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ZF Transmission Fault Codes

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100% found this document useful (4 votes)
6K views48 pages

ZF Transmission Fault Codes

Uploaded by

Antonio Novo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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TRANSMISSION

OPERATION AND DIAGNOSTICS


H8-12XM-6 (H190-280HD 2) [J007];
H13-14XM-6 (H300-330HD 2) [H019];
H16XM-6 (H360HD 2) [H019];
H10-12XM-12EC (H360HD 2-EC) [H019];
H8-12XM-6, H10XMS-6
(H190-280HD 2, H230HDS) [K007];
H13-16XM-6, H10-12XM-12EC
(H300-360HD 2, H360HD 2-EC) [J019]

PART NO. 4034061 1300 SRM 1455


SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Transmission Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
Torque Converter....................................................................................................................................... 6
Operational Phases ................................................................................................................................... 6
Operation............................................................................................................................................................ 7
Hydraulic Operation...................................................................................................................................... 7
Cooling and Lubrication................................................................................................................................ 9
Control System................................................................................................................................................... 10
General ........................................................................................................................................................... 10
Transmission Control Unit (TCU) ................................................................................................................ 11
Self Test ..................................................................................................................................................... 11
Operating Modes ....................................................................................................................................... 11
Normal Mode......................................................................................................................................... 11
Substitute Clutch Control .................................................................................................................... 11
Limp-Home Mode.................................................................................................................................. 11
Transmission Shut Down Mode ........................................................................................................... 11
TCU Shut Down Mode .......................................................................................................................... 11
Transmission Exceed Codes ................................................................................................................. 12
Fault Codes ................................................................................................................................................ 12
Description ............................................................................................................................................ 12
Fault Log Mode.......................................................................................................................................... 12
Access..................................................................................................................................................... 12
Exit ........................................................................................................................................................ 13
Clear ...................................................................................................................................................... 13
Fault Rectification ..................................................................................................................................... 13
Hydraulic Control Valve................................................................................................................................ 13
Hydraulic Control Valve Repair ............................................................................................................... 14
Solenoid Replacement ............................................................................................................................... 15
Pressure Check .......................................................................................................................................... 15
Pressure Specifications ............................................................................................................................. 16
Speed and Temperature Sensors .................................................................................................................. 16
Speed Sensors ............................................................................................................................................ 16
Test ........................................................................................................................................................ 18
Temperature Sensors ................................................................................................................................ 18
Shift Lever ................................................................................................................................................. 18
MONOTROL® Pedal................................................................................................................................. 19
ZF Transmission Test and Calibration ............................................................................................................. 19
Transmission Test and Calibration .............................................................................................................. 19
Precautions ................................................................................................................................................ 19
Stall Test ........................................................................................................................................................ 19
Description................................................................................................................................................. 19
Stall Test Procedure .................................................................................................................................. 19
Inch Pedal Calibration .................................................................................................................................. 20
Description................................................................................................................................................. 20
Brake and Inch Pedal Adjustment ........................................................................................................... 20
Inch Sensor Adjustment/Installation ....................................................................................................... 20
Inch Pedal Calibration .............................................................................................................................. 21
Manual Inch Pedal Calibration Procedure .......................................................................................... 21
Inch Pedal Calibration Error Codes..................................................................................................... 22
Testman Inch Pedal Calibration Procedure......................................................................................... 22

©2012 HYSTER COMPANY i


Table of Contents Transmission

TABLE OF CONTENTS (Continued)


Clutch Calibration ......................................................................................................................................... 22
Description................................................................................................................................................. 22
Clutch Calibration Procedure ................................................................................................................... 23
Manual Clutch Calibration Procedure................................................................................................. 23
Testman Clutch Calibration Procedure ............................................................................................... 24
Testman .............................................................................................................................................................. 25
Description ..................................................................................................................................................... 25
Connection ..................................................................................................................................................... 25
Truck Configuration ...................................................................................................................................... 25
Configuration............................................................................................................................................. 25
Limitations ................................................................................................................................................ 26
Electrical Specifications..................................................................................................................................... 26
Diagrams, Schematics, or Arrangements ......................................................................................................... 26
ZF Transmission Fault Codes ........................................................................................................................... 33
Transmission Exceed Codes.......................................................................................................................... 33
Testman Fault Codes ..................................................................................................................................... 34

This section is for the following models:

H8-12XM-6 (H190-280HD 2) [J007];


H13-14XM-6 (H300-330HD 2) [H019];
H16XM-6 (H360HD 2) [H019];
H10-12XM-12EC (H360HD 2-EC) [H019];
H8-12XM-6, H10XMS-6 (H190-280HD 2, H230HDS) [K007];
H13-16XM-6, H10-12XM-12EC (H300-360HD 2, H360HD 2-EC) [J019]

ii
1300 SRM 1455 Description

General
This manual provides information on operation and The repair procedures for the transmission and con-
diagnostics of the ZF ERGOPOWER (WG161) Trans- trol valve are shown in Transmission, Repair (ZF-
mission as fitted on H019 and J007 series trucks. WG161) 1300 SRM 1456.

Electrical system diagrams are shown in Diagrams


8000 SRM 1500.

Description
GENERAL and to the hydraulic pump(s) that are attached to the
transmission.
The function of the transmission is to transfer engine
power from the engine flywheel to the drive wheels The engine flywheel is connected to the torque con-
verter housing through a drive plate. See Figure 1.

1. DRIVE PLATE 7. POWER TAKE-OFF CONNECTION (PTO)


2. TORQUE CONVERTER 8. FORWARD CLUTCH PACK (KV)
3. INPUT SHAFT 9. REVERSE CLUTCH PACK (KR)
4. TRANSMISSION PUMP 10. 1ST SPEED CLUTCH PACK (K1)
5. INPUT GEAR 11. OUTPUT FLANGE
6. 2ND SPEED CLUTCH PACK (K2) 12. 3RD SPEED CLUTCH PACK (K3)

Figure 1. Transmission Layout

1
Description 1300 SRM 1455

The flexing properties of the drive plate reduce


transfer of axial forces between engine crankshaft
and torque converter. The torque converter drives
the transmission pump and the PTO drives the
attached pump(s) for the hydraulic system of the
truck. The torque converter, transmission pump
and hydraulic pump(s) turn at proportional engine
speed.

The oil pressure generated by the transmission


pump is used for lubrication, internal cooling, and
hydraulic control of the transmission. Without oil
pressure the transmission cannot function.

The torque converter hydraulically connects the en-


gine flywheel with the transmission input shaft. See
Figure 2. It functions as a fluid clutch to smoothly
transfer power from the engine to the transmission,
and as a torque multiplier when speed difference
between engine and transmission input shaft in-
creases. The torque converter has a specific torque
multiplication factor that matches the engine power
characteristics. Speed difference between engine
and transmission input shaft is a measure of engine
power being transferred. With increasing speed
difference, there is also an increased amount of heat
generated in the converter. The heat generated is
removed by the transmission oil which flows through
the torque converter.

The different speed ratios between input shaft and


drive shaft are obtained by engaging and disengaging
AN Input
the different clutches. See Figure 3. Two clutches are
continuously engaged with each other. See Figure 3 PTO Power Take-Off
and Figure 4.
KV Clutch Forward
KR Clutch Reverse
K1 Clutch 1st Speed
K2 Clutch 2nd Speed
K3/AB Clutch 3rd
Speed/Output

Figure 2. Transmission Diagram

2
1300 SRM 1455 Description

A 1st Speed Forward


B 2nd Speed Forward
C 3rd Speed Forward
AN Input
PTO Power Take-Off
KV Clutch Forward
KR Clutch Reverse
K1 Clutch 1st Speed
K2 Clutch 2nd Speed
K3/AB Clutch 3rd Speed/Output

Figure 3. Transmission Powerflow Diagram

3
Description 1300 SRM 1455

1. FORWARD CLUTCH 4. 1ST SPEED GEAR


2. REVERSE CLUTCH 5. 2ND SPEED GEAR
3. INPUT SHAFT 6. 3RD SPEED GEAR AND OUTPUT SHAFT

Figure 4. Gear Engagement

Table 1 provides an overview of the activated The different speeds are obtained by engaging either
solenoids and clutches for the different transmis- the forward or reverse clutch, and by engaging one of
sion speeds. Neutral selection, applying the park the clutches for the first, second, or third speed.
brake and leaving the seat disengages all clutches.
Trucks with a MONOTROL® pedal will only shift to When the transmission is in NEUTRAL, all clutches
NEUTRAL by applying the park brake, or when the are disengaged.
operator has left the seat.
The clutches consist of a clutch pack carrier, which
If clutches belonging to one group would be engaged carries friction discs with external splines, and an
simultaneously, the transmission would lock. The idler gear, which carries steel discs with internal
forward and reverse clutches should not be engaged splines. See Figure 5.
at the same time. Also, the speed clutches for first,
second, and third gear should not be engaged at
the same time. Erroneous clutch engagement is
prevented by the transmission control system.

