Property of American Airlines Overhaul - s3.amazonaws.com · 3-1-1 Orig CD389 Chapter 3 GT110 (24V)...

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Chapter 3GT-110 (24V) Aircraft Tow Tractor Table of Contents

TABLE OF CONTENTSSECTION 1: OVERHAUL DATA................................................................................................. 3-1-1

A. Model GT110 Tow Tractor Overhaul ..................................................................... 3-1-1B. Engine .................................................................................................................. 3-1-1C. Transmission ........................................................................................................ 3-1-6D. Axles ..................................................................................................................... 3-1-6E. Fault Codes For Steering...................................................................................... 3-1-6F. Engine Fault Codes ............................................................................................ 3-1-54G. Transmission Fault Codes .................................................................................. 3-1-59

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Chapter 3Table of Contents GT-110 (24V) Aircraft Tow Tractor

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Chapter 3GT110 (24V) Aircraft Tow Tractor Section 1

SECTION 1: OVERHAUL DATA

A. MODEL GT110 TOW TRACTOR OVERHAUL

(1) The Model GT110 Tow Tractor has many components which must be maintained by a flexibleprogram of preventive maintenance, repair, and overhaul. Overhaul is normally conducted on aperiodic basis or during unscheduled down time. Proper servicing, maintenance,manufacturer's recommendations, and record keeping are important in establishing overhaulperiods.

(2) Tug Technologies Corporation provides periodic maintenance recommendations (Chapter 2,Section 1). Maintenance instructions are also provided in the same section for performingmaintenance on specific components or for performing specific maintenance tasks.Troubleshooting tables (Chapter 2, Section 2), specific to this equipment, have also beenprovided to assist the operator and maintenance personnel in quickly isolating and correctingmost common malfunctions. Removal and installation instructions (Chapter 2, Section 3), areprovided for the removal and installation of the engine and transmission as an assembly.

B. ENGINE

For engine maintenance and overhaul procedures, refer to the Deutz engine manuals located inChapter 5 of this manual. An overhaul of the engine is required at 12,000 hours of operation. Inaddition, an overhaul is necessary if oil consuption is excessive and/or if there is a dramatic loss ofpower.

From the Home Menu, the operator can navigate to the Engine Diagnostics screen by pressing thethird button down on the left hand side. Engine Diagnostics shows the operator inactive fault codesthat have been stored in the engine or transmission electronic controller modules. Upon entering thisscreen the operator is advised to wait while the LCD requests stored inactive fault codes from theengine and transmission electronic controller modules as shown below.

Engine Diagnostics

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Chapter 3Section 1 GT110 (24V) Aircraft Tow Tractor

Figure 3-1. Engine LCD Display Engine Diagnostics

If there are no stored inactive faults codes in either of the engine or transmission electronic controllermodules, the below screen is shown communicating to the operator that there are “NO STOREDFAULT CODES.”

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Figure 3-2. Engine LCD Display "No Stored Fault Codes"

If a stored fault code is found during initial request entering Engine Diagnostics it will be shown in theDiagnostics Message window shown in the figure below.

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Figure 3-3. Engine LCD Display . Inactive Stored Fault Code Display Screen.

If there are multiple stored fault codes, the operator can navigate between the different codes bytoggling the Right, second down and Right, third down buttons which are beside yellow up/downarrows. The Right, fourth down button beside “Get Faults” will initiate the request to pull up storedfault codes again. The Left, fourth down button will navigate the operator back to the Home Menu.The Left, third down button beside “Clear Faults” is a button for service and TUG personnel only.By pressing this button you will be taken to a screen where you are asked to enter a passwordas shown below.

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Figure 3-4. Engine LCD Display . Password Entry Screen.

From the password screen the Top Left and Top Right buttons move from digit to digit in thepassword with the selected digit being underlined. The operator can change the numerical values ofthe password up or down press the Left, second down and the Left, third down buttons. Enter thepassword 1001. Once the desired password has been entered, the operator can press the Left,fourth down button, OK. If the password is correct, the LCD will return to the Engine Diagnosticsscreen showing no stored fault codes. If the password is incorrect, the LCD will again return to theEngine Diagnostics screen still showing all stored inactive fault codes.Pro

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C. TRANSMISSION

A transmission overhaul manual is not included in this publication. A Workshop Manual for ZFTransmission Models 4WG-190/210 is available from ZF or through Tug Technologies Corporation.For Transmission maintenance refer to the ZF transmission Manuals, located in Chapter 5 of thismanual.

D. AXLES

An axle overhaul manual is not included in this publication. An axle overhaul manual for axle modelsPSC-1485-HDB-232-617 can be obtained from Tug Technologies Corporation. For axles maintenancerefer to the Axle Maintenance Manual, located in Chapter 5.

NOTE: Overhaul information, for each component, may be obtaineddirectly from the component manufacturer or by contacting:

TUG Technologies CorporationP.O. Box 3028Kennesaw, GA 30156

Domestic 1-800-989-8499International + 1-770-422-8021Parts Fax: 770-422-8730Warranty Fax: 770-428-7315

Parts: [email protected]

E. FAULT CODES FOR STEERING.

(Will be displayed on the Steering Terminal.)

Alarm List ME Alarm Codes

Table of Contents:

History

1. General1.1 Safety Notes

2. Alarm List2.1 System Alarms (L-Errors)2.2 System Alarms (L-Errors Failop)2.3 Control Unit Alarms (U-Errors)

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History

File Manual_SLC019146_Part4_V0101.doc

01.00 2011-05-09 TH new document based on “Manual_EHLA-Multi_Std_Part 4_V0204.doc”

01.01 2011-08-09 TH added ETC1 fault codes

Version

Subject to technical modifications.

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1 General

The system documentation EHLA® (electro-hydraulic steering system) comprises four parts:

1. System description, installation and maintenance

2. Project specific documentation

3. Commissioning and diagnostics

4. Alarm list

This third part on hand contains the error lists.

For defined characters and abbreviations, see part 1 of the system documentation.

1.1 Safety Notes

Safety note:

Please observe absolutely the safety notes from part 1 of the system documentation.

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2 Alarm list

System alarms that result in functional faults and produce the corresponding fault response may have various causes:

• Electrical faults such as short circuits, cable break or low voltage

• Faults in monitoring the regulation process itself, such as actuating variable, inverse motion, etc.

• Faults from comparing redundant, physical measurements

The alarm codes listed in this document are to be read-out on the display of the steering computer. The alarm codes could be read-out with the diagnostic software “WinPCS” as well and thereby additionally with the alarm code text message.

Alarm codes are separated in “L-Errors” and “U-Errors”.

L errors are codes from the steering system and its components, e.g. valves, electrical signals, CAN messages, …

These alarm codes will be shown in the display of the steering computer as 3 numbers.

These alarm codes can be found in chapter “System Alarms (L errors)”

U errors are faults from the steering computer itself but also could be caused by low voltage, short circuits or similar external events.

These alarm codes will be shown in the display of the steering computer as a single number. In the alarm memory it will be stored with an error location “239” or “240”.

These alarm codes can be found in chapter “Control Unit Alarms (U errors)”

Notes:

1. Some alarm codes are assigned to axles. The indicated axles are the steering computers point of view and are mostly not the same as the vehicle axle numbers. The system schema shows the assignment to the vehicle axles.

2. If there are several steering computers in a vehicle, each could independently indicate an alarm. These alarms have in different steering computers possibly the same code but are addressing different vehicle axles. The system schema shows the assignment between steering computers and the vehicle axles.

3. Finding the right component during trouble shooting is possible with a directed error simulation. By unplugging of one component, an associated alarm code must be indicated on the according steering computer.

Examples:

• „L040-002-01“ (Transducer rear axle 1 track1, cable break), on a 4-axle vehicle with one steering computer: The alarm points to a cable break on an angle transducer of the first controlled axle. At this vehicle type it could be the vehicle axle 3, according to the system schema.

• „L095-023-01“ (rear axle 1, locking state implausible), on a 5-axle vehicle with two steering computers, the second steering computer indicates the alarm: This alarm points to a hydraulic problem of the axle valves on the first controlled axle of the second steering computer. At this vehicle type it could be the vehicle axle 5, according to the system schema.

error U 107

emergency stop

alarm code

004-006-00

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2.1 System Alarms (L-Errors)

Alarms with causes to be found in peripheral devices, e.g. errors in the wiring, failure of sensors or hydraulic problems are known as L-Errors.

To simplify the process of determining the causes of errors, alarm codes are divided into location, type and priority.

An alarm is denoted by the alarm location and alarm type:

• Alarm location : E.g. Angle transducer track 1 of rear axle 1, pressure sensor, ...

• Alarm type : E.g. Cable break, maximum value exceeded, ...

The priority determines the reaction of the steering system to an alarm:

• Priority 0: Warning, the steering characteristics are not affected.

• Priority 1: Move the axle to the next straight position.

• Priority 2: Automatic steer to the straight position.

• Priority 3: Safety-based shut-down to a safe status

The underlying safety strategy in place for this is explained in part 2 of the system documentation.

Structure of the alarm table:

Alarm code Description

aaa - bbb – pp Alarm location aaa Alarm type bbb

aaa - ccc – pp Alarm location aaa Alarm type ccc

Explanations, notes

Alarm type bbb Description

Alarm type ccc Description

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005 - 002 - 00 Digital output 1 (DA1) Cable break


005 - 003 - 00 Digital output 1 (DA1) Short circuit


005 - 005 - 03 Digital output 1 (DA1) Parameter programming

005 - 012 - 00 Digital outputs > max. value






006 - 019 - 02 Digital output 2 (DA2) Deviation











008 - 019 - 02 Digital output 4 (DA4) Deviation


















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Explanations, notes

Cable break A cable break was detected on the corresponding output. Please check the wiring!

Hints for troubleshooting:

• The individual valve coils can be checked via resistance measurement on the relevant terminals on the plug connector with the plug removed: Switching valves typically have approx. 15 to 30 Ohm coil resistance.

• If multiple outputs are issuing a cable break fault, this suggests an interrupted, common return line.

• If no problem is detected via the resistance measurement, it may be that the size of the common return line is too small.

Short circuit A short circuit was detected on the corresponding output. Check the wiring!


• The type of short circuit can be determined using resistance and voltage measurement on the relevant terminals with the control unplugged. Short circuits to earth or to +24V are possible.

• There must not be any voltage greater than 3V on the output terminals!

Parameter prog Internal computer configuration error

> max. value Internal computer configuration error

Deviation A cable break was detected on parallel connected check valves.


020 - 002 - 02 PWM1 Cable break


020 - 003 - 03 PWM1 Short circuit

020 - 005 - 00 PWM1 Parameter programming
















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Explanations, notes

Cable break A cable break was detected on the corresponding output. Check wiring!


• The individual valve coils can be checked via resistance measurement on the relevant terminals with the plug removed: Proportional-flow valves (9V coils) typically have approx. 2.0 to 3.5 Ohm coil resistance



Short circuit Short circuit on the corresponding output. Check the wiring!





Plausibility The initialisation is not correct, review parameters

Parameter prog Internal computer configuration error

Deviation The PWM current could not be set to the intended value due to supply voltage or solenoid resistance.


030 - 002 - 00 Power supply Cable break

030 - 006 - 00 Power supply Timeout

030 - 009 - 03 Power supply Level

030 - 010 - 00 Power supply 5V reference

030 - 011 - 00 Power supply 5V external

030 - 031 - 00 Power supply Speed > 0

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Explanations, notes

Cable break There is no power supply of the steering computer from terminal 15 (ignition). The input signal cannot be read. The signal "Fuse_ignition" must be continually active in normal mode. Check fuse.

Timeout Power supply could not switched off, power hold relay still active.

Level Power supply in range of undervoltage while vehicle is running faster than 2 km/h.

5V reference The reference voltage is outside the permissible range! Check the wiring in the area of the connected angle transducer and the pressure sensors! There may be a short circuit.


• The 5V reference supplies the angle transducers and the pressure sensors. With the control plugged in, measure the voltage (see wiring diagram); it should be 5V. If there are any deviations, the connected angle transducers and sensors should be terminated briefly in sequence to find the faulty connection. The shielding on the connected sensors should also be checked.

5V external The supply voltage "5V external" is outside the permissible range! Check the wiring in the area of the connected angle transducer and the pressure sensors! There may be a short circuit.


• The 5V reference supplies the angle transducers and the pressure sensors. With the control plugged in, measure the voltage (see wiring diagram); it should be 5V. If there are any deviations, the connected angle transducers and sensors should be terminated briefly in sequence to find the faulty connection. The shielding on the connected sensors should also be checked.

Speed > 0 The power supply has been switched on at a speed greater than 10 km/h. The power supply may not be reliable, check the cable!


• There may be a loose contact in the power supply. Has the vehicle been towed?


031 - 005 - 01 Parameter Parameter programming

031 - 019 - 00 Parameter Deviation

031 - 019 - 01 Parameter Deviation

Explanations, notes

Parameter prog Incorrect values in the parameter range, the standard value has been used instead of the programmed value. Remedy: Correct the parameter shown on the display.

Deviation The parameters do not match the approved configuration. The approval number should be entered in P_33. The steering system can be operated for 5 minutes after switching on (L031-019-00), after that the steering system is shut down (L031-019-01).

Remedy:

• Load approved parameter set using WinPCS.

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032 - 002 - 01 Steering pressure sensor Cable break

032 - 004 - 00 Steering pressure sensor Plausibility

Explanations, notes

Cable break The pressure sensor is not issuing a signal. Check the wiring! With the control unit connected, measure the voltage on the pressure sensor or read the voltage using the WinPCS. The voltage should be between 0.5V and 4.5V.

Plausibility The pressure sensor is not sending a signal. The sensor might be an analogue or a CAN sensor.

This error is only available in Failop systems.

Remedy:

Check the sensor values using WinPCS.


033 - 002 - 00 Pressure supply Cable break

033 - 004 - 00 Pressure supply Plausibility

033 - 005 - 03 Pressure supply Parameter programming

033 - 006 - 02 Pressure supply Timeout

033 - 009 - 00 Pressure supply Level

033 - 026 - 02 Pressure supply Pressure build-up

033 - 045 - 00 Pressure supply Maintenance

033 - 047 - 00 Pressure supply signal error

Explanations, notes

Cable break The oil flow switch of this steering circuit is active but the motor is not running.

This error is only available in failop systems.


• Check the signal of the switch and the motor rpm

• If the switch is connected to ground a broken cable might be the cause

signal error The oil flow switch of this steering circuit is not active but the motor is running.

This error is only available in failop systems.


• Check the signal of the switch and the motor rpm

• If the switch is connected to ground a broken cable might be the cause

Plausibility The pressure was built up faster than time defined in P_92 (and P_93).


• Check the pressure accumulators.

Parameter prog The parameterization of the pressure supply in P_80 is incorrect.

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Timeout The pressure could not be built up within the time in P_91 during system operation.


• Check the pressure supply, pump, pressure sensor.

Level Cable break or low oil in the steering oil tank.


