Diagnosis - SystemReaction - Trpubleshooting - AVSandES2 - 6038 - 754 - 109a

Diagnosis, System Reaction,
Troubleshooting
for the AVS shift system AVS/ES2
(Sensors)
6038 754 109a
Subject to alterations in design
Copyright by ZF
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Printed in Germany
Edition: 05.98
6038 754 109a

AVS SHIFT SYSTEM VALIDITY
Validity
This document deals with the software generation 3.3

AVS system, from electronic control unit parts list no.
• EST 14 6009 033 351
• EST 28 6009 051 021
and with Backup Drive Program (EFP) from electronic

control unit parts list no. 6009 033 061.
3
TABLE OF CONTENTS AVS SHIFT SYSTEM
1 Modification Sheet ................................................................................................................................. 5

1.1 Introduction .............................................................................................................................................. 6
1.2 Brief description........................................................................................................................................ 7
1.3 Advantages of the system.......................................................................................................................... 7
1.4 Terminology and abbreviations ................................................................................................................. 8
1.5 AVS system diagram ................................................................................................................................. 9
1.6 Description and function of main system components .............................................................................. 10
2 Overview of diagnosis system ................................................................................................................ 11

2.1 Requirements of a diagnosis-capable system ........................................................................................... 12
2.2 Test set-up using terminal tester ............................................................................................................... 13
2.3 Error recognition possibilities . ................................................................................................................. 16
2.4 Error memory organization....................................................................................................................... 17
2.5 Error memory display ............................................................................................................................... 17
2.6 Description of the actual and required gear display .................................................................................. 17
2.7 Conversion guide HEX —> DEC ............................................................................................................ 18
2.8 Allocation of the errors into error classes.................................................................................................. 18
2.9 Survey of errors ........................................................................................................................................ 19
3 Error diagnosis ....................................................................................................................................... 22
4 Test instructions ......................................................................................................................................120

4.1 Shift cylinders test.....................................................................................................................................120
4.2 Wiring harness check 1.............................................................................................................................121
4.11 Wiring harness check 10........................................................................................................................... 141
4.12 Wiring harness check 11...........................................................................................................................143
4.21 Sensors, function and diagnosis ................................................................................................................161
5 Troubleshooting ......................................................................................................................................165
5.1 Errors which cannot be diagnosed when using AVS and ES 2...................................................................165
Central wiring ...........................................................................................................................................167

Wiring diagram .........................................................................................................................................168
Hydraulic diagram ....................................................................................................................................169
Output signal system (EMC).....................................................................................................................170
4
AVS SHIFT SYSTEM MODIFICATION SHEET
Date Section Description
5
PREFACE AVS SHIFT SYSTEM
1.1 Introduction
This manual is intended for skilled personnel who have

been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with a standard ZF product in

accordance with the state of development at the date
of issue.
However due to continuing development of the product,

repair work may require work practices and test or ad-
justment data which differ from those contained in this
manual. We therefore recommend that work done on
your ZF product is carried out only by skilled mechanics
who have had their practical and theoretical training up-
dated on a regular basis at our After-Sales Service trai-
ning courses.
Service points equipped by ZF Friedrichshafen AG all

over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. special tools
3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out

conscientiously and with care.
The repair work carried out at ZF service points is

guaranteed in accordance with the prevailing con-
tractual warranty conditions.
Damage resulting from work performed by non-ZF per-

sonnel in an improper or unprofessional manner, and any
follow-on costs resulting from such work, are excluded
from the contractual warranty agreement. This also ap-
plies if genuine ZF spares have not been used.
ZF FRIEDRICHSHAFEN AG
Friedrichshafen Division
After-Sales Service
6
AVS SHIFT SYSTEM BRIEF DESCRIPTION / ADVANTAGES OF THE SYSTEM
1.2 Brief Description 1.3.3 For safety
The AVS shift system recommends the most favourable Ÿ The driver is no longer required to perform the work of
gearshift to the driver for the current driving situation. changing gears.
This shift recommendation is shown to the driver on the
display and carried out when the clutch is operated. The Ÿ In critical driving situations (traffic lights, turning off)
driver selects the moment of the shift and therefore ma- the correct gear is always engaged. This means the
kes the decision about whether the recommended gears- driver can concentrate fully on traffic and is not
hift actually suits the driving conditions (overtaking, distracted by searching for the gears.
uphill gradient, downhill gradient ...). The driver can al-
so correct the shift recommendation using the control le- Ÿ Improved synchronizer service life due to equal shift
ver and can therefore carry out a manual gear pre-selec- forces.
tion.
The difference between ES 2 and AVS is that, when Ÿ The clutch retaining system ensures that a gearshift
using ES 2, all downshifts have to be performed manual- is completed, even if the driver releases the clutch
ly by moving the control lever in either the + or - direc- prematurely.
tion. When using AVS, input/output logical up/downs-
hift recommendations are made using engine speed Ÿ The system can recognize failures of its components
modifications. and activate the appropriate emergency functions.
1.3 Advantages of the System Ÿ In AVS, when using the backup drive program (EFP),
there is the option of eliminating functional faults,
1.3.1 For installation such as, gear permanently engaged, transmission shift
to neutral or shifted to GP until the vehicle is taken to a
Ÿ Costly shift linkages are replaced by an easy-to-fit ca- service point.(This option has to be activated manually).
ble harness. In ES 2 (EST 28), the EFP is automatically activated if
the above functional faults occur.
Ÿ Applicable for right-hand and left-hand drive vehicles.
Ÿ In case of total failure, a purely pneumatic emergency
Ÿ Simple installation in tilting cabs. shift system with two forwards gears and one reverse
gear can be used to drive the vehicle to the next service
1.3.2 For the driver point or out of an area of danger.
Ÿ Clear display of which gear is engaged and which is the Ÿ The electronic control unit contains an error memory
next shift to be performed. in which system errors are recognized.
Ÿ The driver can keep both hands on the steering wheel.
7
TERMINOLOGY AND ABBREVIATIONS AVS SHIFT SYSTEM
1.4 Terminology and Abbreviations Interruption/short circuit to positive:

A short circuit to vehicle positive or interruption may
Transmission ratio test: occur due to a mechanical or electrical fault. The control
During a driving cycle, the transmission input speed is unit cannot differentiate between these two errors due to
continuously compared with the transmission output the monitoring circuit type.
speed. These two speeds have to be within a gear-depen-
dent relationship to each other. If this relationship is not Short circuit to earth:
in agreement with the theoretical values, an error is A short circuit to the vehicle earth can result due to a
recognized. mechanical or electrical fault. The output is switched off
to prevent unacceptably high current flows.
Speed gradient:
The control unit continuously calculates the change of Ambient conditions:
speed over time. This is used to obtain a parameter When an error is diagnosed for the first time, 4 ambient
which is proportional to the vehicle acceleration. This parameters are also stored (current gear, required gear,
value is known as the speed gradient and can only take input speed, output speed).
on specific values which are limited by the physical
construction. AVS:
Automatic pre-selection gear change system.
Drive cycle:
The electronics classifies the individual drive cycles into Error in sensor for output speed:
a load status, either coasting, part throttle or full throttle, If the output speed exceeds a limiting value, a gear is
and into various load classes, such as, delay, constant engaged and there is no output speed signal, the system
travel and acceleration. recognizes an output sensor error. This error is also
recognized if the speed gradient of the output speed
Active speed monitoring: signal exceeds a limiting value.
During a shift, the countershaft speed is monitored. If
this speed exceeds a specific threshold, the gearshift is Error in sensor for input speed:
cancelled. The transmission shifts to neutral, calculates If the output speed exceeds a limiting value, a gear is
the correct gear for the vehicle speed and engages that engaged and there is no output speed signal, the system
gear. recognizes an output sensor error. This error is also
recognized if the speed gradient of the output speed
Passive speed monitoring: signal exceeds a limiting value.
Before carrying out a downshift, the system checks
whether the theoretical engine connection speed is Clutch retaining function:
below a programmable limiting speed. If this is not the The clutch retaining is a function which prevents the
case, the display shows the permissible jump and this clutch from engaging before the gearshift is completed.
gearshift is performed when the clutch is depressed.
Pneumatic emergency control system:
MOBiDIG 200: The pneumatic emergency control system enables
Mobile Diagnosis Device according to the ISO Standard further driving using a purely pneumatic control system
9141. (in case of a total failure of the electronic control unit).
When driving with the pneumatic emergency control
Error in load sensor supply voltage: system, 2 forwards gears and 1 reverse gear can be
The control unit supplies a stabilized 5 V voltage for the selected.
load sensor. This voltage is continuously checked by the
control unit. Backup Drive Program:
Software program which enables further driving without
Error in vehicle electrical system voltage: transmission shift signals.
The control unit independently monitors the vehicle
electrical system voltage. EST14:
Electronic control unit
Load sensor error:
The control unit monitors the load sensor input voltage. EST28:
If this is outside a specific area, an error is recognized. A Electronic control unit for MB (freerunning diagnosis)
PWM signal is given as load information in the E-gas/ and ES 2 (sensors).
EDC systems.
8
AVS SHIFT SYSTEM AVS SYSTEM DIAGRAM
176
a 231
1 b 232
178
4 175 171
174
187 177 172
180 170
179
200
189 22 115
23
190 230
110 92
27
210
24
193
225
188
29 220 205 173
X 215
192
28 011 337
1.5 AVS System Diagram 177 Diagnostics connection

178 Connection for elect. engine control (PWM)
Key to diagram 179 Output signal booster module
1 Accelerator pedal 180 Load sensor
4 Clutch pedal 187 Clutch switch
22 1st/2nd and 5th/6th gearshift cylinder 188 Emergency control knob
23 3rd/4th and 7th/8th gearshift cylinder 189 Clutch retaining solenoid valve
24 Reverse gearshift cylinder 190 Gear engaged signal pulser
27 Shift turret 192 Central transmission connection
28 Shift valve for range-change group 193 Valve block connection
29 Compressed air tank, 10 dm3 200 Pulse generating sensor for input speed
110 Emergency control system valve 205 Indicator switch for range-change group engaged
115 Pneumatic connection for emergency control 210 Indicator switch for gear engaged
system 215 Pulse generating sensor for output speed (2nd
170 Cable harness sensor optional)
171 Vehicle circuit connector 1 220 Indicator switch for reverse gear engaged
172 Vehicle circuit connector 2 225 Valve block
173 Pulse generating sensor for tachograph 230 Indicator switch for transmission neutral
(optionally also serves as output signal) 231 Backup Drive Program switch
174 EST 14 electronics 232 Backup Drive Program warning lamp
175 Pre-selector control
a Control lever
b Rotary switch
176 Display
9
MAIN SYSTEM COMPONENTS AVS SHIFT SYSTEM
1.6 Description and function of main system Load sensor (180):

components: The load sensor generates an analog voltage signal de-
pending on the accelerator pedal adjustment. This signal
Pre-selector control (175): gives the EST information about the power requested by
The pre-selector control consists of the control lever (a) the driver.
and rotary switch (b).
PWM signal (178):
Control lever (a): PWM load signal in % provides a load value from EDC-
The control lever is used to make manual corrections to E-gas as a substitute for the load sensor.
the automatic gear pre-selection. Moving the lever once
towards the “+” indicates an upshift of one gear. Moving Interface for emergency control (115):
the lever once towards “-” indicates a downshift of one Connection point for vehicle side routing of pneumatic
gear. The lever can also be moved to the left to pre-select emergency control wires to emergency switch (188).
a gearshift into neutral. Clutch signal (187) must be
fitted for all gearshifts to be performed. EST 14 electric control unit (174):
This control unit processes and monitors the incoming
Rotary switch (b): signals from the sensors and sends out corresponding
The rotary switch is used to pre-select the drive range. control commands to the actuators.
“D” stands for normal driving, “N” for neutral and “R”
for reverse. Diagnostics connection (177):
Plug connection for MOBiDIG 200.
Display (176):
The display shows the gear which is currently engaged. Pulse generating sensor for input speed (200):
Also, a bar display shows one or several up/downshifts. Generates a signal which is used by the EST in order to
calculate the transmission input speed (equivalent to
Backup Drive Program switch (231): engine speed if the clutch is closed.)
This switch is used to activate the Backup Drive Pro- Shift cylinders (1st/2nd and 5th/6th = 22; reverse gear = 24
gram. 3rd/4th and 7th/8th gear = 23)
Pneumatic cylinders for shifting gears.
Backup Drive Program warning lamp (232):
This lamp comes on when the Backup Drive Program is Indicator switches on the transmission:
activated.
Indicator switch for transmission neutral (230):
Shows that the transmission is in neutral.
Clutch switch (187):
The clutch switch is an inductive proximity switch which Indicator switch for gear engaged (210):
releases the signal to start the gearshift process. Shows that a gear is engaged.
Indicator switch for range-change group engaged (205):
Emergency control valve (110): Shows that the range-change group is engaged.
In case the vehicle must be driven using pneumatic
emergency control, this valve enables the flow of air to Shift turret (27):
the transmission when the clutch is opened. The shift turret directs the movement of the pneumatic
cylinders in the direction of the sliding sleeves.
Gear engaged signal pulser (190):
The gear engaged signal pulser generates a slight pulse Valve block (225):
(pressure felt against the foot) at the clutch pedal. This Solenoid valves are fitted in the valve block in order to
indicates to the driver that the gearshift is completed. regulate the flow of air to the shift cylinders.
Clutch retaining solenoid valve (189): Emergency control knob (188):

The clutch retaining solenoid valve prevents the clutch The emergency control knob is a pneumatic valve
from disengaging before the gearshift is completed. This which is used to select the 2 forwards gears, neutral and
prevents the synchronizers attempting to operate against 1 reverse gear when driving using pneumatic emergency
a closed clutch. control.
Shift valve for range-change group (28):

The shift valve for the range-change group is used to
activate the range-change group cylinder. The shift valve
is fitted outside the valve block.
10
2.0 Gesamtübersicht Systemdiagnose
DIAGNOSIS
AVS SHIFT SYSTEM
OUTPUT INPUT Shift sequence Electronic

monitoring monitoring monitoring control unit
Solenoid Display Warning Preselector Transmission Speed Load signal Time Program Program Voltage Backup drive
valves lamp control control sensor monitoring run memory error monitoring program
Short circuit Error in data Short circuit Signal Plausibility Plausibility E-Gas Logic WATCH EPROM Under-
to earth cable to earth coding of signal of signal Interface monitoring DOG TEST voltage
Short circuit Short circuit Gradient Interruption Speed RAM Over-

to positive to positive monitoring monitoring TEST voltage
Interruption Interruption Speed Load sensor

monitoring
Transmission min./max.
ratio test data check
013478
OVERVIEW OF DIAGNOSIS SYSTEM
11
REQUIREMENTS AVS SHIFT SYSTEM
2.1 Requirements of a diagnosis-capable system
◆ Continuous monitoring of the electronic control unit

and system components.
◆ Permanent error memory (EEprom) and memo-

rization of ambient conditions when the error
occurred (input speed, output speed, etc.)
◆ Display of diagnosis data

Display by means of:
- Warning to the driver by a general error message,
for example a warning lamp or display message.
- Indication for the service personnel by a detailed
error display (see Error Memory Display,
Section 2.5).
◆ Unambiguous error classification

To enable the defective part to be established and re-
placed with the minimum amount of troubleshooting.
◆ Storage and display of equipment-specific data or

operating parameters (system identification).
◆ Possibility of testing the equipment using special test

modes.
◆ Microcomputer with standardized serial interface

(ISO 9141).
12
AVS SHIFT SYSTEM TEST SET-UP
2.2 Test set-up using terminal tester
4 7
6
5
8
2
0
20 TER
IG TES
10
BiD ONIC S
MO ECTR RE
EL F4
F3 F
B
F2 E
7
A
F1 D
6 3
C 9 T
2 EN
8
4
5
1
-
.
0 +/
CLR
2.2.1 Set-up components
1 MOBiDIG 200 diagnosis device no. 6008 003 003 6 Terminal tester no. 6008 199 001
(can only be supplied in 68/55-pin adapter version)
2 3-pin diagnosis connector
7 55-pin connector on terminal tester
3 3-core connection cable to vehicle cable harness
8 55-pin adapter socket on terminal tester
4 EST 14/28 control unit
9 Plug-in card no. 6008 298 011 (German)
5 55-pin connector on vehicle cable harness or 6008 298 111 (English)
10 Pinning option for PR 87 and film
13
TERMINAL BOX / MOBIDIG 200 AVS SHIFT SYSTEM
2.2.2 Terminal tester 2.2.3.2 Hardware configuration
The terminal tester is used to tap into or feed in electrical A difference in the configuration of the electronic
signals from the vehicle cable harness. control unit hardware is marked in the 8th line of the
identification block.
This draws a difference between whether the control unit
is fitted with leads K or with leads K and L.
Standard models have K and L leads and this is not
2.2.3 The MOBiDIG 200 specifically noted in the identification block.
The most important characteristics are:
◆ Lead K only:
(Lead K = bi-directional data cable)
MOBiDIG 200
ELECTRONIC TESTER - Communication between MOBiDIG and ECU via
lead K
RES - Read and delete error memory
- Display RAM addresses on-line
F1 F2 F3 F4
- Control unit identification
C D E F
8 9 A B
4 5 6 7
0 1 2 3 SDD
MOBiDIG Data,
CLR +/- • ENT PIN 8 Commands
200
EST
004 415
SD3
The following functions are provided by the PIN 32
MOBiDIG 200
2.2.3.1 System identification