4
1300 SRM 1455 Description

Table 1. Activated Solenoids and Gear Selection

Transmission Gear Activated Clutches


Direction Speed
Forward 3rd Forward + 3rd
Forward 2nd Forward + 2nd
Forward 1st Forward + 1st
Neutral None None
Reverse 3rd Reverse + 3rd
Reverse 2nd Reverse + 2nd
Reverse 1st Reverse + 1st

1. IDLER GEAR 7. PISTON SPRING SPACER


2. CLUTCH END PLATE 8. FRICTION DISCS
3. CLUTCH PACK CARRIER 9. PISTON SPRING SET
4. PISTON SEALS 10. OIL SEALS
5. CLUTCH SHAFT 11. OIL SUPPLY FOR LUBRICATION AND COOLING
6. PISTON

Figure 5. Clutch Components

Friction discs and steel discs are alternately fitted. housing and allow the clutch pack carrier and idler
By pressurizing the clutch piston, the friction discs gear to rotate independently. The clutch pack car-
and steel discs are clamped together, which causes rier, friction discs, piston and compression spring ro-
the clutch pack carrier and idler gear to rotate as tate at the same speed. The idler gear rotates at the
one unit. When hydraulic pressure is released, re- same speed as the inner discs.
turn springs push the piston back against the clutch

5
Description 1300 SRM 1455

Torque Converter from the turbine to the impeller to oppose the direc-
tion of impeller rotation. This leads to significant
A Torque Converter is a fluid coupling that is loss of efficiency and generation of waste heat. In
used to transfer rotating power from the engine, to the torque converter, the returning fluid is redirected
the transmission input shaft. The torque converter (reversed) by the stator so that it aids the rotation
is able to multiply torque when there is a substan- of the impeller, instead of impeding it. The result
tial difference between input and output rotational is that the energy in the returning fluid is recovered
speed. The converter is designed to match the en- and added to the energy being applied to the impeller
gine power so that the most favorable conditions are by the engine. This increase in fluid mass directed to
obtained. the turbine results in increased output torque.
The torque converter is composed of three main com- Due to the flow reversion, the stator is receiving a re-
ponents: action torque. The relation turbine torque/impeller
• Impeller torque is called torque multiplication. The higher
• Turbine Wheel the torque multiplication the greater the speed dif-
• Stator ference of impeller and turbine wheel will be.
For illustration purposes consider two fans represent The maximum torque multiplication is created at
the impeller and the turbine wheel. The two fans are stationary turbine wheel. With increasing output
facing each other and only one of them is turned on, speed, the torque multiplication is decreasing. The
the other fan will also begin to move. torque converter adapts the output speed to a cer-
tain required output torque. this process is infinitely
The first fan (powered) represents the impeller,
variable and is automatically achieved by the torque
which is directly connected to the converter hous-
converter.
ing. The second fan (driven) represents the turbine,
which is connected to the transmission input shaft. When the turbine speed is reaching 80% of the im-
When the non-powered fan (turbine) is stopped, the peller speed, the torque multiplication equals 1.0.
powered fan (impeller) is still able to move. This The turbine torque becomes equal to the impeller
illustrates why the engine does not stall when the torque. From this point on, the converter is work-
truck is stopped and still in gear. ing similar to a fluid clutch.
Now consider a third component, located between the In the stall and acceleration phase the torque on the
two fans (stator), that changes the airflow and en- stator is transferred to the transmission housing. A
ables the powered fan to drive the non-powered fan stator freewheel improves the efficiency in the cou-
at reduced speed and increased force (torque). This pling phase and stator torque is released in the cou-
illustrates the function of the stator. pling phase. In this phase the stator can rotate freely.
The impeller, turbine wheel and stator are arranged
Operational Phases
in a ring shape and oil flows through the components
in the order indicated. A torque converter has three stages of operation:
• Stall. The engine is applying power to the im-
Pressurized oil from the transmission oil pump flows
peller but the turbine cannot rotate. At stall, the
constantly through the converter. The converter
torque converter produces maximum torque mul-
multiplies the torque of the engine and the heat
tiplication. The resulting multiplication is called
generated in the converter is dissipated through the
stall ratio. The actual stall phase only lasts for a
oil leaving the converter.
brief period of time until the vehicle starts to move.
Depending on the speed difference between the im- • Acceleration. The vehicle is accelerating but
peller and the turbine wheel, the transmission input there is a relatively large difference between im-
torque increases when the speed difference between peller and turbine speed. During acceleration,
impeller and turbine wheel increases. the converter torque multiplication is less than
what could be achieved under stall conditions. The
The torque converter’s ability to multiply torque lies torque multiplication depends upon the actual
in the stator. In the classic fluid coupling design, pe- difference between impeller and turbine speed, as
riods of high slippage cause the fluid flow returning well as various other design factors.

6
1300 SRM 1455 Operation

• Coupling. The turbine has reached approxi- torque converter is behaving in a manner similar
mately 80 percent of the impeller speed. Torque to a simple fluid coupling. In this phase the stator
multiplication has essentially ceased and the can rotate freely.

Operation
HYDRAULIC OPERATION particles from entering the transmission pump. The
pump is driven by the torque converter. The pump
Within the ZF Ergopower Transmission all hydraulic transfers oil through the transmission filter, to the
operations are controlled (hypothetically) by the Hy- 16+2 bar (232+29 psi) main pressure valve and the
draulic Control Valve. See Figure 6. 9 bar (131 psi) pressure reducing valve. See Figure 7.
The transmission sump is the main reservoir for
the transmission oil. The sump screen keeps large

1. MAIN PRESSURE VALVE 5. PRESSURE REGULATOR


2. PRESSURE REDUCING VALVE 6. COVER
3. HOUSING 7. VALVE BLOCK
4. CABLE HARNESS CONNECTOR

Figure 6. Hydraulic Control Valve

7
Operation 1300 SRM 1455

NOTE: THE ENCIRCLED NUMBERS REFER TO CHECK PORT NUMBERS. SEE FIGURE 11.
A. COOLING AND LUBRICATION C. PILOT PRESSURE
B. MAIN PRESSURE D. RETURN TO SUMP
1. SUMP 11. TEMPERATURE SENSOR
2. PUMP 12. PRESSURE REDUCING VALVE (RV-9), 9 bar
3. SCREEN (131 psi)
4. FILTER 13. REVERSE CLUTCH
5. FILTER PRESSURE DIFFERENTIAL VALVE 14. FIRST SPEED CLUTCH
(BYPASS VALVE) (FDV) 15. THIRD SPEED CLUTCH
6. MAIN PRESSURE VALVE (HDV), 16+2 bar 16. FORWARD CLUTCH
(232+29 psi) 17. SECOND SPEED CLUTCH
7. TORQUE CONVERTER SAFETY VALVE (WSV), 18. TORQUE CONVERTER BACK PRESSURE
11+2 bar (160+29 psi) VALVE (WGV), 4.3+3 bar (62+44 psi)
8. TORQUE CONVERTER 19. PRESSURE RELIEF VALVE (UEDV), 40±5 bar
9. OIL COOLER (580±72 psi)
10. LUBRICATION OF SHAFTS AND CLUTCHES 20. THERMOSTATIC BY-PASS VALVE

Figure 7. Hydraulic Diagram

8
1300 SRM 1455 Operation

The 16+2 bar (232+29 psi) main pressure valve regu- (62+44 psi). The oil, escaping from the converter and
lates system pressure, by relieving excess oil through leaving the transmission, is directed to an external
the torque converter, oil cooler, and lubrication sys- thermostatic bypass valve that directs the oil over
tem. See Cooling and Lubrication. System pressure the transmission oil cooler or back to the transmis-
is used to fill and pressurize the clutches. sion. The cool oil returning to the transmission en-
ters the lubrication oil circuit, ensuring all lubrica-
The clutches of the transmission are operated by the tion points are supplied with cool oil. See Figure 7.
proportional valves P2 to P6 (see Figure 7). The pro- Also see the section Cooling and Lubrication.
portional valve is composed of the pressure regulator
(Y2-Y6), follow-on slide (NFS) and vibration damper COOLING AND LUBRICATION
(D).
Heat is primarily generated at the torque converter
The 9 bar (131 psi) pressure reducing valve (RV-9) and at the clutch plates during transmission opera-
provides pilot pressure for the proportional valves tion. The heat generated by mechanical friction at
and the pressure regulators. The function of the gears, shafts and bearings is relatively low.
pressure regulators is to activate the follow-on slides
when the control system allows this. The follow-on Heat generated in the torque converter relates di-
slides will modulate the 16+2 bar (232+29 psi) main rectly to the degree of stall, (i.e. the speed differ-
pressure for the respective clutches. ence between engine and turbine). In a stall situa-
tion most of the supplied engine power is transferred
Due to the proportional pressure modulation of each into heat. This heat accumulates in the torque con-
clutch, the pressure to the clutches, which are en- verter because of the reduced oil flow during a stall
gaged in the gear change, will be controlled. In this situation. With increasing turbine speed, the volume
way a hydraulic interaction of the clutches to be en- of added heat reduces, while simultaneously, the in-
gaged and disengaged becomes possible. This allows creased oil flow more rapidly transfers the accumu-
for spontaneous shifting without traction force inter- lated heat.
ruption.
Heat generated at the clutch plates varies with the
The transmission pump is located in the torque con- available engine power at time of clutch engagement
verter bell housing behind the torque converter. The and the duration of clutch engagement. During nor-
transmission pump moves the transmission oil from mal operation, the transmission control system de-
its sump through the sump screen to the transmis- termines the duration of clutch engagement. Dur-
sion filter, located on the side of the transmission, ing inching it is the driver who controls the added
to the main pressure valve at a rate of 105 liter/min heat in the clutch by varying engine power and clutch
(27 gal/min) at 2000 RPM engine speed. engagement. The transmission control system will
close the forward or reverse clutch when a certain
If the transmission oil filter becomes contaminated
amount of generated heat has been exceeded.
(full of debris), the oil flow will bypass the filter. The
differential pressure switch (contamination switch) Only a minor portion of the total transmission pump
will activate the transmission warning light and cen- supply is used for clutch filling. The majority of
tral warning lights. An error will be shown in the transmission oil supply is used for the cooling and
dash display. See ZF Transmission Fault Codes. lubrication circuit that functions at a pressure that
is lower than system pressure. See Figure 7. The
The main pressure valve limits the maximum pres-
main pressure valve admits oil that is not required
sure and relieves excess oil to the converter and lubri-
for clutch filling. The converter safety valve limits
cating circuit. A converter safety valve is installed to
oil pressure to protect the torque converter and oil
protect the converter. In the converter, the oil trans-
cooler. The normal oil flow is through the torque
mits the power from the impeller to the turbine.
converter, the transmission oil cooler and to the
To avoid cavitation, the converter must always be transmission lubrication port. When the trans-
completely filled with oil. Therefore a converter pres- mission is at operating temperature, the volume of
sure back-up valve is mounted at the rear of the con- lubrication oil is 105 liter (27.7 gal) at 2000 rpm.
verter, which has an opening pressure of 4.3+3 bar

9
Control System 1300 SRM 1455

From the transmission lubrication port the oil flows


into channels in the different shafts, which lead to
the shaft bearings for lubrication, and to the inside of
the clutch packs where the oil absorbs the heat that
is generated at the clutch plates. See Figure 8.

