codigos de falhas zf automatizada

8/11/2019 Codigos de Falhas ZF Automatizada

1/127

ZF - AS Tronic lite

VPT

Failure tree(Software VPT-03-15B0003BO)

6070 754 104


2/127

Subject to technical changes

Copyright by ZF

This documentation is protected by copyright. Any

reproduction and dissemination in whatever form - also

in adapted, paraphrased or extraceted form - in

particular as a reprint, photomechanical or electronic

reproduction or involving storage in data-processing

equipment or data networks without approval by the

holder of the copyright is prohibited.

Printed in Germany

ZF Friedrichshafen AG

Competence Contents LKS-T

Edition: 2008-03

6 070 754 104


3/127

Clutch actuator

6070 203 002

Float switch

Transmission actuator Housings

1290 301 242

Power pack

(ECU, reservoir,

accumulator)Clutch housing

1290 201 232

N1 sensor

0501 320 073

Vehicle wiring

harness

6070 303 010

Pressure reservoir

Transmission harness

6070 303 010

Pentosin reservoir


LKS-T 2008-03ZF-AS Tronic lite - 6070 754 104


4/127

Abbreviation List

Ab br evi ati on Meani ng

ABS Antilock Braking System

AD Digital output

ADMHS Output digital ground high current

ASC Anti-Slip Control

CAN Controller Area Network

CCVS CAN messageEBC Electronic Brake Controller

EBS Electronic Brake System

ECU Electronic Controll Unit

EEC CAN message (EEC1/EEC2/EEC3)

E-module Electronics box

ERC CAN message

ETC CAN message

N Neutral

OK Okay

Pentosin fluid for AS lite hydraulic system

PowerPack control, valves, reservoir, pressure accumulator

PTO Power Take off

RG Reverse gear

RMV neg. Directional solenoid valve, negative

RMV pos. Directional solenoid valve, positive

TC1

TCO1 CAN message

VCU Vehicle control unit

VM Ground supply

VP Plus supply

WDC Watch Dog Controller

ZF-Friedrichshafen AG

LKS-T 2008-03 ZF-AS Tronic lite 6070 754 104


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Sorting ZF Error Number

Error Error Error

number number number

ZF ZF ZF

1 52 104

3 53 105

4 54 106

5 55 107

6 56 108

8 57 109

9 60 111

10 61 112

11 62 113

13 63 114

15 64 115

16 65 116

17 66 117

18 67 118

20 68 119

21 70 120

22 71 121

23 72 128

24 73 129

25 74 130

26 75 131

27 76 13828 77 139

29 78 140

30 79 141

31 81 142

33 82 145

34 83 146

35 84 147

36 88 148

37 89 152

40 90 15841 91 159

42 92 162

43 93 172

44 95 173

45 99 174

47 100 175

48 101 183

50 102 184

51 103


LKS-T 2008-03 ZF-AS Tronic lite 6070 754 104


6/127

ZF error 1

J1587 Error Code 254

J1587 FMI 3

SPN 4170

Error Description Safety device (watchdog controller = WDC/redundant cutoff path) does not

function

Error Recognition WDC cannot generate a reset and clear the valve supplies. PPC recognizes

communication error

System Reaction Transmission functions are not initiated, no actuator control

Note: Error that requires immediate stop at a workshop! Greatly limited drive

functions, particular attention required by the driver!

Troubleshooting

Replace power pack

(electronics incl. valve

unit)

Teach in system again- Start up pump

- Ventilate transmission

- Ventilate clutch

- Teach in transmission

- Position clutch

- Teach in touch point

Re-program the software

Measure stated below only to be

carried out when error is actively

present

Immediate feedback to

Friedrichshafen!!!


LKS-T 2008-03 ZF-AS Tronic lite - 6070 754 104


7/127

ZF error 3


J1587 FMI 13

SPN 4121

Error Description Checksum error reading

EEPROM

Error Recognition Checksum

System Reaction Substitute values from data field



Troubleshooting

When error active

Replace power pack

(electronics incl. valve unit)

Teach in system again

- Start up pump

- Ventilate transmission- Ventilate clutch


- Position clutch







8/127

ZF error 4


J1587 FMI 12

SPN 4180

Error Description Error detected by process monitoring

Error Recognition Function calls are not executed in the specified order.

System Reaction Control unit reset

Note: Error has no effect on roadworthiness! Stop at workshop required soon!

Troubleshooting

Replace power pack


unit)


- Start up pump


- Ventilate clutch


- Position clutch





present


Friedrichshafen!!!




9/127

ZF error 5


J1587 FMI 7

SPN 4181

Error Description Securing layer was activated

Error Recognition Activation of securing layer detected: Unintended starting. Starting against

desired direction of travel. Unintended increase in engine torque.

System Reaction Control unit reset


Particular attention required by the driver!

Troubleshooting

Replace power pack


unit)


- Start up pump

- Ventilate transmission- Ventilate clutch


- Position clutch





present


Friedrichshafen!!!




10/127

ZF error 6

J1587 Error Code 27

J1587 FMI 11

SPN 4137

Error Description This error occurs when bleeding of the clutch actuator was not successful.

Error Recognition Bleeding of clutch service issues an error.

System Reaction

Transmission immediately switches to neutral and the clutch opens. System not

Note: Error is a danger to roadworthiness and/or driving safety. Immediate stop is

required - but observe the traffic conditions!

Troubleshooting

Error entered in the error memory

and/or actively present?

System available?

Run the diagnosis service on

clutch ventilation again until it is

concluded successfully.

If possible, set clutch actuator

position to horizontal (raise the

vehicle at the rear).

No

Start vehicle again.

Yes

Run the diagnosis service on

clutch bleeding again until it is

concluded successfully.

Activate the component

ventilation function with

TestmanPro.- Ventilation of clutch or

- Fast ventilation of clutch

Note:Fuse wire or cable clip

fitted on release fork?




11/127

ZF error 8

J1587 Error Code 59

J1587 FMI 3

SPN 4122

Error Description Defective power supply of shift and selector sensor.

Error Recognition Signal outside tolerance.

System Reaction Shift sensor and selector sensor signal maintains the last value applicable.

