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Section F Transmission Section F

The Electronic Monitoring System (EMS) will display an error code in the event of a transmission system failure.

The code appears in the top line of the EMS viewer, in the format: ZFCB ERROR ??.

Errorcode detected Possible causes Solution

12 Logical error in selection signal of l Breakage of the cable between the gear lever andl Check the cables between the
sense. TCU. TCU and the lever of change.
l Defects in the cable that result in l Check the combinations
contact with the battery voltage or ground. of the lever signals of the
l Defects in the gear lever. change F-N-R.

25 Short circuit at battery voltage or l Defects in the cable that result in l Check the cable between the
open circuit at the sensor input of contact with the battery voltage or ground. TCU and the sensor.
temperature of the oil collector of the l Cable not connected to the TCU. l Check the connectors
transmission. l Internal defect in temperature sensor. l Check the sensor of
l Broken connector plug or in contact with the temperature.
battery voltage.

26 Short circuit to ground at the input of the l Defects in the cable that result in Check the cable between the
temperature sensor of the collector contact with the vehicle mass. TCU and the sensor.
transmission oil. l Internal defect in temperature sensor. l Check the connectors.
l Contact connector plug with ground l Check the sensor of
of the vehicle. temperature.

27 Short circuit at battery voltage or l Defects in the cable that result in l Check the cable between the
open circuit at the sensor input contact with the battery voltage. TCU and the sensor.
output temperature of the converter. l Cable not connected to the TCU. l Check the connectors.
l Internal defect in temperature sensor. l Check the sensor of
l Broken connector plug or in contact with the temperature.
battery voltage.

28 Short circuit to ground at the input of the Defects in the cable that result in
translatedText l Check the cable between the
outputtemperaturesensorofthe contact with the mass of the vehicle. TCU and the sensor.
converter. l Internal defect in temperature sensor. l Check the connectors.
l Connector pin in contact with the ground l Check the sensor of
of the vehicle. temperature.

31 Short circuit to the battery voltage or l Defects in the cable that result in l Check the cable between the
open circuit at the sensor input contact with the battery voltage. TCU and the sensor.
motor speed. l Cable not connected to the TCU. l Check the connectors.
l Internal defect in speed sensor. l Check the sensor of
l Broken connector pin or in contact with the speed.
battery voltage.

32 Short circuit to ground at the input of l Defects in the cable that result in l Check the cable between the
motor speed sensor. contact with the vehicle's mass. TCU and the sensor.
l Internal defect in speed sensor. l Check the connectors.
l Check the sensor of
speed.

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Section F Transmission Section F
20 Fault codes (4WG-160/190/210) 20

Errorcode detected Possible causes Solution

33 Logical error in the sensor input of l Defects in cable / connector that result l Check the cable between the
motor speed. in contact with the mass of the vehicle. TCU and the sensor.
l Internal defect in speed sensor. l Check the connectors.
l Incorrect sensor gap size. l Check the sensor of
speed.
l Check the gap of the
sensor.

34 Short circuit at battery voltage or l Defects in the cable that result in l Check the cable between the
open circuit at the sensor input contact with the battery voltage. TCU and the sensor.
turbine speed. l Cable not connected to the TCU. l Check the connectors.
l Internal defect in speed sensor. l Check the sensor of
l Connector pin in contact with the speed.
battery voltage or no contact.

35 Short circuit to ground at the input of the l Defects in cable / connector that result l Check the cable between the
turbine speed sensor. in contact with the mass of the vehicle. TCU and the sensor.
l Internal defect in speed sensor. l Check the connectors.
l Check the sensor of
speed.

36 Logical error in input sensor of l Defects in cable / connector that result l Check the cable between the
turbine speed. in contact with the mass of the vehicle. TCU and the sensor.
l Internal defect in speed sensor. l Check the connectors.
l Incorrect sensor gap size. l Check the sensor of
speed.
l Check the interstice of the
sensor.

37 Short circuit at the battery voltage or l Defects in the cable that result in l Check the cable between the
open circuit at the sensor input contact with the battery voltage. TCU and the sensor.
internal speed. l Cable not connected to the TCU. l Check the connectors.
l Internal defect in speed sensor. l Check the sensor of
l Connector pin in contact with the speed.
battery voltage or no contact.

