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Printed in Germany
ZF Friedrichshafen AG
Competence Contents LKS-T / Editing MC-C
Edition: 2004-02
SW31_13e
1328 754 105
Abbreviations - Contents
AbbreviationMeaning
ABSAnti-locking system
ADVP Digital output power supply (+)
alpha_fp Accelerator pedal position (value in %)
ALInsufficient air (air deficiency)
ASR Anti-slip control
aux_stat_zbr CAN message
BNVehicle power supply
Buka Terminal tester
CAN Controller Area Network (CAN)
ECU Electronic control unit (Transmission control)
EDCElectronic-diesel-control (EDC) (engine electronics)
Eol_ParameterEnd of line (entry of vehicle parameter e.g. rear axle ratio)
ERC1_DR CAN message
ESTElectronic control (e.g. Intarder control EST 48)
FFR Vehicle controller
Fzg Vehicle
GAGate
GBTransmission brake
GVSplitter group
GVLSplitter group, low
GVSSplitter group, high
GPRange change group (planetary group)
GPLRange change group, low
GPSRange change group, high
GS Transmission actuator
HGMain transmission
i_HARear axle ratio
i.OOK
InkIncremental (step)
Kitas
K1Constant 1
K2Constant 2
KMShort circuit to earth/ground
KPShort circuit to positive
KSClutch actuator
m_dd_edc Calculated EDC injection rate (driver's request)
m_mbr Current engine brake torque
m_mot_aktCurrent injection quantity for EDC engine
m_sekret Secondary retarder brake torque from CAN message ERC1 taken from
n_mot Engine speed (rpm)
n_sek Transmission output shaft speed
OEMOriginal equipment manufacturer
PTO Power-take-off
TC1_FT CAN message
UFBFaultfinding, rectification
v_cc_set Cruise control set requested speed
Valeo Clutch manufacturer
VM Supply ground
WSIWheel speed information (CAN message)
z_FbrFoot brake signal
z_kd Kickdown signal
z_low_idleIdling switch signal
z_ret_rück Intarder down-shifting request
IVECOZF
5B
5C
5D
5E
5F
6B
6C
6E
7A
7B
7C
7E
7F
8A
8B
8C
8D
8E
8F
9A
9B
9C
9D
9E
9F
A0
A3
A4
A5
A6
A8
A9
AB
AE
AF
B
B1
B2
B3
B4
B5
B6
B7
B8
BC
BE
BF
C
C0
C1
C2
C5
C7
Error description:Error 02 – 10: Short circuit to ground at output to valve Y2 – Y10.
Error 34 - 42: Interruption at output to valve Y2 – Y10.
Error 66 -74: Short circuit to plus (+) at output to valve Y2 – Y10
Error detection: By ECU hardware, if output is activated.
System response: The automatic shift unit is deactivated. If the error occurs during shifting,
the selected gear remains engaged, depending on the driving condition, or
the ECU tries to shift to an equivalent gear. If both options are not possible,
the main transmission (HG) shifts into neutral. Engagement of selected
substitute gears during standstill and driving is possible.
Short-circuited shift valve outputs are deactivated.
Error present during ignition on, engine start impossible.
Follow-up error possible, ZF error number: 155 (9B), 152 (98) , 150 (96)
148 (94), 144 (90), 136 (88). If 2 errors do occur, then, the system is not
available!
Error rectification:
Completely replace
transmission actuator (in acc.
with rep. manual)
Alternative solution
Disassemble transmission
actuator
(upper-lower section)
Replace transmission actuator
lower section
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_02, 34, 66
Error description: Error 17 Short circuit to ground at output to valve Y1 (GB).
Error 49 Interruption at output to valve Y1 (GB).
Error 81 Short circuit to plus (+) at output to valve Y1 (GB).
Error detection: By ECU hardware, if output is activated.
System response: During travel, upshifts are handled just as downshifts. Input speed is
synchronized by engine speed.
Upshifts are inhibited if target speed is smaller than engine idling speed.