The following data are stored in the identification block
for the AVS/ES2 programs of software generation 2: ~ nOutput
1. 6009033XXX.. = Parts list no. of electronic

control unit
2. 6009233XXX.. = Complete EEPROM
3. 6009333XXX.. = EEPROM contents
: :::::::::::: : : : : : : : : : : : : : : : :
6. XXXXXXXX*XXX = Model * transmission ratio
range
7. XXX*XXXXXXXX = System * no. of gears
8. XXXXXXXXXXXX = Hardware configuration
: :::::::::::: : : : : : : : : : : : : : : : :
: :::::::::::: : : : : : : : : : : : : : : : :
20. :::::::::::: : : : : : : : : : : : : : : : :
14
AVS SHIFT SYSTEM MOBIDIG 200
◆ Lead K and L: SDD

(Lead K = bi-directional data lead and also (K) MOBiDIG Data,
PIN 8 Commands
lead L = uni-directional data lead, also known as 200
excitation lead)
EST
– Communication between MOBiDIG and ECU via
lead K EF1 SD3 (L)
– Read and delete error memory PIN 43 PIN 32
– Display RAM addresses on-line
– Control unit identification
– Show current error as error on the display
~ nOutput
2.2.2.3 Static or dynamic data display
This function enables up to 8 RAM addresses to be dis-

played statically (single sequence) or dynamically (per-
manent read-out of current values) on the display.
2.2.3.4 Menu structure of MOBiDIG functions
Main menu 1/1 1–> Diagnosis 1/1 1 –> Read error memory
2 –> Delete error memory
3 –> Data display
2 –> Identification
3 –> HEX-HEX calculator 1/2 1 –> Addition
HEX-HEX calculator 2/2 2 –> Subtraction
3 –> Division
5 –> Hex –> Dec
6 –> Dec –> Hex
< F4 < F4
15
ERROR RECOGNITION AVS SHIFT SYSTEM
2.3 Error recognition possibilities Display using a logic table
The control unit checks whether the input signals meet GE-signal N-signal Note
specific criteria. If this is the case, no special action is
0 0 Permitted at times
taken. However, if the input signals do not meet the
required criteria, an error is recognized and appropriate 0 1 Transmission in neutral
functions are called up. 1 0 Gear engaged
There are various possibilities for input signal monito- 1 1 Not permitted in normal
ring. The following section deals with the two most operation
important possibilities.
The input signals are checked to see whether the input
combinations are permissible, e.g. possible according to
2.3.1 Plausibility check the logic. If a proscribed transmission status is assigned
for these input signals, an error is recognized.
The input signals from the transmission control lever can
take on various input combinations. However, depending
on the shift phase, only certain input combinations are 2.3.2 Monitoring of analog input signal
permitted. (limit value check)
The load sensor is mechanically linked to the pump-

For example: The “Gear engaged” signal and the “Neu- filling control lever of the injector pump. This generates
tral signal” an analog voltage signal which is dependent on the angle
position of the load sensor. This voltage signal is moni-
tored. The signal must remain within specific limits
(Umin < U < Umax). If the signal moves outside these
1 limits, an appropriate error is recognized.
GE signal
0
Voltage, U U = f (alpha)
1
Fault
N signal
0 Umax.
unacceptable
condition Working range
Umin.
t (time)
Fault
alpha min. alpha max. Angle,

alpha
003 878
16
AVS SHIFT SYSTEM ERROR MEMORY ORGANIZATION
2.4 Error memory organization 2.6 Description of the actual and required gear
display
◆ Up to 10 different errors and the appropriate ambient
conditions can be stored in the error memory. In the 8 and 16-speed transmissions, the gear displays
for actual and required gear are shown differently.
◆ If there are 10 different errors in the error memory, If the actual gear display is the same as the required gear
no further errors can be added. If the error memory is display, the error was stored when driving in one gear.
full, no stored error is over-written.
◆ If an error occurs repeatably, this only increases the 8-speed transmission 16-speed transmission
error frequency counter and the ambient conditions
HEX Gear HEX Gear
are not re-stored.
If an error remains active for several drive cycles, the 81 R gear 81 R gear
error is re-diagnosed in each drive cycle and the error 00 Neutral 00 Neutral
frequency counter is increased by one in each case. 01 1 01 1L
02 2 02 1S
◆ Selective deleting of the error memory is not
possible. Only the entire error memory can be deleted 03 3 03 2L
at once (all memory cells are over-written with “FF”). 04 4 04 2S
05 5 05 3L
06 6 06 3S
2.5 Error memory display
07 7 07 4L
Memory number 08 8 08 4S
01H 09 5L
Error number FNR FFH CNT FFH Error frequency
0A 5S
Ambient condition 1 UB1 FFH UB2 FFH Ambient condition 2
Ambient condition 3 UB3 FFH UB4 FFH Ambient condition 4 0B 6L
0C 6S
Memory number: 0D 7L
Number of memory in which the error is entered.
0E 7S
Error number: 0F 8L
Number for identifying the error. 10 8S
Error frequency counter:

Frequency of occurrence of the specific error. The entries in the error memory are in hexadecimal
notation. For ease of recognition, these should be con-
Ambient conditions: verted to decimal notation.
When an error is stored for the first time, 4 ambient
conditions are also stored. These are not over-written
until the entire error memory is deleted.
Ambient condition 1 = Actual gear

Ambient condition 2 = Required gear
Ambient condition 3 = Input speed
Ambient condition 4 = Output speed
17
CONVERSION GUIDE AVS SHIFT SYSTEM
2.7 Conversion guide 2.8 Allocation of the errors into error classes
Each of the left and right figures are replaced with one The electronic control unit is able to recognize different
decimal number. These two numbers are added together errors in different ways and react accordingly.
and the result is the converted value
The errors are divided according to 3 error classes. The
error is classified depending on the risk it represents to
left figures right figures
the vehicle and its passengers.
HEX DEC HEX DEC
0 = 0 0 = 0
1 = 16 1 = 1
2 = 32 2 = 2 Display Error class Effect
3 = 48 3 = 3 none 1 – no immediate action
4 = 64 4 = 4 – entry in error memory
5 = 80 5 = 5 Spanner- 2 – automatic generation of
6 = 96 6 = 6 symbol emergency operation
functions
7 = 112 7 = 7
– possible to continue
8 = 128 8 = 8 driving with restricted
9 = 144 9 = 9 functions
A = 160 A = 10 – entry in error memory
B = 176 B = 11 Stop symbol 3 – driver must take action
C = 192 C = 12 Spanner- – continue driving with
symbol Backup Drive Program
D = 208 D = 13
of pneumatic emergency
E = 224 E = 14 control
F = 240 F = 15 – entry in error memory
Example of calculation:
Figures read: A E H
= hexadecimal
= right figure = 14
= left figure = 160
174
18
AVS SHIFT SYSTEM SURVEY OF ERRORS
2.9 Survey of errors
AVS / ES 2 with EST 14 electronics
Error number Error description Page

dec 21 hex 15 Short circuit to ground on solenoid valve Y 6 (range-change group pilot control valve) 22
dec 22 hex 16 Short circuit to ground on solenoid valve Y13 (splitter group pilot control valve )
(in 6 S 150 C as crawler, in 8 S 180 as default) 24
dec 23 hex 17 Short circuit to ground on solenoid valve Y1 (gearshift valve for 1st/5th gears) 26
dec 24 hex 18 Short circuit to ground on solenoid valve Y2 (gearshift valve for 2nd/6th gears) 28
dec 25 hex 19 Short circuit to ground on solenoid valve Y3 (gearshift valve for 3rd/7th gears) 30
dec 26 hex 1A Short circuit to ground on solenoid valve Y4 (gearshift valve for 4th/8th gears) 32
dec 27 hex 1B Short circuit to ground on solenoid valve Y5 (gearshift valve for reverse gear) 34
dec 28 hex 1C Short circuit to ground on solenoid valve Y8 (central pneumatic system valve) 36
dec 31 hex 1F Short circuit to ground on solenoid valve Y11 (engine brake solenoid valve) 38
dec 32 hex 20 Short circuit to ground on ignition key stop 40
dec 34 hex 22 Short circuit to ground on backup drive program lamp 42
dec 35 hex 23 Short circuit to ground on solenoid valve Y10 (solenoid valve for signal pulser for gear engaged) 44
dec 36 hex 24 Short circuit to ground on solenoid valve Y9 (clutch retaining (KHV) 46
dec 41 hex 29 Interruption/short circuit to positive on solenoid valve Y6 (range-change group pilot
control valve) 48
dec 42 hex 2A Interruption/short circuit to positive on solenoid valve Y13 (splitter group pilot control valve) 50
dec 43 hex 2B Interruption/short circuit to positive on solenoid valve Y1 (gearshift valve for 1st/5th gears) 52
dec 44 hex 2C Interruption/short circuit to positive on solenoid valve Y2 (gearshift valve for 2nd/6th gears) 54
dec 45 hex 2D Interruption/short circuit to positive on solenoid valve Y3 (gearshift valve for 3rd/7th gears) 56
dec 46 hex 2E Interruption/short circuit to positive on solenoid valve Y4 (gearshift valve for 4th/8th gears) 58
dec 47 hex 2F Interruption/short circuit to positive on solenoid valve Y5 (gearshift valve for reverse gear) 60
dec 48 hex 30 Interruption/short circuit to positive on solenoid valve Y8 (central pneumatic system valve) 62
dec 51 hex 33 Interruption/short circuit to positive on solenoid valve Y11 (engine brake solenoid valve) 64
dec 54 hex 36 Interruption/short circuit to positive on backup drive program lamp 66
dec 55 hex 37 Interruption/short circuit to positive on solenoid valve Y10 (solenoid valve for signal
pulser for gear engaged) 68
dec 56 hex 38 Interruption/short circuit to positive on solenoid valve Y9, clutch retaining solenoid valve 70
dec 61 hex 3D No neutral signal during shift 72
dec 62 hex 3E No gear signal during shift 76
dec 63 hex 3F No gear signal without shift 82
dez 64 hex 40 No R-C group signal during R-C group shift 84
dec 65 hex 41 No R-C group signal without R-C group shift 88
dec 66 hex 42 Excessive speed during gearshift 91
dec 67 hex 43 Gear engaged signal and neutral signal simultaneously 92
dec 68 hex 44 No splitter group signal during splitter group shift 95
dec 71 hex 47 Load sensor voltage too low / load signal from engine ECU not clear 96
dec 72 hex 48 Load sensor voltage too high 98
dec 73 hex 49 Load sensor operating voltage too low 100
dec 74 hex 4A Load sensor operating voltage too high 102
dec 75 hex 4B Vehicle electrical system voltage too low 104
19
SURVEY OF ERRORS AVS SHIFT SYSTEM
Error number Error description Seite

dec 76 hex 4C Vehicle electrical system voltage too high 105
dec 77 hex 4D No input signal 106
dec 78 hex 4E No output signal 108
dec 81 hex 51 Incorrect selector lever coding 110
dec 82 hex 52 Interference in data lead to display 111
dec 83 hex 53 Non-analyzable short circuit 113
dec 84 hex 54 Error in ratio test 114
dec 88 hex 58 Backup drive program activated 115
dec 91 hex 5B Internal error (overload) 116
dec 92 hex 5C Internal error (invalid interrupt) 117
dec 93 hex 5D Internal error (internal memory monitoring) 118
AVS / ES 2 (sensors) with the EST 28 electronics
No. Description Class free- ZF-no. Stop PS

running DEC
11 Ground short circuit to Y6 1 101 21 x
18 Ground short circuit to Y8 2 108 28 x x
19 Ground short circuit to Y11 (engine brake) 1 109 31 x
110 Ground short circuit to AD 10 (engine stop) 1 110 32 x
111 Ground short circuit to gear signal 1 111 33 x
112 Ground short circuit to EFP display 1 112 34 x
113 Ground short circuit to Y10 signal pulser 0 113 35
114 Ground short circuit to Y9 KHV 1 114 36 x
115 Ground short circuit to reverse gear display 1 115 37 x
116 Ground short circuit to AD16 1 116 38 x
117 UB/KS-Plus on Y6 2 117 41 x x
118 UB/KS-Plus on Y13 2 118 42 x x
119 UB/KS-Plus on Y1 2 119 43 x x
120 UB/KS-Plus on Y2 2 120 44 x x
121 UB/KS-Plus on Y3 2 121 45 x x
122 UB/KS-Plus on Y4 2 122 46 x x
123 UB/KS-Plus on Y5 2 123 47 x x
124 UB/KS-Plus on Y8 2 124 48 x x
20
AVS SHIFT SYSTEM SURVEY OF ERRORS
No. Description Class free- ZF-no. Stop PS

running DEZ
125 UB/KS-Plus on Y11 (engine brake) 1 125 51 x
126 UB/KS-Plus on AD 10 engine stop 1 126 52 x
127 UB/KS-Plus on gear signal 1 127 53 x
128 UB/KS-Plus on EFP display 1 128 54 x
129 UB/KS-Plus on Y10 signal pulser 0 29 55
130 UB/KS-Plus on Y9 KHV 2 230 56 x x
131 UB/KS-Plus on reverse gear display 0 31 57
132 UB/KS-Plus on AD16 0 32 58
133 Gear does not disengage 2 233 61 x x
134 Gear does not engage 0 34 62
135 No GE signal without shift 0 35 63
136 Range-change group does not shift 0 36 64
137 No GP group signal without shift 0 37 65
138 Synchronizing excessive speed 0 38 66
139 Neutral / GE signal at same time 2 239 67 x x
140 Splitter group does not shift 0 40 68
141 Load sensor signal too low / PWM interference 1 141 71 x
142 Load sensor signal too high 1 142 72 x
143 Reference voltage too small 1 143 73 x
144 Reference voltage too large 1 144 74 x
145 Operating voltage too small 0 45 75
146 Operating voltage too large 0 46 76
147 Speed sensor failure n-input 1 147 77 x
148 Speed sensor failure n-output 1 148 78 x
149 Incorrect pre-selector switch coding 2 249 81 x x
150 Interference in data lead to display 0 50 82
151 Non-analyzable short circuit 1 151 83 x
152 Ratio / speed error 1 152 84 x
153 GE sensor outside value range 0 53 85
154 GP sensor outside value range 0 54 86
155 GV sensor outside value range 0 55 87
156 Backup drive program active 1 156 88 x
157 Internal error (calculating time) 0 57 91
158 Internal error (interrupt) 0 58 92
159 Internal error (memory space) 0 59 93
Stop: Display “STOP” display MV: Solenoid valve

PS: Display workshop spanner display GE/GN: Gear engaged / transmission neutral
Y1-Y6, Y13: Solenoid valves for transmission shifting GP/GV: Range-change group / splitter group
Y8/Y9: Central pneumatic system solenoid valve / clutch R/N: Reverse / neutral
retaining solenoid valve EMS: Elect. engine control
Y10: DGG (signal pulser for gear engaged) PWM: Pulse width modulated signal
Y11: Engine brake solenoid valve EDC: Electronic Diesel Control
EFP: Backup drive program FMR: Vehicle / engine regulation
UB/KS-Plus: Interruption or short circuit to positive The following errors cannot occur in the present version for MB:
KHV: Clutch retaining solenoid valve 2, 9, 10, 11, 15, 16, 18, 25, 26, 27, 31, 32, 40, 53, 54, 55
21
ERRORS AVS SHIFT SYSTEM
3. Error diagnosis, errors 21-93 – Y6 shut off.

– No automatic gear recommendation, only manual
3.1 Error number: gear pre-selection is permitted, available in high
MOBiDIG: 15 (hexadecimal) range.
DISPLAY: 21 (decimal)
Error recognized while driving and gear range low is
Error class: 2 (Display: workshop spanner and used:
optional warning buzzer) – Gear is maintained.
– Y6 shut off.
Error name: Short circuit to ground on solenoid valve – No automatic gear recommendation, only manual
Y6 (range-change group pilot control gear pre-selection permitted, available in high range.
valve)
Stored ambient conditions: – Actual gear
Error causes: Pinched cable – Intended gear
defective solenoid valve – Input speed
faulty plug connection – Output speed
System reactions: Error recognition: Current monitoring (current is

Error recognition at ignition OFF/ON (stationary): greater than a specific limiting
– Y6 shut-off. value)
– No gear pre-selection.
– Driving continued only with pneumatic emergency Delete error status: Error status maintained
control. throughout a drive cycle.
Error recognition during driving: Notes:

Error is recognized during range shifts from high to
low:
– Shifts into previous gear of high range.
Signal route (error 21)

EST 14
Electrics
22
AVS SHIFT SYSTEM ERRORS
Electrics error path
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 45 Pin F
Solenoid valve Y6
Device
socket,
Pin F
Troubleshooting (error 21)

(Perform Ohm measurement with ECU or electronic control unit plugged in.)
Is wiring harness
OK, NO Repair
see wiring harness wiring harness
check 1,
on page 121
YES
Is valve block Change

and/or solenoid solenoid valve/
valve defective valve block
Test connection
Pin 45 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
23
3.2 Error number: Error recognized while driving in low splitter group:
MOBiDIG: 16 (hexadecimal) – Gear is maintained.
DISPLAY: 22 (decimal) – Y13 shut off.
– No automatic gear recommendation.
Error class: 2 (Display: workshop spanner and – Only manual gear pre-selection in high splitter group
optional warning buzzer) range permitted.
– In order to pre-select other gears, tip switch can be
Error name: Short circuit to ground on solenoid valve operated twice.
Y13 (range-change group pilot control
valve) Stored ambient conditions: – Actual gear
– Intended gear
Error causes: Pinched cable / defective solenoid valve – Input speed
– Output speed
System reactions:
Error recognition at ignition OFF/ON (stationary): Error recognition: Current monitoring (current is
– Y13 shut-off. greater than a specific limiting
– No automatic gear recommendation. value)
– Only gearshifts in high splitter group can be
pre-selected and are carried out. Delete error status: Error status maintained
throughout a drive cycle.
Error recognition during driving:
Error is recognized during splitter group shifts from Notes: – 6 S 150 C, 9 S 109 uses this
high to low: valve as crawler activation
– Shift to previous gear. – in 8 S 180 as spare valve
– Y13 shut off. (is not required)
– Only manual gear pre-selection in high splitter group
range permitted.