• Check the oil level. The input is at +Ub during normal operation.

Pressure build-up The pressure could not be built up within the time in P_91 after starting the system.


• Check the pressure supply, pump, pressure sensor.

Maintenance The pressure filter is blocked, the electric monitoring has failed.


• Check the status of the oil filter. The input is at +Ub during normal operation.


034 – 031 – 01 Generator signal Speed > 0

Explanations, notes

Speed > 0 Vehicle is moving (>20km/h) and the generator signal is not active (motor is off).


• Check the wiring.


035 - 012 - 00 Hydraulic Steering Accumulator > max. value

035 - 013 - 03 Hydraulic Steering Accumulator < min. value

035 - 026 - 02 Hydraulic Steering Accumulator Pressure build-up

Explanations, notes

> max. value Pressure inside the steering accumulator higher than defined in P_90.

< min. value Pressure inside the steering accumulator lower than defined in P_89.

Pressure build-up The pressure could not be built up within the time in P_91 after starting the system.


036 - 002 - 00 Redundant power supply Cable break

036 - 004 - 00 Redundant power supply Plausibility

Explanations, notes

Cable break Power supply for steering computer from clamp 91 (generator) not available even though engine is running. Input signal not available. Signal „Fuse_Generator“ must be active while engine running in normal operation. Check fuse.

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Plausibility Power supply for steering computer from clamp 91 (generator) not plausible. Signal „Fuse_Generator“ active even thoug engine not running. Short circuit supposed.

Hints for troubleshooting :

• First of all signal „Fuse_Ignition“ must be active. Engine may be started and signal „Fuse_Generator“ active only after 1 second.


037 – 002 – 00 Power supply – power hold Cable break

037 – 004 – 00 Power supply – power hold Plausibility

Explanations, notes

Cable break Signal “steady plus“ from battery not available. Power hold relay or fuse defective.

Plausibility Power hold after turning off the ignition did not work.


• Power hold relay defective


038 - 004 - 00 Wheel pump Plausibility

Explanations, notes

Plausibility Signal from the wheel pump absent while vehicle is running.


039 – 004 – 00 Offroad switch Plausibility

Explanations, notes

Plausibility Different states of the offroad switch in a master-slave-system.


040 - 002 - 01 Angle transducer rear axle 1 track 1 Cable break

040 - 003 - 02 Angle transducer rear axle 1 track 1 Short circuit


040 - 005 - 03 Angle transducer rear axle 1 track 1 Parameter programming

040 - 007 - 02 Angle transducer rear axle 1 track 1 Signal failure


040 - 017 - 02 Angle transducer rear axle 1 track 1 Total for track 1 / 2


040 - 018 - 02 Angle transducer rear axle 1 track 1 Differential for track 1 / 2


Explanations, notes

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Cable break The slider voltage is in the cable break area. Check the cabling to this angle transducer.


• The angle transducer may not be supplied with power or has moved out of position too far. A cable break on the power supply is possible too. Use the PC service software to measure the voltage on the corresponding analogue input.

• Voltage > 4.8 V:

- Short circuit of the slider to 24 V.

- Angle transducer too far out of position?

- Cable break of the ground signal

• Voltage < 0.2 V:

- Short circuit of the slider to ground or against vehicle mass

- Cable break between slider and angle transducer.

- Cable break between power supply and angle transducer.


• Potentiometric transducers “530 xxx”: For precise localization, measure the following resistances with the steering computer unplugged:

- Between terminal +5V-Ref and ground. As min. 2 tracks are connected in each case, approx. 1000 Ohm (750 – 1250 Ohm) should be measured. In the event of deviations, there is a cable break / short circuit of the output "5V-Ref." or of "0V-Signal".

Short circuit Short circuit between the two angle transducer tracks. Check the cabling to this angle transducer.

Parameter prog Parameter P_64 programmed incorrectly.

Signal failure Both signals of the angle transducer are instable or erroneous. This occurs in conjunction with other errors at this angle transducer.


• The other errors give more detailed information about the kind of the signal failures.

• Observe the signal voltages and check them for irregularities.

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Total for track 1 / 2 Total of slider voltages is implausible. The second angle transducer track may have reversed supply voltage connections. Error priority 02 for setpoint value sensors, 03 for axles


• For vehicles in use: The angle transducer may be damaged or there may be a wiring problem. Check the linearity of the angle transducer voltages. If there is currently no obvious problem with the angle transducer, check bearings of the sensor, cable, connectors and crimp-connections.

• If the bearing of the angle transducer is damaged, check if there is a problem with the linkage when replacing the angle transducer.

• During commissioning: Display the angle transducer voltages with the WinPCS. When steering the main pivot from the left limit stop to the right limit stop, the voltage on track 1 on the relevant angle transducer should increase. With the correct voltage curve on track 1 (increase in voltage when turning to the right), track 2 of the angle transducer is being powered incorrectly, with the incorrect voltage curve (decreasing voltage when turning to the right), track 1 of the angle transducer is being power incorrectly. On the relevant rack, swap the cables to the pins for powering the relevant track.

Differential for track 1/2 The angle determined between track 1 and 2 deviate by more than the value programmed in parameter P_67. Error priority 02 for setpoint value sensors, 03 for axles


• Alignment is to be done after replacing an angle transducer or steering computer!

• For vehicles in use: proceed as followed described:

• Check the cable of the angle transducer on strand break due to undershooting the minimum bending radius.

• Check the connectors of the angle transducer on marks of moisture, save locking, pull relief and standard conforming Crimp connections.

• Check the connector of the steering computer

• Check the connection of the shielding of the angle transducer.

• During commissioning:

• The angle transducer also needs to be calibrated




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Cable break The slider voltage is in the cable break area. Check the cabling to this angle transducer. Error priority 01 as single error, error priority 02 or 03 with error combinations


• The angle transducer may not be supplied with power or has moved out of position too far. A cable break of the power supply is possible too. Use the PC service software to measure the voltage on the relevant analogue input.

• Voltage > 4.8 V:

- Short circuit of the slider to 24 V.


- Cable break of the ground signal

• Voltage < 0.2 V:

- Short circuit between slider to ground or vehicle mass

- Cable break between slider and angle transducer.

- Cable break between power supply and angle transducer.


• Potentiometric transducers “530 xxx”: For precise localisation, terminate the supply line "5V-ext" to the angle transducer and measure the following resistances with the control unplugged: Between terminal J2.11 and the terminated supply line. A value of approx. 2000 Ohm should be measured. In the event of deviations, there is a cable break / short circuit of the output "5V-ext." or of "0V-Signal".

Short circuit Short circuit between the two angle transducer tracks. Check the cabling to this angle transducer.





042 - 005 - 03 Angle transducer rear axle 2 track 1 Parameter programming







Explanations, notes

Cable break see L040-002-01

Short circuit see L040-003-02 and L040-003-03

Parameter prog see L040-005-03

Signal failure see L040-007-02 and L040-007-03

Total for track 1 / 2 see L040-017-02 and L040-017-03

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Differential for track 1 / 2 see L040-018-02 and L040-018-03




Explanations, notes

Cable break see L041-002-01 and L041-002-02 and L041-002-03

Short circuit see L041-003-03

5V external see L041-011-01


044 - 002 - 01 Angle transducer front axle 1 track 1 Cable break

044 - 003 - 02 Angle transducer front axle 1 track 1 Short circuit

044 - 003 - 03 Angle transducer front axle 1 track 1 Short circuit

044 - 005 - 03 Angle transducer front axle 1 track 1 Parameter programming

044 - 007 - 02 Angle transducer front axle 1 track 1 Signal failure

044 - 007 - 03 Angle transducer front axle 1 track 1 Signal failure

044 - 017 - 02 Angle transducer front axle 1 track 1 Total for track 1 / 2

044 - 017 - 03 Angle transducer front axle 1 track 1 Total for track 1 / 2

044 - 018 - 02 Angle transducer front axle 1 track 1 Differential for track 1 / 2

044 - 018 - 03 Angle transducer front axle 1 track 1 Differential for track 1 / 2

Explanations, notes

Cable break see L040-002-01

Short circuit see L040-003-02 and L040-003-03

Parameter prog see L040-005-03

Signal failure see L040-007-02 and L040-007-03

Total for track 1 / 2 see L040-017-02 and L040-017-03

Differential for track 1 / 2 see L040-018-02 and L040-018-03


045 – 002 – 01 Angle transducer front axle 1 track 2 Cable break

045 – 003 – 03 Angle transducer front axle 1 track 2 Short circuit

Explanations, notes

Cable break see L041-002-01 and L041-002-02 and L041-002-03

Short circuit see L041-003-03

5V external see L041-011-01


052 - 005 - 03 Speed 1 Parameter programming

052 - 006 - 00 Speed 1 Timeout


052 - 016 - 00 Speed 1 Drift

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052 - 018 - 00 Speed 1 Differential

052 - 018 - 01 Speed 1 Differential

052 - 047 - 00 Speed 1 Signal failure

052 - 047 - 01 Speed 1 Signal failure

Explanations, notes

Parameter prog Parameter for speed selection incorrectly programmed.


• Check parameters P_73, P_77 and P_78

Timeout The speed signal from the CAN cannot be received.


• Check the devices providing the speed values (ABS control unit, tachometer)

Drift This signal faulty while two other speed signals are still available

Differential The differential between speeds 1 and 2 is greater than specified (P_74). One of the speed signals may have failed.


• Check the speeds in a test drive. Has the speedometer been re-calibrated (unwound)? Have tyres with a different diameter been used? Adjust the WIZ2 (P_78).

• With proximity initiators: Is the gap between the initiator and metallic trigger correct?

Signal failure All speed signals lost. The speed measurement is not possible any more.

• If all speed signals are received via CAN-Bus: check the CAN-Bus.

• Check the signal generating devices, the signal cables and their connectors.




053 - 016 - 00 Speed 2 Drift

Explanations, notes




Drift This signal is faulty, two other speed signals still available.


054 – 006 – 00 Speed 3 Timeout

054 – 006 – 01 Speed 3 Timeout

054 – 016 – 01 Speed 3 Drift

Explanations, notes

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Drift This signal is faulty, two other speed signals still available.


055 - 004 - 00 Steering angle monitoring, rear axle 1 Plausibility

055 - 005 - 00 Steering angle monitoring, rear axle 1 Parameter programming

055 - 006 - 03 Steering angle monitoring, rear axle 1 Timeout

055 - 019 - 00 Steering angle monitoring, rear axle 1 Deviation



055 - 030 - 00 Steering angle monitoring, rear axle 1 Inverse movement


055 - 041 - 00 Steering angle monitoring, rear axle 1 Factor



055 - 047 - 00 Steering angle monitoring, rear axle 1 Self-monitoring error

056 - 004 - 00 Steering angle monitoring, rear axle 2 Plausibility

056 - 005 - 00 Steering angle monitoring, rear axle 2 Parameter programming

056 - 006 - 03 Steering angle monitoring, rear axle 2 Timeout









056 - 047 - 00 Steering angle monitoring, rear axle 2 Self-monitoring error

Explanations, notes

Plausibility Steering angle monitoring does not match the type of axle. Check the parameterization.

Parameter prog One of the parameters of the steering tolerance monitoring system has been programmed without authorization.

Timeout Axle could not be centered in the space of a minute in case of an error.

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Deviation The actuating variable of the axles has been exceeded for longer than in P_97. The axle could not be positioned properly. The permissible actuating variable also depends on the vehicle speed.


• Are excessive steering forces occurring?

• Is the oil supply sufficient?

• Is the axle blocked?

Inverse movement Axle is moving in the opposite direction to the intended direction.


• Commissioning: Is the direction of the rotation of the angle transducer and the prop. valve correctly connected all around?

• Vehicles in use: Is the prop value slide terminated? Is the angle transducer connected without any wobbling?

Factor The actuating variable of the axles has been exceeded by more than one factor (P_106). The axle will be shut down immediately. The permissible actuating variable also depends on the vehicle speed.


• Are excessive steering forces occurring?

Is the oil supply sufficient?

Self-monitoring error Steering angle monitoring doesn't match the kind of axle reaction.

Hints for troubleshooting

• Check the parameterization.


059 – 004 – 00 Tag axle Plausibility

Explanations, notes

Plausibility Pressure supply for tag axle not available while vehicle is running.


060 - 004 - 03 Adjustment of angle transducer rear axle 1 track 1 Plausibility

060 - 019 - 03 Adjustment of angle transducer rear axle 1 track 1 Deviation

060 - 031 - 00 Adjustment of angle transducer rear axle 1 track 1 Speed > 0

060 - 042 - 00 Adjustment of angle transducer rear axle 1 track 1 0° - adjustment


060 - 043 - 00 Adjustment of angle transducer rear axle 1 track 1 Left adjustment


060 - 044 - 00 Adjustment of angle transducer rear axle 1 track 1 Right adjustment


Explanations, notes

Plausibility The adjustment values of the angle transducer are not completely saved or incorrectly saved.


• Re-adjust the axle!

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Deviation The adjustment values of the angle transducers are not the same in both part computers when using AK5-ECUs.

Speed > 0 In adjustment mode, a vehicle speed greater than 10km/h has been determined.


• Has the speed been measured correctly?

0° - adjustment The saved 0° adjustment value is outside the permissible tolerance of 2350mV to 2650mV.


• The 0° position of the angle transducer must be re-adjusted.

Left adjustment The saved adjustment value of the left-hand limit stop is outside the permissible tolerance.


• The angle transducer needs to be re-calibrated. The voltage on the left-hand limit stop should be smaller than 2000mV. The angle transducer link may need to be adjusted.

Right adjustment The saved adjustment value of the left-hand limit stop is outside the permissible tolerance.


• The angle transducer needs to be re-calibrated. The voltage on the left-hand limit stop should be greater than 3000mV. The angle transducer link may need to be adjusted.








Explanations, notes

Plausibility Adjustment of the angle transducer are not completely saved or incorrectly saved.


• Re-adjust the axle!

0° - adjustment The saved 0° adjustment value is outside the permissible tolerance of 2350mV to 2650mV.


• The 0° position of the angle transducer must be re-adjusted.

Left adjustment The saved adjustment value of the left-hand limit stop is outside the permissible tolerance.


• The angle transducer needs to be re-calibrated The angle transducer link may need to be adjusted.

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Right adjustment The saved adjustment value of the left-hand limit stop is outside the permissible tolerance.


• The angle transducer needs to be re-calibrated The angle transducer link may need to be adjusted.