Prolonged shift time. Stationary: Prolonged teach-in time. Prolonged shift
time when shifting out of neutral. Prolonged shift time out of PTO mode.
The automatic shift unit is deactivated. Driving in manual mode possible.
In case of ZF error 81 (51), gear shifts are inhibited. Shifting into starting
gears and driving off is possible.
Follow-up error possible: ZF error number 155 (9B).
Error rectification:
Replace transmission actuator
(in acc. with rep. manual)
Alternative solution
Disassemble transmission
actuator
(upper-lower section)
Replace transmission actuator
lower section
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_17, 49, 81
Error description: Error 18: Short circuit to ground Y17 valve clutch slowly opening.
Error 50: Interruption. Y17 valve clutch slowly opening.
Error 82: Short circuit to plus (+) Y17 valve clutch slowly opening.
Error detection: By ECU hardware, if output is activated.
System response: ECU output is deactivating. Two valves are responsible for opening and two
valves are responsible for closing (fast, slow). If one Close/Open valve fails,
this function is adopted by the other Close/Open valve. Reduced comfort
when maneuvering and starting. If both closing and opening valve fail, the
system is not available. The automatic shift unit is deactivated. Driving in
manual mode possible.
In case of error 82 gear shifting is completely inhibited. The system is not
available. If the error occurs during travel, attempts are made to keep the
clutch engaged. As soon as the vehicle comes to a standstill and the clutch
opens, the system automatically shifts to neutral.
Error rectification:
Ignition OFF
Disconnect clutch actuator from
transmission actuator and connect it to
terminal tester.
Short circuit
to ground
Interruption
AS IS approx.
Replace clutch
< 10 Ohm or
0 Ohm
actuator
AS IS > 22 Ohm
AS IS approx.
10 -20 Ohm
Contact ZF
Replace clutch
actuator
AS IS approx.
10 -22 Ohm
Contact ZF
Measurements at cable connector to
transmission actuator or in terminal tester.
Resistance measurement Y17 valve clutch
slowly opening: Pin 9 (A) to Pin 16/17 (J)
Short circuit
to plus (+)
- Disconnect clutch actuator.
- Ignition on
- Abort diagnosis and new start.
-Read out the error memor
Error interruption in error
memory
Replace clutch actuator
Error short circuit to plus (+) in
the error memory
Bypass ground
y.
Replace transmission actuator
Note
Correct value = 15.6 Ohm. However, to take proper account of temperature-related factors and
measurement errors and/or measurement conditions, ensure system stays within the above-mentioned
tolerance limits!
ZF Friedrichshafen AG ZF-ASTRONIC_1328_754_105_018,50,82
LKS-T 2003-06-25
Error description: Error 19: Short circuit to ground Y15 valve clutch slowly closing.
Error 51: Interruption Y15 valve clutch slowly closing.
Error 83: Short circuit to plus (+) Y15 valve clutch slowly closing.
Error detection: By ECU hardware, if output is activated.
System response: ECU output is deactivating. Two valves are responsible for opening and two
valves are responsible for closing (fast, slow). If one Close/Open valve fails,
this function is adopted by the other Close/Open valve. Reduced comfort
when maneuvering and starting. If both closing and opening valve fail, the
system is not available. The automatic shift unit is deactivated. Driving in
manual mode possible.
In case of error 83 gear shifting is completely inhibited. The system is not
available. If the error occurs during travel, attempts are made to keep the
clutch engaged. As soon as the vehicle comes to a standstill and the clutch
opens, the system automatically shifts to neutral.
Error rectification:
Ignition OFF
Disconnect clutch actuator from
transmission actuator and connect it to
terminal tester.
Short circuit
to ground
Interruption
AS IS approx.
< 10 Ohm or
0 Ohm
Replace clutch
actuator
AS IS approx.
10 -20 Ohm
Contact ZF
AS IS > 22 Ohm
Replace clutch
actuator
AS IS approx.