EST 14
Electrics
24
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 44 Pin G
Solenoid valve Y13

Device
socket,
Pin G
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 1,
on page 121
YES

Test connection
Pin 44 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
25
3.3 Error number: 1st or 5th gear engaged:

MOBiDIG: 17 (hexadecimal) – Gear remains engaged.
Error class: 2 (Display: workshop spanner and – All gears except 1 or 5 can be pre-selected.
optional warning buzzer)
Error name: Short circuit to ground on solenoid valve – Intended gear
Y1 (gearshift valve for 1st/5th gears) – Input speed
– Output speed
Error causes: Pinched cable, defective solenoid
valve Error recognition: Current monitoring (current is
greater than a specific limiting
System reactions: value)
Error recognition at ignition OFF/ON (stationary):
– Y1 shut-off. Delete error status: Error status maintained
– No automatic gear recommendation. throughout a drive cycle.
– All gears except 1 or 5 can be pre-selected.
Notes:
On changes into 1st or 5th gear:
– Gearshifts interrupted.
– Previous gear re-engaged.
– Y1 shut off.
– All gears except 1 or 5 can be pre-selected.

EST 14
Electrics
26
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 42 Pin A
Solenoid valve Y1
Device
socket,
Pin A
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 1,
on page 121
YES

and/or solenoid solenoid valve /
Test connection
Pin 42 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
27
3.4 Error number: 2nd or 6th gear engaged:

Error class: 2 (Display: workshop spanner and – All gears except 2 or 6 can be pre-selected.
Y2 (gearshift valve for 2nd/6th gears) – Input speed
– Output speed
Error causes: Pinched cable / defective solenoid valve
Error recognition: Current monitoring (current is
System reactions: greater than a specific limiting
Error recognition at ignition OFF/ON (stationary): value)
– Y2 shut-off.
– No automatic gear recommendation. Delete error status: Error status maintained
– All gears except 2 or 6 can be pre-selected. throughout a drive cycle.
– A low starting gear is pre-selected with rotary switch
position “D”. Notes:

On changes into 2nd or 6th gear:
– Y2 shut off.
– All gears except 2nd or 6th can be pre-selected.

EST 14
Electrics
28
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 39 Pin B
Solenoid valve Y2
Device
socket,
Pin B
Is wiring harness
OK, NO Repair
check 1,
on page 121
YES

Test connection
Pin 39 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
29
3.5 Error number: 3rd or 7th gear engaged:

Error class: 2 (Display: workshop spanner and – All gears except 3rd and 7th can be pre-selected.
Y3 (gearshift valve for 3rd/7th gears) – Input speed
– Output speed
– Y3 shut-off.
– All gears except 3rd and 7th can be pre-selected. throughout a drive cycle.

On changes into 3rd or 7th gear:
– Y3 shut off.
– All gears except 3rd or 7th can be pre-selected.

EST 14
Electrics
30
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 4 Pin C
Solenoid valve Y3
Device
socket,
Pin C
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 1,
on page 121
YES

Test connection
Pin 4 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
31
3.6 Error number: 4th or 8th gear engaged:

MOBiDIG: 1A (hexadecimal) – Gear remains engaged.
Error class: 2 (Display: workshop spanner and – All gears except 4th and 8th can be pre-selected.
Y4 (gearshift valve for 4th/8th gears) – Input speed
– Output speed
– Y4 shut-off.
– All gears except 4th and 8th can be pre-selected. throughout a drive cycle.

On changes into 4th or 8th gear:
– Y4 shut off.
– All gears except 4th and 8th can be pre-selected.

EST 14
Electrics
32
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 22 Pin D
Solenoid valve Y4
Device
socket,
Pin D
Is wiring harness
OK, NO Repair
check 1,
on page 121
YES

Test connection
Pin 22 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
33
3.7 Error number: Stored ambient conditions: – Actual gear

MOBiDIG: 1B (hexadecimal) – Intended gear
DISPLAY: 27 (decimal) – Input speed
– Output speed
Error class: 2 (Display: workshop spanner and
optional warning buzzer) Error recognition: Current monitoring (current is
Error name: Short circuit to ground on solenoid valve value)
Y5 (gearshift valve for reverse gear)
Delete error status: Error status maintained
Error causes: Pinched cable / defective solenoid valve throughout a drive cycle.
System reactions: Notes:

– Y5 shut-off.
– Reverse gear only possible with pneumatic
emergency control.
– Forward drive possible in normal operation.
Error recognition during reverse gearshift:

– Gearshift interrupted, Neutral remains engaged.
– Y5 shut off.
– Reverse gear only possible in normal operation.
– Forward drive possible in normal operation.

EST 14
Electrics
34
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 3 Pin E
Solenoid valve Y5
Device
socket,
Pin E
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 1,
on page 121
YES

Test connection
Pin 3 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
35
3.8 Error number: Error recognition: Current monitoring (current is

MOBiDIG: 1C (hexadecimal) greater than a specific limiting
DISPLAY: 28 (decimal) value)
Error class: 3 (Display: stop symbol, workshop Delete error status: Error status maintained
spanner, optional warning buzzer) throughout a drive cycle.
Error name: Short circuit to ground on solenoid valve Notes: Continue driving only using
Y8 (central pneumatic system valve) pneumatic emergency shift.
Error causes: Faulty plug connection

pinched cable / defective solenoid valve
System reactions:
– No error recognition
Error recognition only during gearshift:

– Exit solenoid valve Y8 shut off.
– No gearshift to Neutral possible.
– Last gear operating mode is retained.

– Intended gear
– Input speed
– Output speed

EST 14
Electrics
36
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 1 Pin H
Solenoid valve Y8
Device
socket,
Pin H
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 1,
on page 121
YES

Test connection
Pin 1 (+)
and Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
37

MOBiDIG: 1F (hexadecimal) greater than a specific limiting
Error class: 2 (Display: workshop spanner and Delete error status: Error status maintained
optional warning buzzer) throughout a drive cycle.
Error name: Short circuit to ground on engine brake Notes: Operation function
solenoid valve (gearshift valve for
3rd/7th gears)
Error causes: Pinched cable

faulty plug connection
defective solenoid valve
System reactions:
– No error recognition

– Exit engine exhaust brake shut off.
– Operation without engine brake possible.

– Intended gear
– Input speed
– Output speed

EST 14
Electrics
38
A1
Control unit 171

EST 14 Wiring harness
Pin 49 Pin 12
Solenoid valve Y11
Is wiring harness
OK, NO Repair
check 2,
on page 122
YES
Solenoid Change
valve defectiv solenoid valve
Test connection
Pin 49 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
39

MOBiDIG: 20 (hexadecimal) greater than a specific limiting
Error class: 2 (Display: workshop spanner) Delete error status: Error status maintained through
out a drive cycle.
Error name: Short circuit to ground on ignition stop
key Notes: Operation function
System reactions:
– No engine stop if fused via AVS electronic system.

– No engine stop if fused via AVS electronic system.

– Intended gear
– Input speed
– Output speed
40
41
3.11 Error number: Delete error status: Error status maintained

MOBiDIG: 22 (hexadecimal) throughout a drive cycle.
Notes: Operation function
Error class: 2 (Display: workshop spanner)
Error name: Short circuit to ground on backup drive

program lamp

System reactions:
– Lamp not flashing on at ignition OFF/ON.
Error recognition during driving (only during activati-

on of backup drive program):
– Lamp not lighting up.

– Intended gear
– Input speed
– Output speed

value)

EST 14
Electrics
42
A1
171
Control unit H2
Pin 55 Pin 18
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 2,
on page 122
YES
Short circuit in Change

lamp socket lamp socket
Delete
error memory
Check function
of telltale
Check
error memory
43
3.12 Error number: Error recognition during driving:

MOBiDIG: 23 (hexadecimal) – Output shut off.
DISPLAY: 35 (decimal) – No feedback signal “Gear engaged” on clutch pedal.
– Driving without feedback signal possible.
Error class: 1 (Display: none) – Display available for gear engaged information.
– Automatic gear recommendations continued.
Error name: Short circuit to ground on DGG
solenoid valve (signal pulser for gear Stored ambient conditions: – Actual gear
engaged) – Intended gear
– Input speed
Error causes: Pinched cable / solenoid valve defective – Output speed
System reactions: Error recognition: Current monitoring (current is

Error recognition at ignition OFF/ON (stationary): greater than a specific limiting
– Output shut off. value)
– No feedback signal “Gear engaged” on clutch pedal.
– Driving without feedback signal possible. Delete error status: Error status maintained
– Display available for gear engaged information. throughout a drive cycle.
Notes:

EST 14
Electrics
44
A1
Control unit
Pin 11
Solenoid valve Y10
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 3,
on page 124
YES
Solenoid Change
valve defective solenoid valve
Test connection
Pin 11 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
45

MOBiDIG: 24 (hexadecimal) – Gearshift carried out.
DISPLAY: 36 (decimal) – Clutch hold output shut off.
– On premature clutch engagement (before gearshift is
Error class: 2 (Display: workshop spanner and finished). Central air and display ‘KU’ (clutch) shut
optional warning buzzer) off.
– Upon clutch engagement, gearshift according to
Error name: Short circuit to ground on clutch driving speed.
retaining solenoid valve – Automatic gear recommendations continued.
Error causes: Pinched cable / solenoid valve defective Stored ambient conditions: – Actual gear
faulty plug connection – Intended gear
– Input speed
System reactions: – Output speed
– Clutch output shut off. Error recognition: Current monitoring (current is
– On premature clutch engagement (before gearshift is greater than a specific limiting
finished). Central air and display ‘KU’ (clutch) shut value)
off.
– Upon clutch engagement, gearshift according to Delete error status: Error status maintained
driving speed. throughout a drive cycle.
Notes:

EST 14
Electrics
46
A1
Control unit
Pin 30
Solenoid valve Y9
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 3,
on page 124
YES
Solenoid Change
Test connection
Pin 30 (+) and
Pin 37 (–)
Intended value
10 - 20 Ohm
Delete
error memory
Test drive
Check
error memory
47
3.14 Error number: Error recognition during a gearshift:

MOBiDIG: 29 (hexadecimal) – Central air supply shut off.
DISPLAY: 41 (decimal) – No ‘KU’ (clutch) display.
– Neutral pre-selection only permitted at standstill.
Error class: 3 (Display: stop symbol, workshop
spanner, optional warning buzzer) Stored ambient conditions: – Actual gear
– Intended gear
Error name: Interruption/short circuit to positive on – Input speed
solenoid valve Y6 (range-change group – Output speed
pilot control valve)
Error recognition: Output monitoring circuit
Error causes: Cable breakage
faulty plug connection, Delete error status: Error status deleted as soon as the
pinched cable / solenoid valve defective error is rectified.
System reactions: Notes: Continue driving only with pneu-

Error recognition at ignition OFF/ON (stationary): matic emergency shift!
– Independent of transmission mode only Neutral shift
permitted.
– No gear selection from Neutral permitted.
Error recognition during driving in a high range-

change group gear:
– Clutch holding mode and central air supply shut off.
– No gear pre-selection permitted.
– Transmission solenoid valves activated last remain
energized.

EST 14
Electrics
48
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 45 Pin F
Solenoid valve Y6
Device
socket,
Pin F
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 4,
on page 125
YES

Test connection
Pin 45 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
49

MOBiDIG: 2A (hexadecimal) – Central air supply shut off.
DISPLAY: 42 (decimal) – Previous gear remains engaged.
Error class: 3 (Display: stop symbol, workshop Stored ambient conditions: – Actual gear
spanner, optional warning buzzer) – Intended gear
– Input speed
Error name: Interruption/short circuit to positive on – Output speed
solenoid valve Y13 (range-change group
pilot control valve) Error recognition: Output monitoring circuit
Error causes: Cable breakage Delete error status: Error status deleted as soon as the
faulty plug connection error is rectified.
pinched cable / solenoid valve defective
Notes: Continue driving only with pneu-
System reactions: matic emergency shift!
permitted.
Error recognition during driving in a high splitter

group gear:
energized.

EST 14
Electrics
50
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 44 Pin G
Solenoid valve Y13

Device
socket,
Pin G
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 4,
on page 125
YES

Test connection
Pin 44 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
51

MOBiDIG: 2B (hexadecimal) – Central air supply shut off.
– Input speed
solenoid valve Y1 (gearshift valve for
1st/5th gears) Error recognition: Output monitoring circuit
Notes: Continue driving only with
System reactions: pneumatic emergency shift!
permitted.
Error recognition during driving in a gear:

energized.

EST 14
Electrics
52
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 42 Pin A
Solenoid valve Y1
Device
socket,
Pin A
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 4,
on page 125
YES

Test connection
Pin 42 (+)
and Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
53

MOBiDIG: 2C (hexadecimal) – Central air supply shut off.
– Input speed
2nd/6th gears) Error recognition: Output monitoring circuit
permitted.

energized.

EST 14
Electrics
54
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 39 Pin B
Solenoid valve Y2
Device
socket,
Pin B
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 4,
on page 125
YES

Test connection
Pin 39 (+)
and Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
55

MOBiDIG: 2D (hexadecimal) – Central air supply shut off.
– Input speed
3rd/7th gears) Error recognition: Output monitoring circuit
permitted.

energized.

EST 14
Electrics
56
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 4 Pin C
Solenoid valve Y3
Device
socket,
Pin C
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 4,
on page 125
YES

Test connection
Pin 4 (+)
and Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
57

MOBiDIG: 2E (hexadecimal) – Central air supply shut off.
– Input speed
4th/8th gears) Error recognition: Output monitoring circuit
permitted.

energized.

EST 14
Electrics
58
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 22 Pin D
Solenoid valve Y4
Device
socket,
Pin D
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 4,
on page 125
YES

Test connection
Pin 22 (+) and
Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
59

MOBiDIG: 2F (hexadecimal) – Central air supply shut off.
– Input speed
reverse gear) Error recognition: Output monitoring circuit
permitted.

energized.

EST 14
Electrics
60
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 3 Pin E
Solenoid valve Y5
Device
socket,
Pin E
Is wiring harness
OK,
see wiring harness
NO Repair
wiring harness
check 4,
on page 125
YES

Test connection
Pin 3 (+)
and Pin 37 (–)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
61
3.21 Error number:

MOBiDIG: 30 (hexadecimal) Stored ambient conditions: – Actual gear
DISPLAY: 48 (decimal) – Intended gear
– Input speed
Error class: 3 (Display: stop symbol, workshop – Output speed
spanner, optional warning buzzer)
Error recognition: Output monitoring circuit
Error name: Interruption/short circuit to positive on
solenoid valve Y8 (central pneumatic Delete error status: Error status deleted as soon as the
system valve) error is rectified.
Error causes: Cable breakage Notes: Continue driving only with

faulty plug connection pneumatic emergency shift!
System reactions:
Error recognition at ignition OFF/ON:
energized.

permitted.

EST 14
Electrics
62
A1 A3
Control unit
Wiring harness A3/a
EST 14
Pin 1 Pin H
Solenoid valve Y8
Device
socket,
Pin H
Is wiring harness
OK, NO Repair
see wiring harness
wiring harness
check 4,
on page 125
YES

Test connection
Pin 1 (+) and
Pin 37 (-)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
63
3.22 Error number: Error recognition: – Interruption or short circuit to

MOBiDIG: 33 (hexadecimal) positive (internal) with
DISPLAY: 51 (decimal) assistance from an output
monitoring circuit.
Error class: 2 (Display: workshop spanner and – Short circuit to positive
optional warning buzzer) (external) can only be
recognized if the engine brake
Error name: Interruption/short circuit to positive on is protected by the AVS
engine brake solenoid valve electronic control unit.
Error causes: Pinched cable Delete error status: Error status maintained
plug contact breakage throughout a drive cycle.
feedback from other components
connected to the engine brake valve. Notes: Optional function.
System reactions:
– Interruption: no engine brake function.
– Short circuit to positive: no vehicle operation possible
even with pneumatic emergency shift mode!

