ZF4WG210

ZF FRIEDRICHSHAFEN Aktiengesellschaft
Benennung: fault codes Nr.: DIN Seite 1

Zusatzbenennung: description of fault codes for Ergo control A4 von 25
Diese technische Unterlage darf weder kopiert
noch dritten Personen ohne unsere Erlaubnis 15
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K3 ZFN 904 NDERUNGEN
Erstellt: Geprft: Freigegeben :
Name: Neudorfer Rainer
Abteilung: ACET5
Datum: 2002-06-26
Description
of the
fault codes
for
ERGO-Control EST37
document created for customer "Nordco; 4WG-210" 2003-06-16

ZF Friedrichshafen AG 02-06-26
Faultcodes ERGO-Control EST37
Index of changes:
date index comment software version
So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 2 von 25

1 Introduction
1.1 Abbreviations
o.c. open circuit

s.c. short circuit
OP-Mode operating mode
TCU transmission control unit
EEC electronic engine controller
PTO power take off
1.2 ZF - Display:
If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault
code, if the gear selector is on neutral position.
If more than one fault is detected, each fault code is shown for about 1 second.
left right
h f e d character character
S
T
O
P
a b c g
(special symbols a-h)
1.3 Display during operation

Symbol meaning remarks
1F, 1R actual gear and direction
2F, 2R left digit shows actual gear
3F, 3R right digit shows actual direction
4F
5F
6F
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing direction F or R selected while turbine CAUTION gear will engage if turbine speed drops
speed is too high
NN not neutral, waiting for neutral after to engage a gear, first move shift selector to neutral
power up or a severe fault position and again to F or R position
** oil temperature too low, no gear warm up engine / transmission
available
*N oil temperature low, only one gear warm up engine / transmission
available
1 bar (special manual mode 1st gear

symbol)
2 bars manual mode 2nd gear
3 bars manual mode 3rd gear
4 bars manual mode 4th gear and also 5th and
6th gear in 6WG
4 bars and 2 automatic mode
arrows
Bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed above a certain
limit and lockup clutch not activated
4 WG: Downshift mode activ
Spanner at least one fault activ select neutral to get fault code displayed
Fault code see faultcode list
WS warning sump temperature changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WR warning retarder temperature changes between actual gear/direction while driving,
(spanner)
WT warning torque converter temperature changes between actual gear/direction while driving,
(spanner)
WE warning high engine speed changes between actual gear/direction while driving,
(spanner)
PN direction F or R selected while parking transmission in neutral until parking brake is released
brake engaged CAUTION: vehicle starts to move after release of
parking brake
EE flashing no communication with display checked wiring from TCU to display

1.4 Display during AEB-Mode

symbol meaning remarks
PL AEB - Starter is plugged at the
diagnostic plug
ST AEB-Starter-button is pressed
K1..K4,KV,KR calibrating clutch K1..K4, KV or KR
resp.
_ and Kx wait for start, initialization of clutch Kx,
x: 1, 2, 3, 4, V, R
and Kx fast fill time determination of clutch Kx
= and Kx compensating pressure determination of
clutch Kx
OK calibration for all clutches finished Transmissions stays in neutral, you have to restart the
TCU (ignition off/on) after removing AEB-Starter
STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have to restart the
TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmissions stays in neutral, you have to restart the
calibrated TCU (ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, you have to restart the
E engine speed too low,
raise engine speed
E engine speed too high,
lower engine speed
T transmission oil temperature too low,
heat up transmission
T transmission oil temperature too high
cool down transmission
FT transmission temperature not in defined Transmissions stays in neutral, you have to restart the
range during calibration TCU (ignition off/on)
FB operating mode not NORMAL or Transmissions stays in neutral, you have to restart the
transmission temperature sensor TCU (ignition off/on)
defective or storing of Calibrated values
to EEPROM-has failed.
FO Outputspeed_not_zero Transmissions stays in neutral, you have to restart the
FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the
FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart the
STOP AEB - Starter was used incorrect or is Transmissions stays in neutral, you have to restart the
defective. Wrong device or wrong cable TCU (ignition off/on)
used

2 definition of operating modes

NORMAL:
There's no failure detected in the transmission-system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations. (see following
table)
SUBSTITUTE CLUTCH CONTROL:

TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU
uses the substitute strategy for clutch control. All modulations are only time controlled. (Comparable
with EST 25)
LIMP-HOME:
The detected failure in the system has strong limitations to transmission control. TCU can engage
only one gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator
must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector
into forward or reverse, the TCU will select the limp-home gear .
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home
gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of
the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The
operator has to slow down the vehicle and must shift the gear selector into neutral position.
TRANSMISSION-SHUTDOWN:
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to Neutral. The park brake will operate normally, also the other functions which
use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU-SHUTDOWN:
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The
park brake will engage, also all functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.

ZF Friedrichshafen AG
description of fault codes for ERGO-Control 02-06-26
3 table of fault codes
Fault MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
(hex)
11 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to check the cables from TCU to shift lever failure cannot be detected in
TCU detected a wrong signal neutral check signal combinations of shift lever systems with DW2/DW3 shift
combination for the gear range OP-Mode: transmission positions for gear range lever
cable from shift lever to TCU is shutdown
fault is taken back if TCU
broken
detects a valid signal for the
cable is defective and is contacted to position
battery voltage or vehicle ground
shift lever is defective
12 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to check the cables from TCU to shift lever fault is taken back if TCU
SIGNAL neutral check signal combinations of shift lever detects a valid signal for the
TCU detected a wrong signal OP-Mode: transmission positions F-N-R direction at the shift lever
combination for the direction shutdown
cable from shift lever to TCU is
broken
cable is defective and is contacted to
13 LOGICAL ERROR AT ENGINE DERATING after selecting neutral, TCU check engine derating device This fault is reset after power
DEVICE changes to OP-Mode limp home up of TCU
TCU detected no reaction of engine
while derating device activ
15 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to check the cables from TCU to shift lever fault is taken back if TCU
SIGNAL 2. SHIFT LEVER neutral if selector activ 2 detects a valid neutral signal
TCU detected a wrong signal OP-Mode: transmission check signal combinations of shift lever for the direction at the shift
combination for the direction shutdown if selector activ positions F-N-R lever
cable from shift lever 2 to TCU is
broken

(hex)
25 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, check the cable from TCU to the sensor
TRANSMISSION SUMP TEMPERATURE TCU uses default temperature check the connectors
SENSOR INPUT OP-Mode: normal check the temperature sensor
the measured voltage is too high:
battery voltage
cable has no connection to TCU
temperature sensor has an internal
defect
connector pin is contacted to battery
voltage or is broken
26 S.C. TO GROUND AT TRANSMISSION SUMP no reaction, check the cable from TCU to the sensor
TEMPERATURE SENSOR INPUT TCU uses default temperature check the connectors
the measured voltage is too low: OP-Mode: normal check the temperature sensor
vehicle ground
defect
connector pin is contacted to vehicle
ground
27 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, check the cable from TCU to the sensor
CONVERTER OUTPUT TEMPERATURE TCU uses default temperature check the connectors
SENSOR INPUT OP-Mode: normal check the temperature sensor
the measured voltage is too high:
battery voltage
defect

(hex)
voltage or is broken
28 S.C. TO GROUND AT CONVERTER OUTPUT no reaction, check the cable from TCU to the sensor
TEMPERATURE SENSOR INPUT TCU uses default temperature check the connectors
the measured voltage is too low: OP-Mode: normal check the temperature sensor
vehicle ground
defect
ground
31 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch check the cable from TCU to the sensor
ENGINE SPEED INPUT control check the connectors
TCU measures a voltage higher than check the speed sensor
7.00 V at speed input pin
battery voltage
speed sensor has an internal defect
voltage or has no contact
32 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch check the cable from TCU to the sensor
TCU measures a voltage less than 0.45V control check the connectors
at speed input pin check the speed sensor
cable / connector is defective and is
contacted to vehicle ground
33 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch check the cable from TCU to the sensor This fault is reset after power
TCU measures a engine speed over a control check the connectors up of TCU
threshold and the next moment the check the speed sensor
measured speed is zero check the sensor gap

(hex)
cable / connector is defective and
has bad contact
sensor gap has the wrong size
TURBINE SPEED INPUT control check the connectors
TCU measures a voltage higher than if a failure is existing at output check the speed sensor
7.00 V at speed input pin speed,
cable is defective and is contacted to TCU shifts to neutral
battery voltage OP-Mode: limp home
35 S.C. TO GROUND AT TURBINE SPEED OP-Mode: substitute clutch check the cable from TCU to the sensor
INPUT control check the connectors
TCU measures a voltage less than 0.45V if a failure is existing at output check the speed sensor
at speed input pin speed,
cable / connector is defective and is TCU shifts to neutral
contacted to vehicle ground OP-Mode: limp home
36 LOGICAL ERROR AT TURBINE SPEED OP-Mode: substitute clutch check the cable from TCU to the sensor This fault is reset after power
INPUT control check the connectors up of TCU
TCU measures a turbine speed over a if a failure is existing at output check the speed sensor
threshold and at the next moment the speed, check the sensor gap
measured speed is zero TCU shifts to neutral
cable / connector is defective and OP-Mode: limp home
has bad contact

(hex)
INTERNAL SPEED INPUT control check the connectors
TCU measures a voltage higher than check the speed sensor
7.00 V at speed input pin
battery voltage
38 S.C. TO GROUND AT INTERNAL SPEED OP-Mode: substitute clutch check the cable from TCU to the sensor
INPUT control check the connectors
TCU measures a voltage less than 0.45V check the speed sensor
at speed input pin
contacted to vehicle ground
39 LOGICAL ERROR AT INTERNAL SPEED OP-Mode: substitute clutch check the cable from TCU to the sensor This fault is reset after power
INPUT control check the connectors up of TCU
TCU measures a internal speed over a check the speed sensor
threshold and at the next moment the check the sensor gap
measured speed is zero
has bad contact
3A S.C. TO BATTERY VOLTAGE OR O.C. AT special mode for gear selection check the cable from TCU to the sensor
OUTPUT SPEED INPUT OP-Mode: substitute clutch check the connectors
TCU measures a voltage higher than control check the speed sensor
12.5 V at speed input pin if a failure is existing at turbine
cable is defective and is contacted to speed,
battery voltage TCU shifts to neutral
cable has no connection to TCU OP-Mode: limp home