10 - 22 Ohm
Contact ZF
Measurements at cable connector to
transmission actuator or in terminal tester.
Resistance measurement Y15 valve clutch
slowly closing: Pin 7 (A) to Pin 16/17 (J)
Short circuit
to plus (+)
- Disconnect clutch actuator.
- Ignition on
- Abort diagnosis and new start.
-Read ou
t the error memory.
Error interruption in error
memory
Replace clutch actuator
Error short circuit to plus (+) in
the error memory
Bypass ground
Replace transmission actuator
Note
Correct value = 15.6 Ohm. However, to take proper account of temperature-related factors and
measurement errors and/or measurement conditions, ensure system stays within the above-mentioned
tolerance limits!
ZF Friedrichshafen AG ZF-ASTRONIC_1328_754_105_019,51,83
LKS-T 2003-06-25
Error description: Error 20: Short circuit to ground Y16 valve, fast opening clutch.
Error 52: Interruption.
Error 84: Short circuit to plus (+)
Error detection: By ECU hardware, if output is activated.
System response: ECU output is deactivating. Two valves are responsible for opening and two
valves are responsible for closing (fast, slow). If one Close/Open valve fails,
this function is adopted by the other Close/Open valve. Reduced comfort
when maneuvering and starting. If both closing and opening valve fail, the
system is not available. The automatic shift unit is deactivated. Driving in
manual mode possible.
In case of error 84 gear shifting is completely inhibited. The system is not
available. If the error occurs during travel, attempts are made to keep the
clutch engaged. As soon as the vehicle comes to a standstill and the clutch
opens, the system automatically shifts to neutral.
Error rectification:
Ignition OFF
Disconnect clutch actuator from
transmission actuator and connect it to
terminal tester.
Short circuit
to ground
Interruption
AS IS approx.
Replace clutch
AS IS approx.
< 10 Ohm or
0 Ohm
actuator
10 - 20 Ohm
Contact ZF
AS IS > 22 Ohm
Replace clutch
actuator
AS IS approx.
10 - 22 Ohm
Contact ZF
Measurements at cable connector to
transmission actuator or in terminal tester.
Resistance measurement
slowly closing:
Pin 12 (D) to Pin 16/17 (J)
Y16 valve clutch
Short circuit
to plus (+)
- Disconnect clutch actuator.
- Ignition on
- Abort diagnosis and new start.
-Read out the error memor
Error interruption in error
memory
Replace clutch actuator
Error short circuit to plus (+) in
Bypass ground
y.
the error memory
Replace transmission actuator
Note
Correct value = 15.6 Ohm. However, to take proper account of temperature-related factors and
measurement errors and/or measurement conditions, ensure system stays within the above-mentioned
tolerance limits!
ZF Friedrichshafen AG ZF-ASTRONIC_1328_754_105_020,52,84
LKS-T 2003-06-25
Error description: Error 21: Short circuit to ground Y14 valve clutch fast closing.
Error 53: Interruption Y14 valve clutch fast closing.
Error 85: Short circuit to plus (+) Y14 valve clutch fast closing.
Error detection: By ECU hardware, if output is activated.
System response: ECU output is deactivating. Two valves are responsible for opening and two
valves are responsible for closing (fast, slow). If one Close/Open valve fails,
this function is adopted by the other Close/Open valve. Reduced comfort
when maneuvering and starting. If both closing and opening valve fail, the
system is not available. The automatic shift unit is deactivated. Driving in
manual mode possible.
In case of error 85 gear shifting is completely inhibited. The system is not
available. If the error occurs during travel, attempts are made to keep the
clutch engaged. As soon as the vehicle comes to a standstill and the clutch
opens, the system automatically shifts to neutral.
Error rectification:
Ignition OFF
Disconnect clutch actuator from
transmission actuator and connect it to
terminal tester.
Short circuit
to ground
Interruption
AS IS approx.
Replace clutch
< 10 Ohm or
0 Ohm
actuator
AS IS > 22 Ohm
AS IS approx.