– Intended gear
– Input speed
– Output speed

EST 14
Electrics
64
A1
Control unit 171

Pin 49 Pin 12
Solenoid valve Y11
No engine brake function NO Repair

when activated
wiring harness
➝ interruption
Is wiring harness
OK, see
wiring harness
check 5/5.1,
on page 129
No vehicle operation possible

➝ short circuit to positive
Is wiring harness
OK, see NO Repair
wiring harness check wiring harness
5/5.2, on page 131
YES
Is solenoid Change
Test connection
Pin 49 (+) and
Pin 37 (-)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
65
3.23 Error number: Error recognition: – Output monitoring circuit.

MOBiDIG: 36 (hexadecimal)
DISPLAY: 54 (decimal) Delete error status: Error status deleted as soon as the
error is rectified.
Notes:
Error name: Interruption/short circuit to positive on
backup drive program lamp

pinched cable
System reactions:
– None

– None

– Intended gear
– Input speed
– Output speed

EST 14
Electrics
66
A1
171
Control unit H2
Pin 55 Pin 18
Lamp does not light up

when backup drive program
is activated
➝ interruption
Is lamp H2 NO Replace
OK lamp H2
JA
Is wiring harness
OK, see NO Repair
wiring harness wiring harness
check 5/5.1,
on page 129
YES Lamp lights up without

activation of backup
drive program
➝ short circuit to positive
Is wiring harness
OK, see wiring NO Repair
harness check wiring harness
5/5.2, on page 131
YES
Short circuit or Replace

interruption in lamp socket
lamp socket
Delete
error memory
Check function
of warning lamp
Check
error memory
67

MOBiDIG: 37 (hexadecimal) – Vehicle operation can be continued without feedback
DISPLAY: 55 (decimal) signal "Gear engaged” on clutch pedal.
– Display available for gear engaged information.
Error class: 1 (Display: none) – Automatic gear recommendations continued.
Error name: Interruption/short circuit to positive on Stored ambient conditions: – Actual gear
DGG solenoid valve (signal pulser for – Intended gear
gear engaged) – Input speed
– Output speed
Error causes: Pinched cable / solenoid valve defective
faulty plug connection Error recognition: Output monitoring circuit.
System reactions: Delete error status: Error status deleted as soon as the
Error recognition at ignition OFF/ON (stationary): error is rectified.
– Vehicle operation can be continued without feedback
signal "Gear engaged” on clutch pedal. Notes:
– Display available for gear engaged information.

EST 14
Electrics
68
A1
Control unit
Pin 11
Solenoid valve Y10
Is wiring harness
harness check 6, wiring harness
on page 133
YES
Is solenoid Change
Test connection
Pin 11 (+) and
Pin 37 (-)
Intended value
40 - 90 Ohm
Delete
error memory
Test drive
Check
error memory
69
3.25 Error number: Error recognition at ignition OFF/ON (stationary):

MOBiDIG: 38 (hexadecimal) – Independent of transmission mode only Neutral shift
DISPLAY: 56 (decimal) permitted.
– No gear pre-selection from Neutral permitted.
spanner, optional warning buzzer) Stored ambient conditions: – Actual gear
– Intended gear
Error name: Interruption/short circuit to positive on – Input speed
clutch retaining solenoid valve – Output speed
Error causes: Cable breakage Error recognition: Output monitoring circuit.

pinched cable / solenoid valve defective Delete error status: Error status deleted as soon as the
error is rectified.
System reactions:
Error recognition during driving in a gear: Notes:
– Gear remains engaged.
– No gear pre-selection.
– Neutral pre-selection only possible at standstill.
Error recognition during a gearshift:

– Previous gear remains engaged.

EST 14
Electrics
70
A1
Control unit
Pin 30
Solenoid valve Y9
Is wiring harness
harness check 6, wiring harness
on page 133
YES
Is solenoid Change
Test connection
Pin 30 (+) and
Pin 37 (-)
Intended value
10 - 20 Ohm
Delete
error memory
Test drive
Check
error memory
71

MOBiDIG: 3D (hexadecimal) – Intended gear
– Output speed
spanner, optional warning buzzer) Error recognition: – Error can only be recognized
during gearshift.
Error name: No neutral signal during shift – Time monitoring: N-signal
must be present for a pro-
Error causes: Air escaping / cable breakage / grammed time after
fuse defective disengaging the gear.
mech. defect Delete error status: As soon as the neutral signal is
adjustment: gear engaged switch present again or after a shift
adjustment: shift cylinder attempt is successfully
concluded, the error status is
System reactions: removed again.
– System tries to shift into Neutral using actuated
clutch (display blank). Notes: Possible to continue driving using
– Display shows ‘KU’ (clutch) when clutch unactuated. the backup drive program, in case
repeated shift attempts are
unsuccessful (provided there are
no mech./pneum. defects).

EST 14
Electrics Mechanics Pneumatics
Is it possible to drive with backup drive YES

program * error is in the electrics, see troubles-
hooting on page 73
NO
1. Error is in the pneumatics, see troubles
hooting on page 74
2. Error is in the mechanics, see troubles

hooting on page 75
* Shift times are longer when driving with the backup drive program and as a result of this mechanical shift hindrances are
not always recognized. For this reason, the shift lever adjustment must be observed when shifting (without EFP). If the
shift cylinder tries to engage the gear but cannot cover the complete route, there is a mechanical shift hindrance in the
transmission ➝ error is in the mechanics, see troubleshooting on page 75.
72
Troubleshooting (error 61) / electrics

Signal „Transmission neutral”
A1
Control unit A3/b

2 1
S12
171
Signal „Gear engaged”
A1
Control unit A3/b

2 1
S11
NO Error 67 appears after ignition "OFF-ON” and YES

error 61 re-appears after depressing clutch
Error signal
“Transmission Error signal “Gear and trans-
neutral” mission neutral engaged at the
same time”, see troubleshoo-
YES ting (error 67) on page 92
Is connector NO Attach connector

corrected attached
correctly
to switch S12
YES
NO Check using
Is fuse F2 OK Replace fuse F2
terminal tester
YES
Is wiring harness
A1➝ S12 ➝ 171 NO Repair wiring Delete
OK, see wiring harness harness error memory
check 7, on page 136
YES
NO Replace switch
Is switch S12 OK Test drive
S12
YES
Is switch S12 adjusted cor- NO Check

Correct switch
rectly, see Repair Manual error memory
adjustment
6038 751 101b
73
Signal route (error 61) / pneumatics
P41
Shift cylinder
Schaltzylinder
1/5
1/5 (2/6)
(2/6)
P38
Shift cylinder
Schaltzylinder
3/7
3/7(4/8)
(4/8)
P49
P11
Shift cylinder
Schaltzylinder
R-Gang
Rev. gear A3
P10Vorrat
P10 supply
Do you hear air escaping

from the clutch pedal when it
is activated Possible errors:
WARNING YES loose union screw Rectify leak (clean screw
Do not confuse with burst air line and insert with Loctite)
venting noise of damaged piston sealing ring
shift cylinder of GP valve
NO
Is there the necessary

amount of neutral air when Is there the necessary manufacturer: informa-
NO 6.5 - 10 bar supply check using NO
the clutch is actuated, check tion in error message to
using manometer on connec- manometer on connection P10 BKS-T
tion P38, P41, P49 or P11 (valve block M14x1.5)
YES
YES Error in valve block Replace valve block
Can the shift cylinders be

mechanically shifted, NO
see shift cylinder test, Replace shift cylinders
on page 120
YES
Continue with trouble-

shooting error 61 / mecha-
nics, on page 75
Delete
error memory
Test drive
Check
error memory
74
Troubleshooting (error 61) / mechanics
Change shift turret,

see Repair Manual
6038 751 101b, on pages 2-36
Delete
error memory
Test drive
NO
Can transmission be shifted Contact BKS-T
YES
Check error memory
75

MOBiDIG: 3E (hexadecimal) – Intended gear
– Output speed
Error class: 1 (Display: none)
Error recognition: – Error recognition only during
Error name: No gear signal during shift gearshift.
– Monitoring of engagement time
Error causes: Pinched cable (time from transmission neutral
faulty plug connection to gear engaged)
air pressure too low (should be
6.5 - 8.0 bar) Delete error status: Error status is removed as soon as
gear engaged incorrectly adjusted a shift attempt is successfully
or defective. concluded.
neutral adjustment of shift cylinder
incorrect Notes: Possible to continue driving using
clutch does not separate the backup drive program, in case
neutral selection permanently engaged repeated shift attempts are
(note: opening switch in selector switch) unsuccessful and there are no
clamping lever on shift turret loose mechanical errors.
System reactions:
Error recognition during driving (only on conclusion
of gearshift):
– If feedback "Gear engaged” is not issued upon a
specific engagement period, Neutral is shifted once
again and the gearshift process is repeated. If the
second gearshift is not successful, transmission shifts
into Neutral.
– Gearshifting is repeated after clutch reactuation.

EST 14
Electrics Mechanics Pneumatics Hydraulics
76
Is it possible to drive with backup YES * Error is in the electrics, see

drive program troubleshooting on page 78
NO
Does the vehicle clutch

separate fully, see test NO
instructions for PR87
6038 756 105, on page 42
YES 1. Clutch switch S9 is incorrectly

adjusted, see Repair Manual
1. Error is in the pneumatics, see 6038 751 101b, on pages 02-05
troubleshooting on page 79 for adjustment
2. Error is in the mechanics, see 2. Error is in the hydraulics, see

troubleshooting on page 80 troubleshooting, page 81
* Shift times are longer when driving with the backup drive program and as a result of this mechanical shift
hindrances are not always recognized. For this reason, the shift lever adjustment must be observed when shifting
(without EFP). If the shift cylinder tries to select the gear but cannot cover the complete route, there is a
mechanical shift hindrance in the transmission ➝ error is in the mechanics, see troubleshooting on page 80.
77
Signal route (error 62) / electrics
A1
S11
Control unit A3/b
EST 14 2 1
S14
171
Is the connector correctly NO

Correct attach connector
attached to switch S11
YES
Is wiring harness A1 ➝
S11 ➝ 171 OK, see wiring harn- NO Repair wiring harness
ess check 8, on page 137
YES
Is switch S11 OK
NO Replace switch S11
YES
Is switch S11 adjusted

correctly, see Repair Manual
NO Correct switch adjustment
6038 751 101b, on pages 2-23
Check using terminal tester
Delete
error memory
Test drive
Check error memory
78
P42 P40
Shift cylinder
Schaltzylinder
2/6 1/5
1/5 (2/6)
(2/6)
P37 P39
Shift cylinder
Schaltzylinder
3/7 4/8 3/7 (4/8)
(4/8)
P24
Shift cylinder
Schaltzylinder
R-Gang
Rev. gear
P22
P21
P20
P18
P16
P11
A3 P10
P10 supply
Vorrat
Do you hear air escaping from

the clutch pedal when it is Possible errors:
activated YES loose union screw
Rectify leak, clean screw and
WARNING burst air line
insert with Loctite
Do not confuse with damaged piston sealing ring
venting noise of shift defective flange packing
cylinder of GP valve
NO
Is there the necessary amo- Is there the necessary 6.5-8

unt of neutral air when the NO Fault caused by vehicle manu-
clutch is actuated, check
bar of supply, check using man- NO facturer: information in error
ometer on connection P10
using manometer on connec- (valve block M14x1.5) messages to BKS-T
tion of gear not shifted
YES
YES
Error in valve block Replace valve block
Is the neutral adjustment of

the shift cylinder correct, see NO
Correct adjustment
Repair Manual 6038 751
101b, on pages 2-31 or 2-34
Can the shift cylinders be

mechanically shifted, see NO Replace shift cylinders
shift cylinder test, on
page 120
YES
Delete
Continue with troubleshoo- error memory
ting error 62 / mechanics, on
page 80
Test drive
Check error memory
79
Error number: (error 62) / mechanics

see Repair Manual
6038 751 101b, on pages 2-36
Delete error memory
Test drive
NO
YES
Check error memory
80
Error number: (error 62) / hydraulics
Are the ZF components

(clutch retaining valve, signal
pulser for gear engaged) in the
hydraulic circuit OK
YES NO Rectify leak
Check for leaks, pay special
attention to cutting ring screw
connections
Error in hydraulic circuit made

Contact BKS-T
by vehicle manufacturer
Possible errors:
- oil leaks in the clutch hydraulic circuit
- incorrect ventilation of clutch circuit / instal-
lation
- defective clutch master cylinder
- defective clutch slave cylinder
Note: Clutch retaining valve has a deliberate internal leak so that the clutch closes during a short circuit
(output is closed by the ECU once a short circuit has been recognized)
81
3.28 Error number: Error recognition: Monitoring of selector signals. If

MOBiDIG: 3F (hexadecimal) the gear engaged signal falls off
DISPLAY: 63 (decimal) after the end of the shift and the
neutral transmission signal is
Error class: 1 (Display: none) present, the error is recognized.
Error name: No gear signal without shift Delete error status: Error status is removed as soon as
the gear signal is correctly present
Error causes: Gear skipping again.
cable breakage
switch defective Notes: Possible to continue driving using
switch incorrectly adjusted the backup drive program, in case
loose contact repeated shift attempts are
unsuccessful and there are no
System reactions: mechanical errors.
Error recognition during driving in a gear when gear
loss occurs:
– Command to actuate clutch (display ‘KU’ (clutch)).

– Intended gear
– Input speed
– Output speed

EST 14
Mechanics
82
Gear skipping caused

by insufficient locking forces
in shift turret

see Repair Manual
6038 751 101b, on pages 2-36
Delete error memory
Test drive
NO
YES
Check error memory
83
3.29 Error number: – If vehicle speed-dependent gear in high GP range:

MOBiDIG: 40 (hexadecimal) after shift monitoring period has lapsed, previous gear
DISPLAY: 64 (decimal) is re-engaged.
Error class: 1 (Display: none) Stored ambient conditions: – Actual gear

– Intended gear
Error name: No R-C group signal during R-C group – Input speed
shift – Output speed
Error causes: Cable breakage, switch defective, Error recognition: Shift time monitoring: if the
loose contact, range-change group does not
switch incorrectly adjusted or change over within a programmed
operating mechanism defective time following the shift com-
(bolt, pin contracted) mand, the error is recognized.
air pressure too low Logic monitoring: if the signal
(should be 6.5-10 bar) does not fall off during the range-
flange packing in GP cylinder defective change group shift, the error is
air/oil lose from breather diagnosed.
5/2-way valve defective
Delete error status: Error status is removed as soon as
System reactions: the range-change group changes
When shifting from low to high range-change groups: over successfully.
– Transmission in Neutral.
– With clutch actuated, display blank, attempted range- Notes: Possible to continue driving using
change group. If group changes, vehicle speed- the backup drive program, in case
dependent gear is engaged. repeated shift attempts are
unsuccessful.
When shifting from high to low range-change groups:
– If vehicle speed-dependent gear in low GP range:
gearshift to Neutral (starting gear cannot be engaged).

EST 14
Electrics Mechanics Pneumatics
Is it possible to drive with backup YES Error is in the electrics, see

drive program troubleshooting on page 85
NO
1. Error is in the pneumatics,
see troubles hooting on
page 86
2. Error is in the mechanics, see

troubles hooting on page 87
84
Signal route (error 64) / electrics
A1
S7
Control unit A3/b
EST 14 2 1
Is wiring harness A1➔S7 OK, NO Repair wiring

see wiring harness check 9, on harness
page 140
YES
NO
Is switch S7 with detent OK Replace switch S7
YES
Is switch S7 adjusted correctly,

see Repair Manual 6038 751 NO Correct switch
101b, on pages 2-21 adjustment
(Note: there is a steel washer
under the hex bolt with detent)
Check using
terminal tester
Delete
error memory
Test drive
Check
error memory
85
P32
P30
P26 P25
P31 P29
GP
GP-Ventil
valve
L S
GP-Schaltzyl.
GP
P11
shift cylinder
P11
P17
A3 P10
P10 supply
Vorrat
Do you hear air escaping from the

Possible errors:
clutch pedal when it is activated
WARNING
YES loose union screw
Rectify leak
burst air line
Do not confuse with venting noise
damaged piston sealing ring
of shift cylinder of GP valve
NO
Is there the necessary amo-

Is there the necessary
unt of air at the GP valve when the
amount of air at the GP cylinder NO clutch is actuated, check using YES Change GP valve
when the clutch is actuated, check
manometer on connection P31
using manometer on connection
or P32
NO
Is there the necessary 6.5-10

Fault caused by vehicle
bar of the supply, check using NO
manometer on connection P10 manufacturer: information in
(valve block) error message to BKS-T
YES
YES
Error in valve block Replace valve block
Delete
error memory
Test drive
Continue with trouble-
shooting error 64 / mechanics,
on page 87
Check error memory
86
Are the pivot bolts of the

NO Correct
shift lever tightened correctly
(GP) in housing, part 3
YES
Disassemble GP cylinder
YES
Are cylinders and pistons OK NO

(use black piston rings) Replace shift cylinders
YES
Does piston rod have free

wheel (i.e. can the range-change
NO Change transmission/
group be shifted mechanically) and/or GP group
YES
Is flange packing in
Delete
cylinder OK
error memory
YES
Test drive
Check electrics and
pneumatics again
Check error memory
87
3.30 Error number: Delete error status: Error status is removed as soon as
MOBiDIG: 41 (hexadecimal) the signal is correctly present
DISPLAY: 65 (decimal) again.
Error class: 1 (Display: none) Notes: Possible to continue driving using

the backup drive program, in
Error name: No R-C group signal without case repeated shift attempts are
R-C group shift unsuccessful.

switch defective
switch incorrectly adjusted
loose contact
System reactions:
– Continued operation possible in engaged range.