To expedite the warming up process, a thermostat


valve is fitted between the torque converter outlet
port and the transmission cooler. The thermostat
starts opening at 70°C (158°F) and is completely
opened at 85°C (185°F). At temperatures below 70°C
(158°F), oil flow is directly returned to the transmis-
sion. At temperatures above 85°C (185°F), the entire
oil flow from the outlet port has to pass the cooler
before it is returned to the transmission.

1. OIL CHANNEL

Figure 8. Cooling and Lubrication

Control System
GENERAL During shifting the following criteria will be consid-
ered:
The control system of the ZF Ergopower Trans- • Speed of engine, turbine, central gear train and
mission consists of the Transmission Control Unit output.
(TCU). Several switches and senders provide in- • Transmission temperature.
formation to the TCU. The hydraulic control valve • Shifting mode (up, down, reverse shifting, and
regulates pressures depending on signals from the speed engagement out of neutral).
TCU. • Load condition (full or part load, traction during
shifting).

10
1300 SRM 1455 Control System

TRANSMISSION CONTROL UNIT (TCU) Substitute Clutch Control

The TCU has software to control the operation of the The TCU CANNOT change the gears or the direc-
transmission and performs the following functions: tion under the control of the normal clutch modula-
• Perform self-test and troubleshooting. tion. The TCU uses the substitute strategy for clutch
• Functional control of the transmission. control, all modulations are time controlled. The dis-
– Automatic shifting. play will show t_SCC.
– Inching.
• Enter a protection mode when required. Limp-Home Mode
– Improper pressures, temperatures, and speeds.
The detected failure in the system has strong limita-
– No operator present.
tions to transmission control. The TCU will only be
– Parking brake applied.
able to engage one gear in either direction. In some
– Gear or direction change at improper speeds.
cases only one direction will be possible. The display
• Logging a fault code when circumstances have ex-
will show t_LMP.
ceeded certain values.
• Allow diagnostics and calibration with a laptop At the first occurrence of the failure, the TCU will
(Testman). shift the transmission into NEUTRAL. The operator
must shift the gear selector into NEUTRAL position.
Depending on the signals of the shift lever and vari-
If the output speed is less than a threshold for NEU-
ous switches and senders, the TCU activates or deac-
TRAL to engage and the operator shifts the gear se-
tivates the pressure regulators in the control valve,
lector into forward or reverse, the TCU will select
which transfer hydraulic pressure to the clutches in
Limp-Home gear. If the speed is less than a threshold
the transmission. If an input signal does not com-
for reverse gear and the TCU has changed into the
ply with the programming of the TCU, the TCU will
Limp-Home gear and the operator selects a shuttle
record the fault and react by activating a protection
shift, the TCU will immediately shift into the Limp-
mode. All events recorded are stored as a fault code
Home gear of the selected direction. If the output
and/or exceed code and are shown on the instrument
speed becomes greater than Limp-Home threshold,
cluster when the fault occurs. Faults can also be read
the TCU shift the transmission into NEUTRAL. The
at a later point in time, making it possible to trace in-
operator must slow the lift truck down and shift the
termittent problems.
gear selector into the NEUTRAL position to restart
Protection modes and self tests are part of the TCU the Limp-Home mode.
programming and cannot be influenced.
Transmission Shut Down Mode
The TCU is located in the side console of the cab. The
If there is a severe failure detected by the TCU, con-
gauges and displays on the dashboard are used to
trol of transmission will be disabled. The TCU will
read transmission related information. For diagnos-
shut off the solenoid valves for the clutches and the
tics and settings, it is more convenient to use a laptop
common power supply (VPS1). The TCU will shift
loaded with the Testman software.
the transmission into NEUTRAL.
Self Test The operator must slow down the truck. The trans-
mission will remain in NEUTRAL.
At power up a series of checks is performed. If the
TCU fails these checks, it will shut off all outputs. TCU Shut Down Mode
The transmission cannot be operated until the prob-
lem is rectified. The relevant fault code will be dis- Occurs when the TCU has detected a severe failure
played. that disables control of the system. The display will
show t_SHT.
Operating Modes
At this time the TCU will shut down all solenoid
Normal Mode valves and both common power supplies (VPS1 and
VPS2).
There is NO failure detected in the transmission sys-
tem or the failure has little or no effect on transmis- The transmission will stay in NEUTRAL.
sion control. The TCU will perform with little or no
limitations.

11
Control System 1300 SRM 1455

Transmission Exceed Codes circumstances have changed, and all faults have
ceased to exist, the hour meter/fault code display
During operation of the truck, the TCU controller will show engine running hours again.
may display transmission exceed codes on the LCD
of the instrument cluster. These exceed codes reflect Fault code t_CON indicates a communication prob-
that the request made by the operator will not be exe- lem.
cuted because of certain circumstances. See the sec-
tion Transmission Exceed Codes for a list of trans-
mission exceed codes and a description of the encoun-
tered circumstances.

Fault Codes
Description

The LCD can show different modes:


• Hour Meter Mode
• Error Mode (only shown if there are active errors)
• Calibration Mode (special entry condition) Fault code t-CON is shown when the instrument
• Error Log Mode (special entry condition) cluster does not receive a cyclic message or receives
incorrect messages from the TCU.
Under normal operating conditions the LCD will
show only the hour meter. If there are active errors Fault Log Mode
it will scroll between Hour and Error Mode.
Access
During TCU start-up the display will show te_NN.
It verifies if all conditions are met before it allows The instrument cluster has a memory that records
normal operation. each fault when it occurs. These faults that have
occurred can be reviewed at a later point in time by
During start-up the LCD can show 1,2 or 3 if some entering into the fault log mode. Proceed as follows
quick ignition ON is done or diagnostic switch is to enter into the fault log mode:
pressed, this is part of the special entry condition
sequence for Error mode. 1. Apply parking brake.

• Hourmeter reading 2. Turn ON ignition, but do not start lift truck.

3. Press service switch 3 times, press approxi-


mately for one second and release for one second
(this represents one cycle). After the first cycle,
the display will show a 1. After the second cycle,
the display will show a 2. After the third cycle,
the display will show a 3.
When the hourglass is shown, the LCD display is
in hour meter mode and is showing engine running The display is now in fault log mode. When no faults
hours. have been recorded, the LCD display shows "clear."
When faults have been recorded, the display shows a
If the transmission controller detects a fault, the
letter and 4 numbers for each fault code. For trans-
LCD will show a fault code instead of the engine
mission fault codes, the letter is "t".
running hours.
After the fault code, three further numbers are
Fault codes starting with "t" refer to transmission ex-
shown.
ceed and fault codes. Refer to the section ZF Trans-
mission Fault Codes in this manual for a list of exceed The numbers represent the following:
codes and fault codes. • Fault code
• Hourmeter reading at last occurrence
When more than one fault occurs at the same time,
• Hourmeter reading at first occurrence
the fault codes will be displayed in succession. When
• Number of occurrences of current fault

12
1300 SRM 1455 Control System

Each number is shown for 3 seconds, after which the To rectify problems with switches, solenoids and sen-
following number is shown. The faults will be shown sors, look up their actual location, and test the com-
in the opposite sequence of occurrence: The most re- ponent. The location of the pressure regulators are
cent fault first and the first occurred fault last. When shown in the section Hydraulic Control Valve. The
all recorded fault codes have been shown, the display location of sensors and switches are shown in the sec-
will continue to repeat these recorded fault codes un- tion Speed and Temperature Sensors, and Figure 11.
til the user exists the fault log mode. Test values of solenoids and sensors are shown in
Electrical Specifications.
Exit
NOTE: The Testman software and the manual Dia-
To exit the fault log mode, turn the ignition OFF grams 8000 SRM 1500 have wire and input refer-
and ON and leave ignition ON for more than 2 sec- ences that relate to the TCU.
onds. The cluster will return to normal mode when
the parking brake is released or when the engine is To determine the exact location of a harness problem,
started. look up the reference number of the component in-
volved in Diagrams 8000 SRM 1500. The legend of
Clear Diagrams 8000 SRM 1500 shows the related connec-
tor code and wire harness. Information for these con-
To clear the fault codes logged in the display, proceed
nectors are shown in the legends for Figure 20. The
as follows:
positions of the connector pin numbers are shown in
1. Access into the fault log mode. See Access. Figure 21 through Figure 29. The figures represent
the view facing the pin side of the connector, NOT
2. Clear the fault log by pressing the service switch the harness side of the connector.
three more times (one second on, one second off).
This is a repetition of the procedure to access the Figure 20 show the wire harnesses that are relevant
fault log mode. See Access. for the TCU wiring. Actual location of the connectors
can be derived from their position on the harness and
If the data-erasing process is successful, the display from their description. At the legend of the wire har-
will show ’clear’. If the data-erasing process is not ness figures, pin location figures are shown for con-
successful, the display will show the fault codes in nectors interconnecting between harnesses.
the memory, shown in the order by the time of the
occurrence. To return to the normal mode, follow the To identify the harness problem, first determine con-
procedure as described in Exit. nectivity between the TCU and the connector of the
component that was indicated in the ZF Transmis-
Fault Rectification sion Fault Codes. If an unsatisfactory result is re-
turned, measure connectivity from harness to har-
Fault codes are listed in the section ZF Transmission ness.
Fault Codes, which provides a description of the fault
and the reaction of the TCU. Each fault code repre- HYDRAULIC CONTROL VALVE
sents a specific error or malfunction.
The hydraulic control valve is located at the left-hand
In most cases the suggested rectification is by check- side of the transmission and contains the pressure
ing electrical functionality between the TCU, the regulator valves and check ports. Function of the hy-
wiring and the sensors, solenoids, or switches. draulic control valve depends on available pump sup-
ply pressure and the activation of the pressure reg-
Before disassembling components for test purposes, ulators. Activation of the pressure regulators is con-
connect the Testman software. The software allows trolled by the TCU. Hydraulic function of the control
verification of the functionality of speed sensors, con- valve is schematically shown in Figure 7.
tamination switch, temperature sensor, shift lever,
inch sensor, solenoids and throttle sensor. In case The location of the different pressure regulators are
several possible defects are indicated, the Testman shown in Figure 9.
software may narrow down the number of possible
defects, preventing unnecessary removal of compo-
nents that function correctly.

