is broken x check signal combinations systems with
x cable is defective and is contacted to battery voltage or of shift lever positions for DW2/DW3 shift
vehicle ground gear range lever
x shift lever is defective fault is taken back
if TCU detects a
valid signal for
the position
12 5010 12 LOGICAL ERROR AT DIRECTION SELECT SIGNAL TCU shifts transmission to neutral x check the cables from TCU fault is taken back
TCU detected a wrong signal combination for the direction OP-Mode: transmission shutdown to shift lever if TCU detects a
x cable from shift lever to TCU is broken x check signal combinations valid signal for
x cable is defective and is contacted to battery voltage or of shift lever positions F-N- the direction at
vehicle ground R the shift lever
x shift lever is defective
14 5030 12 LOGICAL ERROR AT PARKBRAKE STATUS TCU shifts transmission to DCO- x check the cables from
Parkbrake-status-signal measured by TCU State electronic boxes to status
and parkbrake-status-signal send by CAN don't fit OP-Mode: normal switches
x one of the cables from status-switch to electronic box is x check signals of the status
broken switches
x one of the status-switches is defective
15 5040 12 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2. SHIFT TCU shifts transmission to neutral x check the cables from TCU fault is taken back
LEVER if selector activ to shift lever 2 if TCU detects a
TCU detected a wrong signal combination for the direction OP-Mode: transmission shutdown x check signal combinations valid neutral
-1-
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)
x cable from shift lever 2 to TCU is broken if selector activ of shift lever positions F-N- signal for the
x cable is defective and is contacted to battery voltage or R direction at the
vehicle ground shift lever
x shift lever is defective
16 5060 4 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal x check the cables from TCU
feedback axle connection measured by to feedback axle connection
TCU and output signal axle connection don't fit switch
x axle can’t be connected or disconnected due to x check signals of the
mechanical problem feedback axle connection
x one of the cables from feedback axle connection -switch switch
to TCU is broken
1)
17 5060 4 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 1 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a s.c. to vehicle ground no. 1 device
x cable is defective and is contacted to vehicle ground x check the connectors from
x customer specific function no. 1 device has an internal customer specific function
defect no. 1 to TCU
x connector pin is contacted to vehicle ground x check the resistance of
customer specific function
no. 1 device
1)
18 5060 3 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION customer specific x check the cable from TCU to see chapter 4
NO. 1 customer specific function
TCU detected a wrong voltage at the output pin, that looks no. 1 device
like a s.c. to battery voltage x check the connectors from
x cable is defective and is contacted to battery voltage customer specific function
x customer specific function no. 1 device has an internal no. 1 to TCU
defect x check the resistance of
x connector pin is contacted to battery voltage customer specific function
no. 1 device
1)
19 5060 5 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 1 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a o.c. for this output pin no. 1 device
-2-
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)
x cable is defective and has no connection to TCU x check the connectors from
x customer specific function no. 1 device has an internal customer specific function
defect no. 1 device to TCU
x connector has no connection to TCU x check the resistance of
customer specific function
no. 1 device
1)
1A 5070 4 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 2 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a s.c. to vehicle ground no. 2 device
x cable is defective and is contacted to vehicle ground x check the connectors from
x customer specific function no. 2 device has an internal customer specific function
defect no. 2 device to TCU
x connector pin is contacted to vehicle ground x check the resistance of
customer specific function
no. 2 device
1)
1B 5070 3 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION customer specific x check the cable from TCU to see chapter 4
NO. 2 customer specific function
TCU detected a wrong voltage at the output pin, that looks no. 2 device
like a s.c. to battery voltage x check the connectors from
x cable is defective and is contacted to battery voltage customer specific function
x customer specific function no. 2 device has an internal no. 2 device to TCU
defect x check the resistance of
x connector pin is contacted to battery voltage customer specific function
no. 2 device
1)
1C 5070 5 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 2 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a o.c. for this output pin no. 2 device
x cable is defective and has no connection to TCU x check the connectors from
x customer specific function no. 2 device has an internal customer specific function
defect no. 2 device to TCU
x connector has no connection to TCU x check the resistance of
customer specific function
no. 2 device
-3-
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)
1)
1D 5080 4 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 3 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a s.c. to vehicle ground no. 3 device
x cable is defective and is contacted to vehicle ground x check the connectors from
x customer specific function no. 3 device has an internal customer specific function
defect no. 3 device to TCU
x connector pin is contacted to vehicle ground x check the resistance of
customer specific function
no. 3 device
1)
1E 5080 3 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION customer specific x check the cable from TCU to see chapter 4
NO. 3 customer specific customer
TCU detected a wrong voltage at the output pin, that looks specific function no. 3
like a s.c. to battery voltage device
x cable is defective and is contacted to battery voltage x check the connectors from
x customer specific function no. 3 device has an internal customer specific function
defect no. 3 device to TCU
x connector pin is contacted to battery voltage x check the resistance of
customer specific function
no. 3 device
1)
1F 5080 5 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 3 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a o.c. for this output pin no. 3 device
x cable is defective and has no connection to TCU x check the connectors from