– Intended gear
– Input speed
– Output speed
Error recognition: – If the range-change group

engaged signal does fall off
after the shift is completed, the
error is diagnosed.

EST 14
Electrics Mechanics
Is power flow through the YES Possible to drive with backup

transmission ensured drive program
NO
Error is in the mechanics, see Error is in the electrics, see
troubleshooting, on page 90 troubleshooting, on page 89
88
A1
S7
Control unit A3/b
EST 14 2 1
S14
171
Is the connector correctly NO

Correctly attach connector
attached to switch S7
YES
Is wiring harness A1 ➝ S7
➝ 171 OK, see wiring harness
NO Repair wiring harness
YES
Is switch S7 OK
YES
Is switch S7 adjusted cor-

rectly, see Repair Manual
6038 751 101b Seite 2-21
Delete error memory
Test drive
Check error memory
89

GP skipping
➝ no positive power flow
Check GP detent
change, if necessary
NOTE: only place
one steel washer under hex bolt
as sealing ring
Change transmission (GP change)
Delete error memory
Test drive
Check error memory
90

MOBiDIG: 42 (hexadecimal) – Intended gear
– Output speed
Error recognition: Speed monitoring on the
Error name: Excessive speed during gearshift countershaft. Programmed
limiting speed exceeded
during gearshift.
Error causes: Compressed air lines incorrectly
connected Delete error status: Error status is removed as soon
solenoid valves incorrectly connected in as the input speed is below
the valve block the programmed limiting speed
rapid speed increase during shift (down during a shift.
hill) with clutch only half actuated
input/output pulse sensor defective or Notes:
incorrectly adjusted (input)
System reactions:
– If overspeed is sensed on countershaft during gear
engagement, Neutral is selected and the vehicle
speed-dependent gear calculated in Neutral gear
position is engaged.
– If active shift interlock in highest gear is activated,
Neutral position is selected.
– Gearshifting is only repeated after re-actuation of
clutch.
Possible error causes:
– Compressed air lines incorrectly connected

– Solenoid valves incorrectly connected in the valve block
– Rapid speed increase during shift (downhill) with clutch only half actuated.
Measures for rectifying error:
– Check compressed air lines, see Repair Manual 6038 751 101b, on pages 2-40 or 2-43
– Adjust input/output speed sensor
– Check solenoid valve connections, see circuit diagram, page 170
91
3.32 Error number: Error recognition during a gearshift (error only

MOBiDIG: 43 (hexadecimal) recognized during a gearshift in main transmission):
– Gearshift interrupted.
Error class: 3 (Display: stop symbol, workshop – In engaged condition display ‘KU’ (clutch).
spanner, optional warning buzzer) – During actuated clutch no display.
Error name: Gear engaged signal and neutral signal Stored ambient conditions: – Actual gear
simultaneously – Intended gear
– Input speed
Error causes: Cable breakage – Output speed
pinched cable, Error recognition: Plausibility check of input
shirt circuit in a switch combinations.
incorrect switch adjustment
Delete error status: Error status is removed as soon
System reactions: as only the signal is present after
Error recognition at ignition OFF/ON (stationary): a shift to neutral.
Notes: Possible to continue driving using
Error recognition during driving in a gear: the backup drive program, in case
– Gear is retained. repeated shift attempts are
– No gear pre-selection permitted. unsuccessful and there are no
– Neutral shift only possible with vehicle stationary via mech. defects!
rotary switch Neutral position.

EST 14
Electrics Mechanics
Driving with backup drive

program is possible
Error is in the electrics,

see troubleshooting, page 93
* If the error is in the “Gear engaged” branch, there is a possibility that it is a mechanical error. Procedure to be followed is
described in troubleshooting (error 67) electrics / error signal “Gear engaged”, on page 94
92

Signal "Transmission neutral”
A1
Control unit A3/b

2 1
S12
Signal "Gear engaged”
A1
Control unit A3/b

2 1
S11
Error 67 appears after ignition “OFF-ON” YES

NO and error 61 reappears after depressing
clutch
Error signal “Trans- Error signal “Gear

mission neutral” engaged”, see
troubleshooting
JA (error 67) on page 94
Is wiring harness
A1➝ S12 OK, see wiring NO Repair wiring
harness check 7, on harness
page 136
JA Check using
terminal tester
NO Replace switch
Is switch S12 OK
S12
JA Delete
error memory
Is switch S12 adjusted
correctly, see Repair NO Correct switch
Manual 6038 751 101b, adjustment
on pages 2-26
Test drive
Check
error memory
93
Error signal
“Gear engaged”
Is wiring harness A1➝ S11

NO
OK, see wiring harness Repair wiring harness
YES
Is switch S11 OK
YES
Is switch S11 adjusted cor-

rectly, see Repair Manual
6038 751 101b, on pages 02-23
Is shift turret OK NO Change shift turret

Possible errors:
checklist no. 40 and 41
old version:
(with blocking pieces)
- blocking pieces worn
- blocking pieces rusted
Delete error memory
- operating mechanism
Gear engaged, adjusted
incorrectly, or worn
new version:
- tolerance problems in housing Test drive
cover GE/GN of control
components for GE
- operating mechanism pinching
(pins, bolts, bushes)
Check error memory
94
3.33 Error number: Error recognition: Logic monitoring: if the splitter

MOBiDIG: 44 (hexadecimal) group signal does not fall off
DISPLAY: 68 (decimal) during splitter group shift, the
error is diagnosed.
Error class: 1 (Display: none) Shift monitoring: if the splitter
does not change over within a
Error name: No splitter group signal during splitter programmed time after the shift
group shift command, the error is recognized.
Error causes: Cable breakage, switch defective, Delete error status: Error status is removed when a
switch incorrectly adjusted gear is shifted.
loose contact
operating mechanism defective Notes: Possible to continue driving using
air pressure too low the backup drive program, in
air leaking case repeated shift attempts are
GV cylinder rolls defective unsuccessful, and there are no
mech. defects.
System reactions:
– No further gearshifts possible.
– With clutch actuated, display blank.
– If clutch not actuated, display ‘KU’ (clutch).
– With next clutch actuation, vehicle speed-dependent
gear is engaged.

– Intended gear
– Input speed
– Output speed
95
3.34 Error number: Error recognition: Voltage monitoring of load sensor

MOBiDIG: 47 (hexadecimal) voltage.
DISPLAY: 71 (decimal) Monitoring of pulse width
modulated signal.
Error name: Load sensor voltage too low / load signal the load sensor voltage is once
from E-gas/EDC/EMS not clear again above a prescribed limiting
value or when a correct pulse
Error causes: Incorrect adjustment of load sensor width-modulated signal is
insufficient load sensor supply voltage present.
load sensor malfunction
load signal not clear Notes: The AVS shift system can be
continue to be operated. Shift
System reactions: recommendations do not
– Only full-load shift recommendations are issued. correspond to dynamic status.

– Intended gear
– Input speed
– Output speed

EST 14/28
Electrics
Error path, electrics

A1 4-pin plug connection A13
3 are assigned
Pin
Control unit 1 *
25
2
EST 14/28 24
18 3
(Pin arrangement,
BN connector vehicle-dependent)
E-gas
Control unit Pin Pin
13 13 EDC
EST 14
EMS
* new: non-contact load sensor 0501 209 635

96 (Adapter cable 6029 005 018 required for conversions in old vehicle wiring harnesses)
Correctly attach connector or con-

vert to non-contact load sensor
Is connector connection NO (LG) no. 0501 209 635 by using
correctly attached to load sensor adapter cable on old LG connector
on vehicle wiring harness no.
6029 005 018
YES
Is wiring harness A1 ↔ NO
A13 OK, see wiring harness Repair wiring harness
YES
1. Check injector pump idle
Is load sensor adjustment NO speed/full load limit stop,
correct, see Repair Manual correct if necessary
6038 751 101b 2. Correct load sensor adjustment
YES
Load sensor defective Replace load sensor
Check function using PR 87

in acc. with test instructions
6038 756 005, on page 16
Delete error memory
Test drive
Check error memory
97
MOBiDIG: 48 (hexadecimal) the load sensor voltage is once
DISPLAY: 72 (decimal) again beneath a prescribed
limiting value.
Notes:
Error name: Load sensor signal too high
Error causes: Incorrect adjustment of load sensor

excessive load sensor supply voltage
System reactions:
– Only full-load shift recommendations are issued.

– Intended gear
– Input speed
– Output speed
Error recognition: Voltage monitoring of load sensor

voltage.

EST 14
Electrics

3 are assigned
Pin
Control unit 1 *
25
2
EST 14/28 24
18 3
(Pin arrangement,
E-gas
13 13 EDC
EST 14
EMS


Is wiring harness or convert to non-contact
NO load sensor (LG) no. 0501
A1 → A13 OK, see 209 635 by using adapter
wiring harness check 14, cable on old LG connector
on page 148 on vehicle wiring harness
no. 6029 005 018
YES
1. Check injector pump

Is load sensor idle speed/
adjustment NO full load limit stop,
correct, see correct if necessary
Repair Manual
2. Correct load sensor
6038 751 101b
adjustment
YES
Check function using

PR 87 in acc. with
test instructions
6038 756 105, on
page 16
Delete error memory
Test drive
Check
error memory
99
3.36 Error number: Error recognition: Voltage monitoring of supply

MOBiDIG: 49 (hexadecimal) voltage for load sensor.
Error class: 2 (Display: workshop spanner) the supply voltage to the load
sensor is once again above
Error name: Load sensor operating voltage too low a prescribed limiting value.
Error causes: Insufficient load sensor supply voltage Notes:
System reactions:
– None

– None

– Intended gear
– Input speed
– Output speed

EST 14
Electrics

3 are assigned
Pin
Control unit 1 *
25
2
EST 14/28 24
18 3
(Pin arrangement,
E-gas
13 13 EDC
EST 14
EMS

Correctly attach connector or

Is wiring harness convert to non-contact load
A1 → A13 OK, see NO sensor (LG) no. 0501 209
wiring harness check 14, 635 by using adapter cable
on page 150 on old LG connector on
vehicle wiring harness no.
6029 005 018
YES

PR 87 in acc. with
test instructions
6038 756 105, on
page 16
Delete error memory
Test drive
Check
error memory
101
3.37 Error number: Error recognition: Voltage monitoring of supply

MOBiDIG: 4A (hexadecimal) voltage for load sensor.
Error class: 2 (Display: workshop spanner) the supply voltage to the load
sensor is once again beneath
Error name: Load sensor operating voltage too high a prescribed limiting value.
Error causes: Excessive load sensor supply voltage too Notes:

high
System reactions:
– None

– None

– Intended gear
– Input speed
– Output speed

EST 14
Electrics

3 are assigned
Pin
Control unit 1 *
25
2
EST 14/28 24
18 3
(Pin arrangement,
E-gas
13 13 EDC
EST 14
EMS


Is wiring harness or convert to non-contact load
NO sensor (LG) no. 0501 209 635
A1 ↔ A13 OK, see by using adapter cable on
wiring harness check 16, old LG connector on
on page 151 vehicle wiring harness no.
6029 005 018
YES

PR 87 in acc. with
test instructions
6038 756 105, on
page 16
Delete error memory
Test drive
Check
error memory
103
3.38 Error number: Delete error status: Error status is removed as soon
MOBiDIG: 4B (hexadecimal) as the vehicle electrical system
DISPLAY: 75 (decimal) voltage is above a specific
limiting value.
Notes: For intended levels, see
Error name: Vehicle electrical system voltage too low installation guide.
System reactions:
– Control induces reset below specified voltage.
Display reading ‘KU’ (clutch).

– Intended gear
– Input speed
– Output speed
Error recognition: Voltage monitoring of supply

voltage.
104
MOBiDIG: 4C (hexadecimal) the vehicle electrical system
DISPLAY: 76 (decimal) voltage is beneath a specific
limiting value.
Notes: For intended levels, see
Error name: Vehicle electrical system voltage too installation guide.
high
System reactions:
– No reaction.
– Peripheral components may be damaged above
a specific limit voltage.

– Intended gear
– Input speed
– Output speed
Error recognition: Voltage monitoring of supply

voltage.
105
3.40 Error number:

MOBiDIG: 4D (hexadecimal)
Error name: No input signal
Error causes: Input sensor failure (countershaft)

cable breakage
incorrect adjustment
(sensor / toothed disc clearance) should
be 0.8 +– 0.2
0,5 mm (see original)
System reactions:
– No diagnosis possible.

– Engine exhaust brake function controlled by output
speed.
– Shift recommendation calculated by output.
– No active speed monitoring possible.
– Passive downshift interlock reduced.
– No ratio test possible.
– Reverse gear engaged without input signal.

EST 14/28
Electrics
19-pin
A1
central connector
Pin B1
Control unit
EST 14/28 14 Wiring harness J
2 1
36
K
106
Is connector correctly NO Attach

attached to plug correctly
inductive sensor B1
YES
Is wiring harness
A1 → B1 OK, see NO Repair wiring
wiring harness check 17, harness
on page 153
YES
Is input speed sensor

B1 correctly adjusted, NO Correct
see Repair adjustment
Manual 6038 751 101,
on pages 2-19
YES
Input speed sensor Replace input

B1 defective speed sensor
Check function in acc.

with test instructions
6038 756 005 for PR 87,
on page 42
Delete error memory
Test drive
Check
error memory
107
3.41 Error number: – Reverse gear can only be pre-selected on ignition

MOBiDIG: 4E (hexadecimal) of ON.
DISPLAY: 78 (decimal) – After Neutral shift and pre-selection of forward drive
range, a search gear (6th or 7th gear) is pre-selected.
Error class: 2 (Display: workshop spanner) After gear engagement recommended gearshifts are
calculated based on transmission input speed.
Error name: No output signal – After search gear has been engaged, starting gear is
engaged in stationary condition of vehicle.
Error causes: Output sensor failure
faulty plug connection Stored ambient conditions: – Actual gear
sensor / toothed disc clearance – Intended gear
not within tolerance. – Input speed
cable breakage / output sensor signal – Output speed
amplifier failure
speedo signal (D 3, B7) too low Error recognition: Speed gradient exceeds limit value.
(max. load induct. 200 mA) Plausibility check with drive
disc washer loose signal.
System reactions: Erasure of

Error recognition at ignition OFF/ON (stationary): error status: The status “output sensor error” will be
– No diagnosis possible. erased as soon as an output signal is
recognized.
– Passive downshift interlock calculated from Remarks:
transmission input speed.
– No gear ratio test possible.

EST 14
Electrics
A11
A1
2 1
Control unit
EST 14 Wiring harness 4 3
Pin 43
108 A12

signal amplifier A 12
YES

pulse sensor A 11
YES
Change output speed

sensor A 11
YES
Has error 78 YES

been rectified
NO
Is output speed sensor

A11 adjusted correctly, NO Correct
see Repair adjustment
Manual 6038 751 101a
YES
Is wiring harness
A1 → A12 → A11 OK, NO Repair
see wiring harness check wiring harness
18, on page 155
YES
Signal amplifier
A12 defective Replace
signal amplifier
Check in acc. with

test instructions
6038 756 105 for PR 87,
on page 43
Delete error memory
Test drive
Check
error memory
109

MOBiDIG: 51 (hexadecimal) – Intended gear
– Output speed
spanner, optional warning buzzer) Error recognition: Plausibility check of selector
lever signals.
Error name: Incorrect selector lever coding
Delete error status: Error status is deleted as soon as
Error causes: Cable breakage the selector lever signals (after
faulty plug connection Neutral) once again satisfy the
pinched cable plausibility check.
short circuit in selector lever
System reactions: pneumatic emergency shift if the
Error recognition at ignition OFF/ON (stationary): error status is maintained.
– Neutral is pre-selected automatically and engaged
upon clutch actuation.
– Drive range pre-selection only permitted after Neutral
position set on rotary switch.

– Unrestricted operation continued in last speed range
selected (forwards or reverse).
– If Neutral shift is possible on drive range selector,
forward operating range only permitted after Neutral
set on rotary switch.
Check selector lever coding using

PR 87
in acc. with test instructions
6038 756 105, on pages 10-11
YES
If necessary, change
pre-selector switch
110
3.43 Error number: Delete error status: Error status deleted as soon as the
MOBiDIG: 52 (hexadecimal) error is rectified.
Notes:
Error name: Interference in data lead to display

System reactions: – No further display function.

– Display reading: flashing "EE”.
– Warning device no longer
activated.
– No influence on other
functions.

– Intended gear
– Input speed
– Output speed
Error recognition: Output signals cannot be read

back.