13
Control System 1300 SRM 1455

1. MAIN PRESSURE VALVE 5. PRESSURE REGULATOR


2. PRESSURE REDUCING VALVE 6. COVER
3. HOUSING 7. VALVE BLOCK
4. CABLE HARNESS CONNECTOR

Figure 9. Solenoid Locations

The location of the main components of the control


valve are shown in Figure 10.

Hydraulic Control Valve Repair


Repairs to the control valve, in most circumstances,
are limited to replacing solenoids and gaskets. Hy-
draulic components of the control valve may be in-
spected, are available for replacement, but cannot be
adjusted.

For details of control valve replacement see the man-


ual Transmission, Repair (ZF-WG161) 1300 SRM
1456. 1. MAIN PRESSURE VALVE WITH SPRING
2. VIBRATION DAMPER WITH SPRING
3. FOLLOW-ON SLIDE WITH SPRING

Figure 10. Control Valve Components

14
1300 SRM 1455 Control System

Solenoid Replacement None of the oil pressures are adjustable. If a pressure


is out of specification, the cause has to be established
For details of solenoid replacement see the manual by further checking.
Transmission, Repair (ZF-WG161) 1300 SRM
1456. The control valve includes the main pressure valve
and (pilot) pressure reducing valve.
Pressure Check
The check ports for various clutches can be pressur-
All transmission oil pressures can be measured at ized with air. The amount of air pressure applied
the side of the control valve by using M10X1 fitting. should be approximately 14 bar (200 psi). When ap-
See Figure 11 and for list of check port numbers and plying air pressure to the check ports, clutch engage-
their description. The port numbers mentioned at ment and obvious leaks can be established. For the
each check point correspond with the port numbers location of the ports see Figure 11.
as shown on Figure 7.

Port Number Description Port Pressure


51 Torque Converter In 11-13 bar (159+29 psi)
53 Forward Clutch 16-18 bar (232+29 psi)
55 Reverse Clutch 16-18 bar (232+29 psi)
56 1st Gear Clutch 16-18 bar (232+29 psi)
57 2nd Gear Clutch 16-18 bar (232+29 psi)
58 3rd Gear Clutch 16-18 bar (232+29 psi)
65 System Pressure 16-18.5 bar (232+36 psi)

Figure 11. Check Ports, Control Valve

15
Control System 1300 SRM 1455

Pressure Specifications factor for the TCU to determine in the automatic


selection mode, if a next higher or lower gear
Temperature of the oil must be 80 to 90°C (180 to is to be selected. During calibration, a sudden
199°F) for correct pressure measurement. change in converter speed ratio is used to deter-
mine the clutch piston position, at the moment
In the cooling and lubrication circuit the torque con-
the clutch starts clamping.
verter causes additional flow resistance with increas-
• Transmission Ratio
ing speed difference between engine and transmis-
– Each selected transmission gear has a specific
sion input shaft.
transmission ratio. When one of the direction
clutches is closed and the output speed has
SPEED AND TEMPERATURE SENSORS
reached a certain value for checking, then the
Before disassembling components for test purposes, actual ratio is compared with the specified ratio.
connect the Testman software. The software allows If deviation exceeds limits, one of the clutches is
verification of the functionality of several compo- assumed to be slipping. A fault is flagged and
nents, preventing unnecessary removal. the TCU enters the Shut Down Mode.
• Gear Ratio
The location of the speed sensors are included in Fig- – If the turbine, internal or output speed sensor
ure 12. fails, then the TCU calculates the ‘actual ratio’
based on the value of the remaining sensors. This
Speed Sensors allows continued operation of the transmission.
Speed sensor failure is indicated by a fault code.
The function of the speed sensors is to determine the If the engine speed sensor fails, or if more than
rotation speed of the different groups of gears. The one speed sensor fails, then the TCU will enter
TCU calculates the speed ratios between the differ- the Limp Home Mode and flag a fault.
ent groups and compares the calculated values with • Maximum Torque During Inching
the programmed values. If deviation exceeds an al- – The TCU programming interprets the inching
lowable value, the TCU generates a fault code and pedal position as the required pressure for the
eventually enters a protection mode. Below are a few inching clutch. The heat generated in the inching
examples of speed inputs and ratios that are moni- clutch is proportional to the power transferred
tored by the TCU: by the torque converter (= converter speed ratio).
• Converter Speed Ratio When the power transferred is at too high level
– The ratio between engine speed and turbine during too long a time, the TCU will release pres-
speed is called the converter speed ratio, which sure in the clutch and flag a fault.
is a measure of the power being transferred
through the converter. This ratio is a major

16
1300 SRM 1455 Control System

Marking on
Hydraulic Oil Pressure or
Item Item Description the Hydraulic
Temperature
Diagram
1 Turbine Speed Sensor
2 Intermediate Speed Sensor
3 System Pressure (M10X1) 16-18.5 bar (232+36 psi) 65
4 Converter Pressure (M10X1) 11-13 bar (159+29 psi) 51
5 Filter contamination switch
6 Breather
7 Output Speed Sensor
8 Control Valve Wiring Connector
9 Engine Speed Sensor
10 Converter pressure back-up valve (M14X1.5) 4.3-7.3 bar (62+44 psi) 52/63
11 1st Speed Clutch Pressure (M10X1) 16-18 bar (232+29 psi) 56
12 Converter Output Temperature Sensor
13 From Heat Exchanger
14 To Heat Exchanger
15 Reverse Clutch Pressure (M10X1) 16-18 bar (232+29 psi) 55
16 3rd Speed Clutch Pressure (M10X1) 16-18 bar (232+29 psi) 58
17 Forward Clutch Pressure (M10X1) 16-18 bar (232+29 psi) 53
18 2nd Speed Clutch Pressure (M10X1) 16-18 bar (232+29 psi) 57

Figure 12. Measuring Points and Connections

17
Control System 1300 SRM 1455

1. SELECTOR HANDLE 2. DIRECTION INDICATOR 3. DRIVE PROGRAM SELECTOR

Figure 13. Shift Lever

Test Shift Lever


Testman shows functionality of each of the speed sen- The shift lever is mounted on the left side of the steer-
sors under "Speeds/Torque Monitor". Electrical func- ing column and provides information to the TCU. The
tionality can be tested by checking resistance over direction of travel is selected by moving the lever
the sensors. from the middle neutral position to the up position
to go forward or to the lower position to go in the re-
Temperature Sensors verse direction. To select the desired drive program,
rotate the selector handle to the desired position 1
There are two temperature sensors which measure through 3. See Figure 13 and Table 2.
the temperature at two different locations as follows:
• Sump Temperature (pump supply), Port 63 Table 2. Gear Selection
– This sensor is integrated in the control valve
wiring harness and is connected with the TCU. Drive Program Powertrain Gear
The signal to the TCU is translated into a Selector Position Available
CANbus signal to the dashboard and repre-
Position 1 1st Gear
sents transmission sump temperature. Testman
indicates functionality of this sensor under Position 2 2nd and 3rd Gear
‘Speeds/Torque Monitor’.
Position 3 Automatic
• Torque Converter Out, Port 52
Transmission (1st
– This sensor is connected with the TCU. The
to 3rd)
function is to trigger a protection mode. Test-
man indicates functionality of this sensor under
"Speeds/Torque Monitor".

18
1300 SRM 1455 ZF Transmission Test and Calibration

MONOTROL® Pedal
The MONOTROL pedal controls the speed of the en-
gine and the direction of travel. See Figure 14. There
are two switches in the MONOTROL® pedal assem-
bly. When the parking brake is released, the park-
ing brake switch permits battery power to flow to the
MONOTROL® pedal switches.

When the MONOTROL® pedal is in the forward po-


sition, the forward pedal switch is actuated. Battery
power flows through the forward pedal switch to the
TCU. When the MONOTROL® pedal is in the reverse
position, the reverse pedal switch is activated. Bat-
tery power flows through the reverse pedal switch to
the TCU. Figure 14. MONOTROL® Pedal

ZF Transmission Test and Calibration


TRANSMISSION TEST AND CALIBRATION CAUTION
Precautions Release the accelerator immediately if the en-
gine speed increases to its governed speed:
Before testing or calibrating the transmission, verify Cummins Diesel Engine, 2425 rpm ±2%
the following:
• Make sure the coolant level in the engine cooling CAUTION
system is correct.
Performing a stall test in 1st gear may damage
• Make sure the parking brake and service brakes
the internal parts of the drive axle.
operate correctly.
• Make sure the oil level in the transmission is at Perform the stall test in 2nd gear only (gear se-
"Full Level" when hot. lector position 2).
• Make sure the transmission oil temperature is at
least 71°C (160°F). 1. Connect a laptop computer to the diagnostic
connector in the side console. Select the screen
See the Operating Manual for instructions on how (Speeds/Torque Monitor) to read the engine
to add coolant and transmission oil. speed.