x customer specific function no. 3 device has an internal customer specific function
defect no. 3 device to TCU
x connector has no connection to TCU x check the resistance of
customer specific function
no. 3 device
21 5090 3 S.C. TO BATTERY VOLTAGE AT CLUTCH CUTOFF INPUT clutch cutoff function is disabled x check the cable from TCU to
the measured voltage is too high: OP-Mode: normal the sensor
x cable is defective and is contacted to battery voltage x check the connectors
-4-
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)
x clutch cut off sensor has an internal defect x check the clutch cutoff
x connector pin is contacted to battery voltage sensor
22 5090 4 S.C. TO GROUND OR O.C. AT CLUTCH CUTOFF INPUT clutch cutoff function is disabled x check the cable from TCU to
the measured voltage is too low: OP-Mode: normal the sensor
x cable is defective and is contacted to vehicle ground x check the connectors
x cable has no connection to TCU x check the clutch cutoff
x clutch cut off sensor has an internal defect sensor
x connector pin is contacted to vehicle ground or is broken
23 5100 3 S.C. TO BATTERY VOLTAGE AT LOAD SENSOR INPUT retarder function is affected x check the cable from TCU to availability of
the measured voltage is too high: TCU uses default load the sensor retarder depends
x cable is defective and is contacted to battery voltage OP-Mode: normal x check the connectors on default load
x load sensor has an internal defect x check the load sensor sensor
x connector pin is contacted to battery voltage x check the assembly
tolerances of load sensor
24 5100 4 S.C. TO GROUND OR O.C. AT LOAD SENSOR INPUT retarder function is affected x check the cable from TCU to availability of
the measured voltage is too low: TCU uses default load the sensor retarder depends
x cable is defective and is contacted to vehicle ground OP-Mode: normal x check the connectors on default load
x cable has no connection to TCU x check the load sensor sensor
x load sensor has an internal defect x check the assembly
x connector pin is contacted to vehicle ground or is broken tolerances of load sensor
25 5110 3 S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION SUMP no reaction, x check the cable from TCU to
TEMPERATURE SENSOR INPUT TCU uses default temperature the sensor
the measured voltage is too high: OP-Mode: normal x check the connectors
x cable is defective and is contacted to battery voltage x check the temperature sensor
x cable has no connection to TCU
x temperature sensor has an internal defect
x connector pin is contacted to battery voltage or is broken
26 5110 4 S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE no reaction, x check the cable from TCU to
SENSOR INPUT TCU uses default temperature the sensor
the measured voltage is too low: OP-Mode: normal x check the connectors
x cable is defective and is contacted to vehicle ground x check the temperature sensor
x temperature sensor has an internal defect
x connector pin is contacted to vehicle ground
-5-
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)
27 5110 4 S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER / no reaction, x check the cable from TCU to
TORQUECONVERTER TEMPERATURE SENSOR INPUT TCU uses default temperature the sensor
the measured voltage is too high: OP-Mode: normal x check the connectors
x cable is defective and is contacted to battery voltage x check the temperature sensor
x cable has no connection to TCU
x temperature sensor has an internal defect
x connector pin is contacted to battery voltage or is broken
28 5120 4 S.C. TO GROUND AT RETARDER / TORQUECONVERTER no reaction, x check the cable from TCU to
TEMPERATURE SENSOR INPUT TCU uses default temperature the sensor
the measured voltage is too low: OP-Mode: normal x check the connectors
x cable is defective and is contacted to vehicle ground x check the temperature
x temperature sensor has an internal defect sensor
x connector pin is contacted to vehicle ground
29 5130 3 S.C. TO BATTERY VOLTAGE OR O.C. AT PARKING BRAKE TCU uses default value x check the cable from TCU to
SENSOR INPUT OP-Mode: normal the sensor
the measured voltage is too high: x check the connectors
x cable is defective and is contacted to battery voltage x check the parking brake
x cable has no connection to TCU sensor
x sensor has an internal defect
x connector pin is contacted to battery voltage or is broken
2A 5130 4 S.C. TO GROUND PARKING BRAKE SENSOR INPUT TCU uses default value x check the cable from TCU to
the measured voltage is too low: OP-Mode: normal the sensor
x cable is defective and is contacted to vehicle ground x check the connectors
x sensor has an internal defect x check the parking brake
x connector pin is contacted to vehicle ground sensor
2B 5313 12 INCHSENSOR-SIGNAL MISMATCH During inching mode: TCU shifts x check the cable from TCU to
the measured voltage from CCO and CCO2 signal don’t to neutral the sensor
match: While not inching: no change x check the connectors
x cable is defective OP-Mode: normal x check sensor
x sensor has an internal defect
-6-
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)
31 5140 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch control x check the cable from TCU to
ENGINE SPEED INPUT the sensor
TCU measures a voltage higher than 7.00 V at speed input x check the connectors
pin x check the speed sensor
x cable is defective and is contacted to battery voltage
x cable has no connection to TCU
x speed sensor has an internal defect
x connector pin is contacted to battery voltage or has no
contact
32 5140 4 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch control x check the cable from TCU to
TCU measures a voltage less than 0.45V the sensor
at speed input pin x check the connectors
x cable / connector is defective and is contacted to vehicle x check the speed sensor
ground
x speed sensor has an internal defect
33 5140 12 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch control x check the cable from TCU to This fault is reset
TCU measures a engine speed over a threshold and the next the sensor after power up of
moment the measured speed is zero x check the connectors TCU
x cable / connector is defective and has bad contact x check the speed sensor
x speed sensor has an internal defect x check the sensor gap
x sensor gap has the wrong size
34 5150 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch control x check the cable from TCU to
TURBINE SPEED INPUT if a failure is existing at output the sensor
TCU measures a voltage higher than 7.00 V at speed input speed, x check the connectors
pin TCU shifts to neutral x check the speed sensor
x cable is defective and is contacted to battery voltage OP-Mode: limp home
