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Zusatzbenennung: EP90 Forklift EST65 A4 von 24
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K3 ZFN 904 ÄNDERUNGEN
Erstellt: Geprüft: Freigegeben :
Name: Angstenberger Schwarz
Abteilung: TE-AB TE-AB
Datum: 2006-02-03 2006-02-03

Description
of the
fault codes
for
EP90 Forklift EST65
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Faultcodes EP90 Forklift EST65

Index of changes:
date comment software version
2006-02-03 initial version based on ErgoPower KPT0
2006-06-08 Fault codes for CCO/Inching, After Torque Converter Temperature KPT2
2006-07-07 updated clutch names KPT2
2006-09-14 add overtemp converter faultcode KPT2
2006-11-28 add F3-Fault code description V001
2009-05-11 add hints to fault code 0x3E V008
2009-11-09 add fault code 0x21and 0x22 V010
2011-12-19 add fault code 0x42 and 0x43, change description of faultcode 0x2B V011
2013-10-09 add fault code 0x44 and 0x45 V012

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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

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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,
in neutral only displayed if no fault is detected
(spanner)
WT warning torque converter temperature changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WE warning high engine speed changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WV warning high output speed (velocity) changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WL warning high transmission input torque changes between actual gear/direction while driving,
(load) in neutral only displayed if no fault is detected
(spanner)
WO warning high transmission output torque changes between actual gear/direction while driving,
(load) in neutral only displayed if no fault is detected
(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

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1.4 Display during AEB-Mode

symbol meaning remarks
PL AEB - Starter is plugged at the
diagnostic plug
ST AEB-Starter-button is pressed
KA..KE, calibrating clutch KA..KE, KV or KR KA, KB for 2 gear transmission
KV,KR resp. KC, KD, KE for 3 gear transmission
_ and Kx wait for start, initialization of clutch Kx,
x: A, B, C, D, E, 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
TCU (ignition off/on)
∆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
TCU (ignition off/on)
FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the
TCU (ignition off/on)
FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart the
TCU (ignition off/on)
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

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1.5 Display during Inchpedal Calibration

symbol meaning remarks
push down the pedal slowly until
IP ⇓ endposition is reached and hold this
position
Release the pedal slowly until
IP ⇑ endposition is reached
A problem occurred, release the pedal If the expected enposition could not be reached,
IP ⇑ flashing slowly until endposition is reached release the pedal and try again
OK Finished inchpedal calibration
successful
FN and Stop Shift lever not in Neutral position Calibration is aborted
FS and Stop sensor supply voltage AU1 is out of the Calibration is aborted
specified range
FO and Stop Outputspeed is not zero Calibration is aborted
SL and Stop sensor voltage below specified rangel Calibration is aborted
SU and Stop sensor voltage above specified rangel Calibration is aborted
IL and Stop sensor position for released pedal out of Calibration is aborted
specified range
IU and Stop sensor position for pressed pedal out of Calibration is aborted
specified range
TO and Stop time-out calibration, pedal not moved Calibration is aborted
after calibration start
DL and Stop angle between pedalpositions released Calibration is aborted
and pressed to small
DU and Stop angle between pedalpositions released Calibration is aborted
and pressed to big
FI and Stop sensor signal 1 and 2 don't match Calibration is aborted
together

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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.