062 – 004 – 03 Adjustment of angle transducer rear axle 2 track 1 Plausibility

062 – 042 – 00 Adjustment of angle transducer rear axle 2 track 1 0° - adjustment

062 – 042 – 03 Adjustment of angle transducer rear axle 2 track 1 0° - adjustment

062 – 043 – 00 Adjustment of angle transducer rear axle 2 track 1 Left adjustment

062 – 043 – 03 Adjustment of angle transducer rear axle 2 track 1 Left adjustment

062 – 044 – 00 Adjustment of angle transducer rear axle 2 track 1 Right adjustment

062 – 044 – 03 Adjustment of angle transducer rear axle 2 track 1 Right adjustment

Explanations, notes

Plausibility see L060-004-03

Speed > 0 see L060-031-00

0° - adjustment see L060-042-00 and L060-042-03

Left adjustment see L060-043-00 and L060-043-03

Right adjustment see L060-044-00 and L060-044-03








Explanations, notes






064 - 004 - 03 Adjustment of angle transducer front axle1 track 1 Plausibility

064 - 042 - 00 Adjustment of angle transducer front axle1 track 1 0° - adjustment

064 - 042 - 03 Adjustment of angle transducer front axle1 track 1 0° - adjustment

064 - 043 - 00 Adjustment of angle transducer front axle1 track 1 Left adjustment

064 - 043 - 03 Adjustment of angle transducer front axle1 track 1 Left adjustment

064 - 044 - 00 Adjustment of angle transducer front axle1 track 1 Right adjustment

064 - 044 - 03 Adjustment of angle transducer front axle1 track 1 Right adjustment

Explanations, notes

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Speed > 0 see L060-031-03

0° - adjustment see L060-042-03

Left adjustment see L060-043-03

Right adjustment see L060-044-03


065 – 042 – 00 Adjustment of angle transducer front axle1 track 2 0° - adjustment

065 – 042 – 03 Adjustment of angle transducer front axle1 track 2 0° - adjustment

065 – 043 – 00 Adjustment of angle transducer front axle1 track 2 Left adjustment

065 – 043 – 03 Adjustment of angle transducer front axle1 track 2 Left adjustment

065 – 044 – 00 Adjustment of angle transducer front axle1 track 2 Right adjustment

065 – 044 – 03 Adjustment of angle transducer front axle1 track 2 Right adjustment

Explanations, notes






074 - 021 - 03 software Locking cycle

074 - 046 - 00 software Overload

074 - 050 - 00 software Wrong signature E²Prom

Explanations, notes

Locking cycle For commissioning purposes only by MOBIL ELEKTRONIK.

Overload For commissioning purposes only by MOBIL ELEKTRONIK.

Wrong signature E²Prom For commissioning purposes only by MOBIL ELEKTRONIK.


075 – 012 – 00 CAN link > max. value

Explanations, notes

> max. value The CAN messages cannot be processed. Too many messages have been configured.


• Check the configuration of the CAN messages.


076 - 004 - 00 Control console Plausibility

076 - 006 - 00 Control console Timeout

Explanations, notes

Plausibility The sequences of CAN communication with the control console are not correct. No more signals will be accepted form this console.

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Timeout The CAN connection from this ECU to the control console is lost.


• Check wiring and fuses.


077 – 004 – 03 Axle configuration Plausibility

077 – 005 – 03 Axle configuration Parameter programming

Explanations, notes

Plausibility At least one parameter between P_49 and P_50 programmed incorrectly.

Parameter prog At least one parameter between P_224 and P_228 programmed incorrectly.


078 - 005 - 00 Steering suppression Parameter programming

Explanations, notes

Parameter prog Parameter P_25 programmed incorrectly.


• Check the configuration of the steering suppression.


079 – 005 – 00 Steering angle reduction Parameter programming

Explanations, notes

Parameter prog Parameter P_120 or P_121 programmed incorrectly.


• Check the configuration of the steering angle reduction.


080 - 005 - 00 Global setpoint value ramp Parameter programming

Explanations, notes

Parameter prog At least one of the parameters P_443 to P_445 is programmed incorrectly.


• Check the configuration of the setpoint value ramp.


081 - 009 - 00 Fuse monitoring Level

Explanations, notes

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Level The digital input is not active.


• Check the redundant fuse (3 Ampere) of the error signal lamp or the wiring.


083 – 004 – 00 Steering program buttons Plausibility

083 – 005 – 00 Steering program buttons Parameter programming

Explanations, notes

Plausibility The operating elements for the steering program selection are not activated correctly. No more activations will be accepted.


• Is a button stuck or is there a short circuit on the inputs?

Parameter prog Parameters P_112 and P_128 are programmed incorrectly.


• Check the values


084 - 004 - 00 Steering line reduction Plausibility

084 - 005 - 00 Steering line reduction Parameter programming

084 - 021 - 00 Steering line reduction Locking cycle

Explanations, notes

Plausibility Parameter P_14 or P_15 programmed incorrectly. End of steering line reduction smaller than beginning.




Locking cycle The axle could not be locked after completing the steering line reduction process. The steering program "tight curve" should be ended automatically, but the axle could not be locked.


085 – 005 – 00 Bus stop automated system Parameter programming

Explanations, notes





086 - 004 - 00 Speed limitation Plausibility

086 - 045 - 02 Speed limitation Maintenance

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Explanations, notes

Plausibility The vehicle speed should be limited but the speed measured exceeded 30km/h.


• Check the vehicle behaviour and wiring

Maintenance Parameter P_160 or P_183 programmed incorrectly. No digital output for speed limitation set.




087 – 004 – 00 CAN master Plausibility

087 – 006 – 00 CAN master Timeout

087 – 018 – 00 CAN master Differential

Explanations, notes

Plausibility Parameter P_043 or P_044 programmed incorrectly. No slaves defined.



Timeout The CAN link for this control unit to the main control (SLC master) is broken.



Differential The positions of the angle transducers on the front axles on both steering circuits differ too greatly.


• Check the angle measured.

• Adjust the front axles again.


088 - 006 - 00 CAN slave 1 Timeout

088 - 018 - 00 CAN slave 1 Differential

088 - 047 - 00 CAN slave 1 Inoperative

089 - 005 - 00 CAN slave 2 Parameter programming

089 - 006 - 00 CAN slave 2 Timeout

089 - 018 - 00 CAN slave 2 Differential

089 - 047 - 00 CAN slave 2 Inoperative

Explanations, notes

Parameter programming Parameter P_043 programmed incorrectly. More than two slaves defined.

Timeout The CAN link for this control unit to the other control (SLC slave) is broken.



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Differential The positions of the angle transducers on the front axles on the steering circuits differ too greatly.


• Check the angle measured.

• Adjust the front axles again.

Inoperative The other control (SLC slave) is not working any more. It has an error.


• Check the functions on the other computer. It may be possible to operate the steering in a limited way.


090 - 004 - 03 Axle blocking / locking, rear axle 1 Plausibility

090 - 016 - 00 Axle blocking / locking, rear axle 1 Drift


090 - 021 - 00 Axle blocking / locking, rear axle 1 Locking cycle

090 - 022 - 00 Axle blocking / locking, rear axle 1 Unlocking cycle

090 - 023 - 00 Axle blocking / locking, rear axle 1 Locking implausible


090 - 024 - 00 Axle blocking / locking, rear axle 1 Unlocking implausible


091 - 004 - 03 Axle blocking / locking, rear axle 2 Plausibility



091 - 021 - 00 Axle blocking / locking, rear axle 2 Locking cycle

091 - 022 - 00 Axle blocking / locking, rear axle 2 Unlocking cycle





Explanations, notes

Plausibility Undefined status of the axle block / locking


• Replace the software. Pro

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Drift Deviation from the locking position or locking not possible; actual angle is greater than 0°. The permissible deviation is specified in P_94.


• The locked axle has moved out of the 0° position or it does not fully move to the 0° position for locking.

• During the initial commissioning process: Adjust the axle.

• For vehicles in use: Check that the angle transducer link is not loose. In a test drive, observe the actual angle of the axle. It should not move more than 0.5°. Is it possible that the axles are twisting, especially when driving around a corner? Does the angle change when they are compressed?

Locking cycle For axles with mech. locking only: The axle could not be locked when the locking cycle elapsed.


• Check the cylinder switch on the mechanical locking system!

Unlocking cycle For axles with mech. locking only: The axle could not be unlocked when the unlocking cycle elapsed.


• Check the cylinder switch and compressed air!

Locking implausible For axles with mech. locking only: The cylinder switches for the locked axle are not in the correct position.


• Check the cylinder switches!

Unlocking implausible For axles with mech. locking only: The cylinder switches for the unlocked axle are not in the correct position.


• Check the cylinder switch / compressed air!


095 – 019 – 00 Actuator test, rear axle 1 Deviation

095 – 021 – 02 Actuator test, rear axle 1 Locking cycle failed

095 – 023 – 00 Actuator test, rear axle 1 Locking implausible


095 – 026 – 02 Actuator test, rear axle 1 Pressure build-up

095 – 027 – 02 Actuator test, rear axle 1 Pressure reduction

095 – 031 – 00 Actuator test, rear axle 1 Speed > 0



095 – 231 – 02 Actuator test, rear axle 1 Bypass

095 – 232 – 03 Actuator test, rear axle 1 Neutral

095 – 234 – 03 Actuator test, rear axle 1 Left

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095 – 235 – 03 Actuator test, rear axle 1 Right

095 – 236 – 02 Actuator test, rear axle 1 Locking position

096 – 019 – 00 Actuator test, rear axle 2 Deviation

096 – 021 – 02 Actuator test, rear axle 2 Locking cycle failed



096 – 026 – 02 Actuator test, rear axle 2 Pressure build-up

096 – 027 – 02 Actuator test, rear axle 2 Pressure reduction




096 – 231 – 02 Actuator test, rear axle 2 Bypass

096 – 232 – 03 Actuator test, rear axle 2 Neutral

096 – 234 – 03 Actuator test, rear axle 2 Left

096 – 235 – 03 Actuator test, rear axle 2 Right

096 – 236 – 02 Actuator test, rear axle 2 Locking position

Explanations, notes

Deviation The axle is not straight.

Locking cycle failed The test of the centring action has failed, the centring pressure has collapsed in the process (< 50bar).


• It may be that there is a leak in the centring circuit or an faulty hydraulic accumulator.

Locking implausible Test of the axle locking/emergency shut down failed. The axle is still moveable without actuated valves.

Reservoir empty again (> 12 x) when switching on the steering system.


• Locking axle, trailing axle: Impossible to activate the fail-safe-state. Axle moving during the actuator test even though the locking valve or bypass valve is switched off. Locking valve or bypass valve defective.

• Centering axle: Possible oil lack in the centering circuit.

Pressure build-up The test of the pressure build-up being prepared in the centring part to check the seal, has failed.


• It may be that the filling valve is not working or the signal “Motor running” (filling check or motor speed) is incorrect.

Pressure reduction The test for the pressure reduction being prepared has failed.


• It may be that the bleeder valve and/or centring valve are not opening.

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Speed > 0 The vehicle speed determined was greater than 0 km/h during the actuator test. The actuator test has been cancelled.


• Start driving before the actuator test is complete.

• With a stationary vehicle: Check the speed signals.

Bypass The test for the functioning of the bypass valve in the neutral position has failed.


• Monitor the steering pressure, the pressure must not increase in the switched-off status when the proportional-flow valve is activated manually, and the axle must not move.

Neutral The test for the functioning of the neutral position of the proportional-flow valve has failed.


• All valves except for the bypass valve are switched off, there may be a leak in the neutral position of the proportional-flow valve, or the proportional-flow valve slider may be stuck in out of position.

Left The test for a functional steering circuit in the left-hand direction has failed.


• The axle control circuit is not functioning hydraulically on the left-hand side, check the hydraulics and the proportional-flow valve

Right The test for a functional steering circuit in the right-hand direction has failed.


• The axle control circuit is not functioning hydraulically on the right-hand side, check the hydraulics and the proportional-flow valve

Locking position The axle has deviated by more than specified in P_110 when testing the locking position.


• There may be air in the centring circuit.


099 - 002 - 00 Lowside switch Cable break

099 - 003 - 00 Lowside switch Short circuit

099 - 004 - 00 Lowside switch Plausibility

099 - 045 - 00 Lowside switch Maintenance

Explanations, notes

Cable break No current measurable even though the low side switch is on. Maybe no valve connected.

Short circuit Current measurable even though the lowside switch is off (AK4).

Plausibility The digital outputs and their internal feedback are different.


• Check for wrong wiring.

Maintenance Current measurable even though the lowside switch is off (AK5).

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100 - 005 - 03 Digital input DE1 Parameter programming

100 - 012 - 00 Digital inputs > max. value

100 - 012 - 03 Digital inputs > max. value
















Explanations, notes

Parameter prog Internal computer configuration error.


• Rectify the error in the parameter set.

> max. value Internal computer configuration error.




120 – 003 – 03 Analogue input AE1 Short circuit






Explanations, notes

Short circuit Short circuit between the analogue inputs.


• Check the wiring of the specified inputs!

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130 - 002 - 00 Proportional valve ‘A’ rear axle 1 Cable break


130 - 003 - 00 Proportional valve ‘A’ rear axle 1 Short circuit


130 - 007 - 00 Proportional valve ‘A’ rear axle 1 Initialization error


130 - 019 - 00 Proportional valve ‘A’ rear axle 1 Deviation

131 - 002 - 00 Proportional valve ‘B’ rear axle 1 Cable break


131 - 003 - 00 Proportional valve ‘B’ rear axle 1 Short circuit


131 - 007 - 00 Proportional valve ‘B’ rear axle 1 Initialization error


131 - 019 - 00 Proportional valve ‘B’ rear axle 1 Deviation







132 - 019 - 00 Proportional valve ‘A’ rear axle 2 Deviation







133 - 019 - 00 Proportional valve ‘B’ rear axle 2 Deviation

Explanations, notes

Cable break A cable break was detected on the corresponding output. Check wiring!





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Short circuit Short circuit on the corresponding output. Check the wiring!





Initialization error Error while initialization of proportional outputs. Check the parameters.

Deviation The PWM current could not be set to the intended value due to supply voltage or solenoid resistance.


140 – 005 – 03 Digital input CAN-DE1 via CAN Parameter programming
















Explanations, notes





156 - 006 - 00 CAN-terminal Timeout

Explanations, notes

Timeout The CAN connection from this ECU to the control console is lost.



