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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 3055 2002-03-09

1/17
Failure codes System reactions
fault-recovery condition
probable source
Code

Fault description System reaction (RESET=battery main switch

of failure
OFF)
2 Short circuit to ground at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y2 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Splitter; DD: high, OD: low) blocked, continued driving not possible. System not available.

3 Short circuit to ground at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y3 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Splitter; DD: low, OD: high) blocked, continued driving not possible. System not available.

4 Short circuit to ground at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y4 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Select) blocked, continued driving not possible. System not available.
5 Short circuit to ground at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y5 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Select) blocked, continued driving not possible. System not available.
6 Short circuit to ground at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y6 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Shift) blocked, continued driving not possible. System not available.
7 Short circuit to ground at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y7 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Shift) blocked, continued driving not possible. System not available.
8 Short circuit to ground at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y8 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Range) blocked, continued driving not possible. System not available.
9 Short circuit to ground at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y9 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Range) blocked, continued driving not possible. System not available.
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

2/17
Failure codes System reactions
10 Short circuit to ground at Driving: No gearshifting possible! No neutral shifting possible! Selected gear remains engaged! Vehicle start After RESET and no short shift actuator
output stage to Y10 (Main permitted if engaged gear <= lowest gear in high range group is engaged. After ignition on, system not circuit to ground
valve) available
11 Short circuit to ground at Warning buzzer and warning lamp permanently activated After RESET and no short vehicle el.
output stage to warning circuit to ground system
buzzer and warning lamp
12 Short circuit to ground at No reverse light activation possible. No further system restrictions After RESET and no short vehicle el.
output stage to reverse circuit to ground system
light relay (E-Module)
15 Short circuit to ground at Output cannot be activated After RESET and no short vehicle el.
output stage to AD 24 circuit to ground system
17 Short circuit to ground at Driving: Increased shifting time for upshifts. Upshifts blocked, when input target speed is below engine idle After RESET and no short shift actuator
output stage to Y1 (inertia speed. Stationary: Increased self adjustment time. Increased shifting time when shifting out of neutral. circuit to ground
brake valve)
18 Short circuit to ground at Decreased comfort when maneuvering and starting off. After RESET and no short shift actuator /
output stage to Y17 (valve circuit to ground clutch actuator
clutch disengage slow)
19 Short circuit to ground at Decreased comfort when maneuvering and starting off. After RESET and no short shift actuator /
output stage to Y15 (valve circuit to ground clutch actuator
clutch engage slow)
20 Short circuit to ground at Increased shifting time. Decreased comfort when maneuvering and starting off. After RESET and no short shift actuator /
output stage to Y16 (valve circuit to ground clutch actuator
clutch disengage fast)
21 Short circuit to ground at Increased shifting time. Decreased comfort when maneuvering and starting off. After RESET and no short shift actuator /
output stage to Y14 (valve circuit to ground clutch actuator
clutch engage fast)
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

3/17
Failure codes System reactions
22 Short circuit to ground at No display. Warning buzzer and warning lamp not available. after RESET, if the failure vehicle
output ADVP will not be sensed electrical
system
25 Short circuit to ground at display flashing "EE". No system restrictions. No short circuit to ground vehicle el.
output SD to display or after RESET. system
27 Error on ”engine Reduced functionality for automatic mode and start gear calculation, if deviation of substitute parameters After receiving a correct FMR
configuration message” and real values is high. Target speed for downshifting can be reduced. Quality of clutch disengagement for message or after RESET.
(engine configuration) stopping can be reduced.
31 Error on ”Actual engine No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to Signal available or after --> "specials"
retarder - percent torque” standstill medium start off gear will be shifted. No other functional restrictions. No information about engine RESET.
signal (ERC1_ER) brake torque. If exhaust brake is active, shifting quality at start of shifting may be poor. Engine brake is
considered not active.
34 Interruption at output stage Driving: Gearshifting blocked. after RESET, if the failure shift actuator
to Y2 (Valve Splitter) Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
35 Interruption at output stage Driving: Gearshifting blocked. after RESET, if the failure shift actuator
to Y3 (Valve Splitter) Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
36 Interruption at output stage Driving: Gearshifting blocked. after RESET, if the failure shift actuator
to Y4 (Valve Select) Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
37 Interruption at output stage Driving: Gearshifting blocked. after RESET, if the failure shift actuator
to Y5 (Valve Select) Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
38 Interruption at output stage Driving: Gearshifting blocked. after RESET, if the failure shift actuator
to Y6 (Valve Shift) Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