10 - 20 Ohm
Contact ZF
Replace clutch
actuator
AS IS approx.
10 - 22 Ohm
Contact ZF
Measurements at cable connector to
transmission actuator or in terminal tester.
Resistance measurement
slowly closing:
Pin 8 (B) to pin 16/17 (J)
Y14 valve clutch
Short circuit
to plus (+)
- Disconnect clutch actuator.
- Ignition on
- Abort diagnosis and new start.
-Read out the error memor
Error interruption in error
memory
Replace clutch actuator
Error short circuit to plus (+) in
the error memory
Bypass ground
y.
Replace transmission actuator
Note
Correct value = 15.6 Ohm. However, to take proper account of temperature-related factors and
measurement errors and/or measurement conditions, ensure system stays within the above-mentioned
tolerance limits!
ZF Friedrichshafen AG ZF-ASTRONIC_1328_754_105_021,53,85 ZFLKS-T 2003-06-25
Error description: Error 22: Short circuit to ground at ADVP output.
Error 54: Interruption at ADVP output.
Error 86: Short circuit to plus (+) at ADVP output.
Error detection: By ECU hardware.
System response: Error 22, 54: During driving, gear shifts are inhibited.
The clutch opens as soon as the vehicle comes to a standstill.
stops, neutral position is automatically engaged
. Other gear shifts not possible.
When vehicle
System not available.
Notice: Regardless of the location where the short circuit is produced
(whether at the n_ab1 sensor, range selector, on the GS (transmission
actuator) or at a location at the wiring harness), with the current system
configuration in place, this will result in the vehicle being stranded.
Error 86: System still available.
Error rectification:
ADVP pin 11 after ignition
ON: Nominal: approx. 24 V
Replace transmission actuator
(in acc. with rep. manual)
Wiring/Range selector
Iveco-end OK
Repair Iveco wiring/range
selector
Check ZF output speed sensor,
sensor 1 (transmission wiring GS
(transmission actuator)– KS (clutch
actuator) – sensor).
Replace/Repair output speed
sensor
Repair/Replace ZF wiring
Replace transmission actuator
(in acc. with rep. manual)
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_22, 54, 86
Iveco error number: 19
Error display: In vehicle display: 19
MobiDig/ Testman 25
Error description: Short circuit to ground at SD output to display.
Error detection: Repeated reading of the signal to be transferred.
System response: ”EE“ message flashing on display. No further system responses.
Error rectification:
MUX vehicles do not use this
output!
Check wiring/plug
transmission actuator pin 9 at
vehicle-end.
Replace vehicle-end wiring.
Display (position/connection)
possibly check pin 1 to pin 3!
Replace/Repair display.
Internal defect at transmission
actuator plug
Replace transmission actuator.
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_25
Iveco error number: 1A
Error display: In vehicle display: 1A
MobiDig/ Testman: 26
Error description: CAN engine configuration timeout.
Error detection: An error is set after the message timeout.
System response: The substitute signals saved in the control unit are used since there are no
CAN message signals. Reduced function possible during automatic
operations and starting gear calculation.
Connecting speed for downshifts may be too low.
Poor clutch opening possible when stopping.
Error rectification:
Message is generated in the EDC.
Check whether error is saved in
EDC (timeout).
Error active?
Check fuse box
fuses!
Further errors saved to
transmission electronic unit?
e.g. error 33/113/178
Software possibly old version;
program most recent version.
Conduct CAN bus check as in case
of error 28 because this is a timeout
error!
Error saved in
EDC?
Replace EDC
(OEM)
Check EDC and/or
engine speed
signal (OEM)
Error not saved
in EDC
EDC
deactivation
relay defective?
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_26
Iveco error number: 1B
Error display: In vehicle display: 1B
MobiDig/ Testman: 27
Error description: Signal error engine configuration message.
Error detection: No signal or signal defective.