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3 table of fault codes

Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
11 5000 12 48 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to • check the cables from TCU to shift lever failure cannot be detected in all
TCU detected a wrong signal combination neutral • check signal combinations of shift lever systems with DW2/DW3 shift
for the gear range OP-Mode: transmission positions for gear range lever
• cable from shift lever to TCU is broken shutdown
fault is taken back if TCU
• cable is defective and is contacted to detects a valid signal for the
battery voltage or vehicle ground position
• shift lever is defective
12 5010 12 46 LOGICAL ERROR AT DIRECTION SELECT TCU shifts transmission to • check the cables from TCU to shift lever fault is taken back if TCU all
SIGNAL neutral • check signal combinations of shift lever detects a valid signal for the
TCU detected a wrong signal combination OP-Mode: transmission positions F-N-R direction at the shift lever
for the direction shutdown
• cable from shift lever to TCU is broken
• cable is defective and is contacted to
battery voltage or vehicle ground
• shift lever is defective
21 5090 3 32 S.C. TO BATTERY VOLTAGE AT CLUTCH clutch cutoff / inching function • check the cable from TCU to the sensor all
CUTOFF / INCHPEDAL INPUT is disabled • check the connectors
the measured voltage is too high: OP-Mode: normal • check the clutch cutoff / inch pedal
• cable is defective and is contacted to sensor
battery voltage
• clutch cut off / inch pedal sensor has
an internal defect
• connector pin is contacted to battery
voltage

22 5090 4 29 S.C. TO GROUND OR O.C. AT CLUTCH clutch cutoff / inching function is • check the cable from TCU to the sensor all
CUTOFF / INCHPEDAL INPUT disabled • check the connectors
the measured voltage is too low: OP-Mode: normal • check the clutch cutoff / inch pedal
• cable is defective and is contacted to sensor
vehicle ground
• cable has no connection to TCU

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Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
• clutch cut off / inch pedal sensor has
an internal defect
• connector pin is contacted to vehicle
ground or is broken

25 5110 3 33 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, • check the cable from TCU to the sensor all
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:
• cable is defective and is contacted to
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 5110 4 30 S.C. TO GROUND AT TRANSMISSION SUMP no reaction, • check the cable from TCU to the sensor all
TEMPERATURE SENSOR INPUT TCU uses default temperature • check the connectors
the measured voltage is too low: OP-Mode: normal • check the temperature sensor
• cable is defective and is contacted to
vehicle ground
• temperature sensor has an internal
defect
• connector pin is contacted to vehicle
ground
27 5120 3 76 S.C. TO BATTERY VOLTAGE OR O.C. AT no reaction, • check the cable from TCU to the sensor all
RETARDER / TORQUECONVERTER TCU uses default temperature • check the connectors
TEMPERATURE SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too high:
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• temperature sensor has an internal
defect
• connector pin is contacted to battery

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Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
voltage or is broken
28 5120 4 74 S.C. TO GROUND AT RETARDER / no reaction, • check the cable from TCU to the sensor all
TORQUECONVERTER TEMPERATURE TCU uses default temperature • check the connectors
SENSOR INPUT OP-Mode: normal • check the temperature sensor
the measured voltage is too low:
• cable is defective and is contacted to
vehicle ground
• temperature sensor has an internal
defect
• connector pin is contacted to vehicle
ground
2B 5313 12 135 INCHSENSOR-SIGNAL MISMATCH During inching mode: TCU shifts • check the cable from TCU to the sensor all
the measured voltage from CCO and to neutral • check the connectors
CCO2 signal don’t match or Brake Pedal while inching is switched off: no • check sensor
Position is used for Inching and is not change
defined OP-Mode: normal
• cable is defective
• sensor has an internal defect
31 5140 3 38 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the sensor all
ENGINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 • check the speed sensor
V at speed input pin
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• speed sensor has an internal defect
• connector pin is contacted to battery
voltage or has no contact
32 5140 4 34 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor all
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
• speed sensor has an internal defect