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160 - 005 - 03 Digital output CAN-DA1 via CAN Parameter programming
















Explanations, notes





179 – 002 – 00 J1939 message „ETC1“ Cable break

179 – 004 – 00 J1939 message „ETC1“ Plausibility

179 – 006 – 00 J1939 message „ETC1“ Timeout

Explanations, notes

Cable break Signal “Transmission Outpur Shaft Speed” within message faulty

Plausibility Signal “Transmission Outpur Shaft Speed” within message not available

Timeout Message not available


180 – 002 – 00 J1939 message „TCO1“ Cable break

180 – 004 – 00 J1939 message „TCO1“ Plausibility

180 – 006 – 00 J1939 message „TCO1“ Timeout

Explanations, notes

Cable break Signal “Tachograph Vehicle Speed” within message faulty

Plausibility Signal “Tachograph Vehicle Speed” within message not available



181 - 002 - 00 J1939 message „EBC2“ Cable break

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181 - 004 - 00 J1939 message „EBC2“ Plausibility

181 - 006 - 00 J1939 message „EBC2“ Timeout

Explanations, notes

Cable break Signal “Front Axle Speed” within message faulty

Plausibility Signal “Front Axle Speed” within message not available



182 - 002 - 00 J1939 message „CCVS“ Cable break

182 - 004 - 00 J1939 message „CCVS“ Plausibility

182 - 006 - 00 J1939 message „CCVS“ Timeout

182 - 012 - 00 J1939 message „CCVS“ > max. value

Explanations, notes

Cable break Signal “Wheel_Based VehicleSpeed” within message faulty

Plausibility Signal “Wheel_Based VehicleSpeed” within message not available


> max. value „parking brake active“ on speed > 30 km/h


183 – 002 – 00 J1939 message „EEC1“ Cable break

183 – 004 – 00 J1939 message „EEC1“ Plausibility

183 – 006 – 00 J1939 message „EEC1“ Timeout

Explanations, notes

Cable break Signal “Engine Speed” within message faulty

Plausibility Signal “Engine Speed” within message not available



184 - 002 - 00 J1939 message „ETC2“ Cable break

184 - 004 - 00 J1939 message „ETC2“ Plausibility

184 - 006 - 00 J1939 message „ETC2“ Timeout

184 - 012 - 00 J1939 message „ETC2“ > max. value

Explanations, notes

Cable break Signal “CurrentGear” within message faulty

Plausibility Signal “CurrentGear” within message not available


> max. value „reverse gear active“ on speed > 30 km/h


185 – 002 – 00 J1939 message „Time_Date“ Cable break

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185 – 006 – 00 J1939 message „Time_Date“ Timeout

Explanations, notes

Cable break Signal “TimeDate” within message not available



186 - 006 - 00 J1939 message „Veh_Dist_high_Res“ Timeout

Explanations, notes



187 – 002 – 00 J1939 message „Door_Ctrl“ Cable break

187 – 004 – 00 J1939 message „Door_Ctrl“ Plausibility

187 – 006 – 00 J1939 message „Door_Ctrl“ Timeout

187 – 012 – 00 J1939 message „Door_Ctrl“ > max. value

Explanations, notes

Cable break Signal “Position Of Doors” within message faulty

Plausibility Signal “Position Of Doors” within message not available


> max. value „doors open“ on speed > 30km/h


189 - 002 - 00 CAN message “Bedien” Cable break

189 - 004 - 00 CAN message “Bedien” Plausibility

189 - 006 - 00 CAN message “Bedien” Timeout

189 - 012 - 00 CAN message „Bedien “ > max. value

Explanations, notes

Cable break Signal within message faulty

Plausibility Signal within message not available


> max. value „parking brake active“ on speed > 30km/h or „vehicle support active“ on speed > 30km/h


190 - 002 - 01 Centring pressure Cable break

190 - 006 - 01 Centring pressure Timeout

190 - 012 - 00 Centring pressure > max. value

190 - 013 - 00 Centring pressure < min. value


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185 – 006 – 00 J1939 message „Time_Date“ Timeout

Explanations, notes

Cable break Signal “TimeDate” within message not available



186 - 006 - 00 J1939 message „Veh_Dist_high_Res“ Timeout

Explanations, notes



187 – 002 – 00 J1939 message „Door_Ctrl“ Cable break

187 – 004 – 00 J1939 message „Door_Ctrl“ Plausibility

187 – 006 – 00 J1939 message „Door_Ctrl“ Timeout

187 – 012 – 00 J1939 message „Door_Ctrl“ > max. value

Explanations, notes

Cable break Signal “Position Of Doors” within message faulty

Plausibility Signal “Position Of Doors” within message not available


> max. value „doors open“ on speed > 30km/h


189 - 002 - 00 CAN message “Bedien” Cable break

189 - 004 - 00 CAN message “Bedien” Plausibility

189 - 006 - 00 CAN message “Bedien” Timeout

189 - 012 - 00 CAN message „Bedien “ > max. value

Explanations, notes




> max. value „parking brake active“ on speed > 30km/h or „vehicle support active“ on speed > 30km/h


190 - 002 - 01 Centring pressure Cable break

190 - 006 - 01 Centring pressure Timeout

190 - 012 - 00 Centring pressure > max. value



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193 - 002 - 00 CAN message “Oil Level” Cable break

193 - 004 - 00 CAN message “Oil Level” Plausibility

193 - 006 - 00 CAN message “Oil Level” Timeout

Explanations, notes





194 – 005 – 03 CAN message “SLC-Speed” Timeout

Explanations, notes

Timeout Message for internal signals not available (speed signal from pulse input)


195 - 005 - 03 Steering control setting Parameter programming

Explanations, notes

Parameter prog The parameterisation of the steering control setting (P_189, P_199, P_418 - P_422, P_430 - P_434) is incorrect.

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2.1 System Alarms (L-Errors Failop)

These errors can just occur in Failop systems with dual circuits per axle


200 - 004 - 00 Failop-main circuit Plausibility

200 - 006 - 00 Failop-main circuit Timeout

200 - 047 - 00 Failop-main circuit inoperative

Explanations, notes

Plausibility The alive signal in a CAN message is not changing anymore. The data is not valid.

Timeout The CAN connection between the circuits is cut off.

inoperative The signal “no error” can not be read in any more. The other steering circuit has errors. The steering system is available in a shortened way.


• Check the other steering circuit for its correct function and eliminate possibly available errors.

• Check the wiring between the steering circuits.


201 – 004 – 00 Failop-aux.circuit Plausibility

201 – 006 – 00 Failop-aux.circuit Timeout

201 – 047 – 00 Failop-aux.circuit inoperative

Explanations, notes

Plausibility The alive signal in a CAN message is not changing anymore. The data is not valid.

Timeout The CAN connection between the circuits is cut off.

inoperative The signal “no error” can not be read in any more. The other steering circuit has errors. The steering system is available in a shortened way.


• Check the other steering circuit for its correct function and eliminate possibly available errors.

• Check the wiring between the steering circuits.


210 - 005 - 00 Bypass valve - Main Circuit Parameter programming

210 - 012 - 00 Bypass valve - Main Circuit > max. value

Explanations, notes

Parameter programming Parameter for the valve outputs are not valid.

Check parameters, load a proofed set of parameters.

> max. value The pressure is too high in a switched off main circuit (the bypass valve is open). The pressure must decrease to lower than 20bar (see P_407).

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211 - 005 - 00 Bypass valve - Aux.circuit Parameter programming

211 - 012 - 00 Bypass valve - Aux.circuit > max. value

Explanations, notes

Parameter programming Parameter for the valve outputs are not valid.

Check parameters, load a proofed set of parameters.

> max. value The pressure is too high in a switched off aux.circuit (the bypass valve is open). The pressure must decrease to lower than 20bar (see P_407).


212 – 206 – 03 Prop.valve – Main Circuit Stick open

Explanations, notes

Stick open While a test procedure the pressure is not decreasing even when the prop.valve is not active. The slider of the valve is sticking in an open position.


213 - 209 - 03 Prop.valve - Aux.circuit Stick open

213 - 212 - 00 Prop.valve - Aux.circuit Axle is blocked

Explanations, notes

Stick open While a test procedure the pressure is not decreasing even when the prop.valve is not active. The slider of the valve is sticking in an open position.

Axle is blocked The axle seems to be blocked. Both pressure sensors are reading high pressure.


214 – 004 – 00 Comparing of circuit output Plausibility

Explanations, notes

Plausibility Both circuits are comparing their output via CAN. The result of both circuits are differing too much.


215 - 200 - 00 Selftest Main Circuit CAN connection

215 - 201 - 00 Selftest Main Circuit Circuits not synchronized

215 - 202 - 00 Selftest Main Circuit Volume switch implausible

215 - 203 - 00 Selftest Main Circuit Pressure sensor invalid

215 - 204 - 00 Selftest Main Circuit Bypass valve in main circuit

215 - 205 - 00 Selftest Main Circuit Prop.valve in main circuit

215 - 206 - 00 Selftest Main Circuit Prop.valve in main circuit implausible

215 - 207 - 00 Selftest Main Circuit Bypass valve in aux. circuit

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215 - 208 - 00 Selftest Main Circuit Prop.valve in aux. circuit

215 - 209 - 00 Selftest Main Circuit Prop.valve in aux. circuit implausible

215 - 211 - 00 Selftest Main Circuit Circuits not synchronized, aborting

Explanations, notes

CAN connection The selftest could not be initiated due to a failure in the CAN connection.

Circuits not synchronized The selftest could not be initiated.

Volume switch implausible

The volume switch and the motor revolutions are implausible: - The volume switch is active despite the motor is not running. - The volume switch is not active despite the motor is running.

Pressure sensor invalid The pressure sensor of the mentioned circuit can not provide a valid signal.

Bypass valve in main circuit

The bypass valve of the main circuit has no effect. The main circuit can not get active or can not be bypassed.

Prop.valve in main circuit On activating the prop.valve the matching pressure should rise. No response from the pressure can be recognized. The prop.valve will be assumed to be defective.

Prop.valve in main circuit implausible

The pressure should decrease when a prop.valve is switched off. No response from the pressure can be recognized. The prop.valve will be assumed to be sticking open.

Bypass valve in aux. circuit

The bypass valve of the aux.circuit has no effect. The aux.circuit can not get active or can not be bypassed.

Prop.valve in aux. circuit On activating the prop.valve the matching pressure should rise. No response from the pressure can be recognized. The prop.valve will be assumed to be defective.

Prop.valve in aux. circuit implausible

The pressure should decrease when a prop.valve is switched off. No response from the pressure can be recognized. The prop.valve will be assumed to be sticking open.

Circuits not synchronized, implausible

The selftest has been aborted due to a failure.


216 - 200 - 00 Selftest Aux.circuit CAN connection

216 - 201 - 00 Selftest Aux.circuit Circuits not synchronized

216 - 202 - 00 Selftest Aux.circuit Volume switch implausible

216 - 203 - 00 Selftest Aux.circuit Pressure sensor invalid

216 - 204 - 00 Selftest Aux.circuit Bypass valve in main circuit

216 - 205 - 00 Selftest Aux.circuit Prop.valve in main circuit

216 - 206 - 00 Selftest Aux.circuit Prop.valve in main circuit implausible

216 - 207 - 00 Selftest Aux.circuit Bypass valve in aux. circuit

216 - 208 - 00 Selftest Aux.circuit Prop.valve in aux. circuit

216 - 209 - 00 Selftest Aux.circuit Prop.valve in aux. circuit implausible

216 - 211 - 00 Selftest Aux.circuit Circuits not synchronized, abording

Explanations, notes

CAN connection The selftest could not be initiated due to a failure in the CAN connection.

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Circuits not synchronized The selftest could not be initiated.

Volume switch implausible

The volume switch and the motor revolutions are implausible: - The volume switch is active despite the motor is not running. - The volume switch is not active despite the motor is running.

Pressure sensor invalid The pressure sensor of the mentioned circuit can not provide a valid signal.

Bypass valve in main circuit

The bypass valve of the main circuit has no effect. The main circuit can not get active (pressure must rise higher than P_411) or can not be bypassed (pressure must fall lower than P_407).

Prop.valve in main circuit On activating the prop.valve the matching pressure should rise (higher than P_411). No response from the pressure can be recognized. The prop.valve will be assumed to be defective.

Prop.valve in main circuit implausible

The pressure should decrease when a prop.valve is switched off (lower than P_408). No response from the pressure can be recognized. The prop.valve will be assumed to be sticking open.

Bypass valve in aux. circuit

The bypass valve of the aux.circuit has no effect. The aux.circuit can not get active (pressure must rise higher than P_411) or can not be bypassed (pressure must fall lower than P_407).

Prop.valve in aux. circuit On activating the prop.valve the matching pressure should rise (higher than P_411). No response from the pressure can be recognized. The prop.valve will be assumed to be defective.

Prop.valve in aux. circuit implausible

The pressure should decrease when a prop.valve is switched off (lower than P_408). No response from the pressure can be recognized. The prop.valve will be assumed to be sticking open.

Circuits not synchronized, implausible

The selftest has been aborted due to a failure.

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2.2 Control Unit Alarms (U-Errors)

Alarms which point to a functional error in the control unit, including errors in the power supply or a supply of error signals, are known as U-Errors.

U-Errors are dealt with on the system side as L-Errors with priority 3, i.e. the system is shut down for safety reasons.

Structure of the alarm table:


aaa - bbb - pp Steering electronics Error type bbb

aaa - ccc - pp Steering electronics Error type ccc

Explanations, notes

Error type bbb Description

Error type ccc Description


239 - 001 - 03 Steering electronics Internal error




Explanations, notes

Internal error Replace control unit


239 – 005 – 03 Steering electronics parameters inconsistent

Explanations, notes

inconsistent Parameters are inconsistent.


• Re-program the parameters using the WinPCS software

• Replace control unit


239 - 006 - 03 Steering electronics, function software inconsistent

Explanations, notes

inconsistent The function software is inconsistent.


• Re-flash the function software




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Explanations, notes



239 – 010 – 03 Steering electronics, 5Vexternal Too high/too low

Explanations, notes

Too high/too low Voltage on 5Vexternal too high/too low


• Check output for a short circuit after Ub/Gnd











Explanations, notes



239 – 019 – 03 Steering electronics, safety switch Switch-on test

Explanations, notes

Switch-on test Test of the internal safety switch has failed.


• Check digital outputs for short circuit after +Ub




Explanations, notes



239 – 021 – 03 Steering electronics of digital output DA1 Switch-on test


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Explanations, notes

Switch-on test Test of the digital outputs has failed.





239 - 099 - 03 Steering electronics Supply voltage

Explanations, notes

Supply voltage No power supply present for the safety outputs.


• Measure voltage



239 – 101 – 03 Steering electronics Internal error




Explanations, notes



239 - 105 - 03 Steering electronics, 5Vexternal Too high/too low

Explanations, notes

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Too high/too low Voltage on 5Vexternal too high/too low


• Check output for a short circuit after Ub/Gnd



239 – 106 – 03 Steering electronics, power supply Too high

239 – 107 – 03 Steering electronics, power supply Too low

Explanations, notes

Too high Supply voltage too high (>31V).


• Measure voltage


Too low Supply voltage too low (<14V).


• Measure voltage



239 - 108 - 03 Steering electronics, temperature Too high

Explanations, notes

Too high Internal temperature too high (>85°C).


• Check temperature








Explanations, notes



239 - 114 - 03 Steering electronics +5Vref Outside tolerance

239 - 115 - 03 Steering electronics +5Vext Outside tolerance

Explanations, notes

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Outside tolerance Reference voltage outside the tolerance.


• Measure voltage and check sensors for short circuits



239 – 116 – 03 Steering electronics, safety switch Monitoring

Explanations, notes

Monitoring Test of the internal safety switch has failed.





239 - 121 - 03 Steering electronics of digital output DA1 Monitoring
















Explanations, notes

Monitoring Test of the digital outputs has failed.