x cable has no connection to TCU
x speed sensor has an internal defect
x connector pin is contacted to battery voltage or has no
contact
-7-
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)
35 5150 4 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch control x check the cable from TCU to
TCU measures a voltage less than 0.45V if a failure is existing at output the sensor
at speed input pin speed, x check the connectors
x cable / connector is defective and is contacted to vehicle TCU shifts to neutral x check the speed sensor
ground OP-Mode: limp home
x speed sensor has an internal defect
36 5150 12 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch control x check the cable from TCU to This fault is reset
TCU measures a turbine speed over a threshold and at the if a failure is existing at output the sensor after power up of
next moment the measured speed is zero speed, x check the connectors TCU
x cable / connector is defective and has bad contact TCU shifts to neutral x check the speed sensor
x speed sensor has an internal defect OP-Mode: limp home x check the sensor gap
x sensor gap has the wrong size
37 5160 3 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch control x check the cable from TCU to
INTERNAL SPEED INPUT the sensor
TCU measures a voltage higher than 7.00 V at speed input x check the connectors
pin x check the speed sensor
x cable is defective and is contacted to battery voltage
x cable has no connection to TCU
x speed sensor has an internal defect
x connector pin is contacted to battery voltage or has no
contact
38 5160 4 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch control x check the cable from TCU to
TCU measures a voltage less than 0.45V the sensor
at speed input pin x check the connectors
x cable / connector is defective and is contacted to vehicle x check the speed sensor
ground
x speed sensor has an internal defect
39 5160 12 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute clutch control x check the cable from TCU to This fault is reset
TCU measures a internal speed over a threshold and at the the sensor after power up of
next moment the measured speed is zero x check the connectors TCU
x cable / connector is defective and has bad contact x check the speed sensor
x speed sensor has an internal defect x check the sensor gap
x sensor gap has the wrong size
-8-
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)
3A 5170 3 S.C. TO BATTERY VOLTAGE OR O.C. AT special mode for gear selection x check the cable from TCU to
OUTPUT SPEED INPUT OP-Mode: substitute clutch control the sensor
TCU measures a voltage higher than 12.5 V at speed input if a failure is existing at turbine x check the connectors
pin speed, x check the speed sensor
x cable is defective and is contacted to battery voltage TCU shifts to neutral
x cable has no connection to TCU OP-Mode: limp home
x speed sensor has an internal defect
x connector pin is contacted to battery voltage or has no
contact
3B 5170 4 S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear selection x check the cable from TCU to
TCU measures a voltage less than 1.00V OP-Mode: substitute clutch control the sensor
at speed input pin if a failure is existing at turbine x check the connectors
x cable / connector is defective and is contacted to vehicle speed, x check the speed sensor
ground TCU shifts to neutral
x speed sensor has an internal defect OP-Mode: limp home
3C 5170 12 LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear selection x check the cable from TCU to This fault is reset
TCU measures a output speed over a threshold and at the OP-Mode: substitute clutch control the sensor after power up of
next moment the measured speed is zero if a failure is existing at turbine x check the connectors TCU
x cable / connector is defective and has bad contact speed, x check the speed sensor
x speed sensor has an internal defect TCU shifts to neutral x check the sensor gap
x sensor gap has the wrong size OP-Mode: limp home
3E 5180 2 OUTPUT SPEED ZERO DOESN’T FIT TO OTHER special mode for gear selection x check the sensor signal of This fault is reset
SPEED SIGNALS OP-Mode: substitute clutch control output speed sensor after power up of
if transmission is not neutral and the shifting has finished, if a failure is existing at turbine x check the sensor gap of TCU
TCU measures outputspeed zero and turbine speed or speed, output speed sensor
internal speed not equal to zero. TCU shifts to neutral x check the cable from TCU to
x speed sensor has an internal defect OP-Mode: limp home the sensor
x sensor gap has the wrong size
40 5200 2 FCAN MESSAGE ‘GEAR RANGE SELECT (ZF_3_IDENT)’ gear range set from 1st to 5th x check FWD controller
contains invalid data x check wire of CAN-Bus
-9-
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)
41 5210 2 TCU RECEIVES MESSAGES ‘GEAR RANGE SELECT ignore FWD commands x reconfigure with
(ZF_3_IDENT)’ AND ‘FRONT WHEEL DRIVE STATUS’ TCU Configuration
(V_IDENT_FWD) ALTHOUGH CONFIGURATION STATES Command
THAT FWD CONTROLLER IS NOT INSTALLED (ID PC)
50 5220 9 FMR1 TIMEOUT TCU operates like jake brake is off x check engine controller
Timeout of CAN-message FMR1 from engine controller and exhaut brake is off. x check wire of CAN-Bus
x interference on CAN-Bus OP-Mode: normal x check cable to engine
x CAN wire/connector is broken controller
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
x engine controller is defective
51 5230 9 FMR2 TIMEOUT OP-Mode: substitute clutch control x check engine controller
Timeout of CAN-message FMR2 from engine controller x check wire of CAN-Bus
x interference on CAN-Bus x check cable to engine
x CAN wire/connector is broken controller
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
x engine controller is defective
52 5240 9 EAMODUL1 TIMEOUT TCU shifts to neutral and uses x check I/O controller
Timeout of CAN-message EAM1 from I/O - controller substitute gear selector x check wire of CAN-Bus
x interference on CAN-Bus OP-Mode: normal x check cable to I/O controller
x CAN wire/connector is broken
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
52 5240 9 SSM1 TIMEOUT TCU closes Park Brake if output x check SSM1 controller
Timeout of CAN-message SSM1 from SSM speed is below 0.5 km/h x check wire of CAN-Bus
x interference on CAN-Bus OP-Mode: normal x check cable to SSM
x CAN wire/connector is broken
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
-10-
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)
54 5260 9 GEAR RANGE SELECT TIMEOUT gear range set from 1st to 5th x check wire of CAN-Bus
Timeout of CAN-message ‘Gear Range Select x check FWD controller
(ZF_3_IDENT)’
x interference on CAN-Bus