4/17
Failure codes System reactions
39 Interruption at output stage Driving: Gearshifting blocked. after RESET, if the failure shift actuator
to Y7 (Valve Shift) Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
40 Interruption at output stage Driving: Gearshifting blocked. after RESET, if the failure shift actuator
to Y8(Valve Range) Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
41 Interruption at output stage Driving: Gearshifting blocked. after RESET, if the failure shift actuator
to Y9 (Valve Range) Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
42 Interruption at output stage No gearshifting possible! No neutral shifting possible! Selected gear remains engaged; Vehicle start No interruption and output shift actuator
to Y10 (Main valve) permitted if gear <= lowest gear in high range group is engaged. After ignition on, system not available not activated or after
RESET.
44 Interruption at output stage No reverse light activation possible. No further system restrictions No interruption and output vehicle
to reverse light relay (E- not activated or after electrical
Module) RESET. system
49 Interruption at output stage Driving: Upshifts during driving are controlled like downshifts. Input speed will be synchronized by engine No interruption and output shift actuator
to Y1 (inertia brake valve) speed. Upshifts blocked, when input target speed is below engine idle speed. Increased shifting time. not activated or after
Stationary: Increased self adjustment time. Increased shifting time when shifting out of neutral. RESET.
50 Interruption at output stage Decreased comfort when maneuvering and starting off. No interruption and output shift actuator /
valve Y17 (clutch not activated or after clutch actuator
disengage slow) RESET.
51 Interruption at output stage Decreased comfort when maneuvering and starting off. No interruption and output shift actuator /
valve Y15 (clutch engage not activated or after clutch actuator
slow) RESET.
52 Interruption at output stage Increased shifting time. Decreased comfort when maneuvering and starting off. No interruption and output shift actuator /
valve Y16 (clutch not activated or after clutch actuator
disengage fast) RESET.
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

5/17
Failure codes System reactions
53 Interruption at output stage Increased shifting time. Decreased comfort when maneuvering and starting off. No interruption and output shift actuator /
to large Y14 (clutch not activated or after clutch actuator
engage fast) RESET.
54 Interruption at output ADVP 1. After ignition ON: No display function, warning buzzer and warning lamp not avaiilable. Starting off not after RESET, if the failure vehicle el.
possible. will not be sensed system
2. During operation: Driving: Gearshifting blocked. Stationary: Clutch opens, when coming to standstill.
Neutral automatically engaged at standstill. Gearshifting blocked, continued driving not possible. System not
available.
66 Short circuit to positive at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y2 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Splitter) blocked, continued driving not possible. System not available.
67 Short circuit to positive at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y3 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Splitter) blocked, continued driving not possible. System not available.
68 Short circuit to positive at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y4 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Select) blocked, continued driving not possible. System not available.
69 Short circuit to positive at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y5 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Select) blocked, continued driving not possible. System not available.
70 Short circuit to positive at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y6 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Shift) blocked, continued driving not possible. System not available.
71 Short circuit to positive at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y7 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
Shift) blocked, continued driving not possible. System not available.
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