STALL TEST 2. Put a capacity load on the forks to prevent the


wheels from turning.
Description
3. Put the lift truck against an object that cannot
The stall test provides indications for the condition move.
of the engine, transmission clutches, and torque con-
verter. The stall test is performed with the transmis- 4. Select 2nd gear forward by moving the gear se-
sion engaged and operating the engine at full throt- lector forward in position 2.
tle while blocking the drive wheels. The stall speed
should be around 2050 rpm ± 50 rpm. 5. Push the accelerator pedal to full throttle.

6. Read the engine (stall) speed and release the


Stall Test Procedure throttle pedal.

CAUTION If the stall speed is 50 to 200 rpm below the specifica-


Do not hold the throttle open for more than 15 tion, the engine is not operating at full power. Check
seconds at a time. Permit the engine to operate if engine fault codes are present and rectify any indi-
at idle speed for two minutes between tests. cated problems.

19
ZF Transmission Test and Calibration 1300 SRM 1455

If the stall speed is higher than specification, the en- 2. Position the top of the inching pedal and the
gaged clutch(es) may not be holding or the torque brake pedal at equal height. Adjust the adjust-
converter is damaged. Check if transmission fault ment bolt for the brake pedal coupling so that
codes are present and rectify any indicated problems. the inching pedal has no free play.

If no transmission fault codes are present and the


stall speed is much higher than specification, remove
the torque converter for inspection or replacement.

If stall speed is only slightly higher than specifica-


tion, consider service life of the torque converter and
the option to replace the torque converter immedi-
ately or at a later point in time.

INCH PEDAL CALIBRATION


NOTE: At initial startup (new controller), Inch Pedal
Calibration is required before Clutch Calibration.
Truck will not move if inch pedal is not calibrated.
Also the truck will not enable inching mode if the
transmission is not calibrated. Both situations will
1. BRAKE PEDAL
generate an error code in the display. 2. INCHING PEDAL
3. ADJUSTMENT BOLT FOR BRAKE PEDAL
Description 4. ADJUSTMENT BOLT FOR BRAKE PEDAL
COUPLING
Inching is a controlled traction and braking mode. It 5. ADJUSTMENT BOLT FOR INCH PEDAL
enables higher engine speeds for increased hydraulic
function speeds, while truck travel speed remains Figure 15. Pedal Assembly
low. The inching function is obtained by relating
the inching pedal position to clutch pressure. The Inch Sensor Adjustment/Installation
relation between pedal position and clutch pressure 1. Connect a laptop, loaded with Testman software,
results in a natural reaction of the operator to de- to the diagnostic connector located in the side
press the inching pedal further when the actual truck console. See Figure 16. It would also be possi-
speed is too high. A further depressed inching pedal ble to use a multimeter and verify output signal
causes the pressure in the inching clutch to become at pin 2 (Analog output 1).
lower, which reduces truck speed, regardless of en-
gine speed. In case too much heat is generated, the 2. Select Analog Inputs in Testman.
TCU will trigger fault code thots or thotc (s=sump,
c=converter). 3. Verify Inch Sensor 1 (AU1 [V]) voltage for the
inching sensor is between 0.7-0.9V (700-900 mV).
The inching pedal sensor has to be calibrated for two
pedal positions, Inching pedal completely depressed 4. If voltage is incorrect, proceed as follows:
and Inching pedal released. Calibration is required
when the inching sensor has been replaced, the TCU a. Raise the Cab until the latch locks in the par-
is replaced, or when it becomes loose. Before cali- tial open position. See Operator’s Cab 100
brating the inching sensor, verify adjustment of the SRM 1390 for proper procedure.
brake pedal and the inching sensor. Incorrect sensor b. Loosen the two mounting bolts of the inching
calibration triggers fault codes during inch pedal cal- sensor.
ibration.
c. Rotate the sensor in the slotted holes until
Brake and Inch Pedal Adjustment output voltage is between 0.7-0.9V (700-900
mV) in released pedal position.
1. Turn the adjustment bolt for the brake pedal un-
til there is no play between the bolt on the brake d. Tighten the two mounting bolts and verify
valve and the roller under the brake pedal. See output voltage is still correct.
Figure 15.

20
1300 SRM 1455 ZF Transmission Test and Calibration

the calibration process is activated, and the calibra-


tion switch is in on position (switch toggled down) the
LCD will display step by step instructions as to what
to do next.

1. Park truck on level ground with a minimum of


5 m (16.5 ft) clearance between the truck and any
object.

2. Make sure pedals and inch sensor have been cor-


rectly adjusted. Refer to Brake and Inch Pedal
Adjustment and Inch Sensor Adjustment/Instal-
lation sections of this manual for proper proce-
dures.

3. Apply the park brake.

4. Verify the Forward/Reverse lever is in NEU-


TRAL.
1. TCU 5. Turn OFF the ignition.
2. DIAGNOSTIC CONNECTOR
3. CALIBRATION SWITCH 6. Turn the calibration switch on (flip the switch to
the down position) and sit in the operator’s seat.
Figure 16. Calibration Switch Location
7. Turn the ignition key switch ON but DO NOT
NOTE: When activating the transmission calibration
start the truck.
switch, brake accumulator charging is disabled to
eliminate possible RPM fluctuations that would af- 8. The inch pedal calibration mode is now active.
fect transmission clutch pack calibration. The LCD will show the next sequence:
• tP_dn should now be on the LCD; the operator
Inch Pedal Calibration should press the inch pedal all the way down to
the end stop position.
NOTE: For Inch Pedal calibration, either the calibra-
• tP_UP should now be on the LCD; the operator
tion switch or the Testman software may be used, but
should release the inch pedal and allow it to
never a combination of the two. If the Testman soft-
return to the released position.
ware is connected, the calibration switch CANNOT
be used for calibration. The display will not show cal- Table 3. Inch Pedal Calibration LCD Display
ibration information.
Inch Pedal Down tP_dn
Manual Inch Pedal Calibration Procedure
Inch Pedal Up tP_UP
When the calibration switch is on (switch in down
position see Figure 16) the dash display will acti- Calibration Set tPSEt
vate the calibration mode. The transmission warning
light will be ON and the hour meter will not show. If 9. When all values are within range the LCD will
there are active errors, the display will scroll between display:
calibration mode and error mode. The Transmission • tPSEt, indicating inch pedal calibration is
inch pedal calibration mode is set on LCD, when the ready.
calibration switch is set active, the ignition key is on
and the engine is NOT running. 10. After calibration is ready, switch OFF ignition
and set the calibration switch to the off position
NOTE: The following procedure is the manual cali- (flip the calibration switch to the up position).
bration procedure for Inch Pedal calibration. Once

21
ZF Transmission Test and Calibration 1300 SRM 1455

Inch Pedal Calibration Error Codes Testman Inch Pedal Calibration Procedure

During the Inch Pedal calibration process an error 1. Park truck on level ground with a minimum of
code may occur. The LCD will show "TPYXX" or 5 m (16.5 ft) clearance between the truck and any
"tPrET" indicating calibration errors have occurred. object.
Certain error codes allow for adjustments to be made
and calibration can be retried, indicated on the LCD 2. Apply the parking brake.
by "tPrET". Other error codes will stop the calibra-
3. Verify the forward/reverse lever is in NEU-
tion process and need to be resolved before restarting
TRAL.
the calibration process.
4. Turn OFF ignition.
Table 4. Inch Pedal Calibration LCD Display
5. Connect a laptop computer, with the Testman
Calibration Retry tPrET software loaded, to the Diagnostic Connector in
Calibration Error tpyxx the side console. See Figure 16.

6. Ensure that someone is sitting in the operator’s


Table 5. Inch Pedal Calibration Error Codes seat.

Y XX Value Meaning 7. Turn the ignition to the ON position, but DO


NOT start the truck.
4 10 Shift Lever NOT in Neutral/No signal
from Operator’s Presence Seat Switch 8. Select Inch Sensor Calibration from the Testman
4 11 Sensor Supply Voltage is out of menu and follow the instructions on the screen.
Specified Range
9. After calibration is complete, switch OFF igni-
4 12 Output Speed NOT = 0. tion and disconnect laptop computer from diag-
nostic connector in the side console.
4 13 Sensor Voltage Below Specified Range.
4 14 Sensor Voltage Above Specified Range CLUTCH CALIBRATION
4 15* Sensor Position for Released Pedal
Description
Out of Specified Range.
4 16* Sensor Position for Pressed Pedal The TCU is programmed to quickly fill the clutch un-
Out of Specified Range. til the piston starts clamping the discs and only then
raise clutch pressure further within a certain period
4 18 Time-Out Calibration, Pedal not moved of time until full engagement has been reached.
After Calibration Start.
When shifting up, the clutch to be released will start
4 19* Angle Between Pedal Positions Released
relieving its pressure at the same moment when the
and Pressed to Small.
engaging clutch starts clamping. For a short period of
4 20* Angle Between Pedal Positions Released time, these two clutches are both partially engaged.
and Pressed to Big. This provides the feature to shift up a gear smoothly
under full traction.
4 21 Sensor Signal 1 and 2 don’t match
together. See NOTE. As the clutch plates wear, they will get slightly thin-
ner. This implies that the piston of the engaging
NOTE: The inch sensor has a redundant signal 2. clutch will have longer travel until the piston starts
Signal 2 is 50% of signal 1. If signal 2 is out of clamping the discs. The releasing clutch would start
range by more than 10%, error code tp421 will be slipping too early. The transmission would no longer
displayed. If this occurs the inch sensor needs to shift smoothly.
be replaced.
The TCU has a calibration program to readjust
the clutch filling time and pressure to reach full
engagement. Clutch filling time is determined by
the elapsed time between clutch fill start and the

22
1300 SRM 1455 ZF Transmission Test and Calibration

moment when the turbine speed sensor detects a mode. The transmission warning light will be ON
change in speed (touch detection). The time to reach and the hour meter mode will not show. LCD Trans-
full engagement is determined by the elapsed time mission clutch pack calibration mode is set on "LCD"
between touch detection and full clutch engagement. when transmission service switch is set active and
the engine RPM is between 700-900 RPM (engine
After every oil change (2000 hours) it is recom- idle). If active error codes are present, the LCD will
mended that the clutch calibration program is scroll between the error codes and the transmission
performed. The clutch calibration program must calibration mode. See Table 6.
be started after initial transmission installation,
replacement of the transmission, replacement of the 1. Park truck on level ground with a minimum of
hydraulic control valve, or replacement of the TCU. 5 m (16.5 ft) clearance between the truck and any
object.
During clutch calibration the truck display or Test-
man software will assist the service technician with 2. Apply the parking brake.
messages informing him as to what actions may
be necessary to take or what stage the calibration 3. Verify the forward/reverse lever is in NEU-
process is in. TRAL.