(hex)
3B S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear selection check the cable from TCU to the sensor
TCU measures a voltage less than 1.00VOP-Mode: substitute clutch check the connectors
at speed input pin control check the speed sensor
if a failure is existing at turbine
contacted to vehicle ground speed,
speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
3C LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear selection check the cable from TCU to the sensor This fault is reset after power
TCU measures a output speed over a OP-Mode: substitute clutch check the connectors up of TCU
threshold and at the next moment the control check the speed sensor
measured speed is zero if a failure is existing at turbine check the sensor gap
cable / connector is defective and speed,
has bad contact TCU shifts to neutral
speed sensor has an internal defect OP-Mode: limp home
3E OUTPUT SPEED ZERO DOESNT FIT TO special mode for gear selection check the sensor signal of output speed This fault is reset after power
OTHER SPEED SIGNALS OP-Mode: substitute clutch sensor up of TCU
if transmission is not neutral and the control check the sensor gap of output speed
shifting has finished, if a failure is existing at turbine sensor
TCU measures outputspeed zero and speed, check the cable from TCU to the sensor
turbine speed or internal speed not equal TCU shifts to neutral
to zero. OP-Mode: limp home
54 DCT1 TIMEOUT OP-Mode: normal check display computer

Timeout of CAN-message DCT1 from check wire of CAN-Bus
display computer check cable to display computer
interference on CAN-Bus
CAN wire/connector is broken

(hex)
CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
check the cable from TCU to the

1)
71 S.C. TO BATTERY VOLTAGE AT CLUTCH TCU shifts to neutral see chapter 4
K1 OP-Mode: limp home gearbox
the measured resistance value of the if failure at another clutch is check the connectors from TCU to the
valve is out of limit, the voltage at K1 pending gearbox
valve is too high. TCU shifts to neutral check the regulator resistance 1)
cable / connector is defective and OP-Mode: TCU shutdown check internal wire harness of the
has contact to battery voltage gearbox
has contact to another regulator
output of the TCU
regulator has an internal defect

1)
72 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral see chapter 4
the measured resistance value of the OP-Mode: limp home gearbox
valve is out of limit, the voltage at K1 if failure at another clutch is check the connectors from gearbox to
valve is too low. pending TCU
cable / connector is defective and TCU shifts to neutral check the regulator resistance 1)
has contact to vehicle ground OP-Mode: TCU shutdown check internal wire harness of the
regulator has an internal defect gearbox

1)
73 O.C. AT CLUTCH K1 TCU shifts to neutral see chapter 4
valve is out of limit. if failure at another clutch is check the connectors from gearbox to
cable / connector is defective and pending TCU
has no contact to TCU TCU shifts to neutral check the regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire harness of the
gearbox
1)
the measured resistance value of the if failure at another clutch is check the connectors from gearbox to
valve is out of limit, the voltage at K2 pending TCU

(hex)
output of the TCU

1)

1)
gearbox
1)
output of the TCU

(hex)
1)

1)
gearbox
1)
output of the TCU

1)

(hex)
1)
gearbox
1)
KV OP-Mode: limp home gearbox
valve is out of limit, the voltage at KV pending TCU
output of the TCU

1)
85 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral see chapter 4
valve is out of limit, the voltage at KV if failure at another clutch is check the connectors from gearbox to

1)
86 O.C. AT CLUTCH KV TCU shifts to neutral see chapter 4
gearbox
1)

(hex)
KR OP-Mode: limp home gearbox
valve is out of limit, the voltage at KR pending TCU
output of the TCU

1)
88 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral see chapter 4
valve is out of limit, the voltage at KR if failure at another clutch is check the connectors from gearbox to

1)
89 O.C. AT CLUTCH KR TCU shifts to neutral see chapter 4
gearbox
check the cable from TCU to the backup
1)
91 S.C. TO GROUND AT RELAY REVERSE backup alarm will be on until see chapter 4
WARNING ALARM TCU power down even if fault alarm device
TCU detected a wrong voltage at the vanishes (loose connection) check the connectors from backup alarm
output pin, that looks like a s.c. to OP-Mode: normal device to TCU
vehicle ground check the resistance 1) of backup alarm
cable is defective and is contacted to device
vehicle ground
backup alarm device has an internal
defect

(hex)
ground

1)
92 S.C. TO BATTERY VOLTAGE AT RELAY no reaction see chapter 4
REVERSE WARNING ALARM OP-Mode: normal alarm device
TCU detected a wrong voltage at the check the connectors from backup alarm
output pin, that looks like a s.c. to device to TCU
battery voltage check the resistance 1) of backup alarm
cable is defective and is contacted to device
battery voltage
defect
voltage

1)
93 O.C. AT RELAY REVERSE WARNING no reaction see chapter 4
ALARM OP-Mode: normal alarm device
TCU detected a wrong voltage at the check the connectors from backup alarm
output pin, that looks like a o.c. for this device to TCU
output pin check the resistance 1) of backup alarm
cable is defective and has no device
connection to TCU
defect
connector has no connection to TCU
check the cable from TCU to the starter

1)
94 S.C. TO GROUND AT RELAY STARTER no reaction see chapter 4
INTERLOCK OP-Mode: normal interlock relay
TCU detected a wrong voltage at the check the connectors from starter
output pin, that looks like a s.c. to interlock relay to TCU
vehicle ground check the resistance 1) of starter
cable is defective and is contacted to interlock relay
vehicle ground
starter interlock relay has an
internal defect

(hex)
ground

1)
95 S.C. TO BATTERY VOLTAGE AT RELAY no reaction see chapter 4
STARTER INTERLOCK OP-Mode: normal interlock relay
TCU detected a wrong voltage at the check the connectors from starter
output pin, that looks like a s.c. to interlock relay to TCU
battery voltage check the resistance 1) of starter
cable is defective and is contacted to interlock relay
battery voltage
internal defect
voltage

1)
96 O.C. AT RELAY STARTER INTERLOCK no reaction see chapter 4
TCU detected a wrong voltage at the OP-Mode: normal interlock relay
output pin, that looks like a o.c. for this check the connectors from starter
output pin interlock relay to TCU
cable is defective and has no check the resistance 1) of starter
connection to TCU interlock relay
internal defect

1)
A5 O.C. AT WARNING SIGNAL OUTPUT no reaction see chapter 4
TCU detected a wrong voltage at the OP-mode: normal warning device
output pin, that looks like a o.c. for this check the connectors from warning
output pin device to TCU
cable is defective and has no check the resistance 1) of warning device
connection to TCU
warning device has an internal
defect

(hex)
B1 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral check pressure at clutch K1
TCU calculates a differential speed at OP-Mode: limp home check main pressure in the system
closed clutch K1. If this calculated value if failure at another clutch is check sensor gap at internal speed
is out of range, TCU interprets this as pending sensor
slipping clutch. TCU shifts to neutral check sensor gap at output speed sensor
low pressure at clutch K1 OP-Mode: TCU shutdown check signal at internal speed sensor
low main pressure check signal at output speed sensor
wrong signal at internal speed replace clutch
sensor
wrong signal at output speed sensor
wrong size of the sensor gap
clutch is defective

sensor
clutch is defective

sensor

(hex)
clutch is defective
B5 SLIPPAGE AT CLUTCH KV TCU shifts to neutral check pressure at clutch KV

closed clutch KV. If this calculated if failure at another clutch is check sensor gap at internal speed
value is out of range, TCU interprets pending sensor
this as slipping clutch. TCU shifts to neutral check sensor gap at turbine speed sensor
low pressure at clutch KV OP-Mode: TCU shutdown check signal at internal speed sensor
low main pressure check signal at turbine speed sensor
sensor
wrong signal at turbine speed sensor
clutch is defective
B6 SLIPPAGE AT CLUTCH KR TCU shifts to neutral check pressure at clutch KR

closed clutch KR. If this calculated if failure at another clutch is check sensor gap at internal speed
value is out of range, TCU interprets pending sensor
this as slipping clutch. TCU shifts to neutral check sensor gap at turbine speed sensor
low pressure at clutch KR OP-Mode: TCU shutdown check signal at internal speed sensor
low main pressure check signal at turbine speed sensor
sensor
wrong signal at turbine speed sensor
clutch is defective
B7 OVERTEMP SUMP no reaction cool down machine

TCU measured a temperature in the oil OP-Mode: normal check oil level
sump that is over the allowed threshold. check temperature sensor

(hex)
C3 OVERTEMP CONVERTER OUTPUT no reaction cool down machine
TCU measured a oil temperature at the OP-Mode: normal check oil level
converter ouput that is over the allowed check temperature sensor
threshold.
D1 S.C. TO BATTERY VOLTAGE AT POWER see fault codes no. 21 to 2C check cables and connectors to sensors, fault codes no. 21 to no. 2C
SUPPLY FOR SENSORS which are supplied from AU1 may be a reaction of this fault
TCU measures more than 6V at the pin check the power supply at the pin AU1
AU1 (5V sensor supply) (should be appx. 5V)
D2 S.C. TO GROUND AT POWER SUPPLY FOR see fault codes no. 21 to 2C check cables and connectors to sensors, fault codes no. 21 to no. 2C
SENSORS which are supplied from AU1 may be a reaction of this fault
TCU measures less than 4V at the pin check the power supply at the pin AU1
AU1 (5V sensor supply) (should be appx. 5V)
D3 LOW VOLTAGE AT BATTERY shift to neutral check power supply battery

measured voltage at power supply is OP-Mode: TCU shutdown check cables from batteries to TCU
lower than 10 V (12V device) check connectors from batteries to TCU
lower than 18 V (24V device)
D4 HIGH VOLTAGE AT BATTERY shift to neutral check power supply battery
measured voltage at power supply is OP-Mode: TCU shutdown check cables from batteries to TCU
higher than 18 V (12V device) check connectors from batteries to TCU
higher than 32.5 V (24V device)
D5 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral check fuse
TCU switched on VPS1 and measured OP-Mode: TCU shutdown check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 check connectors from gearbox to TCU
and measured VPS1 is still on replace TCU
cable or connectors are defect and
are contacted to battery voltage
are contacted to vehicle ground
permanent power supply KL30
missing
TCU has an internal defect