6/17
Failure codes System reactions
72 Short circuit to positive at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y8 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
range low) blocked, continued driving not possible. System not available.
73 Short circuit to positive at Driving: Gearshifting blocked. after RESET, if the failure shift actuator
output stage to Y9 (Valve Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
range high) blocked, continued driving not possible. System not available.
74 Short circuit to positive at Driving: Gearshifting of all gears possible. Stationary: All starting gears can be engaged. Driving with start No short circuit to positive shift actuator
output stage to Y10 (Main off gear possible. and output not activated or
valve) after RESET.
75 Short circuit to positive at Warning buzzer and warning lamp not available. After RESET and no short vehicle
output stage to warning circuit to positive. electrical
buzzer (E-Module) system
76 Short circuit to positive at Reverse driving lamp permanently engaged. No further functional restrictions. After RESET and no short vehicle
output stage to AD 23 = circuit to positive. electrical
relay for reverse driving system
lamp (E-Module)
79 Short circuit to positive at Output permanently active. No further functional restrictions. After RESET and no short vehicle
output stage to AD 24 circuit to positive. electrical
system
81 Short circuit to positive at Driving: Gearshifting blocked. Stationary: Shift of start off gears possible. Main valve will be only activated No short circuit to positive shift actuator
output stage to Y1 (inertia during shifting, if clutch is opened. Start off possible. and output not activated or
brake valve) after RESET.
82 Short circuit to positive at Gearshifting generally blocked, system not available. Driving and gear engaged: Attempt to keep clutch no short circuit to positive shift actuator /
output stage to valve Y17 engaged (prevention with engagement valves). Stationary: Engagement valves are switched off, automatic or after RESET. clutch actuator
(clutch disengage slow) neutral shifting when clutch is disengaged. Continuous driving not possible.
83 Short circuit to positive at Gearshifting generally blocked, system not available. Driving: Required clutch position maintained via no short circuit to positive shift actuator /
output stage to valve Y15 disengagement valve. Stationary: Automatic neutral shifting after a certain time. or after RESET. clutch actuator
(clutch engage slow)
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

7/17
Failure codes System reactions
84 Short circuit to positive at Gearshifting generally blocked, system not available. Driving and gear engaged: Attempt to keep clutch no short circuit to positive shift actuator /
output stage to valve Y16 engaged (prevention with engagement valves). Stationary: Engagement valves are switched off, automatic or after RESET. clutch actuator
(clutch disengage fast) neutral shifting when clutch is disengaged.
85 Short circuit to positive at Gearshifting generally blocked, system not available. Driving: Required clutch position maintained via no short circuit to positive shift actuator /
output stage to valve Y14 disengagement valve. Stationary: Automatic neutral shifting after a certain time. or after RESET. clutch actuator
(clutch engage fast)
86 Short circuit to positive at 1. After ignition off/on Failure will be detected during initialization. E-Modul does not switch off. Display can After RESET vehicle
output ADVP not be switched off. No restrictions on system availability. After ignition off, display is flashing EE. 2. During electrical
operation No restrictions on system availability. system
89 Short circuit to positive at display flashing "EE". No system restrictions. no short circuit to positive vehicle
output SD to display or after RESET. electrical
system
90 Communication error Driving: Gearshifting blocked. after RESET, if the failure shift actuator
between controller 1 and Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
controller 2 (ECU failure) blocked, continued driving not possible. System not available.
92 Error on ”ABS active” No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to Signal available or after ABS/ASR
signal (EBC1) standstill medium start off gear will be shifted. No other functional restrictions. RESET.
93 Error on ”ASR engine No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to Signal available or after ABS/ASR
control active” signal standstill medium start off gear will be shifted. No other functional restrictions. RESET.
(EBC1)
94 Error on ”ASR brake No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to Signal available or after ABS/ASR
control active” signal standstill medium start off gear will be shifted. No other functional restrictions. RESET.
(EBC1)
95 Error on ”Cruise control No other functional restrictions Signal available or after
active” signal (CCVS) RESET.
96 Error on ”Cruise control set No other functional restrictions, gear hunting in cruise control possible Signal available or after
speed” (CCVS) RESET.
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