Switch off position control in shift direction and selector direction, shifts are

Note: Error is a danger to roadworthiness and/or driving safety. Immediate stop

is required - but observe the traffic conditions!

Troubleshooting

Replace power pack


unit)


- Start up pump


- Ventilate clutch- Teach in transmission

- Position clutch





present.

Note:If ZF errors 61 and 62 occur as well, no measures are required with regard to

both errors (61, 62), software error!




12/127

ZF error 9

J1587 Error Code 63

J1587 FMI 11

SPN 3101

Error Description Transmission output signal is faulty.

Error Recognition All redundant signal sources for the transmission output speed offer no valid

signal.

System Reaction Static substitute value is used.

No more shifts possible, the automatic shift unit is deactivated. If the vehicle



Troubleshooting

Signal comes from CAN

(in TCO1 message)

CAN error 10, 11 activelypresent?

TCO inspectionCheck number of teeth (specified:

Does the vehicle have mechanical

engagement?

- Clutch closes?

- Transmission gear shifted?

Other CAN errors (timeouts)

present

Process CAN errors according to

failure tree!

Check clutch parts, terminal,

support, etc.!

Remove transmission and check

shift elements!




13/127

ZF error 10


J1587 FMI 8

SPN 904

Error Description Front axle speed is faulty.

Error Recognition Signal outside tolerance, signal marked as invalid.

System Reaction Static backup value and switch to a redundant signal

Deactivate adaption of ratio rear axle and dynamic tyre radius (relation of

Note: The error can be rectified at the next workshop stop (servicing date)!

Troubleshooting

Signal comes from CAN

(in EBC2 message)

CAN error 9, 11 actively present? Tachograph inspection

Check number of teeth (specified: 6)


engagement?

- Clutch closes?



present


failure tree!


support, etc.!


shift elements!




14/127

ZF error 11


J1587 FMI 8

SPN 1623

Error Description Transmission output speed (tachograph) faulty.


System Reaction Static backup value , redundant source for internal output shaft speed will be

used.

Deactivate adaption of ratio rear axle and dynamic tyre radius (relation of


Troubleshooting

Signal coming from CAN

(tachograph)

CAN error 9, 10 actively present? Tachograph inspection

Check number of teeth (specified: 6)


engagement?- Clutch closes?



present


failure tree!


support, etc.!


shift elements!




15/127

ZF error 13


J1587 FMI 0

SPN 161

Error Description Transmission input speed faulty.

Error Recognition Signal outside tolerance, the plausibility check between inputshaft speed and

engine speed detect an implausible signal!

System Reaction Modelbased backup value (output shaft speed)

Shift lock (allowing N, allowing drive-off gear, both driving directions). ISMA



Troubleshooting

Check / Replace speed sensorSpeed sensor visual inspection:

Wiring OK

connection OK

Check wiring to speed sensor at

transmission end.

Check

- PIN 11 (EF1) control to speed sensor PIN 1 (signal)

- PIN 4 (VMG1) control to speed sensor PIN 2 (Gnd)

Replace transmission-end wiring.Processing of speed signal in

control OK

Are other speed signals missing?

Replace power pack


unit)


- Start up pump


- Ventilate clutch


- Position clutch


Re-program the software.




16/127

ZF error 15

J1587 Error Code 27

J1587 FMI 7

SPN 4194

Error Description The clutch point closed is not plausible.

Error Recognition Taking the initial point of clutch closed, it was not possible to achieve the

minimum travel from clutch closed to clutch open!

System Reaction

Shift neutral, clutch open.

Troubleshooting

Check clutch travel!The transmission system is to determine the clutch contact

point and adapt it to ensure reproducible engagement

comfort when starting and after shifts and/or to ensure that,

during standstill, the clutch is opened far enough when a

gear has been selected.

Signals for clutch closed status (neutral).

Relative clutch travel = 0 %

Transmission input speed = engine speed

Absolute clutch travel > absolute clutch takeover point

Signals for clutch open status (gear engaged)

Relative clutch travel = 75% - 100 %

Transmission input speed = 0 rpm

Absolute clutch travel =/< absolute clutch takeover point

Signals OK Signals not OK

Ventilate clutch system using the

diagnosis tester and teach in

again.

Check / Adjust mechanical clutch parts

according to assembly instruction; ventilate

clutch system using the diagnosis tester and

teach in again.




17/127

ZF error 16

J1587 Error Code 55

J1587 FMI 0

SPN 3127

Error Description Signal for temperature sensor next to processor faulty.


System Reaction Substitute value (signal of temperature sensor next to output stage pump)

Note: Error has no influence on roadworthiness and/or driving safety; however,

it should be inspected and/or rectified before driving off. The warning lamp onlylights up when the vehicle comes to a standstill!

Troubleshooting

Replace power pack(electronics incl. valve unit)


- Start up pump


- Ventilate clutch


- Position clutch



When error active




18/127

ZF error 17

J1587 Error Code 55

J1587 FMI 0

SPN 4171

Error Description Signal of temperature sensor next to pump final stage is faulty.


System Reaction Substitute value (signal of temperature sensor next to processor)

Note: Error has no influence on roadworthiness and/or driving safety; however,

it should be inspected and/or rectified before driving off. The warning lamp onlylights up when the vehicle comes to a standstill!

Troubleshooting

Replace power pack



- Start up pump


- Ventilate clutch


- Position clutch



Error active?




19/127


20/127

ZF error 20


J1587 FMI 8

SPN 4103

Error Description One or more signals from message "engine configuration" is/are faulty.

Error Recognition In this message are signal low idle speed and TrqEngRef, the signals outside of

tolerance, signals marked as invalid.



Troubleshooting

The following signals are included in the "engine

configuration" message:

- Engine governed speed

- Engine idling speed

- Engine speed characteristic curve item 2, 3, 4, 5, 7

- Engine torque item 1, idling

- Engine torque item 2, 3, 4, 5- Engine reference torque

Signals are issued by the EDC.OEM

Check tachograph.

Message issued by central computer. Central

computer sends a speed value far below approx.

700 rpm.