(hex)
D6 ERROR VALVE POWER SUPPLY VPS2 shift to neutral check fuse
TCU switched on VPS2 and measured OP-Mode: TCU shutdown check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 check connectors from gearbox to TCU
and measured VPS2 is still on replace TCU
are contacted to battery voltage
are contacted to vehicle ground
permanent power supply KL30
missing
TCU has an internal defect
E4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction check the cable from TCU to the display
TCU sends data to the display and OP-Mode: normal check the connectors at the display
measures allways a high voltage level on change display
the connector
cable or connectors are defective
and are contacted to vehicle ground
display has an internal defect
E5 DISPID1_TIMEOUT TCU select parameter set with check display controller

Timeout of CAN-message DISPID1 ID0 check wire of CAN-Bus
from display controller OP-Mode: Limp Home check cable to display controller
interference on CAN-Bus
CAN wire/connector is broken
CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
E6 ILLEGAL ID REQUEST VIA CAN transmission stay neutral

OP-Mode: TCU shutdown
F1 GENERAL EEPROM FAULT no reaction replace TCU often shown together with
TCU can't read non volantile memoy OP-Mode: normal fault code F2
TCU is defective

(hex)
F2 CONFIGURATION LOST transmission stay neutral Reprogramm the correct configuration

TCU has lost the correct configuration OP-Mode: TCU shutdown for the vehicle (e.g. with cluster
and can't control the transmission. controller,...)
interference during saving data on
non volatile memory
TCU is brand new or from another
vehicle
F3 APPLICATION ERROR transmission stay neutral replace TCU !! This fault occurs only if an
something of this application is wrong OP-Mode: TCU shutdown test engineer did something
wrong in the application of
the vehicle
F5 CLUTCH FAILURE transmission stay neutral check clutch TCU shows also the affected
AEB was not able to adjust clutch filling OP-Mode: TCU shutdown clutch on the Display
parameters
One of the AEB-Values is out of
limit
F6 CLUTCH ADJUSTMENT DATA LOST no reaction, execute AEB

TCU was not able to read correct clutch default values = 0 for AEB
adjustment parameters offsets used
interference during saving data on OP-Mode: normal
non volatile memory
TCU is brand new

4 measuring of resistance at actuator/sensors and cable
4.1 actuator:
1
2
G
open circuit: R12 R1G R2G

short cut to ground: R12 R; R1G 0, R2G R or R1G R, R2G 0 (for s.c. to ground, G is connected to vehicle ground)
short cut to battery: R12 R; R1G 0, R2G R or R1G R, R2G 0 (for s.c. to battery, G is connected to battery voltage)
4.2 cable:
UBat
P (power supply)
TCU
Actuator /
1 2
Sensor
C (chassis)
Gnd
open circuit: R12 R1P R1C R2P R2C