System response: The substitute signals saved in the control unit are used since there are no
CAN message signals. Reduced function possible during automatic
operations and starting gear calculation.
Connecting speed for downshifts may be too low.
Poor clutch opening possible when stopping.
Error rectification:
Message is generated in the EDC.
Check whether error is saved in
EDC
(timeout).
Further errors saved to
transmission electronic unit?
e.g. error 27, 31
Software possibly old version;
program most recent version.
CAN bus check as in the case of
error 28 because this is a timeout
error!
Error saved in
EDC?
Check EDC and/or
engine speed
signal (OEM)
Error not saved
in EDC!
EDC
deactivation
relay defective?
Replace EDC
(OEM)
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_27
Iveco error number: 1C
Error display: In vehicle display: 1C
MobiDig/ Testman 28
Error description: Signal error "current driveline retarder torque percentage“
Error detection: No signal or signal defective.
System response: The automatic unit fails. Therefore, the drive resistance of the starting gear
cannot be calculated. If vehicle comes to a standstill, mid-starting gear is
selected. No other functional restrictions.
Error rectification:
Ignition off!
Connect terminal tester between
transmission actuator (GS) and
vehicle wiring.
CAN H Pin 8 to GS
CAN L Pin 12 to GS
CAN H+ Pin 14 from GS
CAN L+ Pin 13 from GS
Further CAN errors present
(183, 184, etc.)?
Ignition off!
CAN bus test with digital multimeter
Resistance measurement between CAN H and CAN L - ignition off!
Further Intarder errors
(e.g. 27, 29)?
Nominal: 60 Ohm
AS IS: approx. 0 Ohm Short circuit from CAN H to
CAN L
AS IS: approx. 120 Ohm Connection to one terminator
damaged.
AS IS: high ohm reading CAN interrupted and/or both
Check/Replace Intarder
terminators dama
ged/not connected.
electronics.
Start vehicle again.
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_28
Iveco error number: 1D
Error display: In vehicle display: 1D
MobiDig/ Testman 29
Error description: Signal error: "Engine cooling performance increase".
Error detection: No signal or signal defective.
System response: No downshift requests are issued by the Intarder so to increase the engine
speed for improving cooling performance!
Error rectification:
Ignition off!
Connect terminal tester between
transmission actuator (GS) and
vehicle wiring.
CAN H Pin 8 to GS
CAN L Pin 12 to GS
CAN H+ Pin 14 from GS
CAN L+ Pin 13 from GS
Further CAN errors present
(183, 184, etc.)?
Ignition off!
CAN bus test with digital multimeter
Resistance measurement between CAN H and CAN L - ignition off!
Further Intarder errors
(e.g. 27, 28)?
Nominal: 60 Ohm
AS IS: approx. 0 Ohm Short circuit from CAN H to
CAN L
AS IS: approx. 120 Ohm Connection to one terminator
damaged.
AS IS: high ohm reading CAN interrupted and/or both
Check/Replace Intarder
terminators dama
ged/not connected.
electronics.
Start vehicle again.
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_29
Iveco error number: 1E
Error display: In vehicle display: 1E
MobiDig/ Testman 30
Error description: Signal error: "Driveline retarder configuration".
Error detection: No signal or signal defective.
System response: The automatic shift unit is deactivated. If vehicle comes to a standstill, mid-
starting gear is selected. No other functional restrictions.
Error rectification:
Ignition off!
Connect terminal tester between
transmission actuator (GS) and
vehicle wiring.
CAN H Pin 8 to GS
CAN L Pin 12 to GS
CAN H+ Pin 14 from GS
CAN L+ Pin 13 from GS
Further CAN errors present
(183, 184, etc.)?
Ignition off!
CAN bus test with digital multimeter
Resistance measurement between CAN H and CAN L - ignition off!
Further Intarder errors
(e.g. 27, 28)?
Nominal: 60 Ohm
AS IS: approx. 0 Ohm Short circuit from CAN H to
CAN L
AS IS: approx. 120 Ohm Connection to one terminator
damaged.