239 – 161 – 03 Steering electronics of digital input DE1 Monitoring





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Explanations, notes

Monitoring Error on digital input.


• Measure voltage



239 - 201 - 03 Steering electronics of analogue input AE1 Monitoring








Explanations, notes

Monitoring Error on analogue input


• Measure voltage



239 - 221 - 03 Steering electronics of analogue output AA1 Monitoring

239 - 222 - 03 Steering electronics of analogue output AA2 Monitoring

Explanations, notes

Monitoring Error on analogue output


• Measure voltage


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F. ENGINE FAULT CODES

(Will be displayed on LCD dash display.)

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BLINK

CODESPN FMI Component/Location Description (ErrorLocation)

Error Code

SERDIAID

Self

Curing

- 11 Reserve output Short circuit to Ubatt (output 1) 57 Dummy1CD_Max

- 701 11 Reserve output Short circuit to ground (output 1) 58 Dummy1CD_Min

- 701 11 Reserve output Cable break or ECU internal error (output 1) 59 Dummy1CD_SigNpl

- 702 11 Reserve output Short circuit to Ubatt (output 2) 60 Dummy2CD_Max

- 702 11 Reserve output Short circuit to ground (output 2) 61 Dummy2CD_Min

- 702 11 Reserve output Cable break or ECU internal error (output 2) 62 Dummy2CD_SigNpl

1_1_1 523218 11, 12 CAN message Missing (message "RxCCVS" = cruise control) 112 FrmMngTORxCCVS �

1_1_2 523604 11, 12 CAN message Missing (message "RxEngTemp" = engine temperature) 113 FrmMngTORxEngTemp �

1_1_5 523238 11, 12 CAN message Missing (message "SwtOut" = switch outputs) 117 FrmMngTOSwtOut �

1_1_6 523222 11, 12 CAN message Missing (message "TCO1" = speedo signal) 118 FrmMngTOTCO1 �

1_1_8 898 11, 12 CAN message Missing (message "TSC1-TE") 125 FrmMngTOTSC1TE

1_1_8 523605 11, 12 CAN message Missing (message "TSC1-AE") 120 FrmMngTOTSC1AE

1_1_8 523607 11, 12 CAN message Missing (message "TSC1-DE") 122 FrmMngTOTSC1DE

1_1_8 523609 11, 12 CAN message Missing (message "TSC1-PE") 124 FrmMngTOTSC1PE

1_1_8 523610 11, 12 CAN message Missing (message "TSC1-VE") 127 FrmMngTOTSC1VE

1_1_9 520 11, 12 CAN message Missing (message "TSC1-TR") 126 FrmMngTOTSC1TR

1_1_9 523606 11, 12 CAN message Missing (message "TSC1-AR") 121 FrmMngTOTSC1AR

1_1_9 523608 11, 12 CAN message Missing (message "TSC1-DR") 123 FrmMngTOTSC1DR

1_1_9 523611 11, 12 CAN message Missing (message "TSC1-VR") 128 FrmMngTOTSC1VR

1_2_3 704 11 Coolant temperature warning lamp Cable break or short circuit 54 CTLpCD

1_2_6 29 2, 3, 4, 11 Hand throttle Cable break or short circuit, signal implausible compared to signal of idle sensor 138 HdThrt

1_2_8 105 2, 3, 4, 11 Charge air temperature sensor Cable break or short circuit 149 IATSCD yes

1_3_3 - 2, 3, 4, 11 Customer-specific sensor Cable break or short circuit (sensor 1) 136 GOTSCD yes

1_3_3 - 2, 11 Customer-specific temperature Outside target range with system reaction (temperature 1) 137 GOTSCDSysReac yes

1_3_4 523613 0, 11 Rail pressure Positive deviation (speed dependent) outside target range 211 RailMeUn0 yes

1_3_4 523613 0, 11 Rail pressure Positive deviation (flow dependent) outside target range (� leakage!) 212 RailMeUn1 yes

1_3_4 523613 0, 11 Rail pressure Negative deviation (flow dependent) outside target range 213 RailMeUn2 yes

1_3_4 523613 1, 11 Rail pressure Negative deviation (speed dependent) outside target range 214 RailMeUn3 yes

1_3_4 523613 0, 11 Rail pressure Pressure above target range 215 RailMeUn4 yes

1_3_4 523613 2, 11 Rail pressure Implausible (leakage, injector needle blocked in open position) 216 RailMeUn7 yes

1_3_5 705 2, 3, 4, 5 Oil pressure warning lamp Cable break or short circuit 195 OPLpCD

1_3_5 523615 3, 4, 11 Metering unit valve Flow rate outside target range 176 MeUnCD_ADC

1_3_5 523615 5, 11, 12 Metering unit valve Not connected or output disabled 177 MeUnCDNoLoad

1_3_5 523615 11, 12 Metering unit valve Short circuit to Ubatt 178 MeUnCDSCBat

1_3_5 523615 11, 12 Metering unit valve Short circuit to ground 179 MeUnCDSCGnd

1_3_6 107 0, 11 Air filter condition Pressure loss above target range with system reaction 11 AirFltSysReac yes

1_3_7 2634 3, 11 Main relay Short circuit to Ubatt (relay 1) 182 MnRly1_SCB

1_3_8 2634 4, 11 Main relay Short circuit to ground (relay 1) 183 MnRly1_SCG

1_3_9 523420 11, 14 ECU internal error Watchdog counter exceeds maximum 184 Montr

1_4_ 4 175 2, 3, 4 Oil temperature sensor Cable break or short circuit 201 OTSCD yes

1_4_ 4 175 0, 11 Oil temperature Below target range with system reaction 203 OTSCDSysReac yes

1_4_ 7 157 3, 4, 11 Rail pressure sensor Cable break or short circuit 209 RailCD

1_4_ 7 157 0, 1, 11 Rail pressure sensor Deviation of signal during start or after-run above target range 210 RailCDOfsTst yes

1_4_2 703 2, 3, 4, 5 Engine operating signal lamp Cable break or ECU internal error 81 ESLpCD

1_4_3 523450 2, 3, 4, 11 Multi state switch Cable break or short circuit, input voltage outside target range (switch 1) 189 MSSCD1 yes



1_4_5 1237 2, 11 Override switch Switch hangs 200 OSwCD yes

1_4_6 523470 2, 11, 12, 14 Rail pressure limiting valve Opening failure 208 PRVMon

1_4_6 523470 11, 12 Rail pressure limiting valve Opening failure with system reaction 236 PRVMonSysReac

1_4_9 523490 3, 4, 11, 12 ECU internal error Redundant shut-off conditions detected 218 SOPTst

1_5_1 523350 3, 4, 11, 13 Multiple injectors Short circuit (cylinder bank 1) 153 InjVlvBnk1A yes

1_5_1 523351 5, 13 Multiple injectors Cable break (cylinder bank 1) 154 InjVlvBnk1B yes

1_5_2 523352 3, 4, 11, 13 Multiple injectors Short circuit (cylinder bank 2) 155 InjVlvBnk2A yes

1_5_2 523353 5, 13 Multiple injectors Cable break (cylinder bank 2) 156 InjVlvBnk2B yes

1_5_3 523354 2, 3, 12, 14 ECU internal error Injector power stage A 157 InjVlvChipA

1_5_3 523355 12 ECU internal error Injector power stage B 158 InjVlvChipB

1_5_4 651 3, 4, 11, 13 Single injector Short circuit (injector 1) 159 InjVlvCyl1A yes

1_5_4 651 5, 13 Single injector Cable break (injector 1) 160 InjVlvCyl1B yes

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BLINK


Error Code

SERDIAID

Self

Curing















2_1_ 2 190 11, 12 Engine speed sensor Engine running with cam-shaft speed signal only 75 EngMBackUp yes

2_1_ 6 94 3, 4, 11 Fuel low pressure sensor Below target range with system reaction 90 FlPSCD yes

2_1_ 6 94 2, 11 Fuel low pressure Cable break or short circuit 91 FlPSCDSysReac yes

2_1_2 190 8, 11, 12 Engine speed sensor Speed signal from cam-shaft bad or missing 76 EngMCaS1 yes

2_1_2 190 8, 11, 12 Engine speed sensor Speed signal from crank-shaft bad or missing 77 EngMCrS1 yes

2_1_3 190 2, 11 Engine speed sensor Speed signals of crank-shaft and cam-shaft are phase-shifted 78 EngMOfsCaSCrS

2_1_4 190 0, 11 Overspeed Engine overspeed with system reaction 79 EngPrtSysReacFOC

2_1_4 190 11, 14 Overrun conditions Overrun conditions with system reaction 80 EngPrtSysReacORC yes

2_1_9 1074 3, 4, 5, 11 Engine brake flap actuator Engine brake flap actuator: cable break or short circuit 82 ExFlCD

2_2_ 2 91 2, 8 Accelerator pedal Cable break or short circuit, bad PWM signal range or frequency (digital pedal) 14 APPPwm yes

2_2_ 2 91 8, 11 Accelerator pedal Bad PWM pulse-width repetition rate (digital pedal) 15 APPPwmPer yes

2_2_ 3 102 2, 3, 4 Charge air pressure sensor Cable break or short circuit 32 BPSCD yes

2_2_ 3 102 2, 11 Charge air pressure Outside target range with system reaction 33 BPSCDSysReac yes

2_2_ 4 100 0, 2, 3, 4 Oil pressure sensor Cable break or short circuit 196 OPSCD yes

2_2_ 5 110 2, 3, 4 Coolant temperature sensor Cable break or short circuit 55 CTSCD yes

2_2_ 6 91 2, 3, 4, 11 Accelerator pedal Cable break or short circuit, signalpedal) implausible compared to signal of idle sensor

(analog 12 APP1

2_2_ 7 174 3, 4, 11 Fuel temperature sensor Fuel temp. sensor: cable break or short circuit 133 FTSCD yes

2_2_ 8 97 3, 4, 11 Fuel filter water level sensor filter water level sensor 87 FlFCD yes

2_2_ 8 97 11, 12 Water level in fuel filter Above target range 89 FlFCD_WtLvl

2_3_ 1 100 1, 11 Oil pressure sensor Pressure value implausible low 197 OPSCD1 yes

2_3_ 1 100 0, 11 Oil pressure Above target range 198 OPSCDSysReacHi yes

2_3_ 1 100 1, 11 Oil pressure Below target range 199 OPSCDSysReacLo yes

2_3_ 2 110 0, 11 Coolant temperature Outside target range with system reaction 56 CTSCDSysReac yes

2_3_ 3 105 0, 11 Charge air temperature Above target range with system reaction 150 IATSCDSysReac yes

2_3_ 5 111 1, 11 Coolant level Outside target range with system reaction 37 CLSCDSysReac

2_3_ 7 174 0, 11 Fuel temperature Above target range with system reaction 134 FTSCDSysReac yes

2_3_8 975 2, 3, 4, 5 Fan actuator Fan actuator: cable break or short circuit 83 FanCD

2_3_8 523602 2, 11 Fan speed Above target range with system reaction 86 FanCDSysReac yes

2_4_1 1322 11, 12 Multiple cylinders Misfire detected 46 CmbChbMisfireMul

2_4_1 1323 11, 12 Single cylinder Misfire detected (cylinder 1) 38 CmbChbMisfire1






2_4_1 1346 0, 11 Misfire Misfire detected with system reaction 47 CmbChbSysReac



2_6_1 563 7, 11, 12 Main relay Short circuit to ground or emergency shut-off (relay 3) 187 MRlyCDMnRly2

2_6_1 2634 7, 11, 12 Main relay Short circuit to ground or emergency shut-off (relay 2) 186 MRlyCD

2_6_1 2634 7, 11, 12 Main relay Short circuit to ground or emergency shut-off (relay 3) 188 MRlyCDMnRly3

2_6_3 676 4, 11 Air heater relay Cable break or wrong connection 19 ArHtCD_NoLd

2_6_3 676 2, 5, 11 Air heater relay Inoperable during shut-off 20 ArHtCD_RlyErr

2_6_3 729 3, 4, 5, 11 Air heater relay Cable break or short circuit 17 ArHt1 yes

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Error Code

SERDIAID

Self

Curing

2_6_3 730 3, 4, 5, 11 Air heater magnetic valve Cable break or short circuit 18 ArHt2 yes

2_7_1 639 11, 14 CAN bus off-state Cable break or short circuit, off-state (CAN bus A) 192 NetMngCANAOff yes

2_7_1 1231 11, 14 CAN bus off-state Cable break or short circuit, off-state (CAN bus B) 193 NetMngCANBOff yes

2_7_1 1235 11, 14 CAN bus off-state Cable break or short circuit, off-state (CAN bus C) 194 NetMngCANCOff yes

2_7_1 523500 11, 12 CAN message Time-out of at least one sended message 131 FrmMngTxTO yes

2_8_1 630 11, 12 ECU internal error EEPROM memory access 142 HWEMonEEPROM

2_8_2 1079 3, 4, 11 ECU internal error Wrong voltage of internal 5V reference source 1 219 SSpMon1 yes



2_9_ 2 108 2, 3, 4, 11 ECU internal error Ambient pressure sensor defective 16 APSCD yes

3_1_ 8 168 0, 1, 11 Battery Voltage below target range 22 BattCD yes

3_1_ 8 168 2, 11 Battery voltage Above target range with system reaction 23 BattCDSysReac yes

3_1_4 1638 3, 4, 11, 12 Customer-specific sensor Cable break or short circuit (sensor 2) 139 HOTSCD yes

3_1_4 1638 2, 11 Customer-specific temperature Outside target range with system reaction (temperature 2) 140 HOTSCDSysReac yes

3_2_8 1081 2, 3, 4, 5 Preheating signal lamp Cable break or short circuit 53 CSLpCD

3_3_3 523212 11, 12 CAN message Missing (message "EngPrt" = engine protection) 106 FrmMngTOEngPrt yes

3_3_7 523216 11, 12 CAN message Missing (message "PrHtEnCmd" = preheat and engine command) 110 FrmMngTOPrHtEnCmd yes

3_4_1 1109 2, 11 Shut-off request Shut-off request ignored by operator 48 CoEngShOffDemIgr

4_1_4 2791 3, 11 EGR actuator (external) Short circuit to Ubatt 69 EGRCD_Max

4_1_4 2791 4, 11 EGR actuator (external) Short circuit to ground 70 EGRCD_Min

4_1_5 2791 2, 5, 11 EGR actuator (external) Cable break or ECU internal error 71 EGRCD_SigNpl

4_1_6 2791 2, 3, 4, 5 EGR actuator (external) Cable break or short circuit 72 EGRCDIntEGR

5_1_ 4 158 11, 12 Terminal 15 Ignition ON not detected 226 T15CD

5_1_2 677 3, 4, 11 Start relay Start relay (high side): short circuit 223 StrtCDHS

5_1_2 677 3, 4, 5, 11 Start relay Start relay (low side): cable break or short circuit, disabled by ECU 224 StrtCDLS