short cut to ground: R12 0; R1C R2C 0, R1P R2P
short cut to battery: R12 0, R1C R2C , R1P R2P 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
WE:-/1.3 902 -419
W1 WA:+Z/1.3 900 2
1
VP (+)
X10:1/1.11
X10:2/1.11 -903
1
2
X1:43/1.2 443
3
4 F 3 6 9 12
W2 LX11 B1/X11
X11
WM:AS/1.3 911
A1 X1:64/1.2 464
5 N 2
1
5
4
8
7 10
11
6 R
WA:+Z/1.3 900 1 X1:63/1.2 463
X1:15/1.2 415 2
(+) 6
5
3
2
LX7 A2/X7
X1:65/1.2 465
7 T+
X10:3/1.11 -441
SDDK 8 T- AMP M-N-L 1
VM1 1
902 WE:-/1.3 WE:-/1.3 902 3 (-) 4 1 WY:FS/1.5 947
9 12-pin X10:4/1.11 -903
2 B2
402 X8:15/1.8 X1:18/1.2 418 4 X1:22/1.2 422
VM2 2
-903 WG:-D/1.3
LX6 A5/X6 EUPR 10 LX12 B2/X12
VMG1 3
404 X2:20/1.10
5 AMP M-N-L
6-pin
11 X12 1 2
VMG2 4 6 12
405 X8:16/1.8
ADM4 5 AMP Minitimer
406 X8:4/1.8
ADM3 6
407 X8:3/1.8
X6 X7 2-pin
ADM2 7
944 WT:VPS2/1.5
A5 A2 X10:5/1.11 -442
VPS2 8 getrennt, disconnect 1
AIP5 9
409 X2:11/1.10 X10:6/1.11 -903
2 B3
410 X2:8/1.10
AIP2 10
940 WS:ADM6/1.5 X1:19/1.2 -419 -419 X11:1/1.16
LX13 B3/X13
ADM6 11
906 WJ:+A/1.3 X1:25/1.2 -425 1 WG:-D/1.3 -903
1 1
-903 X11:2/1.16
X13
VPS1 12 CANF_H 2 2
906 WJ:+A/1.3 WP:CL/1.3 -913 2 X1:41/1.2 -441 -441 X12:1/1.16
VPS1 13 CANF_L 3 3
414 X4:1/1.8 WG:-D/1.3 -903 -903 X12:2/1.16
SD1 14
415 X6:2/1.5
LX5 A7/X5
X1:28/1.2 428 4
3 CANF_T
X1:42/1.2 -442
4 4
-442 X13:1/1.16 X10:16/1.11 449
SDDK 15 SCHIRM 5 5 1
WG:-D/1.3 -903 -903 X13:2/1.16 X10:17/1.11 904
EF5 16 6 6 2
417 X2:19/1.10 X1:56/1.2 456 456 X14:1/1.16
ER3 17
418 X6:4/1.5
X5 X1:10/1.2 410
7 7
410 X14:2/1.16
LX15 B15/X15
EUPR 18
-419 X2:1/1.10
A7* X1:32/1.2 432
8 8
432 X14:3/1.16
X15
1
EF1 19
420 X8:22/1.8 4 3
* not used X1:55/1.2 455
9 9
455 X14:4/1.16
46
24
ED3 20
421 X8:6/1.8
2 1
X1:9/1.2 409
10 10
409 X14:5/1.16
KN1 X10:18/1.11 904 1
2 ED10 21 11 11 1
ED7 22
422 X7:10/1.8 AMP JPT LX2 TR1/X2
X1:51/1.2 451
12 12
451 X14:6/1.16
TR1/X10 LX10 X10:19/1.11 417
2 S10 2
423 X8:9/1.8 WJ:+A/1.3 906 906 X14:7/1.16
VPE1 23
424 X3:1/1.10
4-pin
X1:39/1.2 439
13 13
439 X14:8/1.16
LX16 S10/X16 AMP Superseal
VMGA1 24
-425 X5:1/1.5 WH:-A/1.3 904
14 14
904 X14:9/1.16
X16 2-pin
CANF_H 25 22 21 15 15
-913 WP:CL/1.3 20 19 X1:49/1.2 449 449 X15:1/1.16 21 22
CANF_L 26 16 16 19 20
-913 WP:CL/1.3 18 17
WH:-A/1.3 904 904 X15:2/1.16 17 18
CANF_T 27 16 15 17 17 15 16
428 X5:4/1.5 WH:-A/1.3 904 904 X16:1/1.16 X10:7/1.11 456
VGS 28 14 13 18 18 13 14 1 Y1
429 X8:7/1.8 12 11 X1:17/1.2 417 417 X16:2/1.16 11 12 X10:8/1.11 410
ED11 29 10 9 19 19 9 10 2 Y2
430 X8:8/1.8 X1:4/1.2 404 404 X17:1/1.16 X10:9/1.11 432
ED12 30
431 X8:11/1.8
KN1 KN2 8
6
7
5 X1:62/1.2 462
20 20
462 X17:2/1.16
7 8
5 6 X10:10/1.11 455
3 Y3
ED13 31 4 3
21 21 3 4 4 Y4
432 X2:9/1.10 WA:+Z/1.3 900 900 X17:3/1.16 X10:11/1.11 409
AIP3 32
433 X8:13/1.8
A1/X1 "Sachnummer" LX1 LK2 2 1 22 22 1 2
X10:12/1.11 451
5 Y5
ADM8 33 AMP JPT 6 Y6
434 X3:6/1.10 X10:13/1.11 906
ADM7 34
900 X1:45/1.2
AMP JPT X2 X10 22-pin
X10:14/1.11 439
7 VPS1(+)
SD3 35
436 X8:19/1.8 X6:1/1.5
WA 22-pin
X10:15/1.11 904
8 TEMP
A3
SD4 36
948 WZ:AU1/1.5 X2:22/1.10 +Z LX14 A3/X14 9 TEMP
22 AU1 37 10
68 45 438 X3:3/1.10 X4:4/1.8 VPI Kl.15 X1:24/1.2 424
23 EU1 38 1 11
439 X2:14/1.10 X7:2/1.8 WZ:AU1/1.5 948
ER1 39 2 1 2 12
X8:1/1.8 X1:38/1.2 438 18 17 3 5
AMP Timer EF6 40 3 4 13
68-pin -441 X2:3/1.10 X1:61/1.2 461 16 15 6 7 8 9
EF2 41 4 14 13 14
-442 X2:5/1.10 902 X1:1/1.2 WZ:AU1/1.5 948
EF3 42
443 X7:6/1.8 X6:3/1.5
WE X1:34/1.2 434
5 12
10
11
9
10 11 12 13 15
ED4 43 6 8 7
14 15 16 16
444 X8:17/1.8 X4:3/1.8 - WT:VPS2/1.5 944
ED8 44 7 6 5
900 WA:+Z/1.3 X7:1/1.8 VM1(-) X1:57/1.2 457 4 3
VPI 45
904 WH:-A/1.3 X8:14/1.8 WT:VPS2/1.5 944
8 2 1 X14
VMGA2 46 9 Kostal
WS:ADM6/1.5 940
CANB_H 47
-903 X1:3/1.2 LX3 TR2/X3
WT:VPS2/1.5 944
10 AMP JPT 16-pin
CANB_L 48
449 X2:16/1.10 X2:2/1.10
WG 11 18-pin
ER2 49
X2:4/1.10 -D
12
X10:20/1.11 404 B4
AIP7 50 13 1 1
451 X2:12/1.10 X2:6/1.10 VMG1 X10:21/1.11 462
AIP6 51 14 2 2
452 X8:12/1.8 X10:22/1.11 900
ADM1 52
944 WT:VPS2/1.5 904 X1:46/1.2 940 X1:11/1.2 4
15 LX17 B4/X17 3 3
VPS2 53
X2:15/1.10
WH X3:10/1.10
WS X1:14/1.2 414 3
16
AIP8 54
455 X2:10/1.10 X2:17/1.10 -A X8:20/1.8 ADM6
1 SD1 2
1
17 X17 SuperSeal
3-pin
AIP4 55 2 18
456 X2:7/1.10 X2:18/1.10 VMGA2 WE:-/1.3 902
AIP1 56
457 X3:8/1.10 944 X1:8/1.2
LX4 A6/X4
WA:+Z/1.3 900
3 (-)VM
ADM5 57
906 X1:12/1.2 X1:53/1.2
WT 4 (+)VP AMP MNL X3
VPS1 58
X1:13/1.2
WJ X8:18/1.8 VPS2
4-pin
SD2 59
X2:13/1.10 +A X3:7/1.10
X4
SDDL 60
461 X3:4/1.10 VPS1 X3:9/1.10
A6 Kl.15 entspricht 24V ber Zndschloss geschaltet.
EU2 61 Kl.30 entspricht 24V permanent.
462 X2:21/1.10 X3:11/1.10
EF4 62
463 X7:7/1.8 911 X1:67/1.2 Kl.15 corresponds 24V switched over ignition lock.
ED1 63
464 64/1.8 X7:5/1.8
WM 947 X8:21/1.8 Kl.30 corresponds 24V permanent.
ED5 64
465 X7:8/1.8 X8:2/1.8 AS X7:9/1.8
WY F1
ED2 65 Kl.30
466 X8:5/1.8 N-Signal FS B1
ED9 66 Kl.15
911 WM:AS/1.3 948 X1:37/1.2
ED6 67
468 X8:10/1.8 -913 X1:26/1.2 X3:2/1.10
WZ F2 Stecker: Sicht auf Steckseite
VPE2 68
X1:27/1.2
WP X3:5/1.10 AU1
1 Plug: Frontview
P
X5:2/1.5 CL
X1 WA:+Z/1.3 900 S31
2
H1
1 VPI(Kl.15) 1
WM:AS/1.3 911 Alle Relais mit Schutzdioden 1A/400V
2 ED6 2
X1:7/1.2 407 All relais with quench diodes 1A/400V
3 ADM2 3
X1:6/1.2 406
4 ADM3 4
X1:66/1.2 466
5 ED9 5
X1:21/1.2 421
6 ED10 6 Abschirmung empfohlen
X1:29/1.2 429
7 ED11 7 Screening recommended
X1:30/1.2 430
8 ED12 8
X1:23/1.2 423
9 VPE(Kl.30) 9
X1:68/1.2 468
1 0 VPE(Kl.30) 1 0 Verdrillte Leitungen (30 Schlge/m) ab L>2m
X1:31/1.2 431
POS LEGENDE LEGEND X1:52/1.2 452
11 ED13 11 Twisted pair (30 turns/m) for L>2m
12 ADM1 12
X1:33/1.2 433
A1 ELEKTRISCHES STEUERGERT EST-37 EL. CONTROL UNIT EST-37 LX8 BN/X8
WE:-/1.3 902
13 ADM8 13
A2 FAHRSCHALTER VTS-3 SHIFT LEVER VTS-3 14 VM1 14 Entfernung von Knoten CANF_L, CANF_T zum
X1:2/1.2 402
A3 GETRIEBE STEUERBLOCK TRANSMISSION HYDRAULIC BLOCK 15 VM2 15 Elektronikstecker betrgt <= 200mm.
X1:5/1.2 405
A5 DIAGNOSE - SCHNITTSTELLE (STECKER) DIAGNOSTIC - INTERFACE (CONNECTOR) 16 ADM4 16 Polbild X8a
A6 DISPLAY DISPLAY X1:44/1.2 444
17 ED8 17
Distance of knot CANF_L, CANF_T to the
WT:VPS2/1.5 944 ECU-Connector is <= 200mm.
A7 CAN-SCHNITTSTELLE (STECKER) CAN-INTERFACE (CONNECTOR) 18 VPS2 18 22 21
X1:36/1.2 436 20 19
A9 TACHO MIT FREQUENZTEILER (KUNDEN- SPEEDOMETER WITH FREQUENCY DIVIDER 19 SD4 19
21 22
WS:ADM6/1.5 940 18 17
UMFANG) (CUSTOMER SCOPE) 19 20 20 ADM6 20
1 16 15 Busabschlu, wenn Pin 26 und 27 verbunden
17 18 WY:FS/1.5 947 86
15 16
21 FS B3 21 14 13
Bustermination realised, when pin 26 and 27 connected
X1:20/1.2 420 12 11
B2 DREHZAHLGEBER TURBINE SPEED PICK-UP TURBINE 13 14 22 ED3 22
B3 DREHZAHLGEBER INTERN SPEED PICK-UP INTERNAL
11 12
9 10
A9 K1
85 10
8
9
7
6 5
B4 DREHZAHLGEBER ABTRIEB SPEED SENSOR OUTPUT 7 8
5 6 X8 X8a 4 3
3 4 2 1 Stromlaufplan:
F1 SICHERUNG 7,5A FUSE 7,5A 1 2
Kl.31 6029.701.574
F2 SICHERUNG 7,5A FUSE 7,5A AMP JPT
22-pin
AMP JPT
22-pin
Circuit diagram:
H1 LAMPE "DRIVE" ANZEIGE LAMP "DRIVE" INDICATOR
Computer-Zeichnung Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
K1 RELAIS ANLASS SPERRE RELAY STARTER INTERLOCK hnl. Zeichnung Similar Draw. 6029.701.432 ZF Friedrichshafen AG
Original This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
nicht verndern Techn. Information Technical Information Benennung / Description Zeichnungs-Nr. Drawing-No. Ind. Blatt von DIN
S10 SCHALTER FILTERVERSCHMUTZUNG SWITCH FILTER RESTRICTION Bearbeit. Drawn 03-01-27 Sicklinger
Computer drawing. Sheet of
S31 SCHALTER RCKMELDUNG PARKBREMSE SWITCH FEEDBACK PARKING BRAKE
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 02-10-15 Neudorfer
EST-37 4WG-210 Nordco Anschlussplan
original copy
nderungen / Modifications Connection Diagr. 6029.701.573__ 1 1 1
1 2 3 4 5 6 7 8 9 10 11 12
F1
Kl.30
Kl.15
F2
1
P
2
S31 H1
3
45 23 68 21 5
2
B4 VPI VPE1 VPE2 ED10 ADM4
36 1
1 62
SD4 A9
EF4
4 1
VMG2
15 2
SDDK
2
VP (+) 18 4 A5
EUPR
4 43
F ED4
5 67 3 4
N ED6
6
R
7 63 14 1
A2 T+
8 65
ED1 SD1 A6
T- ED2
A1 56 1
AIP1 Y1
10 2
AIP2 Y2
86 32 3
AIP3 Y3
55 4
AIP4 Y4
85 9 5
K1 AIP5
51 6
Y5
AIP6 Y6
12 7
VPS1 VPS1 (+)
13
1 41
Kl.15 entspricht 24V ber Zndschloss geschaltet. VPS1
39 8
EF2 Kl.30 entspricht 24V permanent. ER1 TEMP
B2 2 3
VMG1 VMGA2
46 9
TEMP
Kl.15 corresponds 24V switched over ignition lock.
Kl.30 corresponds 24V permanent.
1 42
B3 2
EF3
17 A3
ER3
2 1
VGS CANF_H CANF_L CANF_T VM1 VM2
28 25 26 27 1 2
S10
4
Anschlussplan:
POS LEGENDE LEGEND 6029.701.573
1 2 Connection Diagr.:
A1 ELEKTRISCHES STEUERGERT EST-37 EL. CONTROL UNIT EST-37
A2 FAHRSCHALTER VTS-3 SHIFT LEVER VTS-3
A3 GETRIEBE STEUERBLOCK TRANSMISSION HYDRAULIC BLOCK * not used
A5 DIAGNOSE - SCHNITTSTELLE (STECKER) DIAGNOSTIC - INTERFACE (CONNECTOR) A7*
A6 DISPLAY DISPLAY
A7 CAN-SCHNITTSTELLE (STECKER) CAN-INTERFACE (CONNECTOR)
A9 TACHO MIT FREQUENZTEILER (KUNDEN- SPEEDOMETER WITH FREQUENCY DIVIDER
UMFANG) (CUSTOMER SCOPE)
Abschirmung empfohlen
Kl.31 Screening recommended
B2 DREHZAHLGEBER TURBINE SPEED PICK-UP TURBINE
B3 DREHZAHLGEBER INTERN SPEED PICK-UP INTERNAL
B4 DREHZAHLGEBER ABTRIEB SPEED SENSOR OUTPUT
Verdrillte Leitungen (30 Schlge/m) ab L>2m
F1 SICHERUNG 7,5A FUSE 7,5A Twisted pair (30 turns/m) for L>2m
F2 SICHERUNG 7,5A FUSE 7,5A
K1 RELAIS ANLASS SPERRE RELAY STARTER INTERLOCK Alle Relais mit Schutzdioden 1A/400V
All relais with quench diodes 1A/400V
H1 LAMPE "DRIVE" ANZEIGE LAMP "DRIVE" INDICATOR
S10 SCHALTER FILTERVERSCHMUTZUNG SWITCH FILTER RESTRICTION

S31 SCHALTER RCKMELDUNG PARKBREMSE SWITCH FEEDBACK PARKING BRAKE
Computer-Zeichnung Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
hnl. Zeichnung Similar Draw. 6029.701.433 ZF Friedrichshafen AG
Original This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
nicht verndern Techn. Information Technical Information Benennung / Description Zeichnungs-Nr. Drawing-No. Ind. Blatt von DIN
Bearbeit. Drawn 03-01-27 Sicklinger
Computer drawing. Sheet of
Do not modify Ind. Anz. Nummer Datum Name Konstr. Design 02-10-15 Neudorfer
EST-37 4WG-210 Nordco Stromlaufplan
original copy
nderungen / Modifications Circuit Diagram 6029.701.574__ 1 1 2
SPARE PARTS CATALOGUE
CD-ROM 'ELCAT' 1/2003 03.09.2003
4 WG-210
ZF parts list no.: 4657 054 060
customer: NORDCO / PYKE

ZF-ELCAT technical information sheet CD 1/2003 03.09.2003
sheet 2
parts list: 4657 054 060 4 WG-210 / / NORDCO / PYKE
item text mod. no.