x CAN wire/connector is broken
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
x FWD Controller is defective
-11-
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)
55 5270 9 FRONT WHEEL DRIVE STATUS TIMEOUT TCU shifts to neutral x check wire of CAN-Bus
Timeout of CAN-message x check FWD controller
‘Front Wheel Drive Status (V_IDENT_FWD)’
x interference on CAN-Bus
x CAN wire/connector is broken
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
x FWD Controller is defective
-12-
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)
56 5280 9 ENGINE CONF TIMEOUT OP-Mode: substitute clutch control x check engine controller
Timeout of CAN-message ENGINE CONF from engine x check wire of CAN-Bus
controller x check cable to engine
x interference on CAN-Bus controller
x CAN wire/connector is broken
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
57 5290 9 EEC1 TIMEOUT OP-Mode: substitute clutch control x check EEC controller
Timeout of CAN-message EEC1 from EEC controller x check wire of CAN-Bus
x interference on CAN-Bus x check cable to EEC
x CAN wire/connector is broken controller
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
58 5300 9 EEC3 TIMEOUT OP-Mode: substitute clutch control x check EEC controller
Timeout of CAN-message EEC3 from EEC controller x check wire of CAN-Bus
x interference on CAN-Bus x check cable to EEC
x CAN wire/connector is broken controller
x CAN wire/connector is defective an has contact to
vehicle ground or battery voltage
59 5310 2 ENGINE SPEED LIMIT FUNCTION DOES NOT WORK PROPERLY OP-Mode: normal x check engine controller
x engine controller is defective After selection neutral only limited x check wire of CAN-Bus
x interference on CAN-Bus gears available, depending on x check cable to engine
application controller
x engine controller may ignore
torque- or speed limit
command from TCU via
TSC1 message
5A 5320 2 PARKBRAKE STATUS SIGNAL no reaction ???? x check cluster controller
CAN signal for parkbrake status is defective x check wire of CAN-Bus
x cluster controller is defective x check cable to cluster
x interference on CAN-Bus controller
-13-
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)
5C 5340 2 AUTO DOWNSHIFT SIGNAL last selection is kept x check cluster controller
CAN signal for automatic downshift is defective x check wire of CAN-Bus
x cluster controller is defective x check cable to cluster
x interference on CAN-Bus controller
5D 5350 2 MANUAL DOWNSHIFT SIGNAL last selection is kept x check cluster controller
CAN signal for manual downshift is defective x check wire of CAN-Bus
x cluster controller is defective x check cable to ????
x interference on CAN-Bus controller
5E 5360 2 CCO REQUEST SIGNAL last selection is kept x check cluster controller
CAN signal for CCO request is defective x check wire of CAN-Bus
x cluster controller is defective x check cable to ????
x interference on CAN-Bus controller
5F 5370 2 SHIFT LEVER SIGNAL TCU shifts to neutral and uses x check I/O controller
CAN signal for shift lever is defective informations from substitute shift x check wire of CAN-Bus
x I/O controller is defective lever x check cable to I/O
x interference on CAN-Bus OP-Mode: normal controller
5F 5370 2 TRANSMISSION NEUTRAL REQUEST SIGNAL OP-Mode: normal x check steering computer
CAN signal for transmission Neutral Request is defective x check wire of CAN-Bus
x steering computer is defective x check cable to steering
x interference on CAN-Bus computer
5F 5370 2 CAN MESSAGE ‘ FRONT WHEEL DRIVE STATUS TCU shifts to neutral x check FWD controller
(V_IDENT_FWD)’ CONTAINS INVALID DATA
60 5380 2 ADDITIONAL BRAKE STATUS SIGNAL no reaction x check I/O controller
CAN signal for additional park brake status is defective OP-Mode: normal x check wire of CAN-Bus
x I/O controller is defective x check cable to I/O controller
x interference on CAN-Bus
61 5390 2 AEB REQUEST SIGNAL no reaction x check I/O controller
CAN signal for AEB request is defective OP-Mode: normal x check wire of CAN-Bus
x I/O controller is defective Last selection is kept x check cable to I/O controller
x interference on CAN-Bus
-14-
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)
-15-
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)
-16-
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)
1)
74 5490 3 S.C. TO BATTERY VOLTAGE AT CLUTCH K2 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at K2 valve is too high. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to battery pending gearbox to TCU
voltage TCU shifts to neutral x check the regulator
x regulator has an internal defect OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
1)
75 5490 4 S.C. TO GROUND AT CLUTCH K2 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at K2 valve is too low. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to vehicle pending gearbox to TCU
ground TCU shifts to neutral x check the regulator
x cable / connector is defective and has contact to another OP-Mode: TCU shutdown resistance 1)
regulator output of the TCU x check internal wire harness
x regulator has an internal defect of the gearbox
1)
76 5490 5 O.C. AT CLUTCH K2 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit. OP-Mode: limp home the gearbox
x cable / connector is defective and has no contact to TCU if failure at another clutch is x check the connectors from
x regulator has an internal defect pending gearbox to TCU
TCU shifts to neutral x check the regulator
OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
1)
77 5500 3 S.C. TO BATTERY VOLTAGE AT CLUTCH K3 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at K3 valve is too high. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to battery pending gearbox to TCU
voltage TCU shifts to neutral x check the regulator
x regulator has an internal defect OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
-17-
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)
1)
78 5500 4 S.C. TO GROUND AT CLUTCH K3 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at K3 valve is too low. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to vehicle pending gearbox to TCU
ground TCU shifts to neutral x check the regulator
x cable / connector is defective and has contact to another OP-Mode: TCU shutdown resistance 1)
regulator output of the TCU x check internal wire harness
x regulator has an internal defect of the gearbox
1)
79 5500 5 O.C. AT CLUTCH K3 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit. OP-Mode: limp home the gearbox
x cable / connector is defective and has no contact to TCU if failure at another clutch is x check the connectors from
x regulator has an internal defect pending gearbox to TCU