5_1_3 624 2, 3, 4, 5 Diagnostic lamp Cable break or short circuit, disabled by ECU 225 SysLamp

5_1_5 523550 11, 12 Terminal 50 Engine start switch hangs 227 T50CD

5_2_ 1 84 0, 8, 12, 14 Vehicle speed signal Speed above target range, signal missing or implausible 232 VSSCD1 yes

5_2_6 523239 2, 12 CAN message Missing or value above target range (message "DecV1" = pseudo pedal) 94 FrmMngDecV1 yes

5_2_7 523240 11, 12 CAN message Missing (message "FunModCtl" = function mode control) 95 FrmMngFunModCtl yes

5_2_8 1072 3, 4, 5, 11 Engine brake (internal) Internal engine brake: cable break or short circuit 52 CRERCD

5_3_1 523561 2 Begin of injection period Outside target range or missing (cylinder 1) 24 BIPCyl1 yes








5_5_5 923 2, 3, 4, 5 Engine power output Engine Power output: cable break or short circuit 74 EngCDTrqCalcOut

5_5_5 523370 11, 14 Rail pressure Compression test active: rail-pressure monitoring is going to be disabled 175 InjVlvErrDet

5_5_5 523550 2, 11 ECU internal error Time processing unit (TPU) defective 228 TPUMon

5_5_5 523600 11, 12 ECU internal error Serial communication interface defective 235 WdCom

5_5_5 523612 11, 14 ECU internal hardware monitoring A recovery occurred which is stored as protected 143 HWEMonRcyLocked

5_5_5 523612 11, 14 ECU internal hardware monitoring A recovery occurred which is not stored 144 HWEMonRcySuppres-sed

5_5_5 523612 11, 14 ECU internal hardware monitoring A recovery occurred which is visible in the error memory 145 HWEMonRcyVisible

5_5_5 523612 3, 11 ECU internal hardware monitoring Overvoltage 146 HWEMonUMaxSupply

5_5_5 523612 4, 11 ECU internal hardware monitoring Undervoltage 147 HWEMonUMinSupply

5_5_5 523617 11, 12 ECU internal error Communication with chip CJ 940 disturbed 141 HWEMonCom

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G. TRANSMISSION FAULT CODES

(Will be displayed on Transmission display.) F or R, no gear Clutch Cutoff F or R flashing direction F or R selected while turbine

speed is too high CAUTION gear will engage if turbine speed drops

NN not neutral, waiting for neutral after power up or a severe fault

to engage a gear, first move shift selector to neutral position and again to F or R position

** oil temperature too low, no gear available

warm up engine / transmission

*N oil temperature low, only one gear available

warm up engine / transmission

1 bar (special symbol)

manual mode 1st gear

2 bars manual mode 2nd gear 3 bars manual mode 3rd gear 4 bars manual mode 4th gear and also 5th and

6th gear in 6WG

4 bars and 2 arrows

automatic mode

Bars flashing 6 WG: converter lockup clutch open 4 WG: Downshift mode activ

difference of engine and turbine speed above a certain limit and lockup clutch not activated

Spanner at least one fault activ select neutral to get fault code displayed Fault code see faultcode list WS warning sump temperature changes between actual gear/direction while driving,

in neutral only displayed if no fault is detected (spanner)

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

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

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

WV warning high output speed (velocity) changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner)

WL warning high transmission input torque (load)

changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner)

WO warning high transmission output torque (load)

changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner)

PN direction F or R selected while parking brake engaged

transmission in neutral until parking brake is released CAUTION: vehicle starts to move after release of parking brake

EE flashing no communication with display checked wiring from TCU to display

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1.4 Display during AEB-Mode

symbol meaning remarks PL AEB - Starter is plugged at the

diagnostic plug

ST AEB-Starter-button is pressed

K1..K4,KV,KR calibrating clutch K1..K4, KV or KR resp.

_ and Kx wait for start, initialization of clutch Kx, x: 1, 2, 3, 4, V, R

≡ and Kx 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 calibrated

Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

Spanner and Kx Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

Δ E engine speed too low, � raise engine speed

∇ E engine speed too high, � lower engine speed

Δ T transmission oil temperature too low, � heat up transmission

∇ T transmission oil temperature too high � cool down transmission

FT transmission temperature not in defined range during calibration


FB operating mode not NORMAL or transmission temperature sensor defective or storing of Calibrated values to EEPROM-has failed.


FO Outputspeed_not_zero Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart the TCU (ignition off/on)

STOP AEB - Starter was used incorrect or is defective. Wrong device or wrong cable used


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1.5 Display during Inchpedal Calibration

symbol meaning remarks 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 slowly until endposition is reached

If the expected enposition could not be 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 specified range

Calibration is aborted

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 specified range


IU and Stop sensor position for pressed pedal out of specified range


TO and Stop time-out calibration, pedal not moved after calibration start


DL and Stop angle between pedalpositions released and pressed to small


DU and Stop angle between pedalpositions released and pressed to big


FI and Stop sensor signal 1 and 2 don't match together


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CD389


3. Table of fault codes

Fault Code (hex)

MEANING OF THE FAULT CODE Possible reason for fault detection

Reaction of the TCU Possible steps to repair Remarks

11 LOGICAL ERROR AT GEAR RANGE SIGNAL

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

or vehicle ground • shift lever is defective

TCU shifts transmission to neutral OP-Mode: transmission shutdown

• check the cables from TCU to shift lever

• check signal combinations of shift lever positions for gear range

failure cannot be detected in systems with DW2/DW3 shift lever

fault is taken back if TCU detects a valid signal for the position

12 LOGICAL ERROR AT DIRECTION SELECT SIGNAL TCU detected a wrong signal combination for the direction • cable from shift lever to TCU is broken • cable is defective and is contacted to battery voltage




• check signal combinations of shift lever positions F-N-R

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

13 LOGICAL ERROR AT ENGINE DERATING DEVICE TCU detected no reaction of engine while derating device activ

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

• check engine derating device This fault is reset after power up of TCU

14 LOGICAL ERROR AT PARKBRAKE STATUS Parkbrake-status-signal measured by TCU and parkbrake-status-signal send by CAN don't fit • one of the cables from status-switch to electronic box

is broken • one of the status-switches is defective

TCU shifts transmission to DCO-State OP-Mode: normal

• check the cables from electronic boxes to status switches

• check signals of the status switches

15 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2. SHIFT

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


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

• check the cables from TCU to shift lever 2

• check signal combinations of shift lever positions F-N-R

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

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3-1-64Orig

CD389


Fault Code (hex)



16 LOGICAL ERROR AT AXLE CONNECTION

feedback axle connection measured by TCU and output signal axle connection don't fit • axle can’t be connected or disconnected due to

mechanical problem • one of the cables from feedback axle connection -

switch to TCU is broken

OP-Mode: normal • check the cables from TCU to feedback axle connection switch

• check signals of the feedback axle connection switch

17 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 1 TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • customer specific function no. 1 device has an

internal defect • connector pin is contacted to vehicle ground

customer specific • check the cable from TCU to customer specific function no. 1 device

• check the connectors from customer specific function no. 1 to TCU

• check the resistance of customer specific function no. 1 device

1) see chapter Fehler! Verweisquelle konnte nicht gefunden werden.

18 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC

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

internal defect • connector pin is contacted to battery voltage


• check the connectors from customer specific function no. 1 to TCU



19 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 1 TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • customer specific function no. 1 device has an

internal defect • connector has no connection to TCU


• check the connectors from customer specific function no. 1 device to TCU



1A S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 2 TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • customer specific function no. 2 device has an






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3-1-65Orig

CD389


Fault Code (hex)



1B S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC






1C O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 2 TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • customer specific function no. 2 device has an





1D S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 3 TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • customer specific function no. 3 device has an





1E S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC



customer specific • check the cable from TCU to customer specific customer specific function no. 3 device



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3-1-66Orig

CD389


Fault Code (hex)



1F O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 3

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






21 S.C. TO BATTERY VOLTAGE AT CLUTCH CUTOFF INPUT the measured voltage is too high: • cable is defective and is contacted to battery voltage • clutch cut off sensor has an internal defect • connector pin is contacted to battery voltage

clutch cutoff function is disabled OP-Mode: normal

• check the cable from TCU to the sensor

• check the connectors • check the clutch cutoff sensor

22 S.C. TO GROUND OR O.C. AT CLUTCH CUTOFF INPUT the measured voltage is too low: • cable is defective and is contacted to vehicle ground • cable has no connection to TCU • clutch cut off sensor has an internal defect • connector pin is contacted to vehicle ground or is

broken

clutch cutoff function is disabled OP-Mode: normal


• check the connectors • check the clutch cutoff sensor

23 S.C. TO BATTERY VOLTAGE AT LOAD SENSOR INPUT the measured voltage is too high: • cable is defective and is contacted to battery voltage • load sensor has an internal defect • connector pin is contacted to battery voltage

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


• check the connectors • check the load sensor sensor • check the assembly tolerances of load

sensor

availability of retarder depends on default load

24 S.C. TO GROUND OR O.C. AT LOAD SENSOR INPUT the measured voltage is too low: • cable is defective and is contacted to vehicle ground • cable has no connection to TCU • load sensor has an internal defect • connector pin is contacted to vehicle ground or is

broken

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


• check the connectors • check the load sensor sensor • check the assembly tolerances of load

sensor

availability of retarder depends on default load

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3-1-67Orig

CD389


Fault Code (hex)



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

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

broken

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


• check the connectors • check the temperature sensor

26 S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE

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




27 S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER / TORQUECONVERTER TEMPERATURE SENSOR INPUT the measured voltage is too high: • cable is defective and is contacted to battery voltage • cable has no connection to TCU • temperature sensor has an internal defect • connector pin is contacted to battery voltage or is

broken




28 S.C. TO GROUND AT RETARDER / TORQUECONVERTER

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




29 S.C. TO BATTERY VOLTAGE OR O.C. AT PARKING BRAKE

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

broken

TCU uses default value OP-Mode: normal


• check the connectors • check the parking brake sensor

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3-1-68Orig

CD389


Fault Code (hex)



2A S.C. TO GROUND PARKING BRAKE SENSOR INPUT

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



• check the connectors • check the parking brake sensor

2B INCHSENSOR-SIGNAL MISMATCH the measured voltage from CCO and CCO2 signal don’t match: • cable is defective • sensor has an internal defect

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


• check the connectors • check sensor

2C S.C. TO BATTERY VOLTAGE OR O.C. AT DLM TRACTION

ADJUST DASHBOARD DEVICE INPUT the measured voltage is too high: • cable is defective and is contacted to battery voltage • cable has no connection to TCU • sensor has an internal defect • connector pin is contacted to battery voltage or is

broken



• check the connectors • check the DLM Traction Adjust

dashboard device

2D S.C. TO GROUND DLM TRACTION ADJUST DASHBOARD

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



• check the connectors • check the DLM Traction Adjust

dashboard device

2E S.C. TO BATTERY VOLTAGE OR O.C. AT DLM STEERING

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

broken



• check the connectors • check the DLM STEERING ANGLE

SENSOR

2F S.C. TO GROUND DLM STEERING ANGLE SENSOR INPUT the measured voltage is too low: • cable is defective and is contacted to vehicle ground



• check the connectors

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3-1-69Orig

CD389


Fault Code (hex)



• sensor has an internal defect • connector pin is contacted to vehicle ground

• check the DLM STEERING ANGLE

SENSOR 31 S.C. TO BATTERY VOLTAGE OR O.C. AT

ENGINE SPEED INPUT TCU measures a voltage higher than 7.00 V at speed input pin • cable is defective and is contacted to battery voltage • cable has no connection to TCU • speed sensor has an internal defect • connector pin is contacted to battery voltage or has

no contact

OP-Mode: substitute clutch control


• check the connectors • check the speed sensor

32 S.C. TO GROUND AT ENGINE SPEED INPUT TCU measures a voltage less than 0.45V at speed input pin • cable / connector is defective and is contacted to

vehicle ground • speed sensor has an internal defect




33 LOGICAL ERROR AT ENGINE SPEED INPUT TCU measures a engine speed over a threshold and the next moment the measured speed is zero • cable / connector is defective and has bad contact • speed sensor has an internal defect • sensor gap has the wrong size



• check the connectors • check the speed sensor • check the sensor gap

This fault is reset after power up of TCU

34 S.C. TO BATTERY VOLTAGE OR O.C. AT TURBINE SPEED INPUT TCU measures a voltage higher than 7.00 V at speed input pin • cable is defective and is contacted to battery voltage • cable has no connection to TCU • speed sensor has an internal defect • connector pin is contacted to battery voltage or has

no contact

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



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3-1-70Orig

CD389


Fault Code (hex)



35 S.C. TO GROUND AT TURBINE SPEED INPUT

TCU measures a voltage less than 0.45V at speed input pin • cable / connector is defective and is contacted to





36 LOGICAL ERROR AT TURBINE SPEED INPUT TCU measures a turbine speed over a threshold and at the next moment the measured speed is zero • cable / connector is defective and has bad contact • speed sensor has an internal defect • sensor gap has the wrong size





37 S.C. TO BATTERY VOLTAGE OR O.C. AT INTERNAL SPEED INPUT TCU measures a voltage higher than 7.00 V at speed input pin • cable is defective and is contacted to battery voltage • cable has no connection to TCU • speed sensor has an internal defect • connector pin is contacted to battery voltage or has

no contact




38 S.C. TO GROUND AT INTERNAL SPEED INPUT TCU measures a voltage less than 0.45V at speed input pin • cable / connector is defective and is contacted to





39 LOGICAL ERROR AT INTERNAL SPEED INPUT TCU measures a internal speed over a threshold and at the next moment the measured speed is zero • cable / connector is defective and has bad contact • speed sensor has an internal defect • sensor gap has the wrong size





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3-1-71Orig

CD389


Fault Code (hex)



3A S.C. TO BATTERY VOLTAGE OR O.C. AT

OUTPUT SPEED INPUT TCU measures a voltage higher than 12.5 V at speed input pin • cable is defective and is contacted to battery voltage • cable has no connection to TCU • speed sensor has an internal defect • connector pin is contacted to battery voltage or has

no contact

special mode for gear selection OP-Mode: substitute clutch control if a failure is existing at turbine speed, TCU shifts to neutral OP-Mode: limp home



3B S.C. TO GROUND AT OUTPUT SPEED INPUT TCU measures a voltage less than 1.00V at speed input pin • cable / connector is defective and is contacted to





3C LOGICAL ERROR AT OUTPUT SPEED INPUT TCU measures a output speed over a threshold and at the next moment the measured speed is zero • cable / connector is defective and has bad contact • speed sensor has an internal defect • sensor gap has the wrong size





3D TURBINE SPEED ZERO DOESN’T FIT TO OTHER SPEED

SIGNALS

- - not used

3E OUTPUT SPEED ZERO DOESN’T FIT TO OTHER SPEED SIGNALS if transmission is not neutral and the shifting has finished, TCU measures outputspeed zero and turbine speed or internal speed not equal to zero. • speed sensor has an internal defect • sensor gap has the wrong size