38 Short circuit to ground at the input of the Defects in cable / connector that result l Check the cable between the
internal speed sensor. in contact with the vehicle's mass. TCU and the sensor.
l Internal defect in speed sensor. l Check the connectors.
l Check the sensor of
speed.

39 Logical error in input sensor of l Defects in cable / connector that result l Check the cable between the
internal speed. in contact with the mass of the vehicle. TCU and the sensor.
l Internal defect in speed sensor. l Check the connectors.
l Incorrect sensor gap size. Check the sensor of
speed.
l Check the gap of the
sensor.

3A Short circuit at battery voltage or l Defects in the cable that result in l Check the cable between the
open circuit at the sensor input contact with the battery voltage. TCU and the sensor.
exit speed. l Cable not connected to the TCU. l Check the connectors.
l Internal defect in speed sensor. l Check the sensor of
l Connector pin in contact with the speed.
battery voltage or no contact.

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Section F Transmission Section F
30 - 11 Error codes (4WG-160/190/210) 19

CodeFau
lire detected Possible causes Solution
failure

3B Short circuit to ground at the input of l Defects in cable / connector that result l Check the cable between the
output speed sensor. in contact with the vehicle's mass. TCU and the sensor.
l Internal defect in speed sensor. l Check the connectors.
l Check the sensor of
speed.

3C Logical error in the sensor input of l Defects in cable / connector that result l Check the cable between the
exit speed. in contact with the mass of the vehicle. TCU and the sensor.
l Internal defect in speed sensor. l Check the connectors.
l Incorrect sensor gap size. l Check the sensor of
speed.
l Check the interstice of
sensor.

3E Zero exit speed does not match. l Internal defect in speed sensor. l Check the cable between the
with other speed signals. Incorrect sensor gap size. TCU and the sensor.
l Check the sensor signal
of output speed.
l Check the interstice of
output speed sensor.

54 ZF computer and EMS do not communicate l Interference in CAN-Bus. l Check the driver of the
through the CAN-Bus. l Cable / connector CAN break. group.
l Defects in CAN cable / connector that l Check the CAN cable.
result in contact with the mass of the Bus.
vehicle or with the battery voltage. l Check the cable to
group controller.

71 Short circuit at the battery voltage in the l Defects in cable / connector that result in l Check the cable between the
clutch K1. in contact with the battery voltage. TCU and the reduction gearbox.
l Defects in cable / connector that result l Check the connectors between
in contact with another regulator output the TCU and the reduction box.
the TCU. l Check the resistance of the
l Internal defect in regulator. regulator.
l Check the wiring harness
inside the reduction box.

72 Short circuit to ground in clutch K1. l Defects in cable / connector that result l Check the cable between the
in contact with the mass of the vehicle. TCU and the reduction box.
l Internal defect in regulator. l Check the connectors between
the TCU and the reduction box.
l Check the resistance of the
regulator.
l Check the wiring harness
inside the gear reducer.

73 Open circuit in the K1 clutch. l Defects in cable / connector that result l Check the cable between the
lacking contact with the TCU. TCU and the reduction box.
l Internal defect in regulator. l Check the connectors between
the TCU and the reduction box.
l Check the resistance of the
regulator.
l Check the wiring harness
inside the gearbox.

74 Short circuit to the battery voltage in the l Defects in cable / connector that result l Check the cable between the
K2 clutch. in contact with the battery voltage. TCU and the reduction gearbox.
l Defects in cable / connector that result l Check the connectors between
in contact with another regulator output the TCU and the reducer box.
the TCU. l Check the resistance of the
l Internal defect in regulator. regulator.
l Check the wiring harness
inside the reduction box.

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Section F Transmission Section F
30 - 12 Error codes (4WG-160/190/210) 30 - 12

Errorcode detected Possible causes Solution

75 Short circuit to ground in the clutch l Defects in cable / connector that result l Check the cable between the TCU and the
K2. in contact with the mass of the vehicle. reduction box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction box.
l Check the resistance of the regulator.
l Check the wiring harness
inside the reduction box.

76 Open circuit in the clutch K2. l Defects in cable / connector that result l Check the cable between the TCU and the
in lack of contact with TCU. reducer gearbox.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction gearbox.
l Check the resistance of the regulator.
l Check the wiring harness
inside the reduction box.