8/17
Failure codes System reactions
97 Error on ”Engine speed” Driving: Time based control of clutch during shifting. Decreased clutch comfort after shifting. Clutch does 1.Signal available and FMR
signal open below fixed value (No clutch opening according coasting condition) Engine speed governor during engine speed < plausible
upshift does not work. Stationary: No special manoeuvering operation possible. Time based control of clutchvalue. 2.After Reset
during starting off. Decreased clutch comfort of manoeuvering and starting.
98 Error on transmission input Driving: Increased shifting time. During upshifting and downshifting clutch will be partially closed when t/m in Input speed plausible or shift actuator
speed signal neutral to substitute input speed by engine speed. If gear is engaged, input speed is substituted by output after RESET
speed. Stationary: Increased shifting time. Decreased clutch comfort in manoeuvering and starting
99 Error on output speed Output speed signal will be calculated depending on system application from redundant output speed Output speed plausible or T/m output
signal 1 information. Redundant speed information will be taken depending on application from vehicle speed signal after RESET sensor
via CAN OR output speed signal from CAN tachograph. Manual shifting of all gears possible. Shifting quality / cable
could be decreased because of less dynamik response of CAN-information.
101 Error on both output speed Driving: Gearshifting blocked. after RESET, if the failure T/m output
signals Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed sensor
blocked, continued driving not possible. System not available. / cable
102 Plausibility error between Driving: Gearshifting blocked during driving including neutral shift attempt. Stationary: Start off gears can be After RESET
transmission input speed engaged. Driving with start off gear possible.
and out-put speed
104 High voltage (Vehicle No system restrictions while driving. circuit voltage within valid vehicle
electrical system voltage range or after RESET. electrical
too high) system
105 Low voltage (Vehicle Driving: Gearshifting blocked. Stationary: Gearshifting blocked. If gear is engaged and driver switches off circuit voltage within valid vehicle
electrical system voltage ignition, attempt to shift to neutral. range or after RESET. electrical
too low) system
107 Stabilised voltage supply at Driving: Clutch is disengaged and engaged by time control. Stationary: Manoeuvering not possible. If start Voltage at AU within valid shift actuator
output AU (clutch sensor does not occur within certain time, transmission is automatically shifted to neutral. New start off gear must range and RESET
supply) out of valid range be engaged by selector lever. Decreased clutch comfort during start off.
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

9/17
Failure codes System reactions
108 Error in selector lever or tip General function (also without failure active): After ignition off/on , a gear can be only shifted, if rotary switch 1. Valid shift lever neutral Gear selector
lever once has been in neutral position. Failure reaction is depending on driving situation and on gear engaged. signal (rotary switch at
1.Failure on tip lever:-> No shifting possible. At standstill, start off gear selected by rotary switch will be neutral) 2. After RESET
engaged. Driving with selected start off gear possible (forward and reverse). 2.Failure on rotary switch: If a
gear is engaged during driving, no gear shifting is possible. At standstill start off gear according last known
(stored) Driving with selected start off gear possible. If at standstill neutral is engaged, no gearshifting is
possible -> system not available. After ignition off T/m will generally shift to Neutral.
109 Plausibility error between System available only from main cabine After RESET and plausible vehicle
crane cabine mode and signals electrical
main cabine mode system
110 ZF CAN timeout 1. After ignition off/on: Failure code will be indicated automatically on display alternating with gear After receiving a correct
information. System not available. 2. During operation: No gearchange possible. When coming to standstill, message or after RESET.
last selected (via rotary switch) startoff gear will be automatically engaged. Continuous driving only with
startoff gear possible. If reverse gear has been engaged, t/m will automatically shifted to neutral. No shift
lever information. Failure code will be indicated automatically on display alternating with gear information.

117 Error in clutch self- System not available. After RESET

adjustment process
118 Clutch does not disengage Driving: Gearshifting blocked. after RESET, if the failure Clutch /
Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed clutch actuator
blocked, continued driving not possible. System not available.
119 Clutch does not engage / Driving: Gearshifting blocked. after RESET, if the failure Clutch /
does not transmit engine Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed clutch actuator
torque blocked, continued driving not possible. System not available.
120 Mechanical failure of small Function taken on by redundant valve.Decreased clutch comfort After RESET clutch actuator
disengagement clutch
valve
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

10/17
Failure codes System reactions
121 Mechanical failure of large Function taken on by redundant valve.Decreased clutch comfort After RESET clutch actuator
disengagement clutch
valve
122 Mechanical failure of small Function taken on by redundant valve.Decreased clutch comfort After RESET clutch actuator
engagement clutch valve