NOTE: The transmission oil temperature gauge mid


Clutch Calibration Procedure
point is 75°C (167°F).
NOTE: For clutch calibration, either the calibration
4. Make sure the transmission oil temperature is at
switch or the Testman software may be used, but
least 71°C (160°F).
never a combination of the two. If the Testman soft-
ware is connected, the calibration switch CANNOT 5. Turn OFF ignition.
be used for calibration. The display will not show cal-
ibration information. 6. Block the drive tires.

To raise the transmission oil temperature, run the 7. Turn the calibration switch on (flip calibration
engine while stalling the torque converter as follows: switch down) and sit in the operators seat.

NOTE: You must start the truck. Turning on the ig-


CAUTION nition only will activate the Inch Pedal calibration
Prior to performing this test establish a 5 m procedure.
(16.5 ft)perimeter around the lift truck without
barriers or obstacles. 8. Start the engine (leave the engine at idle (700-
900 RPM) during the calibration process).
1. Apply the brake pedal (not Inch Pedal) so the lift
truck will not move. 9. The clutch calibration mode is now active. The
complete automatic calibration process takes 3
2. Verify the shift lever / MONOTROL® is in FOR- to 5 minutes. The screen will show TCXXY to
WARD. indicate which step of the calibration process is
being completed. The engine speed will remain
3. Select drive program 2. at idle during calibration. See Table 7.
NOTE: The transmission oil temperature gauge mid NOTE: Do not interfere with calibration process. Ac-
point is 75°C (167°F). tivating any controls or components will interrupt
4. Run the engine at half throttle until the oil tem- the calibration process before completion.
perature is at least 71°C (160°F). 10. When the calibration process is complete, the
Manual Clutch Calibration Procedure LCD will display TC SET.

When the transmission calibration switch is on (tog- 11. After calibration is complete, switch OFF igni-
gled in the DOWN position) the instrument cluster tion and turn the calibration switch off (flip the
LCD will be set to transmission clutch calibration service switch to the up position).

23
ZF Transmission Test and Calibration 1300 SRM 1455

Table 6. Clutch Calibration Codes Table 7. Normal Clutch Calibration Sequence

TCXXY Value Description Display Reading


XX Y VALUE MEANING Reverse Clutch TC060
01 Y Calibrating Clutch 1 Forward Clutch TC050
02 Y Calibrating Clutch 2 Clutch 1 TC010
03 Y Calibrating Clutch 3 Clutch 2 TC020
05 Y Calibrating Forward Clutch Clutch 3 TC030
06 Y Calibrating Reverse Clutch Calibration Set TCSET
07 Y Calibrating Complete - Calibration Set,
Display will show "TC SET" Testman Clutch Calibration Procedure

08 Y Calibration aborted - Canceled 1. Park truck on level ground with a minimum of


5 m (16.5 ft) clearance between the truck and any
09 Y Calibration Aborted While Adjusting
object.
Clutch 1
10 Y Calibration Aborted While Adjusting 2. Apply the parking brake.
Clutch 2
3. Verify the forward/reverse lever is in NEU-
11 Y Calibration Aborted While Adjusting TRAL.
Clutch 3
4. Make sure the transmission oil temperature is at
13 Y Calibration Aborted While Adjusting least 71°C (160°F).
Forward Clutch
5. Turn OFF ignition
14 Y Calibration Aborted While Adjusting
Reverse Clutch 6. Block the drive tires.
XX 0 Default
7. Connect a laptop computer, with the Testman
XX 1 Fault Condition Present software loaded, to the diagnostic connector in
the side console. See Figure 16.
XX 2 Shift Lever not in Neutral / No Signal
from Operator Presence Seat Switch 8. Ensure that someone is sitting in the operator’s
XX 3 Park Brake NOT Applied seat.

XX 4 Output Speed NOT = 0 9. Start the engine, leave the engine at idle (700-
XX 5 900 RPM) during the calibration process.
Transmission Oil Temperature
Below Range 10. Select Transmission clutch calibration from the
XX 6 Transmission Oil Temperature Testman menu and follow the instructions on the
Above Range screen.
XX 7 Engine RPM below Specified Range NOTE: Do not interfere with calibration process.
Activating any controls or components will interrupt
NOTE: When the calibration switch is set active, the calibration process before completion. The Test-
The LCD will show "TCXXY" indicating Transmis- man will show when calibration process has been
sion Clutch calibration active. completed. During calibration the Testman may
• "XX" will show the main clutch calibration code show calibration condition messages or error codes.
CAN message.
• "Y" will show the sub clutch calibration code 11. After calibration is complete, switch off ignition
CAN message. and disconnect laptop computer from diagnostic
connector in the side console.

24
1300 SRM 1455 Testman

Testman
DESCRIPTION the controller other than the truck serial number and
Transmission serial number. Stored values can be
For convenient diagnostic troubleshooting, adjust- found in the Truck Information menu. Only hit "AC-
ing software settings and TCU configuration, the CEPT" in the configuration screen when a new
ZF-Testman diagnostic software is available. controller is installed or the controller is repro-
grammed. Accepting incorrect Configuration leads
The Testman provides menu guidance for the diag-
to wrong drive program selection or loss of TCU con-
nosis of the ZF transmission. It can be used to inter-
figuration.
rogate the electronic control units on the ZF trans-
mission and then process any error messages found
Configuration
by following troubleshooting tips provided.
In the Truck configuration menu, Unit Code, Model,
The Testman system consists of a laptop computer,
Tire Size, Direction Control Option, Truck Serial
diagnostic software, a USB (Universal Serial Bus) ca-
Number and Transmission Serial Number are
ble, Programming adapter, and an adapter cable.
mandatory fields. All fields have to be set during the
configuration in order to activate the correct drive
CONNECTION
program for the truck.
Install the Testman software on a laptop per instruc-
Inching is default enabled but can be disabled at cus-
tions delivered with the Testman software. The help
tomer request. Disabling inching will activate de-
text contains all information required to work with
clutch mode in the controller.
the diagnostic software and also provides the neces-
sary guidance.

Connect the adapter cable to the truck. The truck


diagnostic connector is located in the side console of
the cab. See Figure 16. Start the Testman software
and establish communication. Make sure the igni-
tion key is turned to the ON position.

TRUCK CONFIGURATION
To activate the correct drive program in the TCU, the
controller is configured at the end of the assembly
line.

Truck configuration is only required if the TCU is re-


placed or reprogrammed. The TCU needs to be con-
figured with Testman, using the truck configuration
menu.

When the truck configuration data is not available


from the TCU a Testman Warning Screen indicates
the configuration is lost and truck configuration is
required. See Figure 17.

NOTE: The truck configuration screen opens with de-


fault fields and does not retrieve information from Figure 17. Testman Configuration Screen

25
Diagrams, Schematics, or Arrangements 1300 SRM 1455

Limitations
Testman offers the ability to adjust certain default
maximum values to meet customer specific require-
ments. The values in the controller can be adjusted
within a fixed threshold.

The default values can be adjusted with Testman,


using the Limitations Tab in the Truck Configuration
menu. See Figure 18.

Figure 18. Testman Limitation Screen

Electrical Specifications
Inductive transmitters (engine, turbine, and inter- Working Range - 2 Hz to 5000 Hz
mediate): Supply Voltage - 24 V
Resistance - 1050 (±10%) at 20°C (68°F)
Temperature Range - 40°C ( 40°F) to 150°C Proportional Valves:
(302°F) Resistance - 19 (± 10%) at 20°C (68°F)
Current - 100 to 500 mA
Hall Sensor (output): Pressure Range - 0.8 to 8.3 bar (11.6 to 120.4 psi)
Temperature Range - 40°C ( 40°F) to 150°C
(302°F)

Diagrams, Schematics, or Arrangements


Legend for Figure 19
1. TRANSMISSION CONTROL UNIT (TCU) 8. SHIFT LEVER
2. OUTPUT SPEED SENSOR 9. MONOTROL® PEDAL (OPTIONAL)
3. INTERNAL SPEED SENSOR 10. INCHING PEDAL
4. TURBINE SPEED SENSOR 11. ZF DIAGNOSTIC CONNECTOR
5. ENGINE SPEED SENSOR 12. ZF DISPLAY CONNECTOR
6. TRANSMISSION CONTROL VALVE 13. CALIBRATION SWITCH
7. TORQUE CONVERTER TEMPERATURE
SENSOR

26
1300 SRM 1455 Diagrams, Schematics, or Arrangements

Figure 19. Transmission Control Unit Wiring Diagram

27
Diagrams, Schematics, or Arrangements 1300 SRM 1455

Figure 20. Cab Side Console Harness (Sheet 1 of 2)

28
1300 SRM 1455 Diagrams, Schematics, or Arrangements

Figure 20. Cab Side Console Harness (Sheet 2 of 2)