• check the sensor signal of output speed sensor

• check the sensor gap of output speed sensor



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3-1-72Orig

CD389


Fault Code (hex)



40 GEAR RANGE RESTRICTION SIGNAL

CAN signal for gear range restriction is defective • cluster controller is defective • interference on CAN-Bus

no gear range restriction • check cluster controller • check wire of CAN-Bus • check cable to cluster controller

40 FCAN MESSAGE ‘GEAR RANGE SELECT

(ZF_3_IDENT)’ contains invalid data gear range set from 1st to 5th • check FWD controller

• check wire of CAN-Bus

41 DECLUTCH MODULATION SELECTION SIGNAL - - not used 41 TCU RECEIVES MESSAGES ‘GEAR RANGE SELECT

(ZF_3_IDENT)’ AND ‘FRONT WHEEL DRIVE STATUS’

(V_IDENT_FWD) ALTHOUGH CONFIGURATION STATES

THAT FWD CONTROLLER IS NOT INSTALLED

ignore FWD commands • reconfigure with TCU Configuration Command

(ID PC)

50 FMR1 TIMEOUT Timeout of CAN-message FMR1 from engine controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to

vehicle ground or battery voltage • engine controller is defective

TCU operates like jake brake is off and exhaut brake is off. OP-Mode: normal

• check engine controller • check wire of CAN-Bus • check cable to engine controller

51 FMR2 TIMEOUT Timeout of CAN-message FMR2 from engine controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to

vehicle ground or battery voltage • engine controller is defective



52 EAMODUL1 TIMEOUT Timeout of CAN-message EAM1 from I/O - controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to

vehicle ground or battery voltage

TCU shifts to neutral and uses substitute gear selector OP-Mode: normal

• check I/O controller • check wire of CAN-Bus • check cable to I/O controller

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3-1-73Orig

CD389


Fault Code (hex)



53 ABS TIMEOUT

Timeout of CAN-message ABS from ABS - controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


no reaction • check ABS controller • check wire of CAN-Bus • check cable to ABS controller

54 MDU1 TIMEOUT Timeout of CAN-message MDU1 from cluster controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


TCU keeps old auto downshift information and old manual downshift information OP-Mode: normal

• check cluster controller • check wire of CAN-Bus • check cable to cluster controller

54 DCT1 TIMEOUT Timeout of CAN-message DCT1 from display computer • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


OP-Mode: normal • check display computer • check wire of CAN-Bus • check cable to display computer

54 GEAR RANGE SELECT TIMEOUT Timeout of CAN-message ‘Gear Range Select (ZF_3_IDENT)’ • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to

vehicle ground or battery voltage • FWD Controller is defective

gear range set from 1st to 5th • check wire of CAN-Bus • check FWD controller

55 DNS1 TIMEOUT Timeout of CAN-message DNS1 from OMRON-master • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


TCU shifts to neutral OP-Mode: normal

• check OMRON-master • check wire of CAN-Bus • check cable to OMRON-master

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3-1-74Orig

CD389


Fault Code (hex)



55 SCT1 TIMEOUT

Timeout of CAN-message SCT1 from steering computer • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


OP-Mode: normal • check steering computer • check wire of CAN-Bus • check cable to steering computer

55 FLC1 TIMEOUT Timeout of CAN-message FCL1 from cluster controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


TCU keeps old auto/man selection, old Clutch cutoff selection and old Clutch Cuttoff Setting OP-Mode: normal


55 FRONT WHEEL DRIVE STATUS TIMEOUT Timeout of CAN-message ‘Front Wheel Drive Status (V_IDENT_FWD)’ • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to

vehicle ground or battery voltage • FWD Controller is defective

TCU shifts to neutral • check wire of CAN-Bus • check FWD controller

56 ENGINE CONF TIMEOUT Timeout of CAN-message ENGINE CONF from engine controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to




57 EEC1 TIMEOUT Timeout of CAN-message EEC1 from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to



• check EEC controller • check wire of CAN-Bus • check cable to EEC controller

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3-1-75Orig

CD389


Fault Code (hex)



58 EEC3 TIMEOUT

Timeout of CAN-message EEC3 from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective an has contact to




59 TEST MODE SIGNAL CAN signal for test mode status is defective • cluster controller is defective • interference on CAN-Bus

Testmode is aborted, if activ • check cluster controller • check wire of CAN-Bus • check cable to cluster controller

5A PARKBRAKE STATUS SIGNAL CAN signal for parkbrake status is defective • cluster controller is defective • interference on CAN-Bus

no reaction ???? • check cluster controller • check wire of CAN-Bus • check cable to cluster controller

5B SHIFT QUALITY SEL SIGNAL CAN signal for shift qualtiy selection is defective • cluster controller is defective • interference on CAN-Bus


Not used

5C AUTO DOWNSHIFT SIGNAL CAN signal for automatic downshift is defective • cluster controller is defective • interference on CAN-Bus

last selection is kept • check cluster controller • check wire of CAN-Bus • check cable to cluster controller

5D MANUAL DOWNSHIFT SIGNAL CAN signal for manual downshift is defective • cluster controller is defective • interference on CAN-Bus

last selection is kept • check cluster controller • check wire of CAN-Bus • check cable to ???? controller

5E CCO REQUEST SIGNAL CAN signal for CCO request is defective • cluster controller is defective • interference on CAN-Bus

last selection is kept • check cluster controller • check wire of CAN-Bus • check cable to ???? controller

5F SHIFT LEVER SIGNAL CAN signal for shift lever is defective • I/O controller is defective • interference on CAN-Bus

TCU shifts to neutral and uses informations from substitute shift lever OP-Mode: normal


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3-1-76Orig

CD389


Fault Code (hex)



5F TRANSMISSION NEUTRAL REQUEST SIGNAL

CAN signal for transmission Neutral Request is defective • steering computer is defective • interference on CAN-Bus

OP-Mode: normal • check steering computer • check wire of CAN-Bus • check cable to steering computer

5F CAN MESSAGE ‘ FRONT WHEEL DRIVE STATUS

(V_IDENT_FWD)’ CONTAINS INVALID DATA TCU shifts to neutral • check FWD controller

60 ADDITIONAL BRAKE STATUS SIGNAL CAN signal for additional park brake status is defective • I/O controller is defective • interference on CAN-Bus

no reaction OP-Mode: normal


61 AEB REQUEST SIGNAL CAN signal for AEB request is defective • I/O controller is defective • interference on CAN-Bus

no reaction OP-Mode: normal Last selection is kept


62 PTO TORQUE SIGNAL CAN signal for PTO torque is defective • I/O controller is defective • interference on CAN-Bus

no reaction, TCU uses default PTO torque signal OP-Mode: normal


63 DRIVING MODE SIGNAL CAN signal for driving mode is defective • I/O controller is defective • interference on CAN-Bus

no reaction, TCU uses default driving mode signal OP-Mode: normal


64 STARTING GEAR SIGNAL CAN signal for starting gear is defective • I/O controller is defective

(illegal starting gear) • interference on CAN-Bus

no reaction, TCU uses default starting gear OP-Mode: normal


65 ENGINGE TORQUE SIGNAL CAN signal for engine torque is defective • engine controller is defective • interference on CAN-Bus

OP-Mode:substitute clutch control


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3-1-77Orig

CD389


Fault Code (hex)



69 REFERENCE ENGINE TORQUE SIGNAL

CAN signal for reference of engine torque is defective • engine controller is defective • interference on CAN-Bus



6A ACTUAL ENGINE TORQUE SIGNAL CAN signal for actual engine torque is defective • engine controller is defective • interference on CAN-Bus



6B NOM FRICTION TORQUE SIGNAL CAN signal for nominal friction torque is defective • engine controller is defective • interference on CAN-Bus



6E EEC2 TIMEOUT Timeout of CAN-message EEC2 from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


no reaction, TCU uses default signal accelerator pedal in idle position OP-Mode: normal


71 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 the measured resistance value of the valve is out of limit, the voltage at K1 valve is too high. • cable / connector is defective and has contact to

battery voltage • regulator has an internal defect

TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown

• check the cable from TCU to the gearbox

• check the connectors from TCU to the gearbox

• check the regulator resistance 1) • check internal wire harness of the

gearbox


72 S.C. TO GROUND AT CLUTCH K1 the measured resistance value of the valve is out of limit, the voltage at K1 valve is too low. • cable / connector is defective and has contact to

vehicle ground • cable / connector is defective and has contact to

another regulator output of the TCU • regulator has an internal defect



• check the connectors from gearbox to TCU


gearbox


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3-1-78Orig

CD389


Fault Code (hex)



73 O.C. AT CLUTCH K1

the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to

TCU • regulator has an internal defect





gearbox








gearbox









gearbox


76 O.C. AT CLUTCH K2 the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to






gearbox


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3-1-79Orig

CD389


Fault Code (hex)



77 S.C. TO BATTERY VOLTAGE AT CLUTCH K3

the measured resistance value of the valve is out of limit, the voltage at K3 valve is too high. • cable / connector is defective and has contact to

battery voltage • regulator has an internal defect •




• check the regulator resistance 1) • check internal wire harness of the gearbox









gearbox


79 O.C. AT CLUTCH K3 the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to






gearbox


7A S.C. TO BATTERY VOLTAGE AT CONVERTER CLUTCH no reaction OP-Mode: normal

• check the cable from TCU to the valve

• check the regulator resistance 1)

7B S.C. TO GROUND AT CONVERTER CLUTCH




7C O.C. AT CONVERTER CLUTCH




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3-1-80Orig

CD389


Fault Code (hex)



7D S.C. TO GROUND AT

ENGINE DERATING DEVICE • cable is defective and is contacted to vehicle ground • engine derating device has an internal defect • connector pin is contacted to vehicle ground

engine derating will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal

• check the cable from TCU to the engine derating device

• check the connectors from engine derating device to TCU

• check the resistance 1) of engine derating device


7E S.C. TO BATTERY VOLTAGE AT ENGINE DERATING DEVICE • cable / connector is defective and is contacted to

battery voltage • engine derating device has an internal defect



• check the connectors from backup alarm device to TCU

• check the resistance 1) of backup alarm device

7F O.C. AT ENGINE DERATING DEVICE TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • engine derating device has an internal defect • connector has no connection to TCU



• check the connectors from engine derating device to TCU

• check the resistance 1) of engine derating device








gearbox









gearbox


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3-1-81Orig

CD389


Fault Code (hex)



83 O.C. AT CLUTCH K4

the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to






gearbox


84 S.C. TO BATTERY VOLTAGE AT CLUTCH KV the measured resistance value of the valve is out of limit, the voltage at KV valve is too high. • cable / connector is defective and has contact to






gearbox


85 S.C. TO GROUND AT CLUTCH KV the measured resistance value of the valve is out of limit, the voltage at KV valve is too low. • cable / connector is defective and has contact to







gearbox


86 O.C. AT CLUTCH KV the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to






gearbox


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3-1-82Orig

CD389


Fault Code (hex)



87 S.C. TO BATTERY VOLTAGE AT CLUTCH KR

the measured resistance value of the valve is out of limit, the voltage at KR valve is too high. • cable / connector is defective and has contact to






gearbox


88 S.C. TO GROUND AT CLUTCH KR the measured resistance value of the valve is out of limit, the voltage at KR valve is too low. • cable / connector is defective and has contact to







gearbox


89 O.C. AT CLUTCH KR the measured resistance value of the valve is out of limit. • cable / connector is defective and has no contact to






gearbox


8A S.C. TO GROUND AT DLM TRANSVERSAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • device has an internal defect • connector pin is contacted to vehicle ground

output will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal


• check the connectors • check the resistance of valve


8B S.C. TO BATTERY VOLTAGE AT DLM TRANSVERSAL

OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • device has an internal defect • connector pin is contacted to battery voltage





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3-1-83Orig

CD389


Fault Code (hex)



8C O.C. AT DLM TRANSVERSAL OUTPUT

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





8D S.C. TO GROUND AT DLM INDICATOR LAMP OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • device has an internal defect • connector pin is contacted to vehicle ground


• check the cable from TCU to the device

• check the connectors • check the resistance of device


8E S.C. TO BATTERY VOLTAGE AT DLM INDICATOR LAMP

OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • device has an internal defect • connector pin is contacted to battery voltage





8F O.C. DLM INDICATOR LAMP OUTPUT TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • device has an internal defect • connector has no connection to TCU





91 S.C. TO GROUND AT RELAY REVERSE WARNING ALARM TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • backup alarm device has an internal defect • connector pin is contacted to vehicle ground

backup alarm will be on until TCU power down even if fault vanishes (loose connection) OP-Mode: normal

• check the cable from TCU to the backup alarm device




92 S.C. TO BATTERY VOLTAGE AT RELAY REVERSE WARNING

ALARM TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage




1) see chapter Fehler! Verweisquelle konnte nicht gefunden werden. Pro

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3-1-84Orig

CD389


Fault Code (hex)



• cable is defective and is contacted to battery voltage • backup alarm device has an internal defect • connector pin is contacted to battery voltage


93 O.C. AT RELAY REVERSE WARNING ALARM

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






94 S.C. TO GROUND AT RELAY STARTER INTERLOCK TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • starter interlock relay has an internal defect • connector pin is contacted to vehicle ground


• check the cable from TCU to the starter interlock relay

• check the connectors from starter interlock relay to TCU

• check the resistance 1) of starter interlock relay


95 S.C. TO BATTERY VOLTAGE AT RELAY STARTER

INTERLOCK TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • starter interlock relay has an internal defect • connector pin is contacted to battery voltage






96 O.C. AT RELAY STARTER INTERLOCK TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • starter interlock relay has an internal defect • connector has no connection to TCU






97 S.C. TO GROUND AT PARK BRAKE SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • park brake solenoid has an internal defect • connector pin is contacted to vehicle ground


• check the cable from TCU to the park brake solenoid

• check the connectors from park brake solenoid to TCU

• check the resistance 1) of park brake solenoid


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Fault Code (hex)



98 S.C. TO BATTERY VOLTAGE AT PARK BRAKE SOLENOID

TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • park brake solenoid has an internal defect • connector pin is contacted to battery voltag

no reaction optional: (some customers) TCU shifts to neutral caused by park brake feed back OP-Mode: normal





99 O.C. AT PARK BRAKE SOLENOID TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • park brake solenoid has an internal defect • connector has no connection to TCU

no reaction optional: (some customers) TCU shifts to neutral caused by park brake feed back OP-Mode: normal





9A S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH

SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • converter clutch solenoid has an internal defect • connector pin is contacted to vehicle ground

no reaction OP-mode: normal

• check the cable from TCU to the converter clutch solenoid

• check the connectors from converter clutch solenoid to TCU

• check the resistance 1) of converter clutch solenoid


9B O.C. AT CONVERTER LOCK UP CLUTCH SOLENOID TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • converter clutch solenoid has an internal defect • connector has no connection to TCU

converter clutch always open, retarder not available OP-mode: normal





9C S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP

CLUTCH SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • converter clutch solenoid has an internal defect • connector pin is contacted to battery voltage