123 Mechanical failure of large Function taken on by redundant valve.Decreased clutch comfort After RESET clutch actuator
engagement clutch valve
124 Error on clutch travel signal Driving: Clutch is disengaged and engaged by time control. Stationary: Manoeuvering not possible. If start After RESET and plausible clutch actuator
does not occur within certain time, transmission is automatically shifted to neutral. New start off gear must voltage signal
be engaged by selector lever. Decreased clutch comfort during start off.
125 Error on pressure No system restrictions 1.If pressure level is lower shift actuator
reduction valve (air than threshold. 2.After
pressure too high) RESET
126 Error on pressure sensor No system restrictions on availability, íf external air supply is sufficient. No air pressure indication AL on If voltage level is within shift actuator
signal display in case, air pressure is not sufficient. Self adjustment of transmission and clutch is done time based plausibel range or after
and not related to the sensor signal. Time for adjustment could be longer. RESET.
127 Error on ECU temperature No system restrictions on availability. If voltage level is within shift actuator
sensor signal plausibel range or after
RESET.
128 Error on oil temperature No system restrictions on availability. Shift monitoring time will be depending on ECU temperature signal. If voltage level is within shift actuator
sensor signal plausibel range or after
RESET.
129 No shift sensor signal Driving: Gearshifting blocked. Only shifting out of neutral possible. Stationary: Engagement of starting gears After RESET shift actuator
(Short circuit to positive) possible. Change of starting gears possible.
130 No shift sensor signal Driving: Gearshifting blocked. Only shifting out of neutral possible. Stationary: Engagement of starting gears After RESET shift actuator
(Short circuit to ground) possible. Change of starting gears possible.
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

11/17
Failure codes System reactions
131 No shift sensor signal Driving: Gearshifting blocked. Only shifting out of neutral possible. Stationary: Engagement of starting gears After RESET shift actuator
(Interruption) possible. Change of starting gears possible.
132 Self adjustment error of Driving: Gearshifting blocked. after RESET, if the failure shift actuator /
shift sensor Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed transmission
blocked, continued driving not possible. System not available.
133 No gate select sensor Driving: Only forward gears can be selected, which are allocated in opposite shift-position of the reverse After RESET shift actuator
signal (Short circuit to gear. Stationary: All allowed starting gears can be switched, whose positions are allocated in opposite shift-
positive) position of the reverse gear. No reverse gear shiftable.
134 No gate select sensor Driving: Only forward gears can be selected, which are allocated in opposite shift-position of the reverse After RESET shift actuator
signal (Short circuit to gear. Stationary: All allowed starting gears can be switched, whose positions are allocated in opposite shift-
ground) position of the reverse gear. No reverse gear shiftable.
135 No gate select sensor Driving: Only forward gears can be selected, which are allocated in opposite shift-position of the reverse After RESET shift actuator
signal (Interruption) gear. Stationary: All allowed starting gears can be switched, whose positions are allocated in opposite shift-
position of the reverse gear. No reverse gear shiftable.
136 Gate select sensor self Driving: Gearshifting blocked. after RESET, if the failure shift actuator /
adjustment error Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed transmission
blocked, continued driving not possible. System not available.
137 No range change group Driving: Range group shift during driving blocked. Only gears in engaged range group can be changed. After RESET shift actuator
(GP) sensor signal (Short Stationary: All start off gears can be engaged.
circuit to positive)
138 No range change group Driving: Range group shift during driving blocked. Only gears in engaged range group can be changed. After RESET shift actuator
(GP) sensor signal (Short Only gears in engaged range group can be shifted. Stationary: All start off gears can be engaged.
circuit to ground)
139 No range change group Driving: Range group shift during driving blocked. Only gears in engaged range group can be changed. After RESET shift actuator
(GP) sensor signal Only gears in engaged range group can be shifted. Stationary: All start off gears can be engaged.
(Interruption)
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