77 Short circuit at battery voltage l Defects in cable / connector that result l Check the cable between the TCU and the
in the clutch K3. in contact with the battery voltage. reducer box.
l Defects in cable / connector that result l Check the connectors between the
in contact with another regulator output TCU and the reduction box.
from the TCU. l Check the resistance of the regulator.
l Internal defect in regulator. l Check the wiring harness
inside the gearbox.

78 Short circuit to ground in the clutch l Defects in cable / connector that result l Check the cable between the TCU and the
K3. in contact with the mass of the vehicle. reduction box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction box.
l Check the regulator's resistance.
l Check the wiring harness
inside the gearbox.

79 Open circuit in the K3 clutch. l Defects in cable / connector that result l Check the cable between the TCU and the
in lack of contact with TCU. reduction box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction box.
l Check the resistance of the regulator.
l Check the wiring harness
inside the reduction box.

81 Short circuit at the battery voltage l Defects in cable / connector that result l Check the cable between the TCU and the
in the clutch K4. in contact with the battery voltage. reduction box.
l Defects in cable / connector that result l Check the connectors between the
in contact with another regulator output TCU and the reduction box.
from the TCU. l Check the resistance of the regulator.
l Internal defect in regulator. l Check the wiring harness
inside the reduction gearbox.

82 Short circuit to ground in the clutch l Defects in cable / connector that result l Check the cable between the TCU and the
K4. in contact with the mass of the vehicle. reduction box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction box.
l Check the resistance of the regulator.
l Check the wiring harness
inside the gearbox

83 Open circuit in the K4 clutch. l Defects in cable / connector that result l Check the cable between the TCU and the
in lack of contact with TCU. reduction box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction box.
l Check the resistance of the regulator.
l Check the wiring harness
inside the reducer box.

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Section F Transmission Section F
17 Fault codes (4WG-160/190/210) 30 - 13

Code Errordetected Possible causes Solution

84 Short circuit at battery voltage l Defects in cable / connector resulting l Check the cable between the TCU and the
in the clutch KV. in contact with the battery voltage. reduction box.
l Defects in cable / connector that result l Check the connectors between the
in contact with another regulator output TCU and the reduction box.
from the TCU. l Check the resistance of the regulator.
l Internal defect in regulator. l Check the wiring harness
inside the reduction box.

85 Short circuit to ground in the clutch l Defects in cable / connector that result l Check the cable between the TCU and the
KV. in contact with the mass of the vehicle. reducer box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction box.
l Check the resistance of the regulator.
l Check the wiring harness
inside the reduction box.

86 Open circuit in the KV clutch. l Defects in cable / connector that result l Check the cable between the TCU and the
in lack of contact with the TCU. reduction box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction box.
l Check the resistance of the regulator.
l Check the wiring harness
inside the gearbox.

87 Short circuit to battery voltage l Defects in cable / connector that result l Check the cable between the TCU and the
in the KR clutch. in contact with the battery voltage. reduction box.
l Defects in cable / connector that result l Check the connectors between the
in contact with another regulator output TCU and the reduction gearbox.
of the TCU. l Check the resistance of the regulator.
l Internal defect in regulator. l Check the wiring harness
inside the gear reducer box.

88 Short circuit to ground in the clutch l Defects in cable / connector that result l Check the cable between the TCU and the
KR. in contact with the mass of the vehicle. reduction box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction gearbox.
l Check the resistance of the regulator.
l Check the wiring harness
inside the gearbox.

89 Open circuit in the KR clutch. l Defects in cable / connector that result in l Check the cable between the TCU and the
in lack of contact with the TCU. reduction box.
l Internal defect in regulator. l Check the connectors between the
TCU and the reduction box.
l Check the resistance of the regulator.
l Check the wiring harness
inside the reduction box.

91 Short circuit to ground in the relay of l Defects in cables that result in l Check the cable between the TCU and the
reversing alarm. contact with the vehicle's mass. reverse alarm unit.
l Internal defect in alarm unit of l Check the connectors between the
reverse. TCU and the marching alarm unit
l Connector pin connected to the ground back.
of the vehicle. l Check the resistance of the unit
of the reverse alarm.

92 Short circuit at battery voltage l Defects in cable that result in l Check the cable between the TCU and the
intherunningalarmrelay contact with the battery voltage. reverse alarm unit.
back. l Internal defect in alarm unit of l Check the connectors between the
reverse. TCU and the march alarm unit
l Connector plug connected to the voltage back.
of the battery. l Check the unit's resistance
reverse alarm.