A10 KUNDE:NORDCO/PYKE
A11 CUSTOMER:
A16 IDENT-NR:
A17 CUSTOMER NO.:
A50 PROJEKT-NR.:5212-0
A51 PROJECT-NO.:
B04 FAHRZEUGDATEN:
B05 VEHICLE DATA:
B06 SCHIENENFAHRZEUG
B07 RAIL VEHICLE
B16 FAHRZEUGMASSE: ..,..T
B17 VEHICLE WEIGHT: EMPTY.........T0
B26 MOTOR: SAUER 51V 160
B27 ENGINE/MAKE/TYPE:
B30 MOTORLEISTUNG: P=138 KW BEI N=2300 UPM
B31 ENGINE POWER:
B32 EINSTELLUNG N.FAHRLEISTUNGSBERECHNG.ERFORDERL.
B33 ENGINE PERFORM.ACC.TO TRACTIVE EFFORT CALCUL.
B34 DREHMOMENT: T= 983 NM BEI N=1100 UPM
B35 INPUT TORQUE:
B46 REIFEN: TREIBRAD
B47 TIRES:
B50 R.DYN. 0,305 M
B56 ACHSUEBERSETZUNG:I A-GES.= 5,285
B57 AXLE RATIO: I TOTAL=
B60 ENDGESCHWINDIGK.: 88,0 KM/H
B61 MAX.SPEED:
B70 FAHRLEIST.BERECHNUNG: 4657 706 712
B71 PERFORMACE CALCULATION:
E02 AGGREGATBESCHREIBUNG:
E03 PRODUCT DESCRIPTION
E04 TYP: 4WG-210
E05 TYPE:
E08 EINBAU: GETRENNT
E09 INSTALLATION: SEPARATE
E38 UEBERSETZUNG GESAMT:
E39 RATIOS:
sheet 3
item text mod. no.

E42 1.G=4,152 2.G=2,184 3.G=1,072 4.G=0,636 K01764/02
F02 ANTRIEB:
F03 INPUT:
F10 FLANSCH: HYDROMOTOR ANGEFLANSCHT
F11 FLANGE:
F30 ABTRIEB:
F31 OUTPUT:
F40 FLANSCH: DANA SPICER 1550
F41 FLANGE: LEFT
F44 FLANSCH: DANA SPICER 1550
F45 FLANGE:
G02 NEBENABTRIEB: OHNE
G03 P.T.O.: WITHOUT
G06 KOAX.MOTORABH.:
G07 COAX.ENGINE DRIVEN:
K02 SCHALTUNG: HSG 94
K03 GEAR SELECTION:
K08 ANBAULAGE: HINTEN AM GETRIEBE
K09 MOUNTING POSIT.: REAR AT THE GEARBOX
K10 SPANNUNG: 24 VOLT
K11 VOLTAGE:
K20 ARBEITSDRUCK: 16+2 BAR
K21 OPERATING PRESSURE:
K26 ANSCHL.VERKABELG: SCHRAUBANSCHLUSS
K27 CONNECTION WIRING: SCREW CONNECTION
K64 DIFFERENZDRUCKSCHALTER: MIT SCHLIESSER
K65 DIFF.PRES.SWITSCH: WITH
K68 WARNSCHALTER F.OELTEMPERATUR: OHNE
K69 WARNING SWITCH F.OIL TEMPERATUR:WITHOUT
L02 GANGSCHALTER: MIT K01321/02
L03 GEAR SELECTOR: WITH K01321/02
L04 TYP: VTS-3 K01321/02
L05 TYPE: VTS-3 K01321/02
L64 VERKABELUNG MIT
L65 WIRING: WITH
L92 INDUKTIVGEBER TURB.DREHZAHL : Z=54
L93 INDUCTIVE SENSOR TURB.SPEED
sheet 4
item text mod. no.

L94 INDUKTIVGEBER MITTLERE RADKETTE: Z=55
L95 INDUCT.SENS.INTERMEDIATE GEAR TRAIN
L98 HALL-SENSOR ABTRIEBSDREHZAHL : Z=49
L99 SENSOR OUTPUT SPEED
M02 FESTSTELLBREMSE: OHNE
M03 PARKING BRAKE: WITHOUT
M50 TACHO: OHNE
M51 SPEEDOMETER: WITHOUT
M60 OELMESSSTAB: MIT
M61 OIL DIPSTICK: WITH
M70 ACHSABSCHALTUNG: MIT
M71 AXLE DISCONNECT: WITH
M80 ZF-FILTER: GETRENNT
M81 ZF-FILTER: SEPARAT
N02 WANDLER: OHNE
N03 T-CONVERTER: WITHOUT
P06 NOTLENKPUMPE: OHNE(ANBAUMOEGLICHKEIT)
P07 GROUND DRIV.PUMP: WITHOUT(MOUNTING POSSIBILLITY)
P10 FOERDERMENGE: Q=.. CM3/U
P11 DELIVERY:
P40 ACHSDIFFERENTIAL: OHNE
P41 AXLE DIFFERENTIAL: WITHOUT
R02 ZEICHNUNGEN:
R03 DRAWINGS:
R06 SCHNITT:
R07 SECT.DRAWING:
R16 EINBAU: 4657 654 060
R17 INST.DRAWING:
R20 MOTOR-ANBAU: 4657 500 126
R21 ENGINE CONN.:
R24 GETR.SCHEMA: 4657 700 104
R25 TRANSM.DIAGRAM:
R28 OEL-SCHEMA: 4657 700 094(0)
R29 OIL-DIAGRAM:
R31 DISC SET:
R40 WANDLER: OHNE
R41 TORQUE CONVERTER: WITHOUT
sheet 5
item text mod. no.

R50 BERECHNUNGEN:
R51 CALCULATIONS:
R96 EINBAURICHTLINIEN: 4657 700 078/DEU. 079/ENG.
S02 ZEICHNUNGEN F.ELEKTR.TEILE
S03 DRAWING FOR ELECTR.PARTS
S04 FAHRSCHALTER: 6006 635 006 ( ) EBZ K01321/02
S05 RANGE SELECTOR: K01321/02
S06 STROMLAUFPL.:6006 700 529()FS K01321/02
S07 WIRING DIAGRAM: K01321/02
S08 STEUERUNG: 6009 665 002 (1)EBZ
S09 CONTROL UNIT:
S10 STROMLAUFPLAN 6029 701 574 ()
S65 WIRING DIAGRAM:
S70 ANSCHL.PLAN: 6029 701 573( )
S71 CONNECTION DIAGRAM:
S72 DISPLAY: 6007 603 047
T02 OELEINFUELLMENGE:
T03 OIL CAPACITY:
T20 GESAMT: CA. 27,00L
T21 TOTAL:
T26 OELFUELLUNG: NEIN
T27 OIL FILLING: NO
T30 OELSORTE:SCHMIERSTOFFL.TE ML 03 / GETRIEBE
T31 OIL GRADE:SPECIFICATION TE ML 03 TRANSMISSION
T40 GESAMT-TROCKENMASSE: 427KG
T41 WEIGHT/MASS (DRY):
T46 FARBE: 2 MAIS-GELB RAL 1006
T47 COLOR:
T50 VERPACKUNG: ..........
T51 PACKING:
T60 AGGREGAT OHNE ASBESTHALTIGE TEILE
T61 COMPONENTS OF THIS ASSEMBLY WITHOUT ASBESTOS
X02 BEMERKUNGEN/ZUSATZANGABEN:
X03 MISCELLANEOUS/REMARKS
Z02 *
ZF-ELCAT summary of figures CD 1/2003 03.09.2003
sheet 6
figure part no. description technical information mod. no.

4657 102 012 00 4657 102 008 INPUT
4657 101 025 01 4657 101 047 GEARBOX HOUSING
4657 101 025 02 4657 101 047 GEARBOX HOUSING
4657 101 025 03 4657 101 408 GEARBOX HOUSING
4657 171 010 00 4657 171 022 COUPLING K1
4657 172 007 00 4657 172 007 COUPLING K2
4657 173 003 00 4657 173 007 COUPLING K3
4657 174 005 00 4657 174 017 COUPLING K4
4657 175 002 00 4657 175 007 COUPLING KV
4657 103 004 01 4657 103 006 OUTPUT
4657 103 004 02 4657 103 409 OUTPUT
4657 103 004 03 4657 103 416 OUTPUT
4657 154 014 00 4657 154 012 POWER TAKE-OFF
4657 106 014 01 4657 106 007 GEARSHIFT SYST.
4657 106 014 02 4657 106 406 GEARSHIFT SYST.
4656 159 008 41 4656 159 010 GEARSHIFT SYST. KOMPLETT LIEFERBAR
4656 159 008 42 4656 159 010 GEARSHIFT SYST. KOMPLETT LIEFERBAR
4657 123 010 00 4657 123 006 CONTROL UNIT
4657 120 003 00 4657 120 004 PRESS.REGULATOR
4657 137 002 00 4657 137 002 EMCY.STEER.PUMP
4657 125 007 00 4657 125 010 IND.TRANSMITTER
4657 124 002 00 4657 124 001 TEMP.SENSOR
4656 138 008 00 4656 138 010 FILTER
4646 199 005 00 4646 199 406 LOOSE PARTS
4657 131 017 00 4657 131 014 FILLER NECK
4657 199 035 00 4657 199 016 LOOSE PARTS
4657 183 020 00 4657 183 098 LOOSE PARTS
CD 1/2003 03.09.2003
sheet 7
figure: 4657 102 012 00 INPUT * depending on parts list no.
ZF-ELCAT parts list CD 1/2003 03.09.2003
sheet 8