12/17
Failure codes System reactions
140 Self adjustment error of Driving: Gearshifting blocked. after RESET, if the failure shift actuator /
range change group Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed transmission
sensor in position fast blocked, continued driving not possible. System not available.
141 No splitter group (GV) Shifting of splitter group blocked. Further driving only possible with last selected splitter group position. If After RESET shift actuator
sensor signal (Short circuit desired gear is not shiftable, next higher gear will be engaged.
to positive)
142 No splitter group (GV) Shifting of splitter group blocked. Further driving only possible with last selected splitter group position. If After RESET shift actuator
sensor signal (Short circuit desired gear is not shiftable, next higher gear will be engaged.
to ground)
143 No splitter group (GV) Shifting of splitter group blocked. Further driving only possible with last selected splitter group position. If After RESET shift actuator
sensor signal (Interruption)
desired gear is not shiftable, next higher gear will be engaged.
144 Splitter group (GV) sensor
Driving: Gearshifting blocked. after RESET, if the failure shift actuator /
self adjustment error Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed transmission
blocked, continued driving not possible. System not available.
145 Range change group (GP) Driving: When shifting from low range group to high group, the highest gear in low range group will be 1.After successful range low air press. /
disengagement error shifted. When shifting from high range group to low group, the lowest gear in high range group will be change group shift 2.After shift actuator /
shifted. Stationary: If it is not possible to select low range group, the lowest gear in high range group is RESET transmission
selected as starting gear. New attempt to shift range group is allowed under all driving conditions. No
reverse gear in high range group possible.
146 Changeover error during Driving and stationary: If selected range group could not be engaged, following gear will be shifted: When 1.After successful range shift actuator /
range change group (GP) shifting from low range group to high group, the highest gear in low range group will be shifted. When change group shift 2.After transmission
shifting shifting from high range group to low group, the lowest gear in high range group will be shifted. Stationary: If RESET
it is not possible to select low range group, the lowest gear in high range group is selected as starting gear.

147 Range change group (GP) Driving and stationary: If selected gear could not be engaged, previous range position will be selected.If 1.After successful range low air press. /
does not engage engagement into old range position failed, failure will be set.T/m shifts to neutral. change group shift 2.After shift actuator /
RESET transmission
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