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Section F Transmission Section F
30 - 14 Fault codes (4WG-160/190/210) 30 - 14

CodeFau
lire detected Possible causes Solution
failure

93 Open circuit in alarm relay of l Defects in cable that result in lack of l Check the cable between the TCU and the
reverse. contact with the TCU. reverse alarm unit.
l Internal defect in alarm unit of l Check the connectors between the
reverse. TCU and the marching alarm unit
l Lack of connection between the connector and the back.
TCU. l Check the unit's resistance
reverse alarm.

97 Short circuit to ground in solenoid l Defects in cable that result in l Check the cable between the TCU and the
of the handbrake. contact with the vehicle's mass. handbrake solenoid.
l Internal defect in the brake solenoid l Check the connectors between the
hand. TCU and the handbrake solenoid.
l Connector pin connected to ground l Check the resistance of the solenoid
of the vehicle. of the handbrake.

98 Short circuit at battery voltage l Defects in the cable that result in l Check the cable between the TCU and the
in the handbrake solenoid. contact with the battery voltage. handbrake solenoid.
l Internal defect in the brake solenoid l Check the connectors between the
hand. TCU and the handbrake solenoid.
l Connector pin connected to voltage l Check the resistance of the solenoid
from the battery. of the handbrake.

99 Open circuit in solenoid of l Defects in cable that result in lack of Check the cable between the TCU and the
handbrake. contact with the TCU. handbrake solenoid.
l Internal defect in the brake solenoid l Check the connectors between the
hand. TCU and the handbrake solenoid.
l Lack of connection between the connector and the l Check the resistance of the solenoid
TCU. of the handbrake.

B1 Clutch slipping K1. l Low pressure in the clutch K1. l Check the pressure on the clutch
l Low main pressure. K1.
l Incorrect signal in speed sensor l Check the main pressure in the
internal. system.
l Incorrect signal in speed sensor l Check the gap in the sensor
to exit. of internal speed.
l Incorrect gap size of the l Check the gap in the sensor
sensor. output speed.
l Defects in the clutch. l Check the signal in the sensor of
internal speed.
l Check the signal on the sensor of
exit speed.
l I changed the clutch.

B2 Clutch slipping K2. l Low pressure in the K2 clutch. l Check the pressure in the clutch
l Low main pressure. K2.
Incorrect signal in speed sensor l Check the main pressure in the
internal. system.
l Incorrect signal in speed sensor l Check the gap in the sensor
of exit. internal speed.
l Incorrect size of the interstice of l Check the gap in the sensor
sensor. of output speed.
Clutch defects. l Check the signal on the sensor of
internal speed.
l Check the signal on the sensor of
exit speed.
l I changed the clutch.

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Section F Transmission Section F
15 Fault codes (4WG-160/190/210) 15

Errorcode detected Possible causes Solution

B3 Clutch slipping K3. l Low pressure in the K3 clutch. l Check the pressure in the clutch
l Main low pressure. K3.
l Incorrect signal in speed sensor l Check the main pressure in the
internal. system.
l Incorrect signal on speed sensor l Check the gap in the sensor
out. of internal speed.
l Incorrect interstice size of l Check the gap in the sensor
sensor. of exit speed.
l Clutch defects. l Check the signal on the sensor of
internal speed.
l Check the signal at the sensor of
output speed.
l I changed the clutch.

B4 Clutch slippage K4. l Low pressure in the clutch K4. l Check the pressure in the clutch
l Low main pressure. K4.
l Incorrect signal on speed sensor l Check the main pressure in the
internal. system.
l Incorrect signal in speed sensor l Check the gap in the sensor
exit. of internal speed.
l Incorrect size of the gap of l Check the gap in the sensor
sensor. of output speed.
l Clutch defects. l Check the signal on the sensor of
internal speed.
l Check the signal on the sensor of
exit speed.
l I changed the clutch.

B5 Clutch slipping KV. l Low pressure in the KV clutch. l Check the pressure in the clutch
l Low main pressure. KV.
l Incorrect signal in speed sensor l Check the main pressure in the
internal. system.
l Incorrect signal in speed sensor l Check the gap in the sensor
from the turbine. of internal speed.
l Incorrect size of gap l Check the gap in the sensor
sensor. of the turbine speed.
l Clutch defects. l Check the signal at the sensor of
internal speed.
l Check the signal in the sensor of
turbine speed.
l I changed the clutch.