figure: 4657 102 012 00 INPUT (4657 102 008)
item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant
010 4657 302 005 1 INPUT SHAFT Z=54 IN 4657 302 014 ZF7B 8,520 P
016 4657 302 004 1 INPUT GEAR Z=53 IN 4657 302 002 ZF7B 3,299 P
018 0630 501 056 1 RETAINING RING 100X3 0,040 P
040 0735 371 722 H 1 ROLLER BEARING 0,132 P
060 0634 402 557 1 PISTON RING K01706/00 60 X 3 SH P KA NORMAUS 0,010 P
070 4657 302 011 1 OIL FEEDER GG-25
080 10 CAP SCREW K01110/98 0,053 P
/010 0636 101 120 10 CAP SCREW M 10 X 75 8.8 FE/ZN8CWW 0,052 P
/020 0634 313 215 10 O-RING 9,5 X 1,6 FPM -70-10 WW 0,001 P
090 0634 313 980 1 O-RING 182 X 3 FPM -70-10 0,005 P
100 0634 313 369 1 O-RING 94,5 X 3 FPM -80-10 0,004 P
110 4657 302 012 1 BEARING FLANGE GG-25
120 0636 101 121 18 CAP SCREW M 10 X 90 8.8 0,060 P
CD 1/2003 03.09.2003
sheet 9
figure: 4657 101 025 01 GEARBOX HOUSING * depending on parts list no.
CD 1/2003 03.09.2003
sheet 10
sheet 11

figure: 4657 101 025 01 GEARBOX HOUSING (4657 101 047)
4657 101 025 02 GEARBOX HOUSING (4657 101 047)
010 4657 201 027 H 1 HOUS.FRONT SECT IN 4657 201 026 0,010 P
030 4657 201 020 H 1 HOUS.REAR SECT. IN 4657 201 011 GG-25 P
040 0631 306 792 2 CYLINDRICAL PIN 10 M 6X 40 16MNCR5 E 0,026 P
050 0636 101 115 51 CAP SCREW M 10 X 50 8.8 A3C 0,038 P
060 4656 301 018 1 FIXING PLATE F270 0,090 P
070 0636 101 115 2 CAP SCREW M 10 X 50 8.8 A3C 0,038 P
080 4657 301 032 1 SCREEN SHEET K01671/02 FU270 0,522 P
090 4657 301 033 1 SCREEN SHEET K01671/02 IN 4657 301 048 FU270 0,710 P
100 0636 101 644 5 CAP SCREW M 8 X 12 8.8 FE/ZN8C 0,010 P
120 0730 365 092 H 1 TYPE PLATE IN 0730 365 091 AL-MG-LEG. W 0,004 P
130 0631 311 009 H 4 GROOVED STUD 3x5 ISO 8746 ST 0,001 P
160 4656 301 020 H 1 OIL FEED.HOUSG. IN 4656 301 028 GD-ALFI9CU3 1,000 P
170 4656 301 023 1 GASKET 11950 0,015 P
180 0736 101 334 21 TORX SCREW M8X45 IN 0736 101 263 10.9 0,022 P
200 0736 101 312 15 TORX SCREW M8X30 IN 0736 101 263 10.9 0,100 P
220 0736 101 335 4 TORX SCREW M8X60 IN 0736 101 263 10.9 0,027 P
240 4656 301 018 1 FIXING PLATE F270 0,090 P
250 0636 101 708 2 CAP SCREW M 10 X 40 8.8 A3C 0,032 P
260 4657 301 003 2 COVER GD-ALSI9CU3 0,001 P
270 0634 313 778 2 O-RING 76 X 3 FPM -70-10 0,001 P
280 0636 607 054 12 STUD M 8 X 25 10.9 A3C 0,010 P
300 0637 025 005 12 HEXAGON NUT M 8 10 A2C 0,007 P
310 0630 361 049 1 SEALING CAP 40 FE/ZNPHR8F 0,025 P
350 0501 213 220 1 OIL TUBE 0,725 P
351 0634 313 779 1 O-RING 22 X 3 FPM -70-10 0,001 P
354 4657 301 044 1 OIL TUBE WG-210 ST35 WW. F2 0,480 P
364 0636 101 663 1 CAP SCREW M 8 X 50 8.8 A3C 0,022 P
380 0634 313 779 2 O-RING 22 X 3 FPM -70-10 0,001 P
390 0501 211 343 1 SUCTION TUBE
450 1 SCREW PLUG 0,140 P
/010 0736 305 052 1 SCREW PLUG AUSFG.B IN 0736 305 053 WW 0,140 P
/020 0634 314 304 1 O-RING 35 X 2 FPM -70-10 WW 0,001 P
610 4657 301 050 1 COVER PLATE IN 4644 301 086 F270
620 4642 331 216 2 GASKET IN 4642 331 215 TS 9003 ARMS 0,001 P
630 4657 201 004 1 FILLER NECK KPL.
sheet 12

4657 101 025 02 GEARBOX HOUSING (4657 101 047)
640 0636 010 098 2 HEXAGON SCREW M 8 X 65 8.8 0,029 P
CD 1/2003 03.09.2003
sheet 13
sheet 14

140 0750 131 027 H 1 BREATHER 0,010 P
CD 1/2003 03.09.2003
sheet 15
figure: 4657 171 010 00 COUPLING * depending on parts list no.
sheet 16

figure: 4657 171 010 00 COUPLING (4657 171 022)
010 4657 371 024 1 SHAFT Z=53 IN 4657 371 015 ZF7B 0,010 P
012 0730 361 206 1 SEALING CAP B=4,5 IN 0730 361 105 HERGES 0,001 P
020 0636 607 039 1 STUD M 10 X 16 8.8 0,013 P
042 4657 371 009 1 DISC CARRIER IN 4657 371 003 GG-30 5,650 P
052 4657 371 023 H 1 PISTON GD-ALSI9CU3 0,425 P
054 4646 251 063 1 VALVE KPL. 0,003 P
060 0634 313 643 1 O-RING 75 X 3 FPM -70-10 0,010 P
070 0634 313 796 1 O-RING 158 X 3 FPM -70-10 0,007 P
072 0501 316 541 7 CUP SPRING 0,033 P
080 4656 375 018 1 GUIDE RING F500 0,001 P
092 0501 316 380 1 SNAP RING 0,015 P
106 0501 212 371 1 DISC 0,130 P
110 0501 212 370 9 DISC 0,135 P
120 0501 316 592 9 I.CLUTCH DISC 0,260 P
130 4657 371 005 H 1 END SHIM K1/KV/KR F500 1,000 P
150 1 SNAP RING
0730 513 701 1 SNAP RING S=2,1 IN 0730 513 700 FEDERBWW 0,035 P
0730 513 712 1 SNAP RING S=3,75 IN 0730 513 700 FEDERBWW
160 4657 371 021 1 IDLER Z=23 LH IN 4657 371 020 ZF7B 4,200 P
170 0635 290 114 2 RUNNING DISC 0,060 P
190 0735 368 076 H 2 AX.NEEDLE CAGE 0,050 P
200 0635 290 012 2 AXIAL WASHER 1,000 P
210 0735 321 509 1 NEEDLE CAGE 0,510 P
220 0501 316 378 1 RETAINING RING 0,030 P
sheet 17

figure: 4657 171 010 00 COUPLING (4657 171 022)
250 0734 401 267 2 PISTON RING 0,001 P
CD 1/2003 03.09.2003
sheet 18
sheet 19

figure: 4657 172 007 00 COUPLING (4657 172 007)
010 4657 372 001 1 SHAFT K00407/97 Z=56 IN 4657 372 014 ZF7B 10,530 P
020 0636 607 039 1 STUD M 10 X 16 8.8 0,013 P
052 4657 275 006 H 1 PISTON K01316/98 0,400 P
060 0634 313 643 1 O-RING 75 X 3 FPM -70-10 0,010 P
070 0634 313 719 1 O-RING 142 X 3 FPM -70-10 0,005 P
072 0501 316 541 7 CUP SPRING 0,033 P
080 4656 375 018 1 GUIDE RING F500 0,001 P
092 0501 316 380 1 SNAP RING 0,015 P
106 0501 212 373 1 O.CLUTCH DISC K00046/01 0,085 P
110 0501 212 372 7 DISC K00047/01 0,090 P
120 0501 316 591 7 I.CLUTCH DISC 0,175 P
130 0501 316 594 1 END SHIM 0,480 P
150 1 SNAP RING P
0730 513 684 1 SNAP RING S=2,1 IN 0730 513 683 FEDERS WW 0,030 P
0730 513 685 1 SNAP RING S=2,25 IN 0730 513 683 FEDERSWW 0,040 P
0730 513 696 H 1 SNAP RING S=4,05 IN 0730 513 683 FEDERSWW P
160 4657 372 009 1 IDLER Z=22 LH IN 4657 372 010 ZF7B 4,500 P
170 0635 290 114 2 RUNNING DISC 0,060 P
190 0735 368 076 H 2 AX.NEEDLE CAGE 0,050 P
200 0635 290 012 2 AXIAL WASHER 1,000 P
210 0735 321 508 1 NEEDLE CAGE K01792/99 0,200 P
220 0501 316 378 1 RETAINING RING 0,030 P
sheet 20

figure: 4657 172 007 00 COUPLING (4657 172 007)
250 0734 401 267 2 PISTON RING K00459/98 0,001 P
CD 1/2003 03.09.2003
sheet 21
sheet 22