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Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
33 5140 12 42 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power all
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
• cable / connector is defective and has
bad contact
• speed sensor has an internal defect
• sensor gap has the wrong size
34 5150 3 39 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the sensor all
TURBINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 if a failure is existing at output • check the speed sensor
V at speed input pin speed,
• cable is defective and is contacted to TCU shifts to neutral
battery voltage OP-Mode: limp home
• cable has no connection to TCU
• speed sensor has an internal defect
• connector pin is contacted to battery
voltage or has no contact
35 5150 4 35 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor all
TCU measures a voltage less than 0.45V control • check the connectors
at speed input pin if a failure is existing at output • check the speed sensor
• cable / connector is defective and is speed,
contacted to vehicle ground TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
36 5150 12 43 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power all
TCU measures a turbine speed over a control • check the connectors up of TCU
threshold and at the next moment the if a failure is existing at output • check the speed sensor
measured speed is zero speed, • check the sensor gap
• cable / connector is defective and has TCU shifts to neutral
bad contact OP-Mode: limp home
• speed sensor has an internal defect
• sensor gap has the wrong size
37 5160 3 40 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the sensor all
INTERNAL SPEED INPUT control • check the connectors
TCU measures a voltage higher than 7.00 • check the speed sensor

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Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
V at speed input pin
• cable is defective and is contacted to
battery voltage
• cable has no connection to TCU
• speed sensor has an internal defect
• connector pin is contacted to battery
voltage or has no contact
38 5160 4 36 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor all
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
• speed sensor has an internal defect
39 5160 12 44 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after power all
TCU measures a internal speed over a control • check the connectors up of TCU
threshold and at the next moment the • check the speed sensor
measured speed is zero • check the sensor gap
• cable / connector is defective and has
bad contact
• speed sensor has an internal defect
• sensor gap has the wrong size
3A 5170 3 41 S.C. TO BATTERY VOLTAGE OR O.C. AT special mode for gear selection • check the cable from TCU to the sensor all
OUTPUT SPEED INPUT OP-Mode: substitute clutch • check the connectors
TCU measures a voltage higher than 12.5 control • check the speed sensor
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
• speed sensor has an internal defect
• connector pin is contacted to battery
voltage or has no contact
3B 5170 4 37 S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear selection • check the cable from TCU to the sensor all
TCU measures a voltage less than 1.00V OP-Mode: substitute clutch • check the connectors
at speed input pin control • check the speed sensor
• cable / connector is defective and is if a failure is existing at turbine

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Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
contacted to vehicle ground speed,
• speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
3C 5170 12 45 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 all
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 has speed,
bad contact TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
• sensor gap has the wrong size
3E 5180 2 72 OUTPUT SPEED ZERO DOESN’T FIT TO special mode for gear selection • check the sensor signal of output speed This fault is reset after power all
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 • check the clutch pressure
to zero. OP-Mode: limp home • check for slipping clutches
• speed sensor has an internal defect • check the proportional valves
• sensor gap has the wrong size
42 5220 9 123 EBC1 TIMEOUT clutch cutoff / inching function • check EBC controller all
Timeout of CAN-message EBC1 from is disabled • check wire of CAN-Bus
EEC controller OP-Mode: normal • check cable to EBC controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
43 5230 9 143 TC1 TIMEOUT TCU shifts to neutral • check TC controller all
Timeout of CAN-message TC1 from EEC NN (because of shifting lever) • check wire of CAN-Bus
controller • check cable to TC controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and

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Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
has contact to vehicle ground or
battery voltage
44 5211 9 127 SPEEDLIMIT_PROP1 TCU keeps last valid sent • check Vehicle controller all
Timeout of CAN-message Speed_Limit_Request • check wire of CAN-Bus
SpeedLimit_Prop1 from Vehicle • check cable to Vehicle controller
controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
45 5212 9 128 SPEEDLIMIT_PROP2 TCU keeps last valid sent • check Vehicle controller all
Timeout of CAN-message Speed_Limit_Value • check wire of CAN-Bus
SpeedLimit_Prop1 from Vehicle • check cable to Vehicle controller
controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
54 5260 9 103 VEHICLE1 TIMEOUT TCU shifts to neutral • check vehicle controller all
Timeout of CAN-message Vehicle1 from NN (because of shifting lever) • check wire of CAN-Bus
display computer • check cable to vehicle controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
has contact to vehicle ground or
battery voltage
57 5290 9 106 EEC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller all
Timeout of CAN-message EEC1 from control • check wire of CAN-Bus
EEC controller • check cable to EEC controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and