TCU shifts to neutral x check the regulator
OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
7A 5540 3 S.C. TO BATTERY VOLTAGE AT CONVERTER CLUTCH no reaction x check the cable from TCU to
OP-Mode: normal the valve
x check the regulator
resistance 1)
7B 5540 4 S.C. TO GROUND AT CONVERTER CLUTCH CONVERTER LOCK UP CLUTCH x check the cable from TCU to
SOLENOID CONNECTED AT ADMX: the valve
TCU switch off VPS2 x check the regulator
OP-mode: normal resistance 1)
-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)
1)
81 5510 3 S.C. TO BATTERY VOLTAGE AT CLUTCH K4 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at K4 valve is too high. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to battery pending gearbox to TCU
voltage TCU shifts to neutral x check the regulator
x regulator has an internal defect OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
1)
82 5510 4 S.C. TO GROUND AT CLUTCH K4 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at K4 valve is too low. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to vehicle pending gearbox to TCU
ground TCU shifts to neutral x check the regulator
x cable / connector is defective and has contact to another OP-Mode: TCU shutdown resistance 1)
regulator output of the TCU x check internal wire harness
x regulator has an internal defect of the gearbox
1)
83 5510 5 O.C. AT CLUTCH K4 TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit. OP-Mode: limp home the gearbox
x cable / connector is defective and has no contact to TCU if failure at another clutch is x check the connectors from
x regulator has an internal defect pending gearbox to TCU
TCU shifts to neutral x check the regulator
OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
1)
84 5520 3 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at KV valve is too high. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to battery pending gearbox to TCU
voltage TCU shifts to neutral x check the regulator
x regulator has an internal defect OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
-19-
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)
1)
85 5520 4 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at KV valve is too low. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to vehicle pending gearbox to TCU
ground TCU shifts to neutral x check the regulator
x cable / connector is defective and has contact to another OP-Mode: TCU shutdown resistance 1)
regulator output of the TCU x check internal wire harness
x regulator has an internal defect of the gearbox
1)
86 5520 5 O.C. AT CLUTCH KV TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit. OP-Mode: limp home the gearbox
x cable / connector is defective and has no contact to TCU if failure at another clutch is x check the connectors from
x regulator has an internal defect pending gearbox to TCU
TCU shifts to neutral x check the regulator
OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
1)
87 5530 3 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at KR valve is too high. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to battery pending gearbox to TCU
voltage TCU shifts to neutral x check the regulator
x regulator has an internal defect OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
1)
88 5530 4 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit, the OP-Mode: limp home the gearbox
voltage at KR valve is too low. if failure at another clutch is x check the connectors from
x cable / connector is defective and has contact to vehicle pending gearbox to TCU
ground TCU shifts to neutral x check the regulator
x cable / connector is defective and has contact to another OP-Mode: TCU shutdown resistance 1)
regulator output of the TCU x check internal wire harness
x regulator has an internal defect of the gearbox
-20-
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)
1)
89 5530 5 O.C. AT CLUTCH KR TCU shifts to neutral x check the cable from TCU to see chapter 4
the measured resistance value of the valve is out of limit. OP-Mode: limp home the gearbox
x cable / connector is defective and has no contact to TCU if failure at another clutch is x check the connectors from
x regulator has an internal defect pending gearbox to TCU
TCU shifts to neutral x check the regulator
OP-Mode: TCU shutdown resistance 1)
x check internal wire harness
of the gearbox
1)
8A 5535 4 S.C. TO GROUND AT DLM TRANSVERSAL OUTPUT output will be on until TCU power x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks down even if fault vanishes (loose the valve
like a s.c. to vehicle ground connection) x check the connectors
x cable is defective and is contacted to vehicle ground OP-Mode: normal x check the resistance of valve
x device has an internal defect
x connector pin is contacted to vehicle ground
1)
8B 5535 3 S.C. TO BATTERY VOLTAGE AT DLM TRANSVERSAL OUTPUT no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the valve
like a s.c. to battery voltage x check the connectors
x cable is defective and is contacted to battery voltage x check the resistance of valve
x device has an internal defect
x connector pin is contacted to battery voltage
1)
8C 5535 5 O.C. AT DLM TRANSVERSAL OUTPUT no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the valve
like a o.c. for this output pin x check the connectors
x cable is defective and has no connection to TCU x check the resistance of valve
x device has an internal defect
x connector has no connection to TCU
1)
8D 5536 4 S.C. TO GROUND AT DLM INDICATOR LAMP OUTPUT output will be on until TCU power x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks down even if fault vanishes (loose the device
like a s.c. to vehicle ground connection) x check the connectors
x cable is defective and is contacted to vehicle ground OP-Mode: normal x check the resistance of
x device has an internal defect device
x connector pin is contacted to vehicle ground
-21-
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)
1)
8E 5536 3 S.C. TO BATTERY VOLTAGE AT DLM INDICATOR LAMP no reaction x check the cable from TCU to see chapter 4
OUTPUT OP-Mode: normal the device
TCU detected a wrong voltage at the output pin, that looks x check the connectors
like a s.c. to battery voltage x check the resistance of
x cable is defective and is contacted to battery voltage device
x device has an internal defect
x connector pin is contacted to battery voltage
1)
8F 5536 5 O.C. DLM INDICATOR LAMP OUTPUT no reaction x check the cable from TCU to see chapter 4
OP-Mode: normal the device
TCU detected a wrong voltage at the output pin, that looks x check the connectors
like a o.c. for this output pin x check the resistance of
x cable is defective and has no connection to TCU device