9D S.C. TO GROUND AT RETARDER SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground


• check the cable from TCU to the retarder solenoid

• check the connectors from retarder solenoid to TCU

1) see chapter Fehler! Verweisquelle konnte nicht gefunden werden. Pro

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3-1-86Orig

CD389


Fault Code (hex)



• retarder solenoid has an internal defect • connector pin is contacted to vehicle ground

• check the resistance 1) of retarder solenoid

9E O.C. AT RETARDER SOLENOID TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • retarder solenoid has an internal defect • connector has no connection to TCU






9F S.C. TO BATTERY VOLTAGE AT RETARDER SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • retarder solenoid has an internal defect • connector pin is contacted to battery voltage






A1 S.C. TO GROUND AT DIFFLOCK OR AXLE CONNECTION

SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • difflock solenoid has an internal defect • connector pin is contacted to vehicle ground


• check the cable from TCU to the difflock solenoid

• check the connectors from difflock solenoid to TCU

• check the resistance 1) of difflock solenoid


A2 S.C. TO BATTERY VOLTAGE AT DIFFLOCK OR AXLE

CONNECTION SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • difflock solenoid has an internal defect • connector pin is contacted to battery voltage






A3 O.C. AT DIFFLOCK OR AXLE CONNECTION SOLENOID TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • difflock solenoid has an internal defect • connector has no connection to TCU






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Fault Code (hex)



A4 S.C. TO GROUND AT WARNING SIGNAL OUTPUT

TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • warning device has an internal defect • connector pin is contacted to vehicle ground


• check the cable from TCU to the warning device

• check the connectors from warning device to TCU

• check the resistance 1) of warning device


A5 O.C. AT WARNING SIGNAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • warning device has an internal defect • connector has no connection to TCU






A6 S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • warning device has an internal defect • connector pin is contacted to battery voltage






A7 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 4 TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • customer specific function no. 4 device has an






A8 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC







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Fault Code (hex)



A9 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 4

TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • customer specific function no. 4 device has an






AA S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 5 TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • customer specific function no. 5 device has an






AB S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC







AC O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 5 TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • customer specific function no. 5 device has an






AD S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 6 TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground

customer specific • check the cable from TCU to function 6 device



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Fault Code (hex)



• customer specific function no. 6 device has an


• check the resistance of function 6 device

AE S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC







AF O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 6 TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • customer specific function no. 6 device has an






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


• check pressure at clutch K1 • check main pressure in the system • check sensor gap at internal speed

sensor • check sensor gap at output speed

sensor • check signal at internal speed sensor • check signal at output speed sensor • replace clutch

B2 SLIPPAGE AT CLUTCH K2 TCU calculates a differential speed at closed clutch K2. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch K2 • low main pressure




sensor

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Fault Code (hex)



• wrong signal at internal speed sensor • wrong signal at output speed sensor • wrong size of the sensor gap • clutch is defective

• check signal at internal speed sensor • check signal at output speed sensor • replace clutch

B3 SLIPPAGE AT CLUTCH K3 TCU calculates a differential speed at closed clutch K3. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch K3 • low main pressure • wrong signal at internal speed sensor • wrong signal at output speed sensor • wrong size of the sensor gap • clutch is defective




sensor • check signal at internal speed sensor • check signal at output speed sensor • replace clutch

B4 SLIPPAGE AT CLUTCH K4 TCU calculated a difference speed at TCU calculates a differential speed at closed clutch K4. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch K4 • low main pressure • wrong signal at internal speed sensor • wrong signal at turbine speed sensor • wrong size of the sensor gap • clutch is defective



sensor • check sensor gap at turbine speed

sensor • check signal at internal speed sensor • check signal at turbine speed sensor • replace clutch

B5 SLIPPAGE AT CLUTCH KV TCU calculates a differential speed at closed clutch KV. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch KV • low main pressure • wrong signal at internal speed sensor • wrong signal at turbine speed sensor


• check pressure at clutch KV • check main pressure in the system • check sensor gap at internal speed


sensor • check signal at internal speed sensor • check signal at turbine speed sensor

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Fault Code (hex)



• wrong size of the sensor gap • clutch is defective

• replace clutch

B6 SLIPPAGE AT CLUTCH KR TCU calculates a differential speed at closed clutch KR. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at clutch KR • low main pressure • wrong signal at internal speed sensor • wrong signal at turbine speed sensor • wrong size of the sensor gap • clutch is defective


• check pressure at clutch KR • check main pressure in the system • check sensor gap at internal speed


sensor • check signal at internal speed sensor • check signal at turbine speed sensor • replace clutch

B7 OVERTEMP SUMP TCU measured a temperature in the oil sump that is over the allowed threshold.


• cool down machine • check oil level • check temperature sensor

B8 OVERTEMP RETARDER TCU measured a temperature in the retarder oil that is over the allowed threshold.

TCU disables retarder OP-Mode: normal


B9 OVERSPEED ENGINE

retarder applies if configured OP-Mode: normal

-

BA DIFFERENTIAL PRESSURE OIL FILTER TCU measured a voltage at differential pressure switch out of the allowed range • oil filter is polluted • cable/connector is broken or

cable/connector is contacted to battery voltage or vehicle ground

• differential pressure switch is defective


• check oil filter • check wiring from TCU to

differential pressure switch • check differential pressure switch

(measure resitance)

BB SLIPPAGE AT CONVERTER LOCKUP CLUTCH TCU calculates a differential speed at closed converter lockup clutch. If this calculated value is out of range, TCU interprets this as slipping clutch. • low pressure at converter lockup clutch

• check pressure at converter lockup clutch

• check main pressure in the system • check sensor gap at engine speed

sensor

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CD389


Fault Code (hex)



• low main pressure • wrong signal at engine speed sensor • wrong signal at turbine speed sensor • wrong size of the sensor gap • clutch is defective

• check sensor gap at turbine speed sensor

• check signal at engine speed sensor • check signal at turbine speed sensor • replace clutch

BC OVERSPEED OUTPUT TCU messures an transmission output speed above the defined threshold

No reaction OP-Mode: normal

BD S.C. TO GROUND AT ENGINE BRKAE SOLENOID TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • engine brake solenoid has an internal defect • connector pin is contacted to vehicle ground


• check the cable from TCU to the engine brake solenoid

• check the connectors from engine brake solenoid to TCU

• check the resistance 1) of engine brake solenoid


BE S.C. TO BATTERY VOLTAGE AT ENGINE BRAKE TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • engine brake solenoid has an internal defect • connector pin is contacted to battery voltage






BF O.C. AT ENGINE BRAKE TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • engine brake solenoid has an internal defect • connector has no connection to TCU






C0 ENGINE TORQUE OR ENGINE POWER OVERLOAD TCU calculates an engine torque or engine power above the defined thresholds

OP-Mode: normal

C1 TRANSMISSION OUTPUT TORQUE OVERLOAD TCU calculates an transmission output torque above the defined threshold

OP-Mode: normal Prope

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Fault Code (hex)



C2 TRANSMISSION INPUT TORQUE OVERLOAD

TCU calculates an transmission input torque above the defined threshold

programmable :No reaction or shift to neutral OP-Mode: normal

C3 OVERTEMP CONVERTER OUTPUT TCU measured a oil temperature at the converter ouput that is over the allowed threshold.



C4 S.C. TO GROUND AT JOYSTICK STATUS INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • joystick status indicator has an internal defect • connector pin is contacted to vehicle ground


• check the cable from TCU to joystick status indicator

• check the connectors from joystick status indicator to TCU

• check the resistance 1) of joystick status indicator

C5 S.C. TO BATTERY VOLTAGE AT JOYSTICK STATUS INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage • cable is defective and is contacted to battery voltage • joystick status indicator has an internal defect • connector pin is contacted to battery voltage





C6 O.C. AT JOYSTICK STATUS INDICATOR TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • joystick status indicator has an internal defect • connector has no connection to TCU





C7 S.C. TO GROUND AT OVERTEMP NEUTRAL

INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • overtemp status indicator has an internal defect • connector pin is contacted to vehicle ground


• check the cable from TCU to OVERTEMP NEUTRAL INDICATOR

• check the connectors from OVERTEMP NEUTRAL INDICATOR to TCU

• check the resistance 1) of OVERTEMP NEUTRAL INDICATOR

C8 S.C. TO BATTERY VOLTAGE AT OVERTEMP NEUTRAL

INDICATOR TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage



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CD389


Fault Code (hex)



• cable is defective and is contacted to battery voltage • overtemp status indicator has an internal defect • connector pin is contacted to battery voltage



C9 O.C. AT OVERTEMP NEUTRAL INDICATOR TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • OVETEMP status indicator has an internal defect • connector has no connection to TCU





CA ENGINE_RETARDER CONFIG_TIMEOUT Timeout of CAN-message ENGINE_RETARDER CONFIG from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective an has contact to




CB ERC1 TIMEOUT Timeout of CAN-message ERC1 from EEC controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective an has contact to




fault codes no. 21 to no. 2C may be a reaction of this fault

D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR

SENSORS TCU measures more than 6V at the pin AU1 (5V sensor supply)

see fault codes no. 21 to 2C • check cables and connectors to sensors, which are supplied from AU1

• check the power supply at the pin AU1 (should be appx. 5V)

D2 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS TCU measures less than 4V at the pin AU1 (5V sensor supply)

see fault codes no. 21 to 2C • check cables and connectors to sensors, which are supplied from AU1

• check the power supply at the pin AU1 (should be appx. 5V)

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Fault Code (hex)



D3 LOW VOLTAGE AT BATTERY

measured voltage at power supply is lower than 10 V (12V device) lower than 18 V (24V device)

shift to neutral OP-Mode: TCU shutdown

• check power supply battery • check cables from batteries to TCU • check connectors from batteries to

TCU

D4 HIGH VOLTAGE AT BATTERY measured voltage at power supply is higher than 18 V (12V device) higher than 32.5 V (24V device)


• check power supply battery • check cables from batteries to TCU • check connectors from batteries to

TCU

D5 ERROR AT VALVE POWER SUPPLY VPS1 TCU switched on VPS1 and measured VPS1 is off or TCU switched off VPS1 and measured VPS1 is still on • cable or connectors are defect and are contacted to

battery voltage • cable or connectors are defect and are contacted to

vehicle ground • permanent power supply KL30 missing • TCU has an internal defect


• check fuse • check cables from gearbox to TCU • check connectors from gearbox to

TCU • replace TCU

D6 ERROR VALVE POWER SUPPLY VPS2 TCU switched on VPS2 and measured VPS2 is off or TCU switched off VPS2 and measured VPS2 is still on • cable or connectors are defect and are contacted to

battery voltage • cable or connectors are defect and are contacted to

vehicle ground • permanent power supply KL30 missing • TCU has an internal defect


• check fuse • check cables from gearbox to TCU • check connectors from gearbox to

TCU • replace TCU

D7 S.C. TO GROUND AT DLM LONGITUDINAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to vehicle ground • cable is defective and is contacted to vehicle ground • device has an internal defect • connector pin is contacted to vehicle ground




D8 S.C. TO BATTERY VOLTAGE AT DLM LONGITUDINAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a s.c. to battery voltage



• check the connectors

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Fault Code (hex)



• cable is defective and is contacted to battery voltage • device has an internal defect • connector pin is contacted to battery voltage

• check the resistance of valve

D9 O.C. AT DLM LONGITUDINAL OUTPUT TCU detected a wrong voltage at the output pin, that looks like a o.c. for this output pin • cable is defective and has no connection to TCU • device has an internal defect • connector has no connection to TCU




E1 OPEN CIRCUIT AT DIRECTION SELECT SIGNALS TCU detected a o.c signals for the direction • cable from shift lever to TCU is broken • cable is defective and is contacted to vehicle ground • shift lever is defective



E2 OPEN CIRCUIT AT DIRECTION SELECT SIGNALS OF SHIFTER 2 TCU detected a o.c signals for the direction • cable from shift lever to TCU is broken • cable is defective and is contacted to vehicle ground • shift lever is defective



E3 S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT TCU sends data to the display and measures allways a high voltage level on the connector • cable or connectors are defective and are contacted

to battery voltage • display has an internal defect


• check the cable from TCU to the display

• check the connectors at the display • change display

E4 S.C. TO GROUND AT DISPLAY OUTPUT TCU sends data to the display and measures allways a high voltage level on the connector • cable or connectors are defective and are contacted

to vehicle ground • display has an internal defect


• check the cable from TCU to the display

• check the connectors at the display • change display

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Fault Code (hex)



E5 DISPID1_TIMEOUT

Timeout of CAN-message DISPID1 from display controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


TCU select parameter set with ID0 OP-Mode: Limp Home

• check display controller • check wire of CAN-Bus • check cable to display controller

E5 CL1 TIMEOUT Timeout of CAN-message CL1 from cluster controller • interference on CAN-Bus • CAN wire/connector is broken • CAN wire/connector is defective and has contact to


TCU keeps old information for: status test mode status plock shift quality selection gear range restriction OP-Mode: normal


E6 ILLEGAL ID REQUEST VIA CAN

transmission stay neutral OP-Mode: TCU shutdown

F1 GENERAL EEPROM FAULT TCU can't read non volantile memoy • TCU is defective


• replace TCU

F2 CONFIGURATION LOST TCU has lost the correct configuration and can't control the transmission. • interference during saving data on non volatile

memory • TCU is brand new or from another vehicle


• Reprogramm the correct configuration for the vehicle (e.g. with cluster controller,...)

F2 FWD CONFIGURATION LOST TCU has lost the FWD configuration. • interference during saving data on non volatile

memory • TCU is brand new or from another vehicle

gear range set from 1st to 4th • reconfigure with TCU Configuration Command

(ID PC)

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Fault Code (hex)



F3 APPLICATION ERROR

something of this application is wrong


• replace TCU !! This fault occurs only if an test engineer did something wrong in the application of the vehicle

F4 LIMP HOME REQUEST no fault! indicates that another computer requested limp home via CAN

shift to neutral OP-Mode: limp home

• The external controller has to cancel the request

F5 CLUTCH FAILURE AEB was not able to adjust clutch filling parameters • One of the AEB-Values is out of limit


• check clutch TCU shows also the affected clutch on the Display

F6 CLUTCH ADJUSTMENT DATA LOST OR INCHPEDAL

CALIBRATION DATA LOST TCU was not able to read correct clutch adjustment parameters • interference during saving data on non volatile

memory • TCU is brand new

default values = 0 for AEB offsets used OP-Mode: normal no Inchmode available

• execute AEB

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Property of American Airlines Overhaul - s3.amazonaws.com · 3-1-1 Orig CD389 Chapter 3 GT110 (24V)...

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Transcript of Property of American Airlines Overhaul - s3.amazonaws.com · 3-1-1 Orig CD389 Chapter 3 GT110 (24V)...