13/17
Failure codes System reactions
148 Splitter (GV) does not If failure occurs, t/m shifts into next upper gear. Following gear restrictions are valid: The highest gear which 1.After successful splitter low air press. /
disengage can be selected, is the highest gear in last engaged splitterposition.The lowest gear which can be selected group shift 2.After RESET shift actuator /
is the lowest gear in last engaged splitterposition. transmission
149 Change over error during If failure occurs, t/m shifts into next upper gear. Following gear restrictions are valid: The highest gear which 1.After successful splitter shift actuator /
splitter shifting can be selected, is the highest gear in last engaged splitterposition.The lowest gear which can be selected group shift 2.After RESET transmission
is the lowest gear in last engaged splitterposition.
150 Splitter (GV) does not System not available. 1.After successful splitter low air press. /
engage group shift 2.After RESET shift actuator /
transmission
151 Selector cylinder does not Driving: When failure occurs during shifting, t/m shifts back into the last gear. If last gear is not shiftable 1.After successful selection shift actuator /
disengage because of overspeed condition, the next possible target gear, which is next to last gear will be shifted. process 2.After RESET transmission
When highest shiftable gear could not be shifted because of overspeed condition, then t/m shifts to neutral.
Stationary: If target select position could not be engaged,t/m shifts into neutral. New shifting of start off gear
must be initiated by selector switch.
152 Change over error during Driving: When failure occurs during shifting, gate cylinder shifts back into last gate position and t/m shifts 1.After successful selection shift actuator /
gate selection procedure back into the last gear. If last gear is not shiftable because of overspeed condition, the next possible target process 2.After RESET transmission
gear, which is next to last gear will be shifted. When highest shiftable gear could not be shifted because of
overspeed condition, then t/m shifts to neutral. Stationary: If target select position could not be engaged,t/m
shifts into neutral. New shifting of start off gear must be initiated by selector switch.
153 Selector cylinder does not Driving and stationary: T/m shifts into neutral position. New shifting of gear must be initiated by selector 1.After successful selection shift actuator /
engage switch. If no gate could be engaged, system not available. process 2.After RESET transmission
154 Main transmission gear Driving: Clutch engages in previous gear. Next attempt to shift must be initiated by selector switch. 1.Neutral position could be low air press. /
does not disengage Stationary: Gearshifting only permitted after neutral signal has been reached. Start off and driving can be reached 2.After RESET shift actuator /
tried with engaged gear, if gear is equal or lower than lowest gear in range high position. transmission
155 Main transmission gear Driving: New shifting of start off gear must be initiated by selector switch. 1.Any main gear could be low air press. /
does not engage Stationary: If gear does not engage after several gearshifts t/m will be shifted back to neutral. New shifting o engaged 2.After RESET shift actuator /
start off gear must be initiated by selector switch. transmission
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Failure codes System reactions
156 Wrong gear shifting Automatic neutral shifting. Clutch remains opened, if neutral could not be shifted. New shifting of gear must 1.Correct gear shifting shift actuator /
be initiated by selector switch 2.After RESET transmission
158 Shift sensor signal leaves Valves will be activated again. If gear has been disengaged completely, a suitable gear depending on speed1.gear Gear end position shift actuator /
engaged position during condition will be shifted automatically. has been reached 2.After transmission
driving Reset
159 Range-change group Valves will be activated again. If gear has been disengaged completely, a suitable gear depending on speed1.Range end position has shift actuator /
sensor signal leaves condition will be shifted automatically. been reached. 2.After transmission
engaged position during Reset
driving
160 Splitter sensor signal Valves will be activated again. If gear has been disengaged completely, a suitable gear depending on speed1.Splitter end position has shift actuator /
leaves engaged position condition will be shifted automatically. been reached 2.After Reset transmission
during driving
163 Engine does not react on Driving: Gearshifting blocked. Stationary: Starting allowed. Decreased clutch functionality and comfort. 1. Engine speed increase FMR
torque intervention possible(Test will be started
automatically each time
with t/m in Neutral) 2.After
RESET
164 Error on ”Drivers demand Driving: Gear shifting blocked. Stationary: Clutch opens, when comming to stand still. Whenn stand still T/m Signal available or after --> "specials"
engine percent torque” shifts automatically to Neutral. Start off possible. When coming to standstill, medium start off gear will be RESET.
(EEC1) shifted. No other functional restrictions. Failure codes 164 and 165 always appear together.
165 Error on ”Accelerator pedal Driving: Gear shifting blocked. Stationary: Clutch opens, when comming to stand still. Whenn stand still T/m Signal available or after --> "specials"
position” (EEC2) shifts automatically to Neutral. Start off possible. When coming to standstill, medium start off gear will be RESET.
shifted. No other functional restrictions. Failure codes 164 and 165 always appear together.
166 Permanent idle signal Driving: Shifting during driving allowed. Stationary: No manoeuvering and startoff possible. System not After RESET --> "specials"
available.
167 Error on ”Percent load at No other functional restrictions Signal available or after --> "specials"
current speed” signal RESET.
(EEC2)
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