x device has an internal defect
x connector has no connection to TCU
1)
91 5560 4 S.C. TO GROUND AT RELAY REVERSE WARNING ALARM backup alarm will be on until TCU x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks power down even if fault vanishes the backup alarm device
like a s.c. to vehicle ground (loose connection) x check the connectors from
x cable is defective and is contacted to vehicle ground OP-Mode: normal backup alarm device to TCU
x backup alarm device has an internal defect x check the resistance 1) of
x connector pin is contacted to vehicle ground backup alarm device
1)
92 5560 3 S.C. TO BATTERY VOLTAGE AT RELAY REVERSE WARNING no reaction x check the cable from TCU to see chapter 4
ALARM OP-Mode: normal the backup alarm device
TCU detected a wrong voltage at the output pin, that looks x check the connectors from
like a s.c. to battery voltage backup alarm device to TCU
x cable is defective and is contacted to battery voltage x check the resistance 1) of
x backup alarm device has an internal defect backup alarm device
x connector pin is contacted to battery voltage
1)
93 5560 5 O.C. AT RELAY REVERSE WARNING ALARM no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the backup alarm device
like a o.c. for this output pin x check the connectors from
x cable is defective and has no connection to TCU backup alarm device to TCU
x backup alarm device has an internal defect x check the resistance 1) of
x connector has no connection to TCU backup alarm device
-22-
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)
1)
94 5570 4 S.C. TO GROUND AT RELAY STARTER INTERLOCK no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the starter interlock relay
like a s.c. to vehicle ground x check the connectors from
x cable is defective and is contacted to vehicle ground starter interlock relay to
x starter interlock relay has an internal defect TCU
x connector pin is contacted to vehicle ground x check the resistance 1) of
starter interlock relay
1)
95 5570 3 S.C. TO BATTERY VOLTAGE AT RELAY STARTER INTERLOCK no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the starter interlock relay
like a s.c. to battery voltage x check the connectors from
x cable is defective and is contacted to battery voltage starter interlock relay to
x starter interlock relay has an internal defect TCU
x connector pin is contacted to battery voltage x check the resistance 1) of
starter interlock relay
1)
96 5570 5 O.C. AT RELAY STARTER INTERLOCK no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the starter interlock relay
like a o.c. for this output pin x check the connectors from
x cable is defective and has no connection to TCU starter interlock relay to
x starter interlock relay has an internal defect TCU
x connector has no connection to TCU x check the resistance 1) of
starter interlock relay
1)
97 5580 4 S.C. TO GROUND AT PARK BRAKE SOLENOID no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the park brake solenoid
like a s.c. to vehicle ground x check the connectors from
x cable is defective and is contacted to vehicle ground park brake solenoid to TCU
x park brake solenoid has an internal defect x check the resistance 1) of
x connector pin is contacted to vehicle ground park brake solenoid
1)
98 5580 3 S.C. TO BATTERY VOLTAGE AT PARK BRAKE SOLENOID no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the park brake solenoid
like a s.c. to battery voltage x check the connectors from
x cable is defective and is contacted to battery voltage park brake solenoid to TCU
x park brake solenoid has an internal defect x check the resistance 1) of
x connector pin is contacted to battery voltag park brake solenoid
-23-
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)
1)
99 5580 5 O.C. AT PARK BRAKE SOLENOID no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal the park brake solenoid
like a o.c. for this output pin x check the connectors from
x cable is defective and has no connection to TCU park brake solenoid to TCU
x park brake solenoid has an internal defect x check the resistance 1) of
x connector has no connection to TCU park brake solenoid
1)
9A 5590 4 S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH SOLENOID CONVERTER LOCK UP CLUTCH x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks SOLENOID CONNECTED AT ADMX: the converter clutch solenoid
like a s.c. to vehicle ground TCU switch off VPS2 x check the connectors from
x cable is defective and is contacted to vehicle ground OP-mode: normal converter clutch solenoid to
x converter clutch solenoid has an internal defect TCU
x connector pin is contacted to vehicle ground CONVERTER LOCK UP CLUTCH x check the resistance 1) of
SOLENOID CONNECTED AT AIP7: converter clutch solenoid
TCU switch off VPS2
OP-mode: normal
1)
9B 5590 4 O.C. AT CONVERTER LOCK UP CLUTCH SOLENOID converter clutch always open, x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks retarder not available the converter clutch solenoid
like a o.c. for this output pin OP-mode: normal x check the connectors from
x cable is defective and has no connection to TCU converter clutch solenoid to
x converter clutch solenoid has an internal defect TCU
x connector has no connection to TCU x check the resistance 1) of
converter clutch solenoid
1)
9C 5590 5 S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP CLUTCH no reaction x check the cable from TCU to see chapter 4
SOLENOID OP-mode: normal the converter clutch solenoid
TCU detected a wrong voltage at the output pin, that looks x check the connectors from
like a s.c. to battery voltage converter clutch solenoid to
x cable is defective and is contacted to battery voltage TCU
x converter clutch solenoid has an internal defect x check the resistance 1) of
x connector pin is contacted to battery voltage converter clutch solenoid
1)
9D 5600 4 S.C. TO GROUND AT RETARDER SOLENOID no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-mode: normal the retarder solenoid
like a s.c. to vehicle ground x check the connectors from
x cable is defective and is contacted to vehicle ground retarder solenoid to TCU
x retarder solenoid has an internal defect x check the resistance 1) of
-24-
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)
-25-
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)
1)
A4 5620 4 S.C. TO GROUND AT WARNING SIGNAL OUTPUT no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-mode: normal the warning device
like a s.c. to vehicle ground x check the connectors from
x cable is defective and is contacted to vehicle ground warning device to TCU
x warning device has an internal defect x check the resistance 1) of
x connector pin is contacted to vehicle ground warning device