Signal from the central computer

can only be controlled by using

CANALYZER (nengidle_isig).

Update the central computer

again! Specified signal approx.

700 rpm.


LKS-T 2008-03

ZF-AS Tronic lite - 6070 754 104


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ZF error 21


J1587 FMI 8

SPN 91

Error Description Accelerator pedal position signal is faulty.



ISMA deactivated (calculation of target gear and road resistance). Inhibit take



Troubleshooting

The accelerator position signal is included in the

"EEC2" message issued by the EDC.

Check accelerator pedal / wiring

and / or teach in again / replace.

OEM

Accelerator pedal not OK!


failure tree!

Further CAN errors present?




22/127

ZF error 22


J1587 FMI 8

SPN 513

Error Description Engine torque signal is faulty.


System Reaction Model-based substitute value (No engine intervention active: torque requested

by driver, engine intervention active: delayed specified engine torque).

The automatic shift unit is deactivated. Functions such as adaptation of touch


Troubleshooting

The engine torque signal is included in the

"EEC1" message issued by the EDC.

Other EDC errors and / or CAN errors Process CAN errors according to

failure tree!




23/127

ZF error 23


J1587 FMI 8

SPN 190

Error Description Engine speed signal is faulty.

Error Recognition Signal outside tolerance. Signal marked as invalid.

System Reaction Model-based substitute value is used.

The automatic shift unit is deactivated and shifts are no longer possible. Disable



Troubleshooting

The engine speed signal is included in the

"EEC1" message issued by the EDC


failure tree!




24/127

ZF error 24


J1587 FMI 8

SPN 558

Error Description Signal low idle switch is faulty.


System Reaction Model-based substitute value (from accelerator pedal) is used!

Shift lock general. Inhibit take up (virtual driving pedal = 0). Shift neutral at



Troubleshooting

The idler switch signal is included in the

EEC2 message issued by the EDC.


and / or teach in again / replace.

Accelerator pedal not OK!


failure tree!




25/127

ZF error 25


J1587 FMI 8

SPN 512

Error Description Signal torque driver demand is faulty.


System Reaction Model-based substitute value (engine characteristic curves) is used.

The automatic shift unit is deactivated. Functions such as adaptation of clutch


Troubleshooting

The torque requested by the driver is

included in the EEC1 message issued by

the EDC


and / or teach in again / replace

Accelerator pedal error (ZF error 21/24)

included

Check accelerator pedal

Other EDC errors and/or CAN errors Process CAN errors according to

failure tree!




26/127

ZF error 26


J1587 FMI 8

SPN 92

Error Description Signal "percent load at current speed" is faulty.



Once the vehicle stops, the transmission shifts to neutral! It is no longer possible


Troubleshooting

The relative engine torque is included in the

EEC1 message issued by the EDC.

Other EDC errors and / or CAN errors? Process CAN errors according to

failure tree!




27/127

ZF error 27


J1587 FMI 8

SPN 595

Error Description Signal cruise control active is faulty.


System Reaction Constant substitute value is used.

The automatic shift unit is deactivated.


Troubleshooting

The cruise control active signal is

included in the CCvehSpeed

message.

If accelerator pedal is notactivated, accelerator position

shown must be 0%!

Check accelerator pedal

Other CAN errors? Process CAN errors

according to failure tree!




28/127

ZF error 28


J1587 FMI 8

SPN 86

Error Description Cruisecontrol set speed is faulty


System Reaction Constant substitute value is used.


Troubleshooting

The specified speed is included

in the CCVS message and, in the

case of the SAE standard, in the

EBC1 message.

Other CAN errors? Process CAN errorsaccording to failure tree!




29/127

ZF error 29


J1587 FMI 8

SPN 110

Error Description Engine cooling water temperature signal is faulty.


System Reaction Maintain the last value applicable.


Troubleshooting

Check engine cooling water Engine cooling water is OK

(temperature must also be

checked in EDC and / or lead to

an error message)!

Transmission electronics issueswrong signal

Consultation with FN

Engine cooling water not OK

(temperature must also be

checked in EDC and/or lead to an

error message)!

Check cooling circuit!

OEM!




30/127

ZF error 30

J1587 Error Code 33

J1587 FMI 2

SPN 3124

Error Description Signal clutch position is invalid.


System Reaction Maintain the last value applicable.

The automatic shift unit is deactivated. Functions such as adaptation of clutch



Troubleshooting

Supply voltage /

Travel sensor signal

Interrupt or short circuit to

ground.

Check transmission-end wiring harness for interruption /

short circuit to ground: From transmission connector X3 to

clutch actuator connector X4:

Supply voltage: AU1 Pin 9 to Pin 1 (+)Supply ground: VMGA1 Pin 10 to Pin 2 (-)

Travel sensor signal: EU2 Pin 5 to Pin 3 (signal)

Travel sensor signal: EU1 Pin 8 to Pin 4 (signal)

Wiring harness OK

Repair / Replace wiring harness

No

Connect wiring harness at

transmission end and check

voltage supply at clutch actuator

end Pin 1 to Pin 2, specified: 5V

Voltage supply OK Check / Replace ECU

No

Yes

Check / Replace clutch actuator

Yes

No






31/127

ZF error 31

J1587 Error Code 51

J1587 FMI 13

SPN 4123

Error Description It was repeatedly not possible to determine the clutch contact point.

Error Recognition Even after the maximum number of attempts, the teach-in routine could not teach

in the contact point.

System Reaction Dynamic backup value, last valid value, saved in EEPROM



Troubleshooting

Check clutch travel!The transmission system is to determine the clutch contact

point and adapt it to ensure reproducible engagement comfort

when starting and after shifts and/or to ensure that, during

standstill, the clutch is opened far enough once the gear has

been selected.

Signals for clutch closed status (neutral).






Transmission input speed = 0 rpm

Absolute clutch travel =/< absolute clutch takeover point

Signals OK Signals not OK

Ventilate clutch system using

diagnosis tester and teach in

again.

Check / Adjust mechanical clutch parts

according to assembly instructions; ventilate

clutch system using the diagnosis tester and

teach in again.