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Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
has contact to vehicle ground or
battery voltage
1)
71 5480 3 22 S.C. TO BATTERY VOLTAGE AT CLUTCH KC TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at KC valve is if failure at another clutch is • check the connectors from TCU to the
too high. pending gearbox
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to battery voltage OP-Mode: TCU shutdown • check internal wire harness of the
• regulator has an internal defect gearbox
1)
72 5480 4 10 S.C. TO GROUND AT CLUTCH KC TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at KC valve is if failure at another clutch is • check the connectors from gearbox to
too low. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to vehicle ground OP-Mode: TCU shutdown • check internal wire harness of the
• cable / connector is defective and has gearbox
contact to another regulator output of
the TCU
• regulator has an internal defect
1)
73 5480 5 16 O.C. AT CLUTCH KC TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has pending TCU
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)
74 5490 3 23 S.C. TO BATTERY VOLTAGE AT CLUTCH TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
KD/KA OP-Mode: limp home gearbox
the measured resistance value of the valve if failure at another clutch is • check the connectors from gearbox to
is out of limit, the voltage at KD/KA valve pending TCU
is too high. TCU shifts to neutral • check the regulator resistance 1)
• cable / connector is defective and has OP-Mode: TCU shutdown • check internal wire harness of the
contact to battery voltage gearbox
• regulator has an internal defect

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Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
1)
75 5490 4 11 S.C. TO GROUND AT CLUTCH KD/KA TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at KD/KA valve if failure at another clutch is • check the connectors from gearbox to
is too low. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to vehicle ground OP-Mode: TCU shutdown • check internal wire harness of the
• cable / connector is defective and has gearbox
contact to another regulator output of
the TCU
• regulator has an internal defect
1)
76 5490 5 17 O.C. AT CLUTCH KD/KA TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has pending TCU
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)
77 5500 3 24 S.C. TO BATTERY VOLTAGE AT CLUTCH TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
KE/KB OP-Mode: limp home gearbox
the measured resistance value of the valve if failure at another clutch is • check the connectors from gearbox to
is out of limit, the voltage at KE/KB valve pending TCU
is too high. TCU shifts to neutral • check the regulator resistance 1)
• cable / connector is defective and has OP-Mode: TCU shutdown • check internal wire harness of the
contact to battery voltage gearbox
• regulator has an internal defect
1)
78 5500 4 12 S.C. TO GROUND AT CLUTCH KE/KB TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at KE/KB valve if failure at another clutch is • check the connectors from gearbox to
is too low. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to vehicle ground OP-Mode: TCU shutdown • check internal wire harness of the
• cable / connector is defective and has gearbox
contact to another regulator output of
the TCU

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Faultcodes EP90 Forklift EST65

Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
• regulator has an internal defect
1)
79 5500 5 18 O.C. AT CLUTCH KE/KB TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has pending TCU
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)
84 5520 3 26 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at KV valve is if failure at another clutch is • check the connectors from gearbox to
too high. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to battery voltage OP-Mode: TCU shutdown • check internal wire harness of the
• regulator has an internal defect gearbox
1)
85 5520 4 14 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at KV valve is if failure at another clutch is • check the connectors from gearbox to
too low. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to vehicle ground OP-Mode: TCU shutdown • check internal wire harness of the
• cable / connector is defective and has gearbox
contact to another regulator output of
the TCU
• regulator has an internal defect
1)
86 5520 5 20 O.C. AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has pending TCU
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)
87 5530 3 27 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 4 all

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 ZF Friedrichshafen AG 2013-10-09
Faultcodes EP90 Forklift EST65

Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at KR valve is if failure at another clutch is • check the connectors from gearbox to
too high. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to battery voltage OP-Mode: TCU shutdown • check internal wire harness of the
• regulator has an internal defect gearbox
1)
88 5530 4 15 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit, the voltage at KR valve is if failure at another clutch is • check the connectors from gearbox to
too low. pending TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance 1)
contact to vehicle ground OP-Mode: TCU shutdown • check internal wire harness of the
• cable / connector is defective and has gearbox
contact to another regulator output of
the TCU
• regulator has an internal defect
1)
89 5530 5 21 O.C. AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the see chapter 4 all
the measured resistance value of the valve OP-Mode: limp home gearbox
is out of limit. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has pending TCU
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
B1 5660 2 60 SLIPPAGE AT CLUTCH KC TCU shifts to neutral • check pressure at clutch KC all
TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
closed clutch KC. 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 KC OP-Mode: TCU shutdown • check signal at internal speed sensor
• low main pressure • check signal at output speed sensor
• wrong signal at internal speed sensor • replace clutch
• wrong signal at output speed sensor
• wrong size of the sensor gap
• clutch is defective

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 ZF Friedrichshafen AG 2013-10-09
Faultcodes EP90 Forklift EST65

Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
B2 5665 2 61 SLIPPAGE AT CLUTCH KD/KA TCU shifts to neutral • check pressure at clutch KD/KA all
TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
closed clutch KD/KA. If this calculated if failure at another clutch is • check sensor gap at internal speed
value is out of range, TCU interprets this pending sensor
as slipping clutch. TCU shifts to neutral • check sensor gap at output speed sensor
• low pressure at clutch KD/KA OP-Mode: TCU shutdown • check signal at internal speed sensor
• low main pressure • check signal at output speed sensor
• wrong signal at internal speed sensor • replace clutch
• wrong signal at output speed sensor
• wrong size of the sensor gap
• clutch is defective
B3 5670 2 62 SLIPPAGE AT CLUTCH KE/KB TCU shifts to neutral • check pressure at clutch KE/KB all
TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
closed clutch KE/KB. If this calculated if failure at another clutch is • check sensor gap at internal speed
value is out of range, TCU interprets this pending sensor
as slipping clutch. TCU shifts to neutral • check sensor gap at output speed sensor
• low pressure at clutch KE/KB OP-Mode: TCU shutdown • check signal at internal speed sensor
• low main pressure • check signal at output speed sensor
• wrong signal at internal speed sensor • replace clutch
• wrong signal at output speed sensor
• wrong size of the sensor gap
• clutch is defective

B5 5680 2 64 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV all
TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
closed clutch KV. 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 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
• wrong signal at internal speed sensor • replace clutch
• wrong signal at turbine speed sensor
• wrong size of the sensor gap
• clutch is defective

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 ZF Friedrichshafen AG 2013-10-09
Faultcodes EP90 Forklift EST65

Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
B6 5685 2 65 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR all
TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
closed clutch KR. 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 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
• wrong signal at internal speed sensor • replace clutch
• wrong signal at turbine speed sensor
• wrong size of the sensor gap
• clutch is defective
B7 5700 0 87 OVERTEMP SUMP no reaction • cool down machine all
TCU measured a temperature in the oil OP-Mode: normal • check oil level
sump that is over the allowed threshold. • check temperature sensor
B8 5710 0 88 OVERTEMP CONVERTER no reaction • cool down machine all
TCU measured a temperature in the OP-Mode: normal • check oil level
retarder oil that is over the allowed • check temperature sensor
threshold.
B9 5720 0 89 OVERSPEED ENGINE retarder applies if configured - all
OP-Mode: normal
BC 5745 15 92 OVERSPEED OUTPUT No reaction all
TCU messures an transmission output OP-Mode: normal
speed above the defined threshold
C0 5751 0 183 ENGINE TORQUE OR ENGINE POWER OP-Mode: normal all
OVERLOAD
TCU calculates an engine torque or engine
power above the defined thresholds
C1 5752 0 184 TRANSMISSION OUTPUT TORQUE OP-Mode: normal all
OVERLOAD
TCU calculates an transmission output
torque above the defined threshold
C2 5755 15 93 TRANSMISSION INPUT TORQUE OVERLOAD programmable :No reaction or all
TCU calculates an transmission input shift to neutral
torque above the defined threshold OP-Mode: normal

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 ZF Friedrichshafen AG 2013-10-09
Faultcodes EP90 Forklift EST65

Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
C3 5760 0 91 OVERTEMP CONVERTER OUTPUT no reaction • cool down machine all
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 5810 3 54 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 all
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 5810 4 55 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 all
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 5820 4 53 LOW VOLTAGE AT BATTERY shift to neutral • check power supply battery all
measured voltage at power supply is lower OP-Mode: TCU shutdown • check cables from batteries to TCU
than 10 V (12V device) • check connectors from batteries to TCU
lower than 18 V (24V device)
D4 5820 3 52 HIGH VOLTAGE AT BATTERY shift to neutral • check power supply battery all
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 5830 2 57 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral • check fuse all
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
• cable or connectors are defect and are
contacted to vehicle ground
• permanent power supply KL30 missing
• TCU has an internal defect
D6 5840 2 58 ERROR VALVE POWER SUPPLY VPS2 shift to neutral • check fuse all
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
• cable or connectors are defect and are

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 ZF Friedrichshafen AG 2013-10-09
Faultcodes EP90 Forklift EST65

Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
contacted to battery voltage
• cable or connectors are defect and are
contacted to vehicle ground
• permanent power supply KL30 missing
• TCU has an internal defect
E3 5860 3 50 S.C. TO BATTERY VOLTAGE AT DISPLAY no reaction • check the cable from TCU to the display all
OUTPUT OP-Mode: normal • check the connectors at the display
TCU sends data to the display and • change display
measures allways a high voltage level on
the connector
• cable or connectors are defective and
are contacted to battery voltage
• display has an internal defect
E4 5860 4 49 S.C. TO GROUND AT DISPLAY OUTPUT no reaction • check the cable from TCU to the display all
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
F1 5890 2 51 GENERAL EEPROM FAULT no reaction • replace TCU often shown together with all
TCU can't read non volantile memoy OP-Mode: normal fault code F2
• TCU is defective
F2 5900 13 56 CONFIGURATION LOST transmission stay neutral • Reprogramm the correct configuration all
TCU has lost the correct configuration and OP-Mode: TCU shutdown for the vehicle (e.g. with cluster
can't control the transmission. controller,...)
• interference during saving data on non
volatile memory
• TCU is brand new or from another
vehicle
F3 5910 13 59 APPLICATION ERROR transmission stay neutral • check EP90-CAN Signals dueto This fault occurs only if an all
something of this application is wrong OP-Mode: TCU shutdown consistency test engineer did something
• replace TCU !! wrong in the application of
the vehicle

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 ZF Friedrichshafen AG 2013-10-09
Faultcodes EP90 Forklift EST65

Fault SPN FMI Int. MEANING OF THE FAULT CODE reaction of the TCU possible steps to repair remarks costu
Code Code possible reason for fault detection mer
(hex) (dec)
F5 5930 7 173 CLUTCH FAILURE transmission stay neutral • check clutch TCU shows also the affected all
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 5930 13 174 CLUTCH ADJUSTMENT DATA LOST OR default values = 0 for AEB • execute AEB all
INCHPEDAL CALIBRATION DATA LOST offsets used
TCU was not able to read correct clutch OP-Mode: normal
adjustment parameters no Inchmode available
• interference during saving data on non
volatile memory
• TCU is brand new

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ZF Friedrichshafen AG 2013-10-09
Faultcodes EP90 Forklift EST65

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

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