29
Diagrams, Schematics, or Arrangements 1300 SRM 1455

Legend for Figure 20

Item Connector Description Connector Figure


No.
1 CPS143 Transmission Controller Figure 21
2 CRP81 Armrest Figure 22
3 CRP07 Cab Signals Figure 23
4 CRP06 Cab Power Figure 24
5 CPS25 Diagnostic Switch Figure 25
6 CPS19 Diagnostic Connector Figure 26
7 CPS33 Under Cab Floor Figure 27
8 CPS27 Calibration Switch Figure 28
9 CPS26 Service Switch Figure 29

Figure 21. Transmission Controller Connector Figure 22. Armrest Connector CRP81 of Wire
CPS143 of Wire Harness Cab Side Console Harness Cab Side Console

30
1300 SRM 1455 Diagrams, Schematics, or Arrangements

Figure 23. Cab Signals Connector CRP07 of


Wire Harness Cab Side Console
Figure 25. Diagnostic Switch CPS25 of Wire
Harness Cab Side Console

Figure 24. Cab Power Connector CRP06 of Wire


Harness of Cab Side Console
Figure 26. Diagnostic Connector CPS19 of Wire
Harness Side Console

31
Diagrams, Schematics, or Arrangements 1300 SRM 1455

Figure 29. Service Switch Connector CPS26 of


Wire Harness Side Console

Figure 27. Under Floor Connector CPS33 of


Wire Harness Side Console

Figure 28. Calibration Switch Connector


CPS27 of Wire Harness Side Console

32
1300 SRM 1455 ZF Transmission Fault Codes

ZF Transmission Fault Codes


TRANSMISSION EXCEED CODES
Fault Code Explanation Operator Action
Displayed
Te_nn Not Neutral, waiting for neutral after To engage a gear, first move shift lever
power up or a severe fault. to neutral position and again to F
(forward) or R (reverse) position.
tcold Transmission temperature is below -10°C Operate engine until tcold warning
(14°F) and gears will not be engaged. has cleared.
tERPm Warning high engine speed. Changes between actual gear / direction
while driving, in neutral only displayed
if no fault is detected.
tE101 The vehicle speed is too high to make Be aware that the controller has put
the requested direction change. the transmission into neutral. Slow
down the vehicle to allow the controller
to change direction.
tE201 The engine speed is too high to Lower engine speed.
make the requested direction change
or re-engagement.
tE300 Reduced vehicle speed is active. Be aware.
tE301 The reduced vehicle speed limitation Reduce vehicle speed below the
is active, however, the vehicle speed maximum vehicle speed.
is above the speed limitation.
tE302 The vehicle speed is above the maximum Reduce vehicle speed below the
vehicle speed limit. maximum vehicle speed.
tE600 Operator is not seated and shift lever Shift lever to neutral and/or apply
is NOT in Neutral and/or parking parking brake.
brake is NOT activated.
tE400 Abnormal acceleration is detected. One or both drive wheels are skidding.
Automatic shifting is disabled. Adjust
braking effort to floor conditions.
tE401 Abnormal acceleration is detected. One or both drive wheels are spinning.
Automatic shifting is disabled. Apply
throttle according driving conditions.
tE501 Transmission needs recalibration. Contact Maintenance to have the
transmission recalibrated.
tE701 Turbine speed exceeds the limit. Reduce vehicle speed. The controller
has reduced engine speed to idle.

33
ZF Transmission Fault Codes 1300 SRM 1455

TESTMAN FAULT CODES


Fault Code Description Reaction From TCU
Displayed
t0100 Logical error at directional select signal TCU shifts transmission to neutral
for 3rd gear shift lever position. if selector is active.
t0101 Logical error at gear range signal. TCU shifts transmission to neutral.
t0102 Logical error at direction select signal. TCU shifts transmission to neutral.
t0103 Logical error at Engine Derating Device. After selecting neutral, TCU changes
to Limp Home mode.
t0104 Logical error at park brake status. TCU shifts transmission to DCO-State.
t0105 Logical error at direction select signal TCU shifts transmission to neutral
2nd gear shift lever position. if selector active.
t0106 Logical error at axle connection. Operational mode remains normal.
t0107 S.C. to ground at customer specific No reaction from TCU, customer specific.
function no.1.
t0108 S.C. to battery voltage at customer No reaction from TCU, customer specific.
specific function no.1.
t0109 O.C. at customer specific function no.1. No reaction from TCU, customer specific.
t0110 S.C. to ground at customer specific No reaction from TCU, customer specific.
function no.2.
t0111 S.C. to battery voltage at customer No reaction from TCU, customer specific.
specific function no.2.
t0112 O.C. at customer specific function no.2. No reaction from TCU, customer specific.
t0113 S.C. to ground at customer specific No reaction from TCU, customer specific.
function no.3
t0114 S.C. to battery voltage at customer No reaction from TCU, customer specific.
specific function no.3.
t0115 O.C. at customer specific function no.3. No reaction from TCU, customer specific.
t0201 S.C. to battery voltage at clutch Clutch cutoff / inching function
cutoff / inch pedal input. is disabled.
t0202 S.C. to ground or O.C. at clutch cutoff Clutch cutoff / inching function
/ inch pedal input. is disabled.
t0203 S.C. to battery voltage at load Retarder function is affected.
sensor input.
t0204 S.C. to ground or O.C. at load sensor input. Retarder function is affected.
t0205 S.C. to battery voltage or O.C. at No reaction.
transmission sump temperature
sensor input.
t0206 S.C. to ground at transmission sump No reaction.
temperature sensor input.

34
1300 SRM 1455 ZF Transmission Fault Codes

Fault Code Description Reaction From TCU


Displayed
t0207 S.C. to battery voltage or O.C. No reaction.
at retarder / Torque converter
temperature sensor input.
t0208 S.C. to ground at retarder / Torque No reaction.
converter temperature sensor input.
t0209 S.C. to battery voltage or O.C. at TCU uses default value.
Parking brake sensor input.
t0210 S.C. to ground Parking brake TCU uses default value.
sensor input.
t0211 Inch sensor signal mismatch. During inching mode, TCU shifts
to neutral.
t0212 S.C. to battery voltage or O.C. at DLM TCU uses default value.
Traction Adjust dashboard device input.
t0213 S.C. to ground DLM Traction Adjust TCU uses default value.
dashboard device input.
t0214 S.C. to battery voltage or O.C. at DLM TCU uses default value.
Steering Angle Sensor input.
t0215 S.C. to ground DLM Steering Angle TCU uses default value.
Sensor input.
t0301 S.C. to battery voltage or O.C. at TCU changes to Substitute Clutch
engine speed input. Control mode.
t0302 S.C. to ground at engine speed input. TCU changes to Substitute Clutch
Control mode.
t0303 Logical error at engine speed input. TCU changes to Substitute Clutch
Control mode.
t0304 S.C. to battery voltage or O.C. at TCU changes to Substitute Clutch
turbine speed input Control mode.
t0305 S.C. to ground at turbine speed input. TCU changes to Substitute Clutch
Control mode.
t0306 Logical error at turbine speed input. TCU changes to Substitute Clutch
Control mode.
t0307 S.C. to battery voltage or O.C. at TCU changes to Substitute Clutch
internal speed sensor. Control mode.
t0308 S.C. to ground at internal speed input. TCU changes to Substitute Clutch
Control mode.
t0309 Logical error at internal speed input. TCU changes to Substitute Clutch
Control mode.
t0310 S.C. to battery voltage or O.C. at TCU enters special mode for gear
output speed input. selection.
t0311 S.C. to ground at output speed input. TCU enters special mode for gear
selection.

35
ZF Transmission Fault Codes 1300 SRM 1455

Fault Code Description Reaction From TCU


Displayed
t0312 Logical error at output speed input. TCU enters special mode for gear
selection.
t0315 Output speed Zero doesn’t fit to TCU enters special mode for gear
other speed signals. selection.
t0400 FCAN message Gear Range Select Gear range is set from 1st to 5th.
(ZF_3_IDENT) contains invalid data.
t0401 TCU receives messages Gear Range TCU ignores FWD commands.
Select (ZF_3_IDENT) and Front
Wheel Drive Status (V_IDENT_FWD)
although configuration states that FWD
controller is not installed.
t0500 FMR1 time out. TCU operates like jake brake is off
and exhaust brake is off.
t0501 FMR2 time out. TCU changes to Substitute Clutch
Control mode.
t0502 EA Module 1 time out. TCU shifts to neutral and uses
substitute gear selector.
t0502 SSM1 time out. TCU closes Park Brake if output
speed is below 0.5 km/h.
t0502 Instrument time out. AEB about if active.
t0503 ABS time out. No reaction.
t0504 MDU1 time out. TCU keeps old auto downshift
information and old manual
downshift information.
t0504 DCT1 time out. TCU enters Normal operational mode.
t0505 DNS1 time out. TCU shifts to Neutral.
t0505 SCT1 time out. TCU enters Normal operational mode.
t0505 FLC1 time out. TCU keeps old auto/man selection,
old Clutch cutoff selection and old
Clutch Cutoff Setting.
t0505 JSS time out. TCU shifts to Neutral while Joystick
Steering is active.
t0505 Front Wheel Drive Statues time out. TCU shifts to Neutral.
t0506 ENGINE CONF time out. TCU changes to Substitute Clutch
Control mode.
t0507 EEC1 time out. TCU changes to Substitute Clutch
Control mode.
t0508 EEC3 time out. TCU changes to Substitute Clutch
Control mode.
t0509 AEB-Request and Park Brake Test No reaction.
Signals ON at the same time.