32/127

ZF error 33

J1587 Error Code 3

J1587 FMI 12

3118

Error Description Error clutch control in clutch open direction

Error Recognition None of the clutch open valves can be used due to electrical problems or valve

System Reaction Deactivation of clutch controller in direction clutch open

Shifts are no longer possible. Once the vehicle stops, the transmission shifts to



Troubleshooting

Subsequent error of: Clutch opening valve 2 (117) or

main cutoff relay (109) defective; first process the

errors!

Before consulting FN, please work

through check list AS lite.




33/127

ZF error 34

J1587 Error Code 1

J1587 FMI 11

SPN 3119

Error Description Error clutch control in clutch close direction

Error Recognition None of the clutch open valves can be used due to electrical problems or valve

overload.

System Reaction Deactivation of clutch controller in direction clutch close

Shifts are no longer possible. Once the vehicle stops, the transmission shifts to



Troubleshooting

Before consulting FN, please work

through check list AS lite.






34/127

ZF error 35

J1587 Error Code 59

J1587 FMI 11

SPN 4163

Error Description Deactivation of selector function due to exceeding of period of engagement.

Error Recognition Monitoring of selector function period of engagement

System Reaction Note: Error has no effect on roadworthiness! Stop at workshop required soon!

Troubleshooting

Check hydraulic system

for tightness.

- Storage tank

- Pressure container

- Clutch actuator

- Transmission actuator

- Lines

Sufficient amount of

Pentosin in the storage

tank.

No

Check mechanical parts in

the removed transmission.

Shift elements


- Selector rails

- Synchronizer

- Shifting sleeves




35/127

ZF error 36

J1587 Error Code 58

J1587 FMI 11

SPN 4164

Error Description Deactivation of shift function due to exceeding of period of engagement

Error Recognition Monitoring of shift function period of engagement

System Reaction Note: Error has no effect on roadworthiness! Stop at workshop required soon!

Troubleshooting

Check hydraulic system

for tightness.

- Storage tank

- Pressure container

- Clutch actuator


- Lines

Sufficient amount of

Pentosin in the storage

tank.

No

Check mechanical parts in

the removed transmission.

Shift elements


- Selector rails

- Synchronizer

- Shifting sleeves




36/127

ZF error 37


J1587 FMI 8

SPN 4165

Error Description At least one signal of retarder configuration is invalid.


System Reaction Dynamic substitute value, last value applicable saved to the EEPROM.


Troubleshooting

Check OEM central

computer!

The retarder configuration signals are

issued by the central computer.

Other CAN errors Process CAN errors according tofailure tree!




37/127

ZF error 40


J1587 FMI 8

SPN 597

Error Description Brake switch signal is faulty


System Reaction Substitute signal brake applied when transmission input speed is higher than

threshold for stopping, otherwise substitute value brake not applied.

The automatic shift unit is deactivated!Note: The error can be rectified at the next workshop stop (servicing date)!

Troubleshooting

Brake switch signal is included in

CCVS message

Message is issued by the EDC

Check the following parts:

- EDC (OEM only)

- Brake pedal

- Wiring (signal travel)

- Brake pressure switch

Brake signal can be checked with the

Testman:

- Test inputs-outputs

- Sensors & information

- System information

- Signal brake switch 1 active

- Signal brake switch 0 not active




38/127

ZF error 41


J1587 FMI 8

SPN 563

Error Description ABS (anti brake system) signal is faulty


System Reaction ABS substitute value not active. If error is shown when ABS signal is active, the

signal is held until the service brake is no longer active.

The automatic shift unit is deactivated!


Troubleshooting

Antilock signal is included in EBC1

message.

Message is issued by the EBS (ABS

/ ASC).

Check other errors in the EBS

(OEM only).

ABS signal can be checked with the

Testman:




- Signal ABS 1 active

- Signal ABS 0 not active




39/127


40/127

ZF error 43


J1587 FMI 8

SPN 561

Error Description Engine intervention by ASC (anti slipping control) signal is faulty.





Troubleshooting

Anti slipping signal is included in

EBC1 message.

Message is issued by the EBS (ABS

/ ASC).

Check other errors in the EBS

(OEM only).

ABS signal can be checked with the

Testman:




- Signal ABS 1 active

- Signal ABS 0 not active




41/127

ZF error 44


J1587 FMI 8

SPN 520

Error Description Engine brake torque signal is faulty.





Troubleshooting

Engine brake torque signal is

included in ERC1 message.

Message is issued by the EDC.

Check other errors in the EDC

(OEM only).




42/127

ZF error 45


J1587 FMI 8

SPN 559

Error Description KickDown active signal is faulty.


System Reaction Model-based substitute value (from accelerator pedal) is used!

Troubleshooting

Kickdown signal is included in

EEC2 message.

Message is issued by the EDC.

Check other errors in the EDC

(OEM only)

Kickdown signal can be checked with the Testman:


- Sensors & information- Accelerator position

- Kickdown 0 signal is not active at 0% accelerator position

- Kickdown 1 signal is active at 100 % accelerator position




43/127

ZF error 47

J1587 Error Code 55

J1587 FMI 0

SPN 3193

Error Description Power pack temperature above upper limit value.

Error Recognition The available ECU temperature sensors show a too high temperature.

System Reaction None

Troubleshooting

Temperature signal is created by

- Temperature sensor next to processor and

- Temperature sensor next to engine output

Replace power pack



- Start-up of pump

- Ventilation of

transmission

- Ventilation of clutch

- Teach-in transmission

- Position clutch

- Teach-in touch point


Carry out oil check at transmission acc.

to operating instructions, oil volume,

oil quality (e.g. burnt!)!

Oil volume / quality OK Adjust oil volume and / or in the case of poor

oil quality inspect transmission.

No

Yes

Check ambient temperatures, e.g.

exhaust piping!

Remedial action: Fit a heat shield.




44/127

ZF error 48

J1587 Error Code 55

J1587 FMI 1

SPN 4168

Error Description Power pack temperature below lower limit value.

Error Recognition The available ECU temperature sensors show a too low temperature.

System Reaction Note: The error can be rectified at the next workshop stop (servicing date)!