1)
A5 5620 5 O.C. AT WARNING SIGNAL OUTPUT no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-mode: normal the warning device
like a o.c. for this output pin x check the connectors from
x cable is defective and has no connection to TCU warning device to TCU
x warning device has an internal defect x check the resistance 1) of
x connector has no connection to TCU warning device
1)
A6 5620 3 S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT no reaction x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks OP-mode: normal the warning device
like a s.c. to battery voltage x check the connectors from
x cable is defective and is contacted to battery voltage warning device to TCU
x warning device has an internal defect x check the resistance 1) of
x connector pin is contacted to battery voltage warning device
1)
A7 5630 4 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 4 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a s.c. to vehicle ground no. 4 device
x cable is defective and is contacted to vehicle ground x check the connectors from
x customer specific function no. 4 device has an internal customer specific function
defect no. 4 device to TCU
x connector pin is contacted to vehicle ground x check the resistance of
customer specific function
no. 4 device
1)
A8 5630 3 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION customer specific x check the cable from TCU to see chapter 4
NO. 4 customer specific function
TCU detected a wrong voltage at the output pin, that looks no. 4 device
like a s.c. to battery voltage x check the connectors from
x cable is defective and is contacted to battery voltage customer specific function
no. 4 device to TCU
-26-
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)
x customer specific function no. 4 device has an internal x check the resistance of
defect customer specific function
x connector pin is contacted to battery voltage no. 4 device
1)
A9 5630 5 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 4 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a o.c. for this output pin no. 4 device
x cable is defective and has no connection to TCU x check the connectors from
x customer specific function no. 4 device has an internal customer specific function
defect no. 4 device to TCU
x connector has no connection to TCU x check the resistance of
customer specific function
no. 4 device
1)
AA 5640 3 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 5 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a s.c. to vehicle ground no. 5 device
x cable is defective and is contacted to vehicle ground x check the connectors from
x customer specific function no. 5 device has an internal customer specific function
defect no. 5 device to TCU
x connector pin is contacted to vehicle ground x check the resistance of
customer specific function
no. 5 device
1)
AB 5640 3 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION customer specific x check the cable from TCU to see chapter 4
NO. 5 customer specific function
TCU detected a wrong voltage at the output pin, that looks no. 5 device
like a s.c. to battery voltage x check the connectors from
x cable is defective and is contacted to battery voltage customer specific function
x customer specific function no. 5 device has an internal no. 5 device to TCU
defect x check the resistance of
x connector pin is contacted to battery voltage customer specific function
no. 5 device
-27-
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)
1)
AC 5640 5 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 5 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a o.c. for this output pin no. 5 device
x cable is defective and has no connection to TCU x check the connectors from
x customer specific function no. 5 device has an internal customer specific function
defect no. 5 device to TCU
x connector has no connection to TCU x check the resistance of
customer specific function
no. 5 device
1)
AD 5650 4 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 6 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks function 6 device
like a s.c. to vehicle ground x check the connectors from
x cable is defective and is contacted to vehicle ground customer specific function
no. 6 device to TCU
x customer specific function no. 6 device has an internal x check the resistance of
defect function 6 device
x connector pin is contacted to vehicle ground
1)
AE 5640 3 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC FUNCTION customer specific x check the cable from TCU to see chapter 4
NO. 6 customer specific function
TCU detected a wrong voltage at the output pin, that looks no. 6 device
like a s.c. to battery voltage x check the connectors from
x cable is defective and is contacted to battery voltage customer specific function
x customer specific function no. 6 device has an internal no. 6 device to TCU
defect x check the resistance of
x connector pin is contacted to battery voltage customer specific function
no. 6 device
1)
AF 5650 5 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 6 customer specific x check the cable from TCU to see chapter 4
TCU detected a wrong voltage at the output pin, that looks customer specific function
like a o.c. for this output pin no. 6 device
x cable is defective and has no connection to TCU x check the connectors from
x customer specific function no. 6 device has an internal customer specific function
defect no. 6 device to TCU
-28-
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)
-29-
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)
-30-
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)
-31-
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)
-32-
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)
C6 5770 5 O.C. AT JOYSTICK STATUS INDICATOR no reaction x check the cable from TCU to
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal joystick status indicator
like a o.c. for this output pin x check the connectors from
x cable is defective and has no connection to TCU joystick status indicator to
x joystick status indicator has an internal defect TCU
x connector has no connection to TCU x check the resistance 1) of
joystick status indicator
C7 5780 4 S.C. TO GROUND AT OVERTEMP NEUTRAL INDICATOR no reaction x check the cable from TCU to
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal OVERTEMP NEUTRAL
like a s.c. to vehicle ground INDICATOR
-33-
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)
x cable is defective and is contacted to vehicle ground x check the connectors from
x overtemp status indicator has an internal defect OVERTEMP NEUTRAL
x connector pin is contacted to vehicle ground INDICATOR to TCU