36
1300 SRM 1455 ZF Transmission Fault Codes

Fault Code Description Reaction From TCU


Displayed
t0510 Park brake status signal. No reaction.
t0512 Auto downshift signal. Last selection is kept.
t0513 Manual downshift signal. Last selection is kept.
t0514 CCO request signal. Last selection is kept.
t0515 Shift lever signal. TCU shifts to Neutral and uses
information from substitute shift lever.
t0515 Transmission Neutral Request signal. TCU enters Normal operational mode.
t0515 Can message Front Wheel Drive TCU shifts to Neutral.
Status (V_IDENT_FWD) contains
invalid data.
t0600 Additional brake status signal. No reaction.
t0601 AEB request signal. No reaction.
t0602 PTO torque signal. No reaction.
t0603 Driving mode signal. No reaction.
t0604 Starting gear signal. No reaction.
t0605 Engine torque signal. TCU changes to Substitute Clutch
Control mode.
t0609 Reference engine torque signal. TCU changes to Substitute Clutch
Control mode.
t0610 Actual engine torque signal. TCU changes to Substitute Clutch
Control mode.
t0611 Nom friction torque signal. TCU changes to Substitute Clutch
Control mode.
t0614 EEC2 time out. No reaction.
t0701 S.C. to battery voltage at clutch K1. TCU shifts to Neutral.
t0702 S.C. to ground at clutch K1. TCU shifts to Neutral.
t0703 O.C. at clutch K1. TCU shifts to Neutral.
t0704 S.C. to battery voltage at clutch K2. TCU shifts to Neutral.
t0705 S.C. to ground at clutch K2. TCU shifts to Neutral.
t0706 O.C. at clutch K2. TCU shifts to Neutral.
t0707 S.C. to battery voltage at clutch K3. TCU shifts to Neutral.
t0708 S.C. to ground at clutch K3. TCU shifts to Neutral.
t0709 O.C. at clutch K3. TCU shifts to Neutral.
t0710 S.C. to battery voltage at converter clutch. No reaction.
t0711 S.C. to ground at converter clutch. Converter lock up clutch solenoid
connected at ADMx.
t0712 O.C. at converter clutch. No reaction.

37
ZF Transmission Fault Codes 1300 SRM 1455

Fault Code Description Reaction From TCU


Displayed
t0713 S.C. to ground at derating device. Engine derating will on until TCU
power down, even if fault vanishes
(loose connection).
t0714 S.C. to battery voltage at derating device. No reaction.
t0715 O.C. at engine derating device. No reaction.
t0801 S.C. to battery voltage at clutch K4. TCU shifts to Neutral.
t0802 S.C. to ground at clutch K4. TCU shifts to Neutral.
t0803 O.C. at clutch K4. TCU shifts to Neutral.
t0804 S.C. to battery voltage at clutch KV. TCU shifts to Neutral.
t0805 S.C. to ground at clutch KV. TCU shifts to Neutral.
t0806 O.C. at clutch KV. TCU shifts to Neutral.
t0807 S.C. to battery voltage at clutch KR. TCU shifts to Neutral.
t0808 S.C. to ground at clutch KR. TCU shifts to Neutral.
t0809 O.C. at clutch KR. TCU shifts to Neutral.
t0810 S.C. to ground at DLM transversal Output will be on until TCU power down,
output. even if fault vanishes (loose connection).
t0811 S.C. to battery voltage at DLM No reaction.
transversal output.
t0812 O.C. at DLM transversal output. No reaction.
t0813 S.C. to ground at DLM Indicator Output will be on until TCU power down,
Lamp output. even if fault vanishes (loose connection).
t0814 S.C. to battery voltage at DLM No reaction.
Indicator Lamp output.
t0815 O.C. DLM Indicator Lamp output. No reaction.
t0901 S.C. to ground at relay reverse Output will be on until TCU power down,
warning alarm. even if fault vanishes (loose connection).
t0902 S.C. to battery voltage at relay No reaction.
reverse warning alarm.
t0903 O.C. at relay reverse warning alarm. No reaction.
t0904 S.C. to ground at relay starter interlock. No reaction.
t0905 S.C. to battery voltage at relay No reaction.
starter interlock.
t0906 O.C. at relay starter interlock. No reaction.
t0907 S.C. to ground at park brake solenoid. TCU enters Shutdown mode.
t0908 S.C. to battery voltage at park TCU enters Shutdown mode.
brake solenoid.
t0909 O.C. at park brake solenoid. TCU enters Shutdown mode.

38
1300 SRM 1455 ZF Transmission Fault Codes

Fault Code Description Reaction From TCU


Displayed
t0910 S.C. to ground at converter lock Converter lock up clutch solenoid
up clutch solenoid. connected at ADMx: TCU switch
off VPS2.
t0911 O.C. at converter lock up clutch solenoid. Converter clutch always open,
retarder not available.
t0912 S.C. to battery voltage at converter No reaction.
lock up clutch solenoid.
t0913 S.C. to ground at retarder solenoid. No reaction.
t0914 O.C. at retarder solenoid. No reaction.
t0915 S.C. to battery voltage at retarder No reaction.
solenoid.
t1001 S.C. to ground at difflock or axle No reaction.
connection solenoid.
t1002 S.C. to battery voltage at difflock or No reaction.
axle connection solenoid.
t1003 O.C. at difflock or axle connection No reaction.
solenoid.
t1004 S.C. to ground at warning signal output. No reaction.
t1005 O.C. at warning signal output. No reaction.
t1006 S.C. to battery voltage at warning No reaction.
signal output.
t1007 S.C. to ground at customer specific No reaction from TCU, customer specific.
function no.4.
t1008 S.C. to battery voltage at customer No reaction from TCU, customer specific.
specific function no.4.
t1009 O.C. at customer specific function no.4. No reaction from TCU, customer specific.
t1010 S.C. to ground at customer specific No reaction from TCU, customer specific.
function no.5.
t1011 S.C. to battery voltage at customer No reaction from TCU, customer specific.
specific function no.5.
t1012 O.C. at customer specific function no.5. No reaction from TCU, customer specific.
t1013 S.C. to ground at customer specific No reaction from TCU, customer specific.
function no.6.
t1014 S.C. to battery voltage at customer No reaction from TCU, customer specific.
specific function no.6.
t1015 O.C. at customer specific function no.6. No reaction from TCU, customer specific.
t1101 Slippage at clutch K1. TCU shifts to Neutral.
t1102 Slippage at clutch K2. TCU shifts to Neutral.
t1103 Slippage at clutch K3. TCU shifts to Neutral.

39
ZF Transmission Fault Codes 1300 SRM 1455

Fault Code Description Reaction From TCU


Displayed
t1104 Slippage at clutch K4. TCU shifts to Neutral.
t1105 Slippage at clutch KV. TCU shifts to Neutral.
t1106 Slippage at clutch KR. TCU shifts to Neutral.
thotS Overtemp Sump. No reaction.
t1108 Overtemp Retarder. TCU disables Retarder
t1109 Over speed engine. Retarder applies if configured.
t1110 Differential pressure oil filter. No reaction.
t1111 Slippage at converter lockup clutch. Lockup Clutch is disabled immediately.
After fault code was displayed while
transmission is in Neutral the lockup
clutch will be enabled again.
t1112 Over speed output. No reaction.
t1113 S.C. to ground at Engine Brake Solenoid. No reaction.
t1114 S.C. to battery voltage at Engine No reaction.
Brake Solenoid.
t1115 O.C. at Engine Brake Solenoid. No reaction.
t1200 Engine Torque or Engine Power Overload. TCU enters Normal operational mode.
t1201 Transmission output Torque overload. TCU enters Normal operational mode.
thotc Overtemp converter output. No reaction.
t1204 S.C. to ground at Joystick Status No reaction.
Indicator.
t1205 S.C. to battery voltage at Joystick No reaction.
Status Indicator.
t1206 O.C. at Joystick Status Indicator. No reaction.
t1207 S.C. to ground at Overtemp Neutral No reaction.
Indicator.
t1208 S.C. to battery voltage at Overtemp No reaction.
Neutral Indicator.
t1209 O.C. at Overtemp Neutral Indicator. No reaction.
t1210 Engine Retarder Config_timeout. TCU changes to Substitute Clutch
Control mode.
t1211 ERC1 time out. TCU changes to Substitute Clutch
Control mode.
t1301 S.C. to battery voltage at power See fault codes t0201 to t0212.
supply for sensors.
t1302 S.C. to ground at power supply See fault codes t0201 to t0212.
for sensors.
t1303 Low voltage at battery. TCU shifts to Neutral.

40
1300 SRM 1455 ZF Transmission Fault Codes

Fault Code Description Reaction From TCU


Displayed
t1304 High voltage at battery. TCU shifts to Neutral.
t1305 Error at valve power supply VPS1. TCU shifts to Neutral.
t1306 Error at valve power supply VPS2. TCU shifts to Neutral.
t1307 S.C. to ground at DLM longitudinal Output will be on until TCU power down,
output. even if fault vanishes (loose connection).
t1308 S.C. to battery voltage at DLM No reaction.
longitudinal output.
t1309 O.C. at DLM Longitudinal output. No reaction.
t1403 S.C. to battery voltage at display output. No reaction.
t1404 S.C. to ground at display output. No reaction.
t1405 DISPID1 time out. TCU select parameter set with ID0.
t1406 Illegal ID request via CAN. Transmission to stay in Neutral.
t1501 General EEPROM fault. No reaction.
t1502 Configuration lost. Transmission to stay in Neutral.
t1502 FWD configuration lost. Gear range set from 1st to 4th.
t1503 Application error. Transmission to stay in Neutral.
t1504 Limp home request. Shift into Neutral.
t1505 Clutch failure. Transmission to stay in Neutral.
t1506 Clutch Adjustment Data lost or Inch Default values = 0 for AEB offsets used.
Pedal Calibration Data lost.
t1507 Substitute Clutch Control. TCU changes to Substitute Clutch
Control mode.

41
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42
TECHNICAL PUBLICATIONS

1300 SRM 1455 9/12 (8/12)(4/11) Printed in United Kingdom

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