Troubleshooting




Observe ambient temperature! Error

memory entry serves as information!




45/127

ZF error 50


J1587 FMI 8

SPN 4197

Error Description Overspeed at input shaft

Error Recognition Input shaft speed and gradient of input shaft speed exeeds limits

System Reaction Shifting to neutral and clutch open

Troubleshooting

Immediate feedback to Service ZF

Friedrichshafen!!!




46/127

ZF error 51

J1587 Error Code 27

J1587 FMI 1

SPN 4119

Error Description Implausibility between clutch position and following clutch actuations detected.

Error Recognition Start vehicle again.

System Reaction Shifts are no longer possible. Functions such as adaptation of clutch contact



Troubleshooting

Check oil pressure supply.

Specified oil pressure: 60 bar -

85 bar

Check oil fill!

Lines are tight!

Pump function OK

Check clutch travel

signals

Signals for clutch closed status (neutral)






Transmission input speed = 0 rpmAbsolute clutch travel =< absolute clutch takeover point

Check / Adjust mechanical clutch parts according to assembly instructions. Check clutch actuator for

tightness. Ventilate clutch system using diagnosis tester and teach in again.

Start up vehicle again.




47/127

ZF error 52


J1587 FMI 8

SPN 171

Error Description Ambient temperature signal is faulty.

Error Recognition Signal outside tolerance. Signal marked as invalid.

System Reaction Last value is maintained.

Troubleshooting

CAN Signal comes from EDC

(OEM)




48/127

ZF error 53

J1587 Error Code 55

J1587 FMI 2

SPN 4161

Error Description Difference between 'cECU_isig' and 'cHpuDriver_isig' above permissible limit

value.

Error Recognition Validation with redundant signal.

System Reaction Note: The error can be rectified at the next workshop stop (servicing date)!

Troubleshooting




If the error occurs very frequently,

replace power pack (electronics incl.valve unit)!


- Start-up of pump

- Ventilation of

transmission



- Position clutch






49/127

ZF error 54


J1587 FMI 8

SPN 4110

Error Description PTO1 engaged signal is faulty.

Error Recognition Exceeding the permitted range of value. Signal is marked as invalid

System Reaction Hold last valid value. While initialisation of the ECU take last valid value from

EEPROM

Pto1 off

Troubleshooting

PTO status can be requested via

Testman!


- PTO switch (ZF)

- PTO - VCU wiring (OEM)

- CAN wiring, might be CAN error, PTO

wired via CAN (OEM)

'PTO is engaged' feedback signal is

issued but not correct!

Testman Pro


- PTO status




50/127

ZF error 55


J1587 FMI 8

SPN 4111

Error Description PTO2 engaged signal is faulty.


System Reaction Hold last valid value. While initialisation of the ECU take last valid value from

EEPROM

Pto2 off

Troubleshooting


Testman!


- PTO feedback switch (ZF)

- PTO - VCU wiring (OEM)

- CAN wiring, might be CAN error, PTO

wired via CAN (OEM)

'PTO is engaged' feedback signal is

issued but not correct!

Testman Pro


- PTO status




51/127

ZF error 56


J1587 FMI 8

SPN 4106

Error Description PTO1 request signal is faulty.


System Reaction Static backup value (no PTO request)

Pto1 off

Troubleshooting


Testman!


- PTO request switch (OEM)

- Request switch wiring to VCU (OEM)

- CAN wiring, might be CAN error, PTO wired via CAN (OEM)

Testman Pro


- PTO status




52/127

ZF error 57


J1587 FMI 8

SPN 4107

Error Description PTO2 request signal is faulty.


System Reaction Static backup value (no PTO request)

Pto2 off

Troubleshooting


Testman!


- PTO request switch (OEM)

- Request switch wiring to VCU (OEM)

- CAN wiring, might be CAN error, PTO wired via CAN (OEM)

Testman Pro


- PTO status




53/127

ZF error 60


J1587 FMI 2

SPN 4104

Error Description Invalid signal from pressure sensor

Error Recognition Exceeding the permitted range or plausibility check of system pressure signal

while movement of clutch or shift actor.

System Reaction Invalid pressure sensor signal: constant backup value for system- and cylinder

pressure, the pump control is switched to substitute function

Deactivate hydraulic pump. Deactivate adaptation touch point of clutch. Shifts



Troubleshooting

Check Pentosin pressure supply

Target pressure: 60 bar - 85 bar

Pressure sensor defective!

Check Pentosin filling!

Lines are tight!

Pump function OK

Replace power pack


Seal / Replace leaking

connections / pipes.


- Start-up of pump

- Ventilation of transmission



- Position clutch


Re-program the software.

Note: Please consult FN!




54/127

ZF error 61

J1587 Error Code 59

J1587 FMI 2

SPN 4101

Error Description Signal shifting position sensor is invalid

Error Recognition Evaluated position is not in the valid range of value

System Reaction Hold last valid value.

Position control for shifting and selecting is deactivated! The automatic shift



Troubleshooting

The error is actually in the sensor.

Check pin connection between transmission connector and shift travel sensor

(E31):

Transmission connector Pin 3 (EL2) to Pin 1 (shift travel sensor signal)

Transmission connector Pin 1 (VMAG2) to Pin 2 (shift travel sensor ground)

NOTE: Check connection for interruption!

Check transmission-end wiring

harness.

Check / Replace transmissionactuator

Sensor resistance: 70 -73 ohm

Failure of one sensor can lead to error messages of both sensors!!!!!!!!!!

Both sensors (select and shift)

OK?

Check / Replace power pack




55/127

ZF error 62

J1587 Error Code 60

J1587 FMI 2

SPN 4102

Error Description Signal slecting position sensor is invalid

Error Recognition Evaluated position is not in the valid range of value

System Reaction Hold last valid value.

Position control for selecting is deactivated! The automatic shift unit is



Troubleshooting

The error is actually in the sensor.

Pin connection transmission connector to travel sensor select (E30)

Pin 6 transmission connector (EL1) to Pin 1 (selector travel sensor signal)

Pin 2 transmission connector (VMGA3) to Pin 2 (selector travel sensor ground)

NOTE:Check connection for interruption!

Check transmission-end wiring

harness.

Check / Replace transmission

actuator

Sensor resistance: 70 -73 ohm

Failure of one sensor can lead to error messages of both sensors!!!!!!!!!!

Both sensors (select and shift)

OK?

Check / Replace power pack




56/127

ZF error 63

J1587 Error Code 58

J1587 FMI 7

SPN 4124

Error Description The gear can`t be disengaged

Error Recognition During a shift it was not possible to disengage the gear, even after several

attempts.

System Reaction If the gear could not be shifted after repeated attempts, the gearbox will remain

in the actual gear. New shift requests will be accepted.



Troubleshooting



If required, repair leakages at connection /

supply lines

Shifts at standstill possible with

diagnosis tester

No

Check transmission actuator NOTE: Please remove the transmission from the

vehicle in order to disassemble the transmissionactuator.

Danger of contaminating the hydraulics!

Other errors in the system, check power packYes


- Transmission shift elements

- Transmission actuator sensors


hydraulics

Remove transmission actuator

from transmission.

Error is possibly a subsequent

error of ZF error 61 or 109

Processing of ZF errors 61 and / or 109




57/127

ZF error 64

J1587 Error Code 59

J1587 FMI 7

SPN 4125

Error Description During a gear shift the right gate couldnt be reached

Error Recognition After correctly finished select operation the wrong gate was detected during

shifting.





Troubleshooting




supply lines

Shifts at standstill (gate shifts)

possible with diagnosis tester.

No

Check transmission actuator

NOTE: Please remove the transmission from the

vehicle in order to disassemble the transmission

actuator.


Other errors in the system, check power pack.Yes





hydraulics


from transmission.




58/127

ZF error 65

J1587 Error Code 59

J1587 FMI 12

SPN 4126

Error Description Gearshift select operation failure

Error Recognition During a gear shift the select operation couldnt be finished correctly despite

repeated attempts

System Reaction If the gear could not be shifted after repeated attempts, the gearbox will remain in

the actual gear. New shift requests will be accepted.



Troubleshooting




supply lines

Shifts at standstill (gate shifts)

possible with diagnosis tester.

No




actuator.







hydraulics


from transmission.

Error possible as subsequent error

of ZF errors 61 / 62 / 107 / 112 /

113.

Processing of ZF errors 61 / 62 /

107 / 112 / 113




59/127

ZF error 66

J1587 Error Code 58

J1587 FMI 14

SPN 4127

Error Description Synchronisiation operation failure

Error Recognition During a gear shift the gear couldnt be synchronized despite repeated attempts

System Reaction If the gear could not be shifted after repeated attempts, the gearbox will remain in

the actual gear. New shift requests will be accepted.



Troubleshooting

Check Pentosin pressure supplyTarget pressure: 60 bar - 85 bar

If required, repair leakages at connection /supply lines


diagnosis tester.

No




actuator.




- Transmission shift elements (synchronizers)


- Transmission actuator hydraulics


from transmission.

Error possible as subsequent error

of ZF errors 61 / 62 / 115 / 116

Processing of ZF errors 61 / 62 /

115 / 116




60/127

ZF error 67

J1587 Error Code 58

J1587 FMI 1

SPN 4128

Error Description Shift in gear operation failure

Error Recognition During a gear shift the gear couldnt be engaged despite repeated attempts





Troubleshooting




supply lines


diagnosis tester.

No


NOTE:Please remove the transmission from the


actuator.







hydraulics


from transmission.




61/127

ZF error 68

J1587 Error Code 52

J1587 FMI 1

SPN 4130

Error Description Fluid (Pentosin) level warning, level too low

Error Recognition Respond of float switch


Note: Error has no influence on roadworthiness and/or driving safety; however, it

should be inspected and/or rectified before driving off. The warning lamp only

lights up when the vehicle comes to a standstill!

Troubleshooting

Check error message with

Testman.

AS Tronic product menu




Warning oil reservoir float switch

Refill Pentosin!

Error still active? Check fluid-level sensor signal

-Transmission connector Pin 7 to connector Pin 2(-)

-Float switch

Wiring/Connector faulty,

replace completely

Replace complete float

switch

Replace power pack



- Start-up of pump

- Ventilation of transmission



- Position clutch



Error still active?




62/127

ZF error 70


J1587 FMI 8

SPN 525

Error Description Signal requested gear is invalid

Error Recognition Exceeding the permitted range of value. Signal is marked as invalid. Signal is

not plausible

System Reaction Hold last valid value!

Shift lock general! Shifting to neutral if vehicle standstill. Inhibit take up (virtual



Troubleshooting

Check central computer OEM




63/127

ZF error 71


J1587 FMI 9

SPN 3181

Error Description Message EEC2 timeout

Error Recognition If the message one parameterizable time has been recorded with errors for a long

time or not at all, a timeout error is set.

System Reaction All reactions of the signals included in this message

ISMA deactivated (calculation of target gear and road resistance). Inhibit take

up (virtual driving pedal = 0). Deactivate ReadyToGo/EasyStart if functions are

on.



Troubleshooting

CAN message EEC2 from EDC The following signals are included in the

message:

- Idler switch

-Kickdown switch

- Accelerator position

- Engine torque reserve

Other CAN errors? Check electronics / CAN wiring

(OEM)

Check EDC / accelerator pedal

(OEM)




64/127


65/127

ZF error 73


J1587 FMI 9

SPN 3182

Error Description Timeout of message cruise control / vehicle speed




ISMA deactivated (calculation of target gear and road resistance).


Troubleshooting

CAN message CcVeh_speed

from EDC

Other CAN errors? Check electronics / CAN wiring(OEM)

Check

(OEM)




66/127

ZF error 74


J1587 FMI 9

SPN 4113

Error Description Eng_Temp timeout





Troubleshooting

CAN message Eng_Temp from

EDC

Check cooling water temperature

(OEM)


(OEM)




67/127

ZF error 75


J1587 FMI 9

SPN 4114

Error Description Message Amb_Cond timeout





Troubleshooting

CAN message Amb_Cond from

EDCOEM


(OEM)




68/127

ZF error 76


J1587 FMI 9

SPN 3211

Error Description Message TC1_FT timeout




Shifts are no longer possible. When vehicle stops, neutral position is

automatically engaged. Inhibit take up (virtual driving pedal = 0)

Note: Error is a danger to roadworthiness and/or driving safety. Immediate stopis required - but observe the traffic conditions!