x check the resistance 1) of
OVERTEMP NEUTRAL
INDICATOR
C8 5780 3 S.C. TO BATTERY VOLTAGE AT OVERTEMP NEUTRAL no reaction x check the cable from TCU to
INDICATOR OP-Mode: normal OVERTEMP NEUTRAL
TCU detected a wrong voltage at the output pin, that looks INDICATOR
like a s.c. to battery voltage
x cable is defective and is contacted to battery voltage x check the connectors from
x overtemp status indicator has an internal defect OVERTEMP NEUTRAL
x connector pin is contacted to battery voltage INDICATOR to TCU
x check the resistance 1) of
OVERTEMP NEUTRAL
INDICATOR
C9 5780 5 O.C. AT OVERTEMP NEUTRAL INDICATOR no reaction x check the cable from TCU to
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal OVERTEMP NEUTRAL
like a o.c. for this output pin INDICATOR
x cable is defective and has no connection to TCU x check the connectors from
x OVETEMP status indicator has an internal defect OVERTEMP NEUTRAL
x connector has no connection to TCU INDICATOR to TCU
x check the resistance 1) of
OVERTEMP NEUTRAL
INDICATOR
CA 5790 9 ENGINE_RETARDER CONFIG_TIMEOUT OP-Mode: substitute clutch control x check EEC controller
Timeout of CAN-message ENGINE_RETARDER CONFIG from x check wire of CAN-Bus
EEC controller x check cable to EEC
x interference on CAN-Bus controller
x CAN wire/connector is broken
x CAN wire/connector is defective an has contact to
vehicle ground or battery voltage
-34-
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)
CB 5800 9 ERC1 TIMEOUT OP-Mode: substitute clutch control x check EEC controller
Timeout of CAN-message ERC1 from EEC controller x check wire of CAN-Bus
x interference on CAN-Bus x check cable to EEC
x CAN wire/connector is broken controller
x CAN wire/connector is defective an has contact to
vehicle ground or battery voltage
D1 5810 3 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 to 2C x check cables and connectors fault codes no. 21
TCU measures more than 6V at the pin AU1 (5V sensor to sensors, which are to no. 2C may be
supply) supplied from AU1 a reaction of this
x check the power supply at fault
the pin AU1
(should be appx. 5V)
D2 5810 4 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS see fault codes no. 21 to 2C x check cables and connectors fault codes no. 21
TCU measures less than 4V at the pin AU1 (5V sensor to sensors, which are to no. 2C may be
supply) supplied from AU1 a reaction of this
x check the power supply at fault
the pin AU1 (should be
appx. 5V)
D3 5820 4 LOW VOLTAGE AT BATTERY shift to neutral x check power supply battery
measured voltage at power supply is lower than 10 V (12V OP-Mode: TCU shutdown x check cables from batteries
device) to TCU
lower than 18 V (24V device) x check connectors from
batteries to TCU
D4 5820 3 HIGH VOLTAGE AT BATTERY shift to neutral x check power supply battery
measured voltage at power supply is higher than 18 V (12V OP-Mode: TCU shutdown x check cables from batteries
device) to TCU
higher than 32.5 V (24V device) x check connectors from
batteries to TCU
D5 5830 2 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral x check fuse
TCU switched on VPS1 and measured VPS1 is off or TCU OP-Mode: TCU shutdown x check cables from gearbox
switched off VPS1 and measured VPS1 is still on to TCU
x cable or connectors are defect and are contacted to x check connectors from
battery voltage gearbox to TCU
-35-
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)
-36-
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)
E1 OPEN CIRCUIT AT DIRECTION SELECT TCU shifts transmission to neutral x check the cables from TCU
SIGNALS OP-Mode: transmission shutdown to shift lever
TCU detected a o.c signals for the direction
x cable from shift lever to TCU is broken
x cable is defective and is contacted to vehicle ground
x shift lever is defective
E2 OPEN CIRCUIT AT DIRECTION SELECT TCU shifts transmission to neutral x check the cables from TCU
SIGNALS OF SHIFTER 2 OP-Mode: transmission shutdown to shift lever
TCU detected a o.c signals for the direction
x cable from shift lever to TCU is broken
x cable is defective and is contacted to vehicle ground
x shift lever is defective
E3 5860 3 S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT no reaction x check the cable from TCU to
TCU sends data to the display and measures allways a high OP-Mode: normal the display
voltage level on the connector x check the connectors at the
x cable or connectors are defective and are contacted to display
battery voltage x change display
x display has an internal defect
E4 5860 4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction x check the cable from TCU to
TCU sends data to the display and measures allways a high OP-Mode: normal the display
voltage level on the connector x check the connectors at the
x cable or connectors are defective and are contacted to display
vehicle ground x change display
x display has an internal defect
E5 5271 9 DISPID1_TIMEOUT TCU select parameter set with ID0 x check display controller
Timeout of CAN-message DISPID1 from display controller OP-Mode: Limp Home x check wire of CAN-Bus
x interference on CAN-Bus x check cable to display
x CAN wire/connector is broken controller
x CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
-37-
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)
F3 5910 13 APPLICATION ERROR transmission stay neutral x replace TCU !! This fault occurs
something of this application is wrong OP-Mode: TCU shutdown only if an test
engineer did
something wrong
in the application
of the vehicle
F4 5920 13 LIMP HOME REQUEST shift to neutral x The external controller has
no fault! indicates that another computer requested limp OP-Mode: limp home to cancel the request
home via CAN
F5 5930 7 CLUTCH FAILURE transmission stay neutral x check clutch TCU shows also
AEB was not able to adjust clutch filling parameters OP-Mode: TCU shutdown the affected clutch
x One of the AEB-Values is out of limit on the Display
F6 5930 13 CLUTCH ADJUSTMENT DATA LOST OR INCHPEDAL default values = 0 for AEB offsets x execute AEB
CALIBRATION DATA LOST used
TCU was not able to read correct clutch adjustment OP-Mode: normal
parameters no Inchmode available
x interference during saving data on non volatile memory
x TCU is brand new
-38-
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)
F7 5940 11 SUBSTITUTE CLUTCH CONTROL OP-Mode : substitute clutch x check engine retarder torque
x transmission input torque wrong control x check speed sensors
x engine retarder torque wrong
x speed signal(s) defective
-39-
4. Measuring of resistance at actuator/sensors and cable
4.1 actuator:
1
2
G
4.2 cable:
UBat
P (power supply)
TCU
Actuator /
1 2
Sensor
C (chassis)
Gnd