AS IS: high ohm reading CAN interrupted and/or both
Check/Replace Intarder
terminators damaged/not connected.
electronics.
Start vehicle again.
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_30
Iveco error number: 1F
Error display: In vehicle display: 1F
MobiDig/ Testman 31
Error description: Signal error: "Present engine retarder torque percentage".
Error detection: No signal or signal defective.
System response: The automatic shift unit is deactivated. If vehicle comes to a standstill, mid-
starting gear is selected. No other functional restrictions. No information
about the engine braking torque. If the engine brake is active, the shift
quality may be reduced. It is assumed that the engine brake is not active.
Error rectification:
Ignition off!
Connect terminal tester between
transmission actuator (GS) and
vehicle wiring.
CAN H Pin 8 to GS
CAN L Pin 12 to GS
CAN H+ Pin 14 from GS
CAN L+ Pin 13 from GS
Further CAN errors present
(183, 184, etc.)?
Ignition off!
CAN bus test with digital multimeter
Further Intarder errors
(e.g. 27, 28)?
Resistance measurement between CAN H and CAN L - ignition off!
Nominal: 60 Ohm
AS IS: approx. 0 Ohm Short circuit from CAN H to
CAN L
AS IS: approx. 120 Ohm Connection to one terminator
Check/Replace Intarder
electronics.
AS IS: high ohm reading CAN interrupted and/or both
damaged.
terminators damaged/not connected.
Start vehicle again.
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_31
Iveco error number: 20
Error display: In vehicle display: 20
MobiDig/ Testman 32
Error description: Signal error: "Engine retarder configuration".
Error detection: No signal or signal defective.
System response: The automatic shift unit is deactivated. If vehicle comes to a standstill, mid-
starting gear is selected. No other functional restrictions.
Error rectification:
Ignition off!
Connect terminal tester between
transmission actuator (GS) and
vehicle wiring.
CAN H Pin 8 to GS
CAN L Pin 12 to GS
CAN H+ Pin 14 from GS
CAN L+ Pin 13 from GS
Further CAN errors present
(183, 184, etc.)?
Ignition off!
CAN bus test with digital multimeter
Further Intarder errors
(e.g. 27, 28)?
Resistance measurement between CAN H and CAN L - ignition off!
Nominal: 60 Ohm
AS IS: approx. 0 Ohm Short circuit from CAN H to
CAN L
AS IS: approx. 120 Ohm Connection to one terminator
Check/Replace Intarder
electronics.
AS IS: high ohm reading CAN interrupted and/or both
damaged.
terminators damaged/not connected.
Start vehicle again.
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_32
Iveco error number: 21
Error display: In vehicle display: 21
MobiDig/ Testman 33
Error description: CAN timeout "Motor Retarder configuration".
Error detection: An error is set after the message timeout.
System response: The automatic shift unit is deactivated. If vehicle comes to a standstill, mid-
starting gear is selected. No other functional restrictions.
Error rectification:
Ignition off!
Check fuse box fuses!
Connect terminal tester between
transmission actuator (GS) and
vehicle wiring.
CAN H Pin 8 to GS
CAN L Pin 12 to GS
CAN H+ Pin 14 from GS
CAN L+ Pin 13 from GS
Error active?
Further CAN errors present
(26, 178, 183, 184, etc.)?
Further Intarder errors
(e.g. 27, 28)?
Ignition off!
Check/Replace Intarder
electronics.
CAN bus test with digital multimeter
Resistance measurement between CAN H and CAN L - ignition off!
Nominal: 60 Ohm
AS IS: approx. 0 Ohm Short circuit from CAN H to
CAN L
Start vehicle again.
AS IS: approx. 120 Ohm Connection to one terminator
damaged.
AS IS: high ohm reading CAN interrupted and/or both
terminators damaged/not connected.
ZF Friedrichshafen AG
LKS-T 2004-01 ZF-ASTRONIC_1328_754_105_33
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