Troubleshooting

target gear, target driving range,

PTO request via VCU

Other CAN errors?

Check electronics / CAN wiring

(OEM)




69/127

ZF error 77


J1587 FMI 9

SPN 3091

Error Description Message EBC1 timeout





Troubleshooting

The following signals are included in CAN

message EBC1:

- ASC engine intervention

- ASC brake intervention

- ABS intervention:

- EBS brake switch

- Brake pedal position- EBS status red warning light

- ABS / EBS status yellow warning light

The message is generated in the EBS

Check EBS (OEM)


(OEM)




70/127

ZF error 78


J1587 FMI 9

SPN 3199

Error Description Message EBC2 timeout




Adaptation of output ratio (speed, transmission output speed) function are

deactivated!

Troubleshooting

The following signals are included in CAN message

EBC2:

- Average front axle speed

- Speed of left front wheel in relation to average front

axle speed

- Speed of right front wheel in relation to average front

axle speed

- Speed of left rear wheel in relation to average front axle

speed

- Speed of right rear wheel in relation to average front

axle speed

The message is generated in the EBS

Check EBS (OEM)


(OEM)


LKS-T 2008-03



71/127

ZF error 79


J1587 FMI 9

SPN 3210

Error Description Message TCO1 timeout




Adaptation of output ratio (speed, transmission output speed) function are

deactivated!

Troubleshooting

The signal "output speed via tachograph" is

included in the CAN message TCO1.

Message is generated in the tachograph

Check tachograph (OEM)


(OEM)


LKS-T 2008-03



72/127

ZF error 81


J1587 FMI 2

SPN 3059

Error Description Feedback signal PTO 1 plausibility error

Error Recognition If PTO 1 feedback signal is active but PTO 1 output is not active and PTO 1

request is not active, then the feedback signal is considered incorrect.

System Reaction Model-based substitute value

Pto1 off

Troubleshooting


Testman!

Testman Pro


- PTO status

-"PTO switched on" signal

Actual status PTO signals

- Request signal (driver's switch) = 0

- Activate PTO = 0

- PTO active = 1

Actual


- Activate PTO = 1

- PTO active = 1

or Actual


- Activate PTO = 0

- PTO active = 1

or Actual


- Activate PTO = 1

- PTO active = 1

Check PTO and / or Reed switch (switch

faulty, PTO jams mechanically, actually

activated)!

Switch off PTO via switch and / or check

switch (signal active although switched off)signal goes to central computer, check

central computer (OEM).

Probably a software problem, ignition off /

on, error still active = program latest

software, inform FN!




73/127

ZF error 82


J1587 FMI 2

SPN 3060

Error Description Feedback signal PTO 2 plausibility error

Error Recognition If PTO 2 feedback signal is active but PTO 2 output is not active and PTO 2

request is not active, then the feedback signal is considered incorrect.

System Reaction Model-based substitute value

Pto2 off


Troubleshooting


Testman!

Testman Pro


- PTO status

-"PTO switched on" signal

Actualstatus PTO signals


- Activate PTO = 0

- PTO active = 1

Actual


- Activate PTO = 1

- PTO active = 1

or Actual


- Activate PTO = 0

- PTO active = 1

or Actual


- Activate PTO = 1

- PTO active = 1

Check PTO and/or Reed switch (switch

faulty, PTO jams mechanically, actually

activated)!

Switch off PTO via switch and/or check

switch (signal active although switched off)signal goes to central computer, check

central computer (OEM).

Probably a software problem, ignition off/on,

error still active = program latest software,

inform FN!




74/127

ZF error 83


J1587 FMI 9

SPN 3180

Error Description Message EEC1 timeout




Shifts are no longer possible. Functions such as adaptation of contact point, clutch



Troubleshooting


EEC1:

-Engine torque mode

-Torque requested by driver via the accelerator

pedal/cruise control

-Current engine torque in % of reference torque

-Engine speed

-Engine startup mode

The message is generated in the EDC

Check EDC (OEM)


(OEM)




75/127

ZF error 84


J1587 FMI 9

SPN 3111

Error Description Message Time_Date timeout




Troubleshooting

The following signals are included in CAN

message Time_Date:

-second

-minute

-hours

-month

-day

-year

The message is generated in the TCO

(tachograph)

Check tachograph (OEM)


(OEM)




76/127

ZF error 88


J1587 FMI 9

SPN 3026

Error Description Message Engine_Config timeout




Troubleshooting


Engine_Config (static speed curve):

-Engine idle speed item 1

-Engine speed at item 2, 3, ....5

-Nominal engine speed at item 6

-Max. engine excess speed at item 7

-engine cutoff speed

-Max. time limit of engine excess speed

-Engine torque in percent at idle speed item 1

-Engine torque in percent at item 2, 3, ....5

-Reference engine torque

-Requested speed limit max/min

-Requested torque max/min

The message is generated in the EDC

Check EDC (OEM)


(OEM)




77/127

ZF error 89


J1587 FMI 2

SPN 3177

Error Description Bus off vehicle CAN

Error Recognition CAN controller dezect CAN busoff or error warning


Shifts are no longer possible. Functions such as adaptation of contact point,



Troubleshooting

Error in the vehicle CAN

(subsequent errors possible)

Check vehicle wiring

Individual check of other

electronics

-interruption

-short circuit to plus

-short circuit to ground

Replace electronics

concerned

Inspection together with

OEM




78/127

ZF error 90

J1587 Error Code 59

J1587 FMI 2

SPN 4182

Error Description Selected gear cannot be determined

Error Recognition Evaluation of transmission sensors provide an implausible gear together with the

stored transmission geometry.

System Reaction Last value applicable is maintained.

Further shifts are no longer possible! If the vehicle comes to a standstill, the



Troubleshooting

Check travel sensor signal

Start vehicle again!