B6 Clutch slipping KR. l Low pressure in the KR clutch. l Check the pressure in the clutch
l Low main pressure. KR.
l Incorrect signal in speed sensor l Check the main pressure in the
internal. system.
l Incorrect signal in speed sensor l Check the gap in the sensor
from the turbine. of internal speed.
l Incorrect size of the interstice of l Check the gap in the sensor
sensor. of the turbine speed.
l Defects in the clutch. l Check the signal on the sensor of
internal speed.
l Check the signal on the sensor of
turbine speed.
l I changed the clutch.

B7 Excessive temperature in the collector l Measured oil temperature in the l Cool the machine.
of oil. collector is above the maximum allowable. l Check the oil level.
l Check the temperature sensor.

B8 Excessive temperature at the outlet of l Measured temperature of the oil at the outlet l Cool the machine.
converter. the converter is greater than the maximum l Check the oil level.
admissible. l Check the temperature sensor.

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Section F Transmission Section F
30 - 16 Fault codes (4WG-160/190/210) 30 - 16

Code Fau
lire detected Possible causes Solution
failure

D1 Short circuit at the battery voltage l The TCU measures more than 6 V at the AU1 plug.l Check the cables and connectors to
in the power supply to the (sensor 5 V power supply). the sensors powered from AU1.
sensors. l Check the power supply at the plug
AU1 (should be about 5 V).

D2 Short circuit a mass in the l The TCU measures less than 4 V at the plug. l Check the cables and connectors to
power supply to the AU1 (sensor power supply 5 V). the sensors powered from AU1.
sensors. l Check the power supply at the plug.
AU1 (it should be about 5 V).

D3 Low battery power. l The voltage measured in the unit of l Check the power battery.
The power supply is less than 24 V. l Check the cables from the battery
to the TCU.
l Check the connectors between the
battery and the TCU.

D4 High power in the battery. l The voltage measured in the unit of l Check the power battery.
The power supply is greater than 24 V. l Check the cables from the battery
to the TCU.
l Check the connectors between the
battery and the TCU.

D5 Error in switch 1 for unit of l Defects in cable or connectors that l Check the fuse.
valve power supply result in contact with the voltage of the l Check the cables between the box
VPS1. battery. reducer and the TCU.
l Defects in cables or connectors that l Check the connectors between the box
result in contact with the mass of the reducer and the TCU.
vehicle. l I changed the TCU.
l The power supply is missing.
permanent KL30.
l Check the fuse.
D6 Error in switch 2 for unit of l Defects in cables or connectors that l Check the wires between the box
valve power supply result in contact with the voltage of the reducer and the TCU.
VPS2. battery. l Check the connectors between the box
l Defects in cables or connectors that reducer and the TCU.
result in contact with the mass of the I changed the TCU.
vehicle.
l The power supply unit is missing.
permanent KL30.

E3 Short circuit at battery voltage l Defects in cable or connectors that l Check the cables between the TCU and the
on the output of the viewer. result in contact with the voltage of the viewer.
battery. l Check the connectors in the
l Internal defect in the viewer. viewer.
l Change the viewer.

E4 Short circuit to ground at output of l Defects in cable or connectors that l Check the cables between the TCU and the
viewer. result in contact with the mass of the viewer.
vehicle. Check the connectors in the
l Internal defect in the viewer. viewer.
l Change the viewer.

F1 General failure of the EEPROM. l Defects in the TCU. l I changed the TCU.

F2 Loss of configuration. l Interference when saving data in the l Reprogram the correct configuration
permanent memory. for the vehicle (for example, with the
Is the TCU new from the package or does it proceed? group controller.
of another vehicle.

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Section F Transmission Section F
30 - 17 Error codes (4WG-160/190/210) 30 - 17

Code errordetected Possible causes Solution

F3 Application error. l There is something wrong with the application. l I changed the TCU.

F5 Clutch failure. l One of the AEB values is out of l Check the clutch.
limits.

F6 Loss of adjustment data l Interference when saving the data in the l Run AEB.
clutches. permanent memory.
l The TCU is new to the package or does it come from elsewhere?

from another vehicle.

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