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Failure codes System reactions
169 Cut-off relay in ECU does System not available. after RESET, if the failure shift actuator
not switch off will not be sensed
170 No voltage supply at pin 30 System not available. after RESET, if the failure vehicle el. syst.
or cut-off relay in ECU will not be sensed / shift actuator
does not switch on
171 Error on ”Actual engine Driving: No calculation of vehicle weight and driving resistance possible. No calculation of startoff gear Signal available or after --> "specials"
percent torque” signal possible. Actual engine percent torque will be substituted by drivers demand information. Shift quality could RESET.
(EEC1) be reduced. Stationary: Start off possible. When coming to standstill, medium start off gear will be shifted.
Warning for clutch overload detection and reaction on overload detection could appear earlier.
173 Error on ”Brake switch” Foot brake is considered active and in consequence, clutch disengages always at foot brake related engine Signal available OR with vehicle el.
signal (CCVS) speed (higher engine revolution) decreasing signal edge or system
after RESET.
174 Error on ”Kickdown switch” No Kickdown operation mode possible. No other functional restrictions. Signal available or after --> "specials"
signal (EEC2) RESET.
175 Error on ”Ignition lock” Driving: Gearshifting in general blocked, as soon as no ignition on signal is detected (failure detection might If ignition signal is on (rising vehicle el.
signal (Key 15) be delayed). Standstill: If engine is running , ECU does not switch off. Start off gear shiftable (forward and signal edge) or after system
reverse). Driving with start off gear possible. If engine is not running, t/m will be automatically shifted to RESET.
neutral and ECU switches off. No initialization of system possible. System not available.
177 System-CAN Busoff error Driving: Gearshifting blocked. failure is no longer detected vehicle el.
Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingor after RESET system
blocked, continued driving not possible. System not available.
178 CAN Errorwarning Driving: Gearshifting blocked. failure is no longer detected vehicle el.
Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingor after RESET system
blocked, continued driving not possible. System not available.
179 CAN queue overrun Driving: Gearshifting blocked. failure is no longer detected vehicle el.
Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingor after RESET system
blocked, continued driving not possible. System not available.
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ZF Friedrichshafen AG 12 AS 2302 in Grove GMK 4075 / GMK 4090 2002-03-09

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Failure codes System reactions
188 ECU fault - wrong interrupt Driving: Gearshifting blocked. after RESET, if the failure vehicle el.
Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed system
blocked, continued driving not possible. System not available.
189 ECU fault - stack watch Driving: Gearshifting blocked. after RESET, if the failure vehicle el.
Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed system
blocked, continued driving not possible. System not available.
190 EOL EEPROM parameter Driving: Gearshifting blocked. after RESET, if the failure vehicle el.
out of valid range Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed system
blocked, continued driving not possible. System not available.
191 EOL EEPROM parameter Driving: Gearshifting blocked. after RESET, if the failure vehicle el.
checksum error Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed system
blocked, continued driving not possible. System not available.
192 ECU fault - EEPROM No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to After RESET and EEPROM operating failure
access failure standstill, medium start off gear will be shifted. No other functional restrictions. is readable /
shift actuator
193 ECU temperature too high Driving: Gearshifting blocked. Stationary: Clutch opens, when coming to standstill. Neutral automatically After RESET AND ECU amb. Temp.;
engaged at standstill. Gearshifting blocked, continued driving not possible. Special display indication for temperature below shift actuator;
ECU temperature too high alternating with gear information. System not available. threshold t/m
197 Error on "Front axle speed" No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to Signal available or after vehicle el.
(WSI) standstill, medium start off gear will be shifted. No other functional restrictions. RESET. system
198 Error on "Relative wheel No other functional restrictions Signal available or after vehicle el.
speeds" (WSI) RESET. system
216 IES: CAN_message ID512 No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to After reception of a correct ABS/ASR
(ABS/ASR_ECU) timeout standstill, medium start off gear will be shifted. No other functional restrictions. message or after RESET
217 IES: CAN_message ID513 No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to After reception of a correct ABS/ASR
(ABS/ASR_ECU) timeout standstill, medium start off gear will be shifted. No other functional restrictions. message or after RESET
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Failure codes System reactions
218 IES: CAN_message ID592 Driving: Gearshifting blocked. after RESET, if the failure FMR
(FMR) timeout Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
219 IES: CAN_message ID593 Driving: Gearshifting blocked. after RESET, if the failure FMR
(FMR) timeout Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
222 IES: CAN_message No calculation of driving resistance possible. No automatic calculation of start off gear. When coming to After reception of a correct FMR
ID1104 (FMR) ttimeout standstill, medium start off gear will be shifted. No other functional restrictions. message or after RESET
223 IES: CAN_message Driving: Gearshifting blocked. after RESET, if the failure FMR
ID1360 (FMR) ttimeout Stationary: Clutch opens, when coming to standstill. Neutral automatically engaged at standstill. Gearshiftingwill not be sensed
blocked, continued driving not possible. System not available.
228 IES: plausibility error Driver cabine mode is supposed after RESET vehicle el.
switching crane cabine / system
driver cabine