Signals OK again

Teach in transmission again

(transmission teach-in function)

Signals implausible

Approximate signals!

Travel sensor shift ..... mm

Travel sensor select ..... mm

Replace power pack



- Start-up of pump

- Ventilation of

transmission



- Position clutch



Yes

No

No

Yes

Error is possibly a subsequent

error of ZF error 61Processing of ZF error 61.




79/127

ZF error 91


J1587 FMI 8

SPN 1624

Error Description Vehicle speed from TCO is invalid

Error Recognition Permissible range is exceeded. Signal marked as invalid

System Reaction Maintain last value applicable

Deactivate adapation of ratio rear axle and dynamic tyre radius (relation of

Troubleshooting

OEM Signal from speedometer

(OEM)




80/127

ZF error 92

J1587 Error Code 63

J1587 FMI 8

SPN 4186

Error Description All vehicle speed signals are not available

Error Recognition All redundant sources for vehicle speed are faulty

System Reaction




Troubleshooting

Vehicle speed is generated in

tachograph!

Other tachograph errors also in other

electronics


(OEM)

Check tachograph and / or EDC

(OEM)

Check the following sensors:

-Wheel speed sensors-Output speed sensors




81/127


82/127

ZF error 95


J1587 FMI 2

SPN 4116

Error Description Not all relevant messages can be sent within one ECU cycle (Transmit Queue

Overrun)

Error Recognition Not all messages could be sent in one calculation cycle of the ECU (Transmit

Queue Overrrun).




Troubleshooting

Error in the vehicle CAN

(subsequent errors possible)


Individual check of other

electronics

- interruption

- short circuit to plus

- short circuit to ground

Replace electronics

concerned


OEM




83/127

ZF error 99


J1587 FMI 8

SPN 70

Error Description Parking brake signal is faulty

Error Recognition Signal outside tolerance. Signal is marked as invalid.

System Reaction Constant substitute value parking brake not activated.

Troubleshooting

Check signal path from parking

brake.


OEM.




84/127

ZF error 100


J1587 FMI 5

SPN 4134

Error Description VPHS (Term.30-1) torn off or undervoltage. Pump operation not possible or

restricted. For further supply of valves, you must switch over to Term.30-2 (see

local error reaction).

Error Recognition ECU internal

System Reaction Switchover of ECU supply. Supply takes place via VP (Term.30-2).

The automatic shift unit is deactivated. The hydraulic pump is deactivated.



Troubleshooting


Voltage supply according to

wiring diagram no. 6029 720

001

Supply plus from battery to electronics connection

hydraulics pump Pin 1 VPHS

Check / Replace supply plus fuse F4

Replace / Repair wiring

Inspection together withOEM.


- Start-up of pump

- Ventilation of

transmission



- Position clutch



Replace power pack


If error is not active, it is also

possible that the fuses and/or

connectors were briefly

interrupted during ignition "on"!

Check if possible and/or due to

frequency of errors!




85/127

ZF error 101


J1587 FMI 12

SPN 4135

Error Description VP (Term.30-2) torn off or undervoltage. No impact on function because voltage

is supplied via high-current supply. However, redundant voltage supply is no

longer available.

Error Recognition Comparison of measured voltage with limit value.

System reaction None



Troubleshooting


Voltage supply according to wiring

diagram no. 6029 720 001

Supply plus from battery to electronics connection

hydraulics pump Pin 12 VPE1 and Pin 15 VPE2

Check / Replace supply plus fuse F1



OEM

Replace power pack

If error is not active, it is also

possible that the fuses and/or

connectors were briefly

interrupted during ignition "on"!

Check if possible and / or due to

frequency of errors!




86/127

ZF error 102


J1587 FMI 5

SPN 4136

Error Description VMHS (Term.31-1) torn off or voltage drop too high. ECU supply (incl. valves)

takes place via VM (Term.31-2). The pump operation not possible or restricted.


System Reaction The automatic shift unit is deactivated. The hydraulic pump is deactivated. Shifts



Troubleshooting


Voltage supply according to wiring

diagram no. 6029 720 006Supply ground from battery / accumulator to electronics

connection hydraulic pump Pin 2 VMHS.



OEM

Replace power pack




87/127

ZF error 103


J1587 FMI 5

SPN 3175

Error Description Switch off ignition key (Kl. 15) while driving

Error Recognition Check ignition key (Kl. 15) while driving)

System Reaction Shifts to neutral and setting off gear (reverse/N/1st gear) are possible!

Troubleshooting


Inspection together withOEM

Manual inspection of ignition

lock

Note:Check whether driver consciously

turned off the ignition during operation!

Misuse!




88/127

ZF error 104


J1587 FMI 1

SPN 158

Error Description Supply voltage below bottom limit value.


System Reaction All functions are deactivated. Shifts are blocked during travel. Shifts to neutral



Troubleshooting




001

Check / Replace supply plus/ground and / or wiring

between battery and electronics.

Vehicle voltage target values: 18 V to 29 V

OEM Verkabelung

tauschen / instandsetzen


OEM.

Supply and / or wiring are OK

Check transmission

electronics

NoYes

Check battery!




89/127

ZF error 105


J1587 FMI 0

SPN 158

Error Description Supply voltage exceeds upper limit value.


System Reaction The automatic shift unit is deactivated. Shifts to neutral and setting off gear



Troubleshooting




001

Check / Replace supply plus / ground and/or wiring

between battery and electronics.

Vehicle voltage target values: 18 V to 29 V

OEM replace / repair

wiring


OEM

Supply and / or wiring are OK

Check transmission

electronics

NoYes

Check battery!

OEM: check alternator!




90/127

ZF error 106


J1587 FMI 6

SPN 4138

Error Description Short circuit plus at main cutoff relay 1. This means that the supply of valves

open clutch, clutch close1, select gate 1/2 or reverse gear gate, engaging gears

1/3/5 or gears 2/4/6/R and tact valve cannot be deactivated if the ignition is off

and in case of short circuit to ground of one of these valves.


System Reaction Note: Error that requires immediate stop at a workshop! Great

codigos de falhas zf automatizada

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