EST 14
Electrics
A1 A5
Control unit 4
171
Pin 31
111
Display
flashing “EE”
YES
Is fuse F1 NO Replace
OK fuse F1
YES
Is wiring harness
171 → A1 → A5 NO Repair
OK, see wiring wiring harness
harness check 19.1,
on page 158
YES Display dark
Is wiring harness
171 → A5 NO Repair
OK, see wiring wiring harness
harness check 19.2,
on page 160
YES
Display defective Replace display
Check function
using PR 87, in acc. with
test instructions
6038 756 105,
on page 13
Delete error memory
Test drive
Check
error memory
112
3.44 Error number:

Error class: 2 (Display: workshop spanner and

Error name: Non-analyzable short circuit
System reactions:
– No system reaction.

– Intended gear
– Input speed
– Output speed

value)

113
3.45 Error number: Error recognition: Ratio test does not function for
MOBiDIG: 54 (hexadecimal) error code decimal: 71, 72, 77, 78.
DISPLAY: 84 (decimal) Output speed and transmission
input speed must be within a gear-
Error class: 2 (Display: workshop spanner) dependent speed relationship.
If the speed difference does not
Error name: Error in ratio test correspond to the theoretical
requirement, a ratio error is
Error causes: Gear skipping / tooth breakage recognized.
mechanical fault in transmission
transmission ratio not suitable for prog. Delete error status: Error status maintained
software or vice versa throughout a drive cycle.
System reactions: Notes:

– Diagnosis not possible.

– Passive interlock is reduced.

– Intended gear
– Input speed
– Output speed
114
3.46 Error number: Error recognition: Input ED8 (pin 17) is connected.
DISPLAY: 88 (decimal) Delete error status: Error status maintained
Notes: WARNING
Error name: Backup drive program activated Gear read on the display must not
(Caution: auto-retaining mode) correspond to the gear engaged.
AVS –> by driver Slowly engage clutch when shif-
ES2 –> independently by EST 28 when ting through the group 4-5.
sensor malfunction Deactivate the Backup drive pro-
gram by adjusting switch to OFF
Error causes: and ignition OFF.
System reactions:
– Input signals gear engaged (GE), transmission
Neutral, (GN), range-change group (GP) and splitter
group (GV) are simulated by control unit.
– System functions are retained (gear display, clutch
feedback, clutch hold, speed interlock limits).
– Drive program locked. Gears to be pre-selected by
tip lever.
– Shift times are longer (up to 2 sec.)

– Intended gear
– Input speed
– Output speed
115
3.47 Error number: Notes:

MOBiDIG: 5B (hexadecimal)
Error name: Internal error (overload)
Error causes: Program run-through time not within

tolerance
System reactions:

– Intended gear
– Input speed
– Output speed
Error recognition: Check of program run-through

time.
Delete error status: Error status maintained during

drive cycle.
116

MOBiDIG: 5C (hexadecimal)
Error name: Internal error (invalid interrupt)
Error causes: Software problem
System reactions:
- Reset actuated. Display reading ‘KU’ (clutch).

– Intended gear
– Input speed
– Output speed
Error recognition: Check of program sequence.

117

MOBiDIG: 5D (hexadecimal)
Error name: Internal error (internal memory

monitoring)
Error causes: Internal error
System reactions:

– Intended gear
– Input speed
– Output speed
Error recognition: Check of memory contents.

118
119
4. Test instructions
4.1 Shift cylinders
Test: shift cylinders 1/5 (2/6)

shift cylinders 3/7 (4/8)
1. Release fork head of shift cylinder from shift lever.

Swivel shift cylinder out of shift lever.
Shift cylinder
Shift lever
Piston rod
with fork head
– Ignition on / engine off / air supply min. 6.5-10 bar.

– Activate backup drive program.
2. Perform shift in gear or in neutral.

Observe shift route of piston rod.
Shift cylinder
Shift lever
Piston rod
with fork head
Piston rod covers entire shift route ➪ shift cylinder OK
Piston rod cannot be moved or does not cover

the entire shift route ➪ shift cylinder defective
120
4.2 Wiring harness check 1
Wiring harness: control unit → valve block
– Ignition “OFF”
– Unplug control unit
– Attach terminal tester
– Unplug connector A3/a
Check 1) Short circuit to ground
MULTIMETER
OHM
Terminal tester Terminal tester

(Connection on bridge of faulty (Connection on bridge 37)
solenoid valve)
Solenoid 1 9 17 25 33 41 49
valve Bridge
2 10 18 26 34 42 50
Y1 42 3 11 19 27 35 43 51
Y2 39 4 12 20 28 36 44 52
Y3 4
5 13 21 29 37 45 53
Y4 22
6 14 22 30 38 46 54
Y5 3
Y6 45 7 15 23 31 39 47 55
Y8 1 8 16 24 32 40 48
Y13 44
Multimeter display ≠0 ➪ no ground short circuit
Multimeter display =0 ➪ ground short circuit in the area

around the wiring harness /
connector / solenoid valve
121
Wiring harness: control unit → Engine brake valve

→ lamp H2
– Unplug cable connector from component
Check 2.1) Short circuit to ground
MULTIMETER
OHM

(Connection on appropriate (Connection on bridge 37)
bridge)
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
Y11 49 3 11 19 27 35 43 51
4 12 20 28 36 44 52
Lamp 5 13 21 29 37 45 53
H2 55 6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
see 2.2)
Multimeter display =0 ➪ ground short circuit in area
around the wiring harness
122
Check 2.1) Disconnect vehicle circuit plug 171
MULTIMETER
OHM

(Connection on appropriate 1. Bridge 37
bridge) 2. Bridge 19
3. Ground on vehicle
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
Y11 49 3 11 19 27 35 43 51
4 12 20 28 36 44 52
Lamp 5 13 21 29 37 45 53
H2 55 6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
1. Bridge 37
Multimeter display =0 ➪ ground short circuit in area A1 → 171
Multimeter display =0 ➪ ground short circuit in area A1 → 171 2. Bridge 19
3. Ground on
Multimeter display =0 ➪ ground short circuit in area A1 → 171
vehicle
Ground short circuit is in area around the vehicle circuit plug

→ “Engine brake” valve
→ lamp H2
123
Wiring harness: control unit → “Retaining” clutch

→ “Gear engaged” pulse sensor
– Unplug cable connector from component!
MULTIMETER
OHM

bridge)
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
3 11 19 27 35 43 51
Y9 30
Retaining sole- 4 12 20 28 36 44 52
noid valve 5 13 21 29 37 45 53
Y10 11 6 14 22 30 38 46 54
Gear engaged 7 15 23 31 39 47 55
pulse sensor
8 16 24 32 40 48

124
WARNING
Incorrect wiring harness assembly causes short circuits and interruptions which cannot be diagnosed without
causing further problems. The error can be permanent or only occur sporadically.
When working through wiring harness check 4, you should also check whether the compact cabling is attached
in accordance with the ZF manual.
You should check the following:
1. Check the wiring harness in the area around the valve block:
– are the cable clips attached correctly
– do the wiring harness arrangements comply with each permitted radius (R≥ 20 mm)
– do heat emitting exhausts or water pipes pass by the wiring harness
(if necessary, use heat baffle plate or firewall) in the area around the transmission at a temperature of 100°C
with old cabling version/ 120°C with new version
2. Check the connections between the transmission related wiring harness and the vehicle related wiring harness. If
the cable clips are too tight at these points, this will result in damage to the wiring harness.
3. Does the wiring harness pass by elements which are emitting large amounts of heat (e.g. alternator / exhaust /
retarder)? Are the cable clips tightened correctly in these areas?
4. Is the cabling assembled in a way in which the wires in connectors are not taut?
5. Check the end clamps, are they touching any other parts or rusting? The end clamps must be in dry surroundings.
They must be at least 0.5 - 0.6 m away from the 55-pin connector A1.
125
Wiring harness: control unit → valve block
– Unplug connector A3/a
Check 4.1) Interruption
LIVE CIRCUIT MONITOR
Terminal tester A3/a

(Connection on the bridge of the (Connection with pin belonging to
faulty solenoid valve) the faulty solenoid valve)
Solenoid 1 9 17 25 33 41 49 Solenoid
valve Bridge 2 10 18 26 34 42 50 valve Pin
Y1 42 3 11 19 27 35 43 51 H A Y1 A
G
Y2 39 4 12 20 28 36 44 52
I B
Y2 B
F J C
Y3 4 5 13 21 29 37 45 53 E D
Y3 C
Y4 22 Y4 D
6 14 22 30 38 46 54
Y5 3 Y5 E
7 15 23 31 39 47 55 10-pin connector
Y6 45 Y6 F
8 16 24 32 40 48 on wiring harness
Y8 1 Y8 H
Y13 44 Y13 G
Live circuit monitor ≠0 ➪ signal route OK
Live circuit monitor =0 ➪ interruption in the area aro- see 4.2)

und the wiring harness or
connector
126
Check 4.2) Short circuit to positive
– Connect terminal tester

– Ignition “ON”
– Unplug connector A3/a.
MULTIMETER
VOLT

(Connection on the bridge of the (Connection on bridge 37)
faulty solenoid valve)
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
Y1 42 3 11 19 27 35 43 51
Y2 39 4 12 20 28 36 44 52
Y3 4 5 13 21 29 37 45 53
Y4 22 6 14 22 30 38 46 54
Y5 3 7 15 23 31 39 47 55
Y6 45
8 16 24 32 40 48
Y8 1
Y13 44
Voltage does not deviate from 24 V ➪ no short circuit to positive
Voltage does deviate from 24 V ➪ Short circuit to positive in area around

wiring harness A1 → A3/a
127
WARNING
When working through wiring harness check 4, you should also check whether the compact cabling is attached in
accordance with the ZF manual.
2. Check the connections between the transmission related wiring harness and the vehicle related wiring harness.
If the cable clips are too tight at these points, this will result in damage to the wiring harness.
3. Does the wiring harness pass by elements which are emitting large amounts of heat (e.g. alternator / exhaust /
compressor lines / retarder)? Are the cable clips tightened correctly in these areas?
128
Wiring harness: control unit → “Engine brake” valve

→ Lamp H2
Check 5.1.1) LIVE CIRCUIT MONITOR
Terminal tester Cable connector Y11 or H2

(Connection on relevant (Connection with associated
bridge) pin (+))
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
Y11 49 3 11 19 27 35 43 51
4 12 20 28 36 44 52
Lamp 5 13 21 29 37 45 53
H2 55 6 14 22 30 38 46 54
7 15 23 31 39 47 55 1 2
8 16 24 32 40 48
Live circuit monitor responds ➪ no interruption
see 5.1.2)
Live circuit monitor does not ➪ interruption in area
respond around the wiring harness
129
5.1.2) Disconnect vehicle circuit plug 171 !
Terminal tester 171

(Connection on relevant (Connection with
bridge) associated pin)
Solenoid 1 9 17 25 33 41 49 Solenoid
10 12 14 16 18 20 22
11 13 15 17 19 21
valve Bridge 2 10 18 26 34 42 50 valve Pin
Y11 49 3 11 19 27 35 43 51 Y11 12
4 12 20 28 36 44 52
Lamp 5 13 21 29 37 45 53 Lamp
H2 55 6 14 22 30 38 46 54 H2 18
9
7 15 23 31 39 47 55
8
8 16 24 32 40 48
6
5
4
3
2
Live circuit monitor does not respond ➪ interruption in area around

wiring harness
Interruption is in area around

vehicle circuit plug → “Engine brake” valve
→ lamp H2
130
Wiring harness: control unit → “Engine brake” valve

→ Lamp H2

– Ignition "ON”
Check 5.2.1) MULTIMETER
VOLT

bridge)
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
Y11 49 3 11 19 27 35 43 51
4 12 20 28 36 44 52
Lamp 5 13 21 29 37 45 53
H2 55 6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
Voltage does not deviate - ➪ no short circuit to positive

from 24 V
see 5.2.2)
Voltage does deviate ➪ short circuit to positive in
from 24 V area around wiring harness
131
5.2.2) Disconnect vehicle circuit plug 171
Short circuit to positive MULTIMETER

– Ignition “ON” VOLT
Unplug cable connector from component
– Connect ECU

bridge)
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
Y11 49 3 11 19 27 35 43 51
4 12 20 28 36 44 52
Lamp 5 13 21 29 37 45 53
H2 55 6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
Voltage does not deviate - ➪ no short circuit

from 24 V in area around A1 → 171
Voltage does deviate ➪ short circuit to positive

from 24 V in area around A1 → 171
Short circuit to positive in area around

vehicle circuit plug → “Engine brake” valve
→ Lamp H2
132
WARNING
When working through wiring harness check 4, you should also check whether the compact cabling is attached in
accordance with the ZF manual.
2. Check the connections between the transmission related wiring harness and the vehicle related wiring harness.
If the cable clips are too tight at these points, this will result in damage to the wiring harness
3. Does the wiring harness pass by elements which are emitting large amounts of heat (e.g. retarder / Intarder)?
Are the cable clips tightened correctly in these areas?
133
Wiring harness: control unit → “Clutch retaining” solenoid valve

→ “Gear engaged” pulse sensor
Terminal tester Kabelstecker Y9 bzw.Y10

Connection on bridge Connection with associated
of faulty solenoid valve pin 1 (+)
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
3 11 19 27 35 43 51
Y9 30
Y10 11 4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54 1 2
7 15 23 31 39 47 55
1 2
8 16 24 32 40 48
Y10 Y9
Live circuit monitor does not respond ➪ interruption in area around

wiring harness
see 6.2)
134

MULTIMETER
VOLT

bridge)
Solenoid 1 9 17 25 33 41 49
valve Bridge 2 10 18 26 34 42 50
Y9 30 3 11 19 27 35 43 51
Y10 11 4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
Voltage does not deviate from 24 V ➪ no short circuit to positive
Voltage does deviate from 24 V ➪ short circuit to positive in area around

wiring harness
135
Wiring harness: switch S12 → vehicle circuit plug 171
Check 7 Interruption
S12 171
(Connection with pin 1) (Connection with pin 1)
10 12 14 16 18 20 22
11 13 15 17 19 21
2 1
9
8
7
6
5
4
3
2
Live circuit monitor does not respond ➪ interruption in the

area around
wiring harness S12 → 171
136
Wiring harness: control unit → switch S11
– Unplug connector S11
Terminal tester S11

(Connection on bridge 33) (Connection with pin 2)
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55 2 1
8 16 24 32 40 48
Live circuit monitor does ➪ interruption in the see 8.2)

not respond area around
wiring harness A1→ S11
137
Wiring harness: switch S11 → vehicle circuit plug 171
S11 171
(Connection with pin 1) (Connection with
pin 9 or 10)
10 12 14 16 18 20 22
11 13 15 17 19 21
2 1
9
8
7
6
5
4
3
2
Live circuit monitor does not respond ➪ interruption in the area

around wiring harness →
S11 → 171
138

– Unplug connector S7 !
Check 9) Short circuit to positive
MULTIMETER
VOLT

(Connection on bridge 37) (Connection on bridge 15)
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
Voltage does not deviate ➪ no short circuit to positive

from 24 V
Voltage does deviate ➪ short circuit to positive in area

from 24 V around wiring harness A1 → S7
140
Terminal tester S7
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55 2 1
8 16 24 32 40 48
see 10.2)
Live circuit monitor does ➪ interruption in the area
not respond around wiring harness A1→ S7
141
Wiring Harness: switch S7 → vehicle circuit plug 171
S7 171
(Connection with pin 1) (Connection with pin 9 oder 10)
10 12 14 16 18 20 22
11 13 15 17 19 21
2 1
9
8
7
6
5
4
3
2
Live circuit monitor does not respond ➪ interruption in the area around
wiring harness S7 → 171
142

MULTIMETER
VOLT

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48

from 24 V

143

MULTIMETER
OHM

(Connection on bridge 37 (Connection on bridge 33)
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48

from 24 V

144
Wiring harness: control unit → load sensor
– Unplug connector A13 !
Terminal tester A13

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
1 2
7 15 23 31 39 47 55
4 3
8 16 24 32 40 48
see 13.2)
not respond around wiring harness A1→ A13
145
Terminal tester A13

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
1 2
7 15 23 31 39 47 55
4 3
8 16 24 32 40 48
see 13.3)
146
MULTIMETER
OHM

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48

147
Terminal tester A13

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54 1 2
7 15 23 31 39 47 55 4 3
8 16 24 32 40 48
see 14.2)

148

MULTIMETER
VOLT

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
Voltage deviates by less ➪ no short circuit to positive

than 4,1 V
Voltage deviates by more ➪ short circuit to positive in area

than 4.1 V around wiring harness A13 → A1
149
MULTIMETER
OHM

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48

150

MULTIMETER
VOLT

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
see 16.2)
from 5 V

from 5 V around wiring harness A1 → A13
151
MULTIMETER
VOLT

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
Voltage deviates by less ➪ no short circuit to positive

than 4,1 V
Voltage deviates by more ➪ short circuit to positive in area

than 4.1 V around wiring harness A13 → A1
152
Wiring harness: control unit → input speed sensor
– Unplug connector B1 !
Terminal tester B1
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55 2 1
8 16 24 32 40 48
see 17.2)
not respond around wiring harness A1→ B1
153
Terminal tester B1
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55 2 1
8 16 24 32 40 48

not respond around wiring harness A1→ B1
154
Wiring harness: control unit → signal amplifier → output/input speed sensor
Terminal tester A12