figure: 4657 173 003 00 COUPLING (4657 173 007)
010 4657 373 008 1 SHAFT Z=44 IN 4657 373 006 ZF7B 16,640 P
020 0636 607 039 1 STUD M 10 X 16 8.8 0,013 P
052 4657 275 006 H 1 PISTON K01316/98 0,400 P
060 0634 313 643 1 O-RING 75 X 3 FPM -70-10 0,010 P
070 0634 313 719 1 O-RING 142 X 3 FPM -70-10 0,005 P
072 0501 316 541 7 CUP SPRING 0,033 P
080 4656 375 018 1 GUIDE RING F500 0,001 P
092 0501 316 380 1 SNAP RING 0,015 P
106 0501 212 373 1 O.CLUTCH DISC K00046/01 0,085 P
110 0501 212 372 7 DISC K00047/01 0,090 P
120 0501 316 591 7 I.CLUTCH DISC 0,175 P
130 0501 316 594 1 END SHIM 0,480 P
150 1 SNAP RING P
160 4657 373 004 1 IDLER Z=55 IN 4657 373 003 ZF7B 6,650 P
170 0635 290 114 2 RUNNING DISC 0,060 P
190 0735 368 076 H 2 AX.NEEDLE CAGE 0,050 P
200 0635 290 012 2 AXIAL WASHER 1,000 P
210 0735 321 508 1 NEEDLE CAGE K01792/99 0,200 P
240 0734 401 267 2 PISTON RING K00459/98 0,001 P
CD 1/2003 03.09.2003
sheet 23
sheet 24

figure: 4657 174 005 00 COUPLING (4657 174 017)
010 4657 374 017 1 SHAFT Z=30 IN 4657 374 001 ZF7B 0,010 P
016 4657 374 008 1 GEAR Z=63 IN 4657 374 019 ZF7B 5,100 P
018 0630 501 050 1 RETAINING RING 80X2,5 0,030 P
020 0636 607 039 1 STUD M 10 X 16 8.8 0,013 P
042 4657 374 014 1 DISC CARRIER K01768/97 IN 4657 374 003 GG-30 3,690 P
052 4657 275 006 H 1 PISTON K01316/98 0,400 P
060 0634 313 643 1 O-RING 75 X 3 FPM -70-10 0,010 P
070 0634 313 719 1 O-RING 142 X 3 FPM -70-10 0,005 P
072 0501 316 541 7 CUP SPRING 0,033 P
080 4656 375 018 1 GUIDE RING F500 0,001 P
092 0501 316 380 1 SNAP RING 0,015 P
106 0501 212 373 1 O.CLUTCH DISC K00046/01 0,085 P
110 0501 212 372 6 DISC K00047/01 0,090 P
120 0501 316 591 6 I.CLUTCH DISC K01768/97 0,175 P
130 0501 316 594 1 END SHIM 0,480 P
150 1 SNAP RING P
160 4657 374 007 1 IDLER Z=36 IN 4657 374 006 ZF7B 3,420 P
170 0635 290 114 1 RUNNING DISC 0,060 P
190 0735 368 076 H 2 AX.NEEDLE CAGE 0,050 P
200 0635 290 012 3 AXIAL WASHER 1,000 P
210 0735 321 508 1 NEEDLE CAGE K01792/99 0,200 P
220 0630 501 038 H 1 RETAINING RING 55X2 0,010 P
sheet 25

figure: 4657 174 005 00 COUPLING (4657 174 017)
250 0734 401 267 2 PISTON RING K00459/98 0,001 P
CD 1/2003 03.09.2003
sheet 26
sheet 27

figure: 4657 175 002 00 COUPLING (4657 175 007)
010 4657 375 001 1 SHAFT Z=55 IN 4657 375 010 ZF7B 10,190 P
012 0730 361 206 1 SEALING CAP B=4,5 IN 0730 361 105 HERGES 0,001 P
020 0636 607 039 1 STUD M 10 X 16 8.8 0,013 P
042 4657 375 006 1 DISC CARRIER Z=34 IN 4657 375 004 GG-30 5,440 P
052 4657 275 006 H 1 PISTON K01316/98 0,400 P
060 0634 313 643 1 O-RING 75 X 3 FPM -70-10 0,010 P
070 0634 313 719 1 O-RING 142 X 3 FPM -70-10 0,005 P
074 0730 110 373 1 WASHER F500 0,025 P
080 4656 375 018 1 GUIDE RING F500 0,001 P
090 0732 042 711 1 COMPR.SPRING 0,448 P
092 0501 316 380 1 SNAP RING 0,015 P
106 0501 212 371 1 DISC K00045/01 0,130 P
110 0501 212 370 10 DISC K00043/01 0,135 P
120 0501 316 592 10 I.CLUTCH DISC 0,260 P
130 4657 371 005 H 1 END SHIM K1/KV/KR F500 1,000 P
150 1 SNAP RING
160 4657 375 003 H 1 IDLER Z=52 KV/KR 4657 375 002 ZF7B 4,460 P
170 0735 321 408 1 NEEDLE CAGE 0,082 P
180 0750 116 380 H 1 BALL BEARING K01765/00 0,373 P
sheet 28

figure: 4657 175 002 00 COUPLING (4657 175 007)
230 0734 401 267 2 PISTON RING K00459/98 0,001 P
CD 1/2003 03.09.2003
sheet 29
figure: 4657 103 004 01 OUTPUT * depending on parts list no.
sheet 30

figure: 4657 103 004 01 OUTPUT (4657 103 006)
010 4657 303 003 1 OUTPUT SHAFT Z=49 IN 4657 303 001 ZF7B 20,870 P
040 0750 111 116 H 2 SHAFT SEAL 0,085 P
050 4644 303 259 2 WASHER K00710/99 IN 4620 303 246 C45E WW.42C 0,340 P
060 0636 015 386 4 HEXAGON SCREW 0,003 P
070 1269 302 164 2 TAB WASHER IN 1313 304 043 ST1303 0,012 P
130 0634 303 466 2 O-RING 48 X 4 NBR -70-10 0,002 P
CD 1/2003 03.09.2003
sheet 31
sheet 32

figure: 4657 103 004 02 OUTPUT (4657 103 409)
080 0501 317 935 1 END YOKE K01381/99 3,700 P
085 4657 303 018 H 1 SCREEN SHEET K01381/99 FU270 0,177 P
CD 1/2003 03.09.2003
sheet 33
sheet 34

figure: 4657 103 004 03 OUTPUT (4657 103 416)
115 0501 317 935 1 END YOKE K01382/99 3,700 P
120 4657 303 014 1 SCREEN SHEET FU270 0,185 P
CD 1/2003 03.09.2003
sheet 35
figure: 4657 154 014 00 POWER TAKE-OFF * depending on parts list no.
sheet 36

figure: 4657 154 014 00 POWER TAKE-OFF (4657 154 012)
010 4656 354 009 1 COVER PLATE IN 4656 354 007 F270 0,855 P
012 0634 304 616 H 1 O-RING K00910/98 130 X 3 NBR -90-10 0,004 P
020 0636 016 221 1 HEXAGON SCREW M 12 X 18 10.9 A3C A 0,030 P
CD 1/2003 03.09.2003
sheet 37
figure: 4657 106 014 01 GEARSHIFT SYST. * depending on parts list no.
sheet 38

figure: 4657 106 014 01 GEARSHIFT SYST. (4657 106 007)
010 4657 306 022 1 GASKET 11950 0,001 P
020 4657 306 026 1 DUCT PLATE K01114/03 IN 4657 306 023 GD-ALSI9CU3 0,010 P
020 4657 306 030 1 DUCT PLATE K01114/03 24.06.2004 IN 4657 306 028 GD-ALSI9CU3 P
030 4656 306 132 H 1 INTERM.SHEET HSG-94 SCHALTUNG 15017 0,375 P
040 0736 101 312 36 TORX SCREW M8X30 IN 0736 101 263 10.9 0,100 P
050 0636 607 054 14 STUD M 8 X 25 10.9 A3C 0,010 P
070 0637 025 005 14 HEXAGON NUT M 8 10 A2C 0,007 P
200 0736 101 408 23 TORX SCREW M6X76 IN 0736 101 258 10.9 0,020 P
794 4657 306 031 1 PISTON K00154/03 EN AW-6082[ALSI1MGMN] 0,015 P
798 0732 042 761 1 COMPR.SPRING DRAHT D=1,6 FEDERST 0,009 P
CD 1/2003 03.09.2003
sheet 39
sheet 40

770 4657 306 018 1 SCREW PLUG K00546/98 M16X1,5 F270 0,041 P
778 0634 316 523 1 O-RING K00687/98 13 X 2 FPM -70-10 0,001 P
CD 1/2003 03.09.2003
sheet 41
CD 1/2003 03.09.2003
sheet 42
sheet 43

4656 159 008 42 GEARSHIFT SYST. (4656 159 010)
010 4656 306 112 H 1 VALVE BLOCK IN 4656 306 111 GD-ALSI9CU3 2,200 P
/010 0636 302 053 H 8 SCREW PLUG M 10X1 ST A3C WW 0,100 P
/020 0634 303 280 H 8 O-RING 8x1,5 ZFN 744 NBR-70-10 WW 0,100 P
020 0730 361 070 H 6 ORIFICE A=0,8 IN 0730 361 120 FU270 0,001 P
030 4656 306 095 H 6 PISTON NACHFOLGESCHIEBER EN 0,020 P
040 0732 042 538 6 COMPR.SPRING 0,005 P
050 4656 306 013 6 PISTON EN AW-ALSIMGMN T6 WW. 0,005 P
060 0732 042 539 6 COMPR.SPRING P
070 4656 306 074 1 PISTON REDUZIERVENTIL EN A 0,015 P
080 0732 042 631 1 COMPR.SPRING 0,015 P
090 4656 306 152 1 CONTROL PISTON K00235/03 EN AW-ALSIMGMN T6 WW. 0,035 P
110 0732 042 719 1 COMPR.SPRING 0,033 P
150 4656 306 140 1 GASKET K01177/01 IN 4656 306 139 11970 0,001 P
160 4656 306 116 H 1 HOUSING GD-ALSI9CU3 0,550 P
170 0736 101 257 18 CAP SCREW M5 IN 0736 101 256 10.9 0,005 P
180 0501 314 770 H 3 PRESS.REGULATOR KOMPLETT MIT O-RING 0,001 P
/010 0734 313 134 H 3 O-RING 13,5 X 2 FPM-70-10 P
190 1043 326 045 3 FIXING PLATE CK67GBK MK75 0,001 P
200 0736 101 094 3 CAP SCREW L=12 IN 0736 101 053 8.8 0,003 P
210 4656 306 140 1 GASKET K01177/01 IN 4656 306 139 11970 0,001 P
220 4656 306 116 H 1 HOUSING GD-ALSI9CU3 0,550 P
230 0736 101 257 18 CAP SCREW M5 IN 0736 101 256 10.9 0,005 P
240 0501 314 770 H 3 PRESS.REGULATOR KOMPLETT MIT O-RING 0,001 P
/010 0734 313 134 H 3 O-RING 13,5 X 2 FPM-70-10 P
250 1043 326 045 3 FIXING PLATE CK67GBK MK75 0,001 P
260 0736 101 094 3 CAP SCREW L=12 IN 0736 101 053 8.8 0,003 P
270 4656 206 006 1 WIRING HARNESS 0,100 P
280 4656 306 138 1 GASKET K01177/01 IN 4656 306 137 11970 0,001 P
290 4656 306 054 H 1 COVER AUSFUEHRUNG I GD-AL 0,275 P
300 0736 101 257 14 CAP SCREW M5 IN 0736 101 256 10.9 0,005 P
310 4656 306 138 1 GASKET K01177/01 IN 4656 306 137 11970 0,001 P
320 4656 306 055 H 1 COVER AUSFUEHRUNG II GD-AL 0,535 P
330 1058 327 026 1 RETAINING CLAMP X12CRNI 17 7 0,001 P
340 0736 101 257 14 CAP SCREW M5 IN 0736 101 256 10.9 0,005 P
360 4656 306 133 1 INTERM.SHEET 150178NS 0,350 P
362 0501 316 715 6 SCREEN MASCHENW.200MY 0,001 P
sheet 44

4656 159 008 42 GEARSHIFT SYST. (4656 159 010)
380 4656 306 150 H 1 DUCT PLATE K01856/02 GD-ALSI9CU3 0,660 P
390 0736 101 407 18 TORX SCREW M6X23 IN 0736 101 258 10.9 0,005 P
CD 1/2003 03.09.2003
sheet 45
figure: 4657 123 010 00 CONTROL UNIT * depending on parts list no.
sheet 46

figure: 4657 123 010 00 CONTROL UNIT (4657 123 006)
/010 0636 302 067 1 SCREW PLUG M 26X1,5 ST A3C WW 0,070 P
/020 0634 313 233 1 O-RING 23 X 2 FPM -70-10 WW 0,001 P
/010 0636 302 065 H 1 SCREW PLUG M 16X1,5 ST A3C WW 0,015 P
/020 0634 316 523 1 O-RING 13 X 2 FPM -70-10 WW 0,001 P
CD 1/2003 03.09.2003
sheet 47
figure: 4657 120 003 00 PRESS.REGULATOR * depending on parts list no.
sheet 48

figure: 4657 120 003 00 PRESS.REGULATOR (4657 120 004)
010 0501 211 384 1 VALVE 0,084 P
040 4656 306 107 1 PISTON K01271/03 ALSIMGMN T6 0,025 P
050 0732 042 767 1 COMPR.SPRING K01271/03 FEDERSTAHL 0,036 P
060 4656 306 077 1 PRESSURE PLATE K01271/03 ALMGSI0,5F13 P
070 4656 306 078 1 TAB WASHER K01271/03 F270 0,020 P
CD 1/2003 03.09.2003
sheet 49
figure: 4657 137 002 00 EMCY.STEER.PUMP * depending on parts list no.
sheet 50

figure: 4657 137 002 00 EMCY.STEER.PUMP (4657 137 002)
010 4656 337 001 1 COVER IN 4656 337 008 G-ALSI9MG W 2,500 P
012 4656 337 007 1 COVER K01659/98 F500 0,553 P
020 4656 337 010 1 GASKET K00072/01 11970 0,010 P
022 4656 337 006 1 GASKET K01659/98 11942 0,008 P
040 0736 101 312 23 TORX SCREW K00510/98 M8X30 IN 0736 101 263 10.9 0,100 P
050 0636 015 225 H 8 HEXAGON SCREW K00259/99 M 8 X 18 8.8 A3C 0,010 P
060 0730 260 704 1 PLAIN BEARING PG 3740 20 F 0,025 P
CD 1/2003 03.09.2003
sheet 51
figure: 4657 125 007 00 IND.TRANSMITTER * depending on parts list no.
sheet 52

figure: 4657 125 007 00 IND.TRANSMITTER (4657 125 010)
010 0501 209 719 2 IND.TRANSMITTER KOMPLETT MIT O-RING 0,055 P
/010 0734 313 125 H 2 O-RING 15X2 P
020 0501 317 949 H 1 SPEED TRANSMITT KOMPLETT MIT O-RING 0,040 P
/010 0634 313 728 H 1 O-RING 15,54X 2,62 ZFN 744 ACM-70-10 P
CD 1/2003 03.09.2003
sheet 53
figure: 4657 124 002 00 TEMP.SENSOR * depending on parts list no.
sheet 54

figure: 4657 124 002 00 TEMP.SENSOR (4657 124 001)
054 1 SCREW PLUG M14X1,5 KPL.MIT O-RING 0,015 P
/020 0634 313 366 1 O-RING 11 X 2 FPM -80-10 WW 0,030 P
CD 1/2003 03.09.2003
sheet 55
figure: 4656 138 008 00 FILTER * depending on parts list no.
sheet 56

figure: 4656 138 008 00 FILTER (4656 138 010)
/020 0634 313 233 1 O-RING 23 X 2 FPM -70-10 WW 0,001 P
050 0736 101 366 H 2 TORX SCREW M8X40 IN 0736 101 263 10.9 0,021 P
CD 1/2003 03.09.2003
sheet 57
figure: 4646 199 005 00 LOOSE PARTS * depending on parts list no.
sheet 58

figure: 4646 199 005 00 LOOSE PARTS (4646 199 406)
210 0750 131 061 H 2 EXCHANGE FILTER 1,010 P
220 0501 213 900 H 1 FILTER HEAD K00411/03 1,770 P
/010 0501 210 966 1 SWITCH 0,075 P
CD 1/2003 03.09.2003
sheet 59
figure: 4657 131 017 00 FILLER NECK * depending on parts list no.
sheet 60

figure: 4657 131 017 00 FILLER NECK (4657 131 014)
010 4657 231 011 1 OIL LEVEL TUBE KPL. 1,540 P
020 4657 231 012 1 OIL DIPSTICK KPL. IN 4657 231 005 0,165 P
022 4642 331 216 1 GASKET IN 4642 331 215 TS 9003 ARMS 0,001 P
040 0636 010 741 H 2 HEXAGON SCREW M 8 X 50 10.9 A3C 0,025 P
CD 1/2003 03.09.2003
sheet 61
sheet 62

010 4657 302 009 1 DRIVER Z=30 ZF6 A ZFN
CD 1/2003 03.09.2003
sheet 63
sheet 64

010 6006 035 006 H 1 RANGE SELECTOR K01321/02 VTS-3 1,300 P
020 6029 205 417 1 CABLE CONNECT. W1 EST37 STANDARD KL 2,080 P
040 6029 205 420 1 CABLE CONNECT. W2 EST37 STANDARD GE 1,310 P
050 6029 199 008 1 PLUG 4POL M-N-L BU 0,108 P
060 6029 199 043 1 PLUG JUN. POWER TIMER 22 POL 0,025 P
070 6009 092 178 1 CONTROL UNIT EST-37A
080 6007 203 236 1 DISPLAY O. GEH. MNL (2X4POL) 0,240 P
**** END ****

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Benennung: fault codes Nr.: DIN Seite 1

document created for customer "Nordco; 4WG-210" 2003-06-16

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 2 von 25

o.c. open circuit

(special symbols a-h)

1.3 Display during operation

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 3 von 25

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 4 von 25

1.4 Display during AEB-Mode

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 5 von 25

2 definition of operating modes

SUBSTITUTE CLUTCH CONTROL:

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 6 von 25

3 table of fault codes

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 7 von 25

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 8 von 25

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 9 von 25

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 10 von 25

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 11 von 25

54 DCT1 TIMEOUT OP-Mode: normal check display computer

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 12 von 25

check the cable from TCU to the

check the cable from TCU to the

check the cable from TCU to the

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 13 von 25

check the cable from TCU to the

check the cable from TCU to the

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 14 von 25

check the cable from TCU to the

check the cable from TCU to the

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 15 von 25

check the cable from TCU to the

check the cable from TCU to the

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 16 von 25

check the cable from TCU to the

check the cable from TCU to the

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 17 von 25

check the cable from TCU to the backup

check the cable from TCU to the backup

check the cable from TCU to the starter

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 18 von 25

check the cable from TCU to the starter

check the cable from TCU to the starter

check the cable from TCU to the

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 19 von 25

B2 SLIPPAGE AT CLUTCH K2 TCU shifts to neutral check pressure at clutch K2

B3 SLIPPAGE AT CLUTCH K3 TCU shifts to neutral check pressure at clutch K3

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B5 SLIPPAGE AT CLUTCH KV TCU shifts to neutral check pressure at clutch KV

B6 SLIPPAGE AT CLUTCH KR TCU shifts to neutral check pressure at clutch KR

B7 OVERTEMP SUMP no reaction cool down machine

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 21 von 25

D3 LOW VOLTAGE AT BATTERY shift to neutral check power supply battery

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 22 von 25

E5 DISPID1_TIMEOUT TCU select parameter set with check display controller

E6 ILLEGAL ID REQUEST VIA CAN transmission stay neutral

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F2 CONFIGURATION LOST transmission stay neutral Reprogramm the correct configuration

F6 CLUTCH ADJUSTMENT DATA LOST no reaction, execute AEB

So TE-A J:\DATNBANK\EST37\FEHLERLI\FC392178.DOC Seite 24 von 25

4 measuring of resistance at actuator/sensors and cable

open circuit: R12 R1G R2G

open circuit: R12 R1P R1C R2P R2C

END