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
8 6 4 2
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
7 5 3 1
8 16 24 32 40 48
see 18.2)

155
Wiring harness: vehicle circuit plug 171→ signal amplifier

MULTIMETER
VOLT
Terminal tester A12

1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
8 6 4 2
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
7 5 3 1
8 16 24 32 40 48
Multimeter shows ➪ no interruption see 18.3)

the necessary 24 V
Multimeter does not show ➪ interruption in the area around

the necessary 24 V wiring harness 171→ A12
156
– Unplug connectors A12 and A11!
A11 A12
(Connection on Pin 1; 3; 4) (Connection with pin 4; 5; 6)
2 1 8 6 4 2
4 3
7 5 3 1
Pin associations
A11 A12
1 ➪ 4
3 ➪ 5
4 ➪ 6

157
Wiring harness: control unit → display
Check 19.1.1)
Terminal tester A5
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
1
5 13 21 29 37 45 53
6 14 22 30 38 46 54 2
7 15 23 31 39 47 55 3
8 16 24 32 40 48
4
see 19.1.2)

158
Wiring harness: vehicle circuit plug 171 → control unit
19.1.2) Interruption

MULTIMETER
VOLT

(Connection on bridge 37) (Connection on bridge 2 or 20)
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
5 13 21 29 37 45 53
6 14 22 30 38 46 54
7 15 23 31 39 47 55
8 16 24 32 40 48
Multimeter shows the ➪ no interruption

necessary 24 V on pin 2 or 20
Multimeter does not show the ➪ interruption in area around

necessary 24 V on pin 2 or 20 wiring harness 171 → A1
159
Wiring harness: vehicle circuit plug 171 → display

MULTIMETER
VOLT
Terminal tester A5
1 9 17 25 33 41 49
2 10 18 26 34 42 50
3 11 19 27 35 43 51
4 12 20 28 36 44 52
1
5 13 21 29 37 45 53
6 14 22 30 38 46 54 2
7 15 23 31 39 47 55 3
8 16 24 32 40 48
4
Multimeter shows ➪ no interruption

the necessary 24 V
Multimeter does not show ➪ interruption in the area around

the necessary 24 V wiring harness 171→ A5
160
4.21 Sensors, function and diagnosis 4.21.3 Function once ignition has been switched on
4.21.1 Description of sensors a) When the ignition has been switched on, the GE
sensor must be in an extended neutral range:
The ES 2 shift system with Ecosplit transmission has a Lower limit = 86 IE = 56 hexadecimal
total of 2 route sensors. Upper limit = 108 IE = 6C hexadecimal
a) The “Gear ENGAGED sensor” (GE sensor) on the NOTE

shift turret recognizes the gear engaged position and Note the route signal diagrams of the GE and GP
the neutral position. sensors.
NOTE b) When the ignition has been switched on, the GP

The neutral switch, (without sensor) assembled on the sensor must also be in an extended range of GP high
shift turret, is not connected to the EST 28. It is used (GPL) or GP low (GPS):
e.g. for the vehicle functions: anti-gas or immobiliser. GPL extended upper range = 124 IE = 7C hexa-
decimal
b) The “GP sensor” on the transmission housing GPL extended lower range = 150 IE = 96 hexa-
recognizes whether the planetary range-change decimal
group is in the high or low range GPS extended upper range = 91 IE = 5B hexa-
decimal
4.21.2 Diagnosis GPS extended lower range = 106 IE = 6A hexa-
decimal
If you use test device MOBiDIG 200 and the AVS plug-
in card (plug-in test instruction no. 6038 756 120), you – If the GE and/or GP sensor is not in its extended
have a chance to read the sensor input signals for the range, ”KU” appears in the display (prompt telling
EST 28. you to depress the clutch again).
– Sensor positions can only be determined inside the

computer. (You cannot find the sensor positions by 4.21.4 Gearshift in 4-speed selection
measuring the electric dimensions on the terminal
tester.) A maximum position is determined for each gear selec-
– If you are experiencing shift problems, you can tion (N → 1 to 4/R) and a “GE threshold” is determined
determine the source of the fault by reading the from this.
present sensor position.
– The relative route of the sensors is shown in GE minimum route = 21 IE = 15 hexadecimal
incremental units (IE):
– In the 16 S 221, 1 incremental unit (IE) = 0.19 mm NOTE
of the route on the sensor. This is approx. 0.3 mm on If the vehicle is driven for a long time in the same gear,
the synchromesh/constant mesh. drifting is compensated (e.g. temperature-dependent).
Initially after 2 min and then every 12 sec., all measured
NOTE values are added to together and an average calculated.
Depending on the version, error 88 may be shown on The compensating value is calculated as the difference
the display and in the error memory, when it is really between this average value and the old average value.
error F85/86 (GE and/or GP sensor outside value range) All 5 GE thresholds and the N position are corrected by
which has occurred. Error 88 means: backup drive pro- this compensating value.
gram has been switched on. In versions without error
reading 88 in the display, the backup drive program is
automatically switched on but error 85 or 86 is directly 4.21.5 Gearshift in the GP range-change group
shown in the display.
A GPL and GPS threshold is calculated for the two GP
positions high (GPL) and low (GPS).
161
4.21.6 Failure thresholds
If a sensor position is outside the failure limit, a sensor

failure is diagnosed:
If F 85 and/or F 86 are outside the value range, the
backup drive program is automatically activated.
Upper failure limit of sensors = 150 IE = 96 hexa-
decimal
Lower failure limit of sensors = 85 IE = 55 hexadecimal
NOTE
Should F 85 / 86 fail, this can only have been caused by
an electric fault.
Errors 61 - 68 are diagnosed if there are pneumatic or
mechanical functional faults.
162
Route - signal - diagram Route - signal - diagram
for the GE sensor for the GP sensor
Incremental
Incremente Incremental
Incremente
sensor route
Sensorweg- sensor route
Sensorweg-
units
einheiten units
einheiten
AVS SHIFT SYSTEM
4.21.7 Route - signal - diagram
150
150
124
108 106
86
85 91
85
Immersion
Sensorweg Immersion
Sensorweg
Extended neutral
Neutral-Erweitert depth for
Eintauch- GPS-Erweitert
GPS extended GPL extended
GPL-Erweitert depth for
Eintauch-
sensor travel
tiefe sensor
tiefe travel
Neutral
Neutral-
range
bereich Dist. GP
Abst. GP Dist. GP
Abst. GP
4 IE
GE
GE-Mindestweg
minimum routeXX GP hysteresis
GP-Hysterese
21 IE
Neutral position
Neutralposition X
Abstand
DistanceGE
GEX GP hysteresis
GP-Hysterese
8 IE
GE hysteresis
GE-Hysterese Maximale
Maximum Position
position X
X GPS threshold
GPS-Schwelle GPS threshold
GPL-Schwelle
6 IE 006 673
GPS-Position
GPS position GPL-Position
GPS position
GE-Schwelle
GE thresholdXX
ERRORS
163
164
5 Troubleshooting
Should erroneous functions occur, gather possible cau- (Section 3). The erroneous functions which can be dia-
ses, effects on the system, remedies and safety instruc- gnosed are shown on the display (e.g. STOP, ) and
tions from the following tables. A distinction is made can be identified by calling up the error number.
between erroneous functions which can be diagnosed
(Section 5.1) and those which cannot be diagnosed
5.1 Errors which cannot be diagnosed when using AVS and ES 2
Malfunction Possible causes Remedy
Impacts / grating shifts in the • Clutch switch adjusted incorrectly • Immediately find the nearest ZF
transmission specialist workshop
Reverse gear cannot be selected on • Tooth on tooth position • Repeat reverse gear selection
the first attempt
• Air pressure too low • Check air supply
• Reverse gear engaged when vehicle • Bring the vehicle to a standstill,

is rolling turn rotary switch to ”R” again
One or more gears cannot be • Air pressure too low • Check air supply
engaged
• Clutch not fully separating • Find the nearest ZF specialist work-
shop
No feedback pulse on clutch pedal • Air pressure too low • Check air pressure
• Clutch pedal actuated too rapidly • When gearshifting, fully depress and
hold down clutch until feedback pulse
can be felt on clutch pedal
• Clutch release movement impaired • Repair clutch release (grease OPTI-

MOL); leave Teflon-coated bearing
without grease or only slightly grease
• Pulse sensor defective • Visit a specialist workshop

It is possible to continue driving
normally
Engage clutch pedal whenever a new
gear is shown on the display
Gear cannot be engaged using • Air pressure too low • Check air pressure
pneumatic emergency shifting
• Clutch not fully separating • Fully depress clutch pedal while
holding shift
• 3/2 valve defective / incorrectly • Incorrect adjustment / defective
installed
• Gear adjustment not ventilated for • Hold down clutch for at least 5 sec.
long enough while adjusting gear
165
Malfunction Possible causes Remedy
Gear selected in emergency shift • Neutral adjustment not ventilated • Hold down clutch for at least 5 sec.
operation is too high sufficiently (range-change group in “neutral” position
still in “high” position)
Engine cannot be started • Fuse for immobiliser F2 defective • Change fuse
• Gear has been selected in the • Bring transmission into neutral (if
transmission necessary, with external supply of
compressed air)
• Neutral switch (ES2) defective • Check
Engine cannot be started using • Emergency switch not in “N” • Rotate emergency switch to “N”
pneumatic emergency shifting position and start in acc. with Operating
Instructions 6038 758 101 (see
emergency shifting). Note danger
instructions
• Fuse (F1) defective • Change fuse (F1)
Display remains dark once ignition • Fuse (F1) defective • Change fuse (F1)
- ON • Cabling defective
• Display defective • Possible to continue driving, find a
ZF specialist workshop
Gear is not shifted after clutch • Clutch switch distance too large • Check shift distance
actuation although shift (distance should be 2 to 4 mm)
recommendation is on the display
• Clutch switch defective and/or • Find specialist workshop
cabling defective
Not possible to select gear in “D” • “Tip neutral signal” continuously • Establish link between pins 9 and
position active 10 on 12-pin connector of pre-
selector switch as shown
166
EST control unit
STEUERUNG EST
AVS SHIFT SYSTEM
A3
Valve block
VENTILBLOCK
R(ENTLUEFTUNG)
R(Ventilation)
LW8 (12X2) P10
LUFTVERSORGUNG
Vehicle
FAHRZEUG N P12..15
air supply Y8
Y1 Y2 Y3 Y4 Y5 Y6 Y13
S14
Emergency
NOTSCHALTER switch
N 1/5 2/6 3/7 4/8 R GP(L) GV(L)
P11
P21
P20
P18
P16
P22
P17
P19
P31
Central connection R
GP valve
GP-VENTIL
ZENTRAL-
for emergency
ANSCHLUSS
P32
NOTSCHALTUNG
selection
1 GANG 21 LW4(6X1) 21
4 GANG 22 22
1 LW4(6X1)
LW4(6X1) R GANG 23 23
LW4(6X1)
N 24 24 P48
LW4(6X1)
P30
P29
P42
P37
P38
P46
P39
P45
P24
P49
P23
P44
P40
P41
P47
P25/S
P26/L
L/S GP-ZYLINDER
HYDRAULIKLEITUNG
Clutch KUPPLUNG
hydraulic lead GP cylinder
R
N
LUFTVERSORGUNG
Air supply LW 8 2.Gg.
1.Gg. 3.Gg. 4.Gg.
N/R
SCHALTUNG
Selection
Emergency
NOTSCHALTUNGselection SCHALTZYLINDER
Shift cylinder 006 137
R GANG
SCHALTZYLINDER
Shift cylinder SCHALTZYLINDER
Shift cylinder Reverse Gear
1/2(5/6) GANG 3/4(7/8) GANG
1/2 (5/6) Gear 2/4 (7/8) Gear
HYDRAULIC DIAGRAM
167
AVS SHIFT SYSTEM OUTPUT SIGNAL SYSTEM (EMC)
OUTPUT SIGNALS
Item 860 Type: ON
Entry of output signal from EMC-tested speedo
Speedo signal on an EMC-tested speedo – Connection on speed impulse distributor (GIV). If

– Connection on a separate signal output there are not enough free signal outputs on the E-
The Intarder has its own signal output (terminals B7 speedo, a speed impulse distributor (e.g. Kienzle, see
or D3 of the E-speedo e.g. Kienzle, see diag. 11). No diag. 11) must be used. This additional equipment
other equipment may be connected to these signal provides three output signals and is connected to ter-
outputs. minal B7 of the speedo.
Kl.15
term. 15
2
GIV 8 EF 1
INT
GIV
Speed
Geschwindig.-
impulse
impuls-
distributor
verteiler
B7 4
Fa. Kienzle 5
EMC-
EMV- E-Gas
tested
fester
speedo 6
Tacho term.
Kl. 31
31
Fa. Kienzle
KTCO1318
D3 EF 1 AVS
As
AbofSeriennr.
serial no.
702270
PinPolbild
diagram Pinbelegung:
Pin assignment
2:
2:(+)
(+)supply (term. (Kl.
Versorgung 15) 15)
3 2 1 4:
4:Input V impulse
Eingang (B7)(B7)
V-Impuls
6 5 4 5:
5:Output
AusgangV impulse
V-Impuls E-gas
E-Gas
9 7 6: (–) supply (term. 31)
6: (–) Versorgung (Kl. 31)
8
8: Output V impulse Intarder
8: Ausgang V-Impuls Intarder
GIV
For connection of speed impulse distributor (GIV), see item 860
Counterpieces for vehicle circuit plug and connection

plug on display
• 22-pin connector: • Plug 53

AMP junior power timer connector AMP mounting housing no. 350 780-1
Order no.: 6029 199 025 ZF no.: 0659 055 324
AMP contact pin no.: 926 898-1
• 4-pin connector AMP mate N-lok bush ZF no.: 0659 055 295
ZF no.: 6029 199 008
1 – –
2 Yellow shift output 200mA max. inductive load
3 Black lighting: variable, 0V to + vehicle circuit (term. 58)
4 Green lighting: ON
168
170
STECKERANSICHT:
CONNECTOR DIAGRAM SHOWN:
Pin diagram
POLBILD Pin diagram
POLBILD Pin diagram
POLBILD Pin diagram
POLBILD Pin diagram
POLBILD Pin diagram
POLBILD CADEX SORTED FROM-TO LIST VERBINDUNGSLISTE
X1
X1 X3
X3 X2
X2 X7
X7 X6
X8 X10
X10 STECK VON POS NACH STECK VON POS NACH
POS POS PIN WIRE POS PIN POS POS PIN WIRE POS PIN
WIRING DIAGRAM
19 X13 1 740 X21

55 37 X 4 A 400 X 1 42 162
A M L 114
18 10 7 4 1
54 36 X 4 B 404 X 1 39 X13 2 744 X26
17 1 2 B N U K 11 8 5 2
53 35 3 2 X 4 C 408 X 1 4 X13 3 748 X22
16 4 3 2 1
52 34 C P V T J 12 9 6 3 X 4 D 412 X 1 22 X 3 1 756 X 1 25
15 1 122
51 33 X 4 E 416 X 1 3 X 3 2 760 X 1 24
14 D R S H
50 32 X 4 F 420 X 1 45 X 3 3 764 X 1 18
13
49 31 E F G
12 X 4 G 424 X 1 44 X 9 1 800 X24
48 30 154
11 X 4 H 428 X 1 1 X 9 2 804 X23
47 28
10 CANNON
CANNON
CANNON ROUND
RUNDSTECKER
CONNECTOR
STECKER
AMP MATE N-LOK
AMP MATE-N-LOK
X 4 J 436 X20 X 9 3 808 X 1 47
46 28 CANNON
9 4-POL.SS
4-PIN SS 19-PIN 2-POL.K27
CONNECTOR 3-POL
3-PIN 12-PIN
12-POL. X 2 A 440 X32 X 9 4 812 X37
45 27 19-POLSS
8 BUCHSE BUCHSE 118
BUCHSE BUCHSE X 2 B 444 X24 X 9 6 820 X 1 29
44 26 BUSH BUSH BUSH BUSH
7 STECKERGEHAEUSE X 2 C 450 X 1 33
43 25 X 9 7 824 X 1 32
6 PLUG HOUSING
42 24 X 2 D 454 X36 X 9 8 828 X26
5
41 23 X 2 E 460 X 1 15 X 9 9 832 X25
4
40 22 Pin diagram
POLBILD diagram
PinPOLBILD Pin diagram
POLBILD diagram
PinPOLBILD Pin diagram
POLBILD X 2 F 464 X36 X 9 10 836 X30
3
39 21 X11
X11 X4X4 X5
X5 X12
X12 X13 X13 X 2 G 470 X30 X 9 11 840 X 1 48
2
38 20 X 2 H 474 X39
1 X 9 12 844 X 1 49
X 2 J 480 X 1 14 X 9 13 848 X 1 13
AMP
AMP X 2 K 484 X 1 36
4 1 1 1 X 9 14 852 X22
55-POL. A H
55-PIN
BUCHSE B I G X 9 15 856 X20
5 2 2 2
BUSH X 9 16 860 X 1 43
C J F 6 3 3 3
D E X 9 17 864 X 1 17
4
X 9 18 868 X 1 55
1 2
X 9 19 872 X39
X 9 20 876 X 1 50
CONNECTOR
STECKER CANNON AMP
AMPMATE N-LOK
MATE-N-LOK AMP MATE N-LOK
AMP MATE-N-LOK AMP MATE N-LOK
AMPMATE-N-LOK X10 1 540 X32
2-POL. CANNON 6-POL. 4-POL. 3-POL. 126
MINI-TIMER
MINI-TIMER2-PIN 10-PIN VG 6-PIN 4-PIN 3-PIN X10 2 544 X23
BUCHSE 10-POL.VG BUCHSE STIFT STIFT
BUSH BUSH BUSH PIN PIN X10 3 548 X 1 27
BUCHSE STECKERGEHAEUSE AUFNAHMEGEHAEUSE AUFNAHMEGEHAEUSE
X10 4 552 X 1 10 110 X36 900 X 1 2
PLUG HOUSING MOUNTING HOUSING MOUNTING HOUSING
X10 5 556 X 1 28 X26 904 X 1 8
X10 6 560 X 1 9 X20 908 X 1 19

POLBILD
Pin diagram X10 7 564 X 1 46 X21 912 X 1 20
X9
X9 X10 9 572 X 1 16 X22 916 X 1 37
X10 10 576 X21 X37 920 X 1 52
X10 12 584 X22 X32 924 X 1 51

2 4 6 8 10 12 14 16 18 20 22 X 5 1 600 X25
130
ANSCHLUSSPLAN X 5 2 604 X30
6029 700 714 X 5 3 608 X36

1 3 5 7 9 11 13 15 17 19 21 X 5 4 612 X21
X 5 5 616 X23
X 6 1 630 X30
134
AMP JUN.POWER TIMER AUSFUEHRUNG: AVS BUS X 6 2 634 X37
AMP JUN.POWER TIMER
VERSION X 6 3 638 X20
22-PIN
22-POL BUSH
BUCHSE
X 7 1 650 X 1 11
STROMLAUFPLAN : 6029 700 423 138
X 7 2 654 X20
WIRING DIAGRAM 146 X11 1 710 X 1 30
X11 2 714 X20

-MIT GETRIEBEZENTRALANSCHLUSS(GZA) X12 1 720 X 1 31
150
-WITH TRANSMISSION CABLE CONNECTION
X12 3 728 X22
-OHNE SIGNALVERSTAERKER X12 4 732 X25

-WITOUT SIGNAL BOOSTER
-MIT LASTGEBER
-WITH LOAD SENSOR
006 595
(+)BN
KL.15
F1 F2
AUS
GANG
NEUTRAL
3/4
1
1/2
5
S14 S20 2
A7 A5
1 DIAGNOSE 1 S9 4 DISPLAY
(+) VP 86
1 1 1 1 1
1
1
K SD1
K20 85
S12 2 S11 2 S7 2 S4 2 S17 2
S22 2
K (-) VM
2 3 2 3 3
B1
1 14 51 33 15 2 20 8 17 48 29 52
EF2 ED1 ED2 ED3 VP1 VP2 SDD ED8 ED9 ED10 ED4
2
36 31
VMG2 SD1
10 A2 1 A3
VP1 ED1 3 27 ED16 42 A
AD1 AD3 Y1
4 10 ED12 39 B
AD2 AD4 Y2
5 28 ED13 4 C
AD3 AD5 Y3
6 9 ED14 22 D
AD4 AD6 Y4
7 46 ED15 3 E
AD5 AD7 Y5
9 16 ED6 45 F
AD7 AD1 Y6
AD6 VM1 44 G
AD2 Y13
2 12 A1 1 H
* A13 AD8 Y8 (-)
1 25 AU J
86 2 24 EU1
3 18 VMG1
K1 85
#
*
A13 ENFAELLT BEI
A11 A12
ABTRIEBSGEBER 8 E-GAS/EDC(A10)
1 4 WITHOUT A13
A1 EF AT E-GAS/EDC(A10)
3 5 1 43
U- VMG AF1 EF1
AD14 AD13 AD9 VM1 VM2 SD3 AD12 SD2 AD10
4 6 EF1
30 11 49 37 19 32 55 13 50
U+ AU
# ABTRIEBSGEBER UND SIGNALVERSTAERKER

# A11 1 1 1 1 1
ENTFALLEN BEI EMV-FESTEM TACHO 86
E-TACHO
->ABTRIEBSSIGNAL VOM E-TACHO
D3
(ZF-STROMLAUFPLAN:6029 700 660)
Y9 2 Y10 2 Y11 2 S21 2 H2 2
K3 85
WITHOUT OUT.SPEED SENSOR AND SIGNALBOOSTER
AT EL.MAGN.SHIELDING SPEEDOMETER A10
->OUTPUT SPEED SIGNAL BY SPEEDOMETER
(ZF-WIRING DIAGRAM:6029 700 660)
(-)BN
KL.31
POS LEGENDE (* :OPTION)
VEKABELUNG MIT GETR.ZENTR.ANSCHLUSS VEHICLE WIRING ZENTRALVERKABELUNG TRANSMISSION WIRING
A1 ELEKTR.STEUERGERAET EST 14 EL.CONTROL UNIT EST 14 A11 DREHZAHLSIGNAL ABTRIEB OUPUT SPEED SIGNAL
A2 VORWAEHLSCHALTER PRE-SELECTOR SWITCH (ABTRIEBSGEBER BZW. E-TACHO) (OUTPUT SPEED SENSOR
A3 VENTILBLOCK VALVE BLOCK OR SPEEDOMETER)
A5 DISPLAY DISPLAY B1 DREHZAHLGEBER ANTRIEB INPUT SPEED SENSOR
A7 DIAGNOSE DIAGNOSTIC S7 SCHALTER GP GESCHALTET RANGE GROUP SWITCH
A10 E-GAS/EDC (*)E-GAS/EDC S11 SCHALTER GANG EINGELEGT GEAR ENGAGED SWITCH
A12 SIGNALVERSTAERKER SIGNAL-BOOSTER S12 SCHALTER GETRIEBE NEUTRAL NEUTRAL POSITION SWITCH
A13 LASTGEBER LOAD SENSOR S20 SCHALTER RUECKF.SCHEINWERFER (*)REVERSING LIGHT SWITCH
F1 SICHERUNG 8A FUSE 8A
F2 SICHERUNG 8A FUSE 8A
K1 RELAIS-ANLASSSPERRE RELAY STARTER INTERLOCK
K3 RELAIS-MOTORSTOP (*)RELAY ENGINESTOP
K20 RUECKFAHRSCHEINWERFER RELAIS (*)REVERSING LIGHT RELAY
S4 SCHALTER MOTORBREMSE (*)EXHAUST BRAKE SWITCH
S9 KUPPLUNGSSCHALTER CLUTCH RELEASE SWITCH
S14 NOTSCHALTER EMEREGENCY SWITCH
S17 BREMSE 2 (*)BRAKE 2
S21 SCHALTER DIAGN. L-SIGNAL (*)DIAGN. L-SIGNAL SWITCH
S22 SCHALTER ERSATZFAHRPROGR. ALTERNATIVE-PROGRAM SWITCH
Y9 VENTIL KUPPLUNG-HALTEN CLUTCH RETAINER VALVE
Y10 DRUCKGEBER GANG-GESCHALTET GEAR ENGAGED SIGNAL
Y11 VENTIL MOTORBREMSE EXHAUST-BRAKE VALVE
H2 LAMPE ERSATZFAHRPROGRAMM EIN LAMP ALTERNATIVE-PROGRAM ON
006 136
AVS SHIFT SYSTEM
AVS SHIFT SYSTEM WIRING DIAGRAM
A1
A7 A2 A3/a
740 540
1 (+) 1 AS 400
744 544 A Y1
2 K 2 AS 404
748 548 B Y2
428 3 (-) 3 AD1 408
AD8 1 552 C Y3
900 4 AD2 412
VP1 2 556 D Y4
416 DIAGNOSE 5 AD3 416
AD7 3 560 E Y5
408 X13 6 AD4 420
AD5 4 564 F Y6
7 AD5 424
5 G Y13
8 428
6 572 H Y8
9 AD7
7 576 I
904 L14 10 VP 436
SDD 8 J (-)
560 11
ED14 9 584
552 12 VM
ED12 10
650
AD13 11 L4 X 4
12
L6
848 X10
SD2 13
EF2 14
480
S14 POS LEGENDE (*): OPTION
460
ED3 15 A1 ELEKTR.STEUERGERAET EST 14 EL.CONTROL UNIT EST 14
572 600
ED6 16 1 A2 VORWAEHLSCHALTER PRE-SELECTOR SWITCH
864 604 A3/b A3/a VENTILBLOCK VALVE BLOCK
ED8 17 2
764 608
VMG1 18 3 A3/b TRENNSTELLE ZENTR.VERK. INTERFACE TRANSM.CABLE CONN.
908 612
VM2 19 4 A5 DISPLAY DISPLAY
912 616
VP2 20 5 A7 DIAGNOSE DIAGNOSTIC
21 L7 6 440 A10 E-GAS/EDC (*) E-GAS/EDC
412 A GN
AD6 22 444 A11 DREHZAHLSIGNAL ABTRIEB SPEED SIGNAL OUTPUT
B GN
23 450 A13 LASTGEBER LOAD SENSOR
760 C GE
EU1 24 X 5 454 F1 SICHERUNG 8A FUSE 8A
756 D GE
AU 25 460 F2 SICHERUNG 8A FUSE 8A
E GP
26 464 K1 RELAIS-ANLASSSPERRE RELAY STARTER INTERLOCK
548 F GP
ED16 27 L1 KN1 L2 KN2 L3 470 K20 RELAIS RUECKF.SCHEINW. (*) RELAY REVERSING LIGHT
556 G RF
ED13 28 474 H2 LAMPE ERSATZFAHRPROGRAMM EIN LAMP ALTERNATIVE PROGRAM ON
820 H RF
ED10 29 480 S4 SCHALTER MOTORBREMSE EXHAUST BRAKE SWITCH
710 J N-AN
AD14 30 484 S9 KUPPLUNGSSCHALTER CLUTCH RELEASE SWITCH
720 L8 S9 K N-AN
S14 NOTSCHALTER EMEREGENCY SWITCH
SD1 31
824 L
SD3 32 S16 SCHALTER KICK DOWN (*) KICK DOWN SWITCH
450 630 M
ED2 33 1 S17 SCHALTER BREMSE 2 (*) BRAKE 2 SWITCH
634 N
34 2 S21 SCHALTER DIAGNOSE L-SIGNAL (*) DIAGNOSTIC L-SIGNAL SWITCH
638 P
35 3 s S22 SCHALTER ERSATZFAHRPROGR. ALTERNATIVE PROGRAM SWITCH
484 L9 R
VMG2 36 Y9 VENTIL KUPPLUNG-HALTEN CLUTCH RETAINER VALVE
916 S
VM1 37 Y10 DRUCKGEBER GANG-GESCHALTET GEAR ENGAGED SIGNAL
T
38 X 6 Y11 VENTIL MOTORBREMSE EXHAUST BRAKE VALVE
404 U
AD4 39 K3 RELAIS MOTORSTOP (*) RELAY MOTORSTOP
V
40 L11 Y10
41
650
L5
400
AD3 42 1 OFFENE STECKERSYSTEME IM
860 654 X 2
EF1 43 2 TROCKENRAUM UNTERBRINGEN
424
AD2 44
420 L12 UNSEALED CONNECTORS TO BE
AD1 45
564 ARRANGED IN DRY AREA
ED15 46 X 7
808
ED1 47
840
ED9 48 Y9
844
AD9 49 710
876 1
AD10 50 714
2 A13
924
ED1 51
920 756
ED4 52 1
760
53 2
X11 764
54 3
868
AD12 55 A5 4
470
720
604 1 SD1 1
X 1 630 2 AD1 2 X 3
X30 728
3 VM ED1 3
(+)VP1 732
836 4 VP ED2 4
908 VP2
436
DISPLAY
638
L13 X12
654
X20
(-)VM1 924
714
VM2 440
856
540
X32
ED1
912
576
612
X21 F1
740
VP2 + BN
916 ANSCHLUSSPLAN
584 BORDNETZ 1
X22
728
748
F2 S17 S4 S22 VEHICLE CIRCUIT 1 6029 700 714
VM1
852
900
544 800
454 1 (+)ANL.-SPERRE/START.INTERLOCK 1
616 804
X23 804
464 X36 808
2 ANL.SPERRE/STARTER INTERLOCK 2
AUSFUEHRUNG: AVS BUS
AS 608 VP1 3 3
812
4 KUPPL.SIGNAL/CLUTCH SIGNAL 4 VERSION
920 5 5
820
634 6 BREMSE 2/BRAKE 2 6
444
812
X37 824
7 DIAGNOSE/DIAGNOSTIC L-SIGNAL 7
X24 800 ED4 828
(+)AS 832
8 DIAGNOSE/DIAGNOSTIC K-SIGNAL 8 STROMLAUFPLAN : 6029 700 423
9 (+) VP1,VP2 9
836
10 (+) VP1,VP2 10 WIRING DIAGRAM
600 840
11 MOTORBREMSE/EXH.BRAKE 11
732 844
X25 832 848
12 MOTORBREMSE/EXH.BRAKE 12
(+)VP1,VP2 13 E-GAS/EDC 13
474 852
14 (-) VM1,VM2 14
904
872 X39 856
15 (-) VM1,VM2 15
-MIT GETRIEBEZENTRALANSCHLUSS(GZA)
RF 860
744 16 EINGANG EF1/INPUT EF1 16 -WITH TRANSMISSION CABLE INTERFACE
X26 828
864
17 ERS.F.PROG./IN.ALTERN.PRG. 17
K-SIGNAL 868
18 AUS.E.F.PROG./OUT.ALTERN.PRG 18
872
19 R.SCHEINW.REL./REV.LIGHT REL. 19 A11 -OHNE SIGNALVERSTAERKER
876
20 MOTORSTOP 20 86 86 Y11 S21 K1 86 -WITOUT SIGNAL BOOSTER
21 21
22 22 A10
85 85 85
-MIT LASTGEBER
K3 K20 H2
-WITH LOAD SENSOR
X 9
- BN
006 594
171
CENTRAL WIRING: 6029 700 586 AVS SHIFT SYSTEM
011 486
Explanation of diagram
192 Connection point for central wiring ..............A 3/ b

200 ”Input speed” elect. pulse sensor ..................... B 1
205 ”Range-change group shifted”
display switch ................................................... S 7
210 ”Gear engaged” display switch ...................... S 11
215 ”Output speed” electronic
pulse sensor .................................................... A 11
220*”R gear engaged” display switch .....................S 20
230 ”Transmission neutral” display switch ........... S 12
* Option, only on customer request
172

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Diagnosis, System Reaction,

This documentation is protected by copyright. Any reproduction and dissemination in whatever

6038 754 109a

This document deals with the software generation 3.3

and with Backup Drive Program (EFP) from electronic

1 Modification Sheet ................................................................................................................................. 5

2 Overview of diagnosis system ................................................................................................................ 11

3 Error diagnosis ....................................................................................................................................... 22

4 Test instructions ......................................................................................................................................120

Central wiring ...........................................................................................................................................167

Date Section Description

This manual is intended for skilled personnel who have

This manual deals with a standard ZF product in

However due to continuing development of the product,

Service points equipped by ZF Friedrichshafen AG all

2. Specified equipment, e.g. special tools

3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried out

The repair work carried out at ZF service points is

Damage resulting from work performed by non-ZF per-

1.2 Brief Description 1.3.3 For safety

Ÿ The driver can keep both hands on the steering wheel.

1.4 Terminology and Abbreviations Interruption/short circuit to positive:

1.5 AVS System Diagram 177 Diagnostics connection

1.6 Description and function of main system Load sensor (180):

Clutch retaining solenoid valve (189): Emergency control knob (188):

Shift valve for range-change group (28):

OUTPUT INPUT Shift sequence Electronic

Short circuit Short circuit Gradient Interruption Speed RAM Over-

Interruption Interruption Speed Load sensor

2.1 Requirements of a diagnosis-capable system

◆ Continuous monitoring of the electronic control unit

◆ Permanent error memory (EEprom) and memo-

◆ Display of diagnosis data

◆ Unambiguous error classification

◆ Storage and display of equipment-specific data or

◆ Possibility of testing the equipment using special test

◆ Microcomputer with standardized serial interface

2.2 Test set-up using terminal tester

2.2.1 Set-up components

10 Pinning option for PR 87 and film

2.2.2 Terminal tester 2.2.3.2 Hardware configuration

The most important characteristics are:

2.2.3.1 System identification

1. 6009033XXX.. = Parts list no. of electronic

◆ Lead K and L: SDD

2.2.2.3 Static or dynamic data display

This function enables up to 8 RAM addresses to be dis-

2.2.3.4 Menu structure of MOBiDIG functions

2 –> Delete error memory

3 –> Data display

3 –> HEX-HEX calculator 1/2 1 –> Addition

HEX-HEX calculator 2/2 2 –> Subtraction

5 –> Hex –> Dec

6 –> Dec –> Hex

2.3 Error recognition possibilities Display using a logic table

The load sensor is mechanically linked to the pump-

alpha min. alpha max. Angle,

Error frequency counter: