Transmission Error Codes - Cargadoras

S0607900C
R2
1TRANSMISSION ERROR
CODES (ZF)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TRANSMISSION ERROR CODES (ZF)S0607900C

MODEL
SERIAL NUMBER RANGE
Mega 130
1003 and Up
Mega 160
1021 and Up
Mega 200-V (Tier I & II)
1001 and Up
Mega 250-V (Tier I)
1001 thru 2000
Mega 250-V (Tier II)
2001 and Up
Mega 300-V (Tier I)
1001 thru 2000
2001 and Up
Mega 400-III PLUS
1001 and Up
Mega 400-V
1001 and Up
Mega 500-V
1001 thru 2000
2001 and Up
Copyright 2002 Daewoo

December 2002
Transmission Error Codes (ZF)
S0607900C
Page 1
TABLE OF CONTENTS
Introduction..................................................................................................... 4
Abbreviations.................................................................................................. 4
Display............................................................................................................ 4
Description of Fault Codes ...................................................................... 5
Display During Operation ............................................................................... 6
Definition of Operating Modes........................................................................ 8
Normal .................................................................................................... 8
Substitute Clutch Control ........................................................................ 8
Limp-home .............................................................................................. 8
Transmission shut Down ......................................................................... 8
TCU Shut Down ...................................................................................... 8
Clutch Pack and Solenoid Valve
Cross-reference Table .................................................................................... 9
Table of Fault Codes..................................................................................... 10
Table of Fault Codes - ERGO-Control .......................................................... 32
Measurement of Resistance at Actuator/sensors and Cable ....................... 35
Actuator................................................................................................. 35
Cable..................................................................................................... 35
S0607900C
Page 2
S0607900C
Page 3
INTRODUCTION
The "WG" series of ZF Transmissions use an electronic control system called "ZF-Ergopower."
The Ergo System (for short) allows the transmission to function either in a manual powershift mode, or in a
fully automatic mode.
An LCD display (Figure 1) is in the cab. This display gives the machine operator a continuos status of the
operating condition of the system. It displays normal operational codes, and fault codes.
ABBREVIATIONS
Throughout this section the following abbreviations are used to indicate various conditions.
Abbreviations
ABS
Anti Blocking System
ADM (1 - 6)
Ausgeschaltet Digital Minus

(Switched Off Digital Minus)
AFP
Automatic Filling Parameter

Adjustment
CAN
Controller Area Network
LIS (1 and 2)
Load Isolation System

(Solenoids 1 and 2)
O.C.
Open Circuit
OP-Mode
OPeration Mode
S.C.
Short Circuit
TCU
Transmission Control Unit
VPS (1 and 2)
Variable Power Supply
DISPLAY
If a fault is detected, the display shows a

spanner symbol (g) for a fault. The display
shows the fault code, if the gear selector is in
neutral position.
If more than one fault is detected, each fault
code is shown for about 1 second.
Reference
Letter
Description
a, f
Automatic Range (Upshifting

and Downshifting)
b, c, d, e
left
character
right
character
S
T
O
P
(special symbols a-h)
HBOE630L
Figure 1
Preselected Gear
EST-37 has detected

error and is flashing.
This character will not be

used at the EST-37.
S0607900C
Page 4
an
DESCRIPTION OF FAULT CODES

The first number of the error code is the category that it is grouped into. They are as follows for the first
number.
First Number
Meaning of Number
1 Hex
Digital Input Signal
2 Hex
Analog Input Signal
3 Hex
Speed Signal
4 Hex
CAN Signal Error
5 Hex
CAN Signal Error
6 Hex
CAN Signal Error
7 Hex
Analog Current Output Signal
8 Hex
Analog Current Output Signal
9 Hex
Digital Output Signal
A Hex
Digital Output Signal
B Hex
Transmission Fault, Clutch Error
C Hex
Logical Fault
D Hex
Power Supply
E Hex
High Speed Signal
F Hex
General Fault
S0607900C
Page 5
DISPLAY DURING OPERATION

Symbol
Meaning
1F, 1R
Actual gear and direction.
2F, 2R
Left digit shows actual gear.
3F, 3R
Right digit shows actual direction.
Remarks
---------------
4F
5F
6F
LF, LR
Limp home gear.
F or R, no gear
Clutch Cut Off.
---------------
F or R flashing
Only 6WG.
---------------
Direction F or R selected while

turbine speed is too high.
CAUTION: Gear will engage if
turbine speed drops.
NN
Not neutral, waiting for neutral after

power up or a severe fault.
Go engage a gear, first move shift selector to

neutral position and again to F or R position.
**
Oil temperature too low, no gear

available.
Warm up engine / transmission.
*N
Oil temperature low, only one gear

available.
Warm up engine / transmission.
1 bar (special
symbol)
Manual mode 1. gear.
---------------
2 bars
---------------
3 bars
---------------
4 bars
---------------
4 bars and 2
arrows
Automatic mode.
---------------
Bars flashing
6 WG: converter lockup clutch

open.
Difference of engine and turbine speed above

a certain limit and lockup clutch not activated.
4 WG: Downshift mode active.

Spanner
At least one fault active.
Select neutral to get fault code displayed.
Fault code
See fault code list (See page 10).
---------------
WS
Warning sump temperature.
Changes between actual gear/direction while

driving, in neutral only displayed if no fault is
detected (spanner).
WR
Warning retarder temperature.

detected (spanner).
WE
Warning high engine speed.

detected (spanner).
S0607900C
Page 6
Symbol
PN
Meaning
parking brake engaged.
Remarks
Transmission in neutral until parking brake is
released.
CAUTION: Vehicle starts to move after
release of parking brake.
F or R flashing

turbine speed is to high.
---------------
CAUTION: Gear will engage if

turbine speed drops.
EE flashing
No communication with display.
Checked wiring from TCU to display.
S0607900C
Page 7
DEFINITION OF OPERATING MODES

NORMAL
There is no failure detected in transmission system or failure has no or slight effects on transmission
control. TCU will work without or in special cases with little limitations. (See Table of Fault Codes on page
10.)
SUBSTITUTE CLUTCH CONTROL
TCU cannot change gears or direction under control of normal clutch modulation. TCU uses substitute
strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25.)
LIMP-HOME
The detected failure in the system has strong limitations to transmission control. TCU can engage only one
gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift
the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into
forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear
and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected
direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has
to slow down the vehicle and must shift the gear selector into neutral position.
TRANSMISSION SHUT DOWN
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use
ADM 1 to ADM 6.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU SHUT DOWN
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake
will engage, also all functions are disabled which use ADM 1 to ADM 6.
The transmission will stay in neutral.
NOTE:
S0607900C
Page 8
VPS2: is the LIS (option power supply).
CLUTCH PACK AND SOLENOID VALVE

CROSS-REFERENCE TABLE
Throughout the fault codes, references are made to various clutch packs within the transmission. These
clutch pack references are indicated as K1, K2, etc.
Clutch pack charge pressure is controlled by proportional valves that contain a solenoid valve.
The following chart identifies which solenoid valve corresponds to each clutch pack.
Clutch Pack
Mega 130
4WG-100
Mega 160
4WG-130
Mega 250-V
4WG-190
Mega 300-V
4WG-210
Mega 400-III PLUS

4WG-260
Mega 400-V
4WG-260
Mega 500-V
4WG-310
Solenoid Valve (Proportioning Valve) Number
K1
Y3
Y3
Y3
Y3
Y3
Y3
Y3
K2
Y6
Y6
Y6
Y6
Y6
Y6
Y6
K3
Y4
Y4
Y4
Y4
Y4
Y4
Y4
K4
Y1
Y1
Y1
Y1
Y2
Y2
Y2
KR
Y2
Y2
Y2
Y2
Y1
Y1
Y1
KV
Y5
Y5
Y5
Y5
Y5
Y5
Y5
S0607900C
Page 9
TABLE OF FAULT CODES

The fault codes shown in this table are a complete list of codes that are common to more than one version
of the transmission. Some of the versions are 4WG (four speed) and 6WG (six speed).
NOTE:
Fault
Code
(hex)
11
This fault code list is valid for the ZF Software Versions V 53.x to V58.0
Meaning of the Fault Code
(Possible reason for fault
detection.)
Logical error at gear range

signal.
TCU detected a wrong signal
combination for gear range.
Cable from shift lever to TCU
is broken.
Reaction of the
TCU
TCU shifts
transmission to
neutral.
OP-Mode:
transmission shut
down.
Possible Steps to
Repair
Check cables from
TCU to shift lever.
Check signal
combinations of shift
lever positions for
gear range.
Remarks
Failure cannot be
detected in systems
with DW2/DW3 shift
lever.
Fault is taken back if
TCU detects a valid
signal for position.
Cable is defective and is

contacted to battery voltage or
vehicle ground.
Shift lever is defective.
12
Logical error at direction

select signal.
TCU detected a wrong signal
combination for direction.
Cable from shift lever to TCU
is broken.
TCU shifts
transmission to
neutral.
OP-Mode:
transmission shut
down.
Check cables from

TCU to shift lever.
Check signal
combinations of shift
lever positions
F-N-R.
Fault is taken back if

TCU detects a valid
signal for direction at
shift lever.

contacted to battery voltage or
vehicle ground.
Shift lever is defective.
17 **
S.C. to ground at Solenoid

LIS1 (Function No. 1).
TCU detected a wrong
voltage at output pin, that
looks like a S.C. to vehicle
ground.
contacted to vehicle ground.
Solenoid LIS1 (Function No.
1) device has an internal
defect.
Customer specific.
Check cable from

TCU to Solenoid
LIS1 (Function No.
1) device.
Check connectors
from Solenoid LIS1
(Function No. 1) to
TCU.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS1
(Function No. 1)
device.
Connector pin is contacted

to vehicle ground.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.
S0607900C
Page 10
Fault
Code
(hex)
18 **

detection.)
S.C. to battery voltage at
1).
Reaction of the
TCU
Customer specific.

looks like a S.C. to battery
voltage.
Possible Steps to
Repair
Check cable from
TCU to Solenoid
LIS1 (Function No.
1) device.
Check connectors
from Solenoid LIS1
(Function No. 1) to
TCU.

contacted to battery voltage.
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS1
(Function No. 1)
device.

defect.
to battery voltage.
19 **
O.C. at Solenoid LIS1

(Function No. 1).
Customer specific.

looks like a O.C. for this output
pin.
Check cable from

TCU to Solenoid
LIS1 (Function No.
1) device.
Check connectors
from Solenoid LIS1
(Function No. 1)
device to TCU.
Cable is defective and has

no connection to TCU.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS1
(Function No. 1)
device.

defect.
Connector has no
connection to TCU.
1A **
S.C. to ground at Solenoid

LIS2 (Function No. 2).
ground.
defect.
Customer specific.
Check cable from

TCU to Solenoid
LIS2 (Function No.
2) device.
Check connectors
from Solenoid LIS2
(Function No. 2)
device to TCU.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS2
(Function No. 2)
device.

to vehicle ground.
** Only Series "V"
S0607900C
Page 11
Fault
Code
(hex)
1B **

detection.)
2).
Reaction of the
TCU
Customer specific.

voltage.
Possible Steps to
Repair
Check cable from
TCU to Solenoid
LIS2 (Function No.
2) device.
Check connectors
from Solenoid LIS2
(Function No. 2)
device to TCU.

Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS2
(Function No. 2)
device.

defect.
to battery voltage.
1C **
O.C. at Solenoid LIS2

(Function No. 2).
Customer specific.

pin.
Check cable from

TCU to Solenoid
LIS2 (Function No.
2) device.
Check connectors
from Solenoid LIS2
(Function No. 2)
device to TCU.

1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS2
(Function No. 2)
device.

defect.
Connector has no
connection to TCU.
25
S.C. to battery voltage or O.C.

at transmission sump
temperature sensor input.
The measured voltage is too
high:
No reaction,
TCU uses default
temperature.
OP-Mode: normal.
Check cable from

TCU to sensor.
---------------
Check connectors.
Check temperature
sensor.

Cable has no connection to
TCU.
Temperature sensor has an
internal defect.
to battery voltage or is broken.
** Only Series "V"
S0607900C
Page 12
Fault
Code
(hex)
26

detection.)
S.C. to ground at transmission
sump temperature sensor
input.
The measured voltage is too
low:
Reaction of the
TCU
No reaction,
TCU uses default
temperature.
Possible Steps to
Repair
Check cable from
TCU to sensor.
Remarks
---------------
Check connectors.
OP-Mode: normal.
Check temperature
sensor.
OP-Mode: substitute
clutch control.
Check cable from

TCU to sensor.

Temperature sensor has an
internal defect.
to vehicle ground.
31

at engine speed input.
TCU measures a voltage
higher than 7.00 V at speed
input pin.
---------------
Check connectors.
Check speed sensor.

TCU.
Speed sensor has an
internal defect.
to battery voltage or has no
contact.
32
S.C. to ground at engine

speed input.
TCU measures a voltage less
than 0.45V at speed input pin.
OP-Mode: substitute
clutch control.
Check cable from

TCU to sensor.
---------------
Check connectors.
Check speed sensor.
Cable / connector is
defective and is contacted to
vehicle ground.
Speed sensor has an
internal defect.
** Only Series "V"
S0607900C
Page 13
Fault
Code
(hex)
33

detection.)
Reaction of the
TCU
Logical error at engine speed

input.
OP-Mode: substitute
clutch control.
TCU measures a engine

speed over a threshold and
the next moment the
measured speed is zero.
Possible Steps to
Repair
Check cable from
TCU to sensor.
Check connectors.
Remarks
This fault is reset

after power up of
TCU.
Check speed sensor.

Check sensor gap.
defective and has bad
contact.
Speed sensor has an
internal defect.
Sensor gap is incorrect.
34

at turbine speed input.
OP-Mode: substitute
clutch control.
Check cable from

TCU to sensor.

input pin.
If a failure is existing
at output speed,
Check connectors.

---------------
Check speed sensor.
TCU shifts to neutral.

OP-Mode: limp
home.

TCU.
Speed sensor has an
internal defect.
contact.
35
S.C. to ground at turbine

speed input.
OP-Mode: substitute
clutch control.
Check cable from

TCU to sensor.

at output speed,
Check connectors.
vehicle ground.
---------------
Check speed sensor.
OP-Mode: limp
home.
Speed sensor has an

internal defect.
** Only Series "V"
S0607900C
Page 14
Fault
Code
(hex)
36

detection.)
Reaction of the
TCU
Logical error at turbine speed

input.
OP-Mode: substitute
clutch control.
Check cable from

TCU to sensor.
TCU measures a turbine

speed over a threshold and at
the next moment the
at output speed,
Check connectors.
contact.
Possible Steps to
Repair
Remarks
This fault is reset

after power up of
TCU.
Check speed sensor.

Check sensor gap.
OP-Mode: limp
home.
Speed sensor has an

internal defect.
37

at internal speed input.
OP-Mode: substitute
clutch control.

input pin.
Check cable from

TCU to sensor.
---------------
Check connectors.
Check speed sensor.

TCU.
Speed sensor has an
internal defect.
contact.
38
S.C. to ground at internal

speed input.
OP-Mode: substitute
clutch control.
Check cable from

TCU to sensor.
---------------
Check connectors.
Check speed sensor.
vehicle ground.
Speed sensor has an
internal defect.
** Only Series "V"
S0607900C
Page 15
Fault
Code
(hex)
39

detection.)
Reaction of the
TCU
Logical error at internal speed

input.
OP-Mode: substitute
clutch control.
TCU measures a internal

the next moment the
Possible Steps to
Repair
Check cable from
TCU to sensor.
Check connectors.
Remarks
This fault is reset

after power up of
TCU.
Check speed sensor.

Check sensor gap.
contact.
Speed sensor has an
internal defect.
3A

at output speed input.
Special mode for

gear selection;
Check cable from

TCU to sensor.

input pin.
OP-Mode: substitute
clutch control.
Check connectors.

TCU.
---------------
Check speed sensor.
at turbine speed,
OP-Mode: limp
home.
Speed sensor has an

internal defect.
contact.
3B
S.C. to ground at output

speed input.
Special mode for

gear selection.
Check cable from

TCU to sensor.

OP-Mode: substitute
clutch control.
Check connectors.
vehicle ground.
at turbine speed,
Speed sensor has an

internal defect.
---------------
Check speed sensor.

OP-Mode: limp
home.

** Only Series "V"
S0607900C
Page 16
Fault
Code
(hex)
3C

detection.)
Reaction of the
TCU
Possible Steps to
Repair
Logical error at output speed

input.
Special mode for

gear selection.
Check cable from

TCU to sensor.
TCU measures a output

the next moment the
OP-Mode: substitute
clutch control.
Check connectors.
contact.
Speed sensor has an
internal defect.
at turbine speed,
Remarks
This fault is reset

after power up of
TCU.
Check speed sensor.

Check sensor gap.

OP-Mode: limp
home.

3E
Output speed zero doesnt fit

to other speed signals.
Special mode for

gear selection.
If transmission is not neutral

and the shifting has finished,
OP-Mode: substitute
clutch control.
TCU measures output speed

zero and turbine speed or
internal speed not equal to
zero.
at turbine speed,
Speed sensor has an

internal defect.
Check sensor signal

of output speed
sensor.
This fault is reset

after power up of
TCU.
Check sensor gap of

output speed sensor.
Check cable from
TCU to sensor.
OP-Mode: limp
home.

71

clutch K1.
The measured resistance
value of valve is out of limit,
voltage at K1 valve is too high.
defective and has contact to
battery voltage.
another regulator output of
TCU.

OP-Mode: limp
home.
If failure at another
clutch is pending.
OP-Mode: TCU shut
down.
Check cable from

TCU to gearbox.
Check connectors
from TCU to
gearbox.
Check regulator
resistance. 1)
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Regulator has an internal

defect.
** Only Series "V"
S0607900C
Page 17
Fault
Code
(hex)
72

detection.)
S.C. to ground at clutch K1.

voltage at K1 valve is too low.
OP-Mode: limp
home.
vehicle ground.
defect.
73
clutch is pending.
OP-Mode: TCU shut
down.
O.C. at clutch K1.

value of valve is out of limit.
OP-Mode: limp
home.
defective and has no contact
to TCU.
clutch is pending.

defect.
74
Reaction of the
TCU

clutch K2.
battery voltage.
TCU.

OP-Mode: TCU shut
down.
OP-Mode: limp
home.
clutch is pending.
OP-Mode: TCU shut
down.
Possible Steps to
Repair
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.

defect.
75

OP-Mode: limp
home.
vehicle ground.
defect.
clutch is pending.
OP-Mode: TCU shut
down.
Check cable from

TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.

** Only Series "V"
S0607900C
Page 18
Fault
Code
(hex)
76

detection.)
O.C. at clutch K2.

OP-Mode: limp
home.
to TCU.
clutch is pending.

defect.
77
Reaction of the
TCU

clutch K3.
battery voltage.
TCU.

OP-Mode: TCU shut
down.
OP-Mode: limp
home.
clutch is pending.
OP-Mode: TCU shut
down.
Possible Steps to
Repair
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.

defect.
78

OP-Mode: limp
home.
vehicle ground.
defect.
79
clutch is pending.
OP-Mode: TCU shut
down.
O.C. at clutch K3.

OP-Mode: limp
home.
to TCU.
clutch is pending.

defect.

OP-Mode: TCU shut
down.
Check cable from

TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.

** Only Series "V"
S0607900C
Page 19
Fault
Code
(hex)
7D

detection.)
S.C. to ground at engine
derating device.
Engine derating device has
an internal defect.
Reaction of the
TCU
Engine derating will
be on until TCU
power down even if
fault vanishes (loose
connection).
OP-Mode: normal.

engine derating device.
No reaction.
OP-Mode: normal.
battery voltage.
O.C. at engine derating

device.
Check connectors
from engine derating
device to TCU.
Check cable from

TCU to engine
derating device.
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35. (Only Mega
500-V)
Only Mega 500-V
Check connectors
from backup alarm
device to TCU.

an internal defect.
7F
Check cable from

TCU to engine
derating device.
Check resistance 1)
of engine derating
device.

to vehicle ground.
7E
Possible Steps to
Repair
Check resistance 1)
of backup alarm
device.
No reaction.
OP-Mode: normal.

pin.
Check cable from

TCU to engine
derating device.
Check connectors
from engine derating
device to TCU.

Check resistance 1)
of engine derating
device.

an internal defect.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35. (Only Mega
500-V)
Connector has no
connection to TCU.
81

clutch K4.
battery voltage.
TCU.

OP-Mode: limp
home.
clutch is pending.
OP-Mode: TCU shut
down.
Check cable from

TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.

defect.
** Only Series "V"
S0607900C
Page 20
Fault
Code
(hex)
82

detection.)

OP-Mode: limp
home.
vehicle ground.
defect.
83
clutch is pending.
OP-Mode: TCU shut
down.
O.C. at clutch K4.

OP-Mode: limp
home.
to TCU.
clutch is pending.

defect.
84
Reaction of the
TCU

clutch KV.
voltage at KV valve is too
high.
battery voltage.

OP-Mode: TCU shut
down.
OP-Mode: limp
home.
clutch is pending.
OP-Mode: TCU shut
down.
Possible Steps to
Repair
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
TCU.
defect.
85
S.C. to ground at clutch KV.

voltage at KV valve is too low.
OP-Mode: limp
home.
vehicle ground.
defect.
clutch is pending.
OP-Mode: TCU shut
down.
Check cable from

TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.

** Only Series "V"
S0607900C
Page 21
Fault
Code
(hex)
86

detection.)
O.C. at clutch KV.

OP-Mode: limp
home.
to TCU.
clutch is pending.

defect.
87
Reaction of the
TCU

clutch KR.
voltage at KR valve is too
high.
battery voltage.

OP-Mode: TCU shut
down.
OP-Mode: limp
home.
clutch is pending.
OP-Mode: TCU shut
down.
Possible Steps to
Repair
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
TCU.
defect.
88
S.C. to ground at clutch KR.

voltage at KR valve is too low.
OP-Mode: limp
home.
vehicle ground.
defect.
89
clutch is pending.
OP-Mode: TCU shut
down.
O.C. at clutch KR.

OP-Mode: limp
home.
to TCU.
clutch is pending.

defect.

OP-Mode: TCU shut
down.
Check cable from

TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.
Check cable from
TCU to gearbox.
Check connectors
from gearbox to
TCU.
Check regulator
resistance. 1)
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check internal wire

harness of gearbox.

** Only Series "V"
S0607900C
Page 22
Fault
Code
(hex)
91 **

detection.)
Reaction of the
TCU
S.C. to ground at relay reverse

warning alarm.
Backup alarm will be

on until TCU power
down even if fault
vanishes (loose
connection).

ground.
OP-Mode: normal.

Possible Steps to
Repair
Check cable from
TCU to backup
alarm device.
Check connectors
from backup alarm
device to TCU.
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance 1)
of backup alarm
device.
Backup alarm device has an

internal defect.
to vehicle ground.
92 **
S.C. to battery voltage at relay

reverse warning alarm.
No reaction.
OP-Mode: normal.

voltage.
Check cable from

TCU to backup
alarm device.
Check connectors
from backup alarm
device to TCU.

1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance 1)
of backup alarm
device.

internal defect.
to battery voltage.
93 **
O.C. at relay reverse warning

alarm.
pin.
internal defect.
No reaction.
OP-Mode: normal.
Check cable from

TCU to backup
alarm device.
Check connectors
from backup alarm
device to TCU.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance 1)
of backup alarm
device.
Connector has no
connection to TCU.
** Only Series "V"
S0607900C
Page 23
Fault
Code
(hex)
94 **

detection.)
S.C. to ground at relay starter
interlock.
Reaction of the
TCU
No reaction.
OP-Mode: normal.

ground.
Possible Steps to
Repair
Check cable from
TCU to starter
interlock relay.
Check connectors
from starter interlock
relay to TCU.

Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance 1)
of starter interlock
relay.
Starter interlock relay has an

internal defect.
to vehicle ground.
95 *
O.C. at LIS1 solenoid valve.
No reaction.

value of the valve is out of
limit.
OP-Mode: normal.
Check the
connectors from
valve to TCU.
Cable/connector is defective
and has no contact to TCU.
S.C. to battery voltage at relay
starter interlock.
If fault code 95 and

98 are both being
displayed for about
one second each,
see combined fault
code.
Check the valve

resistance.
Valve has an internal defect.

95 **
Check the cable from

TCU to the valve.
No reaction.
OP-Mode: normal.

voltage.
Check cable from

TCU to starter
interlock relay.
Check connectors
relay to TCU.

1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance 1)
relay.

internal defect.
to battery voltage.
95 *
98 *
Each
fault
code
shown
for about
one
second.
S.C. battery voltage or ground

at LIS1 solenoid valve or LIS2
solenoid valve.
contacted to vehicle ground or
vehicle ground.
No reaction.
OP-Mode: normal.

TCU to the valve.
---------------
Check the connector.

Check the valve.

TCU.
to battery voltage or is broken.
to vehicle ground.

** Only Series "V"
S0607900C
Page 24
Fault
Code
(hex)
96 **

detection.)
Reaction of the
TCU
O.C. at relay starter interlock.
No reaction.

pin.
OP-Mode: normal.
Possible Steps to
Repair
Check cable from
TCU to starter
interlock relay.
Check connectors
relay to TCU.

Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance 1)
relay.

internal defect.
Connector has no
connection to TCU.
98 *
O.C. at LIS2 solenoid valve.
No reaction.

value of the valve is out of
limit.
OP-Mode: normal.
Check the
connectors from
valve to TCU.
Cable/connector resistance
and has no contact to TCU.
Slippage at clutch K1.
TCU calculates a differential

speed at closed clutch K1. If
this calculated value is out of
range, TCU interprets this as
slipping clutch.
OP-Mode: limp
home.
Low pressure at clutch K1.

Low main pressure.
Wrong signal at internal
speed sensor.
Wrong signal at output
speed sensor.
Clutch is defective.
If fault code 95 and

98 are both being
displayed for about
one second each,
see combined fault
code.
Check the valve

resistance.

B1

TCU to the valve.
clutch is pending.
OP-Mode: TCU shut
down.
Check pressure at
clutch K1.
---------------
Check main
pressure in system.
Check sensor gap at
internal speed
sensor.
Check sensor gap at
Check signal at
internal speed
sensor.
Check signal at
Replace clutch.

** Only Series "V"
S0607900C
Page 25
Fault
Code
(hex)
B2

detection.)
Reaction of the
TCU

slipping clutch.
OP-Mode: limp
home.

Low main pressure.
clutch is pending.
OP-Mode: TCU shut
down.

speed sensor.

slipping clutch.
OP-Mode: limp
home.

speed sensor.
speed sensor.
Check main
pressure in system.
Check sensor gap at
internal speed
sensor.
Check sensor gap at
Replace clutch.
Low main pressure.
---------------
Check signal at
Check pressure at
clutch K2.
Remarks
Check signal at
internal speed
sensor.

speed sensor.
B3
Possible Steps to
Repair
clutch is pending.
OP-Mode: TCU shut
down.
Check pressure at
clutch K3.
---------------
Check main
pressure in system.
Check sensor gap at
internal speed
sensor.
Check sensor gap at
Check signal at
internal speed
sensor.
Check signal at
Replace clutch.

** Only Series "V"
S0607900C
Page 26
Fault
Code
(hex)
B4

detection.)
Reaction of the
TCU

slipping clutch.
OP-Mode: limp
home.

Low main pressure.
clutch is pending.
OP-Mode: TCU shut
down.

speed sensor.
Possible Steps to
Repair
Check pressure at
clutch K4.
Remarks
---------------
Check main
pressure in system.
Check sensor gap at
internal speed
sensor.
Check sensor gap at
turbine speed
sensor.
Check signal at
internal speed
sensor.
Wrong signal at turbine

speed sensor.
Check signal at
turbine speed
sensor.
Replace clutch.
B5
Slippage at clutch KV.

speed at closed clutch KV. If
slipping clutch.
OP-Mode: limp
home.
Low pressure at clutch KV.

Low main pressure.
speed sensor.
speed sensor.
clutch is pending.
OP-Mode: TCU shut
down.
Check pressure at
clutch KV.
---------------
Check main
pressure in system.
Check sensor gap at
internal speed
sensor.
Check sensor gap at
turbine speed
sensor.
Check signal at
internal speed
sensor.
Check signal at
turbine speed
sensor.
Replace clutch.

** Only Series "V"
S0607900C
Page 27
Fault
Code
(hex)
B6

detection.)
Reaction of the
TCU
Slippage at clutch KR.

speed at closed clutch KR. If
slipping clutch.
OP-Mode: limp
home.
Low pressure at clutch KR.

Low main pressure.
clutch is pending.
OP-Mode: TCU shut
down.

speed sensor.
Possible Steps to
Repair
Check pressure at
clutch KR.
Remarks
---------------
Check main
pressure in system.
Check sensor gap at
internal speed
sensor.
Check sensor gap at
turbine speed
sensor.
Check signal at
internal speed
sensor.

speed sensor.
Check signal at
turbine speed
sensor.
Replace clutch.
B7
D1
Overtemp sump.
No reaction.
Cool down machine.
TCU measured a temperature

in oil sump that is over
allowed threshold.
OP-Mode: normal.
Check oil level.

power supply for sensors.
See fault codes No.

21 - 2C.
Check temperature
sensor.
TCU measures more than 6V

at the pin AU1 (5V sensor
supply).
D2
S.C. to ground at power

supply for sensors.
Check cables and

connectors to
sensors, which are
supplied from AU1.
Fault codes No. 21 to

No. 2C may be a
reaction of this fault.
Check the power

supply at the pin AU1
(should be
approximately 5V).
See fault codes No.
21 - 2C.
TCU measures less than 4V

at the pin AU1 (5V sensor
supply).
D3
---------------
Check cables and

connectors to
sensors, which are
supplied from AU1.
Fault codes No. 21 to

No. 2C may be a
reaction of this fault.
Check the power

supply at the pin AU1
(should be
approximately 5V).
Low power at battery.
Shift to neutral.
Measured voltage at power

supply is lower than 18 V.
OP-Mode: TCU shut

down.
Check power supply

battery.
---------------
Check cables from

batteries to TCU.
Check connectors
from batteries to
TCU.

** Only Series "V"
S0607900C
Page 28
Fault
Code
(hex)
D4

detection.)
Reaction of the
TCU
High power at battery.
Shift to neutral.
Measured voltage at power

supply is higher than 32 V.
OP-Mode: TCU shut

down.
Possible Steps to
Repair
Check power supply
battery.
Remarks
---------------
Check cables from

batteries to TCU.
Check connectors
from batteries to
TCU.
D5
Error at switch 1 for valve

power supply VPS1.
TCU switched on VPS1 and
measured VPS1 is off or TCU
switched off VPS1 and
measured VPS1 is still on.
Shift to neutral.
Check fuse.
OP-Mode: TCU shut

down.
Check cables from

gearbox to TCU.
---------------
Check connectors
from gearbox to
TCU.
Cable or connectors are

defect and are contacted to
battery voltage.
Replace TCU.

vehicle ground.
Permanent power supply
KL30 missing.
TCU has an internal defect.
D6
Error at switch 2 for valve

power supply VPS2.
TCU switched on VPS2 and
measured VPS2 is off or TCU
switched off VPS2 and
measured VPS2 is still on.
battery voltage.
Shift to neutral.
Check fuse.
OP-Mode: TCU shut

down.
Check cables from

gearbox to TCU.
---------------
Check connectors
from gearbox to
TCU.
Replace TCU.

vehicle ground.
Permanent power supply
KL30 missing.
TCU has an internal defect.
** Only Series "V"
S0607900C
Page 29
Fault
Code
(hex)
E3

detection.)
display output.
Reaction of the
TCU
No reaction.
OP-Mode: normal.
Possible Steps to
Repair
TCU to the display.
TCU sends data to the display

and measures always a high
voltage level on the connector.
Check the
connectors at the
display.

defective and are contacted to
battery voltage.
Change display.
Remarks
---------------
Display has an internal

defect.
E4
S.C. to ground at display

output.
No reaction.
OP-Mode: normal.

TCU to the display.
TCU sends data to the display

and measures always a high
voltage level on the connector.
Check the
connectors at the
display.

defective and are contacted to
vehicle ground.
Change display.
---------------
Display has an internal

defect.
F1
General EEPROM fault.

TCU cannot read nonvolatile
memory.
TCU is defective.
F2
Configuration lost.
TCU has lost the correct
configuration and can't control
the transmission.
Transmission stay
neutral.
Replace TCU.
Often shown
together with fault
code F2.
Reprogram the
correct configuration
for the vehicle (e.g.
with cluster
controller,...).
---------------
Replace TCU!
This fault occurs only

if an test engineer
did something wrong
in the application of
the vehicle.
Check clutch.
TCU shows also the

affected clutch on
the Display.
OP-Mode: TCU shut

down.
Transmission stay
neutral.
OP-Mode: TCU shut
down.
Interference during saving

data on nonvolatile memory.
TCU is brand new or from
another vehicle.
F3
Application error.
Something of this application
is wrong.
F5 **
Clutch failure.
AFP was not able to adjust
clutch filling parameters.
One of the AFP-Values is out
of limit.
Transmission stay
neutral.
OP-Mode: TCU shut
down.
Transmission stay
neutral.
OP-Mode: TCU shut
down.

** Only Series "V"
S0607900C
Page 30
Fault
Code
(hex)
F6 **

detection.)
Reaction of the
TCU
Clutch Adjustment Data lost.
No reaction,
TCU was not able to read

correct clutch adjustment
parameters.
Default values = 0 for

AFP offsets used.
Possible Steps to
Repair
Execute AFP.
Remarks
---------------
OP-Mode: normal.
Interference during saving

data on nonvolatile memory.
TCU is brand new.
** Only Series "V"
S0607900C
Page 31
TABLE OF FAULT CODES - ERGO-CONTROL

Error Code
Number
Meaning of Error Code
Remarks
11
Logical error at gear range signal.
12
Logical error at direction select signal.
21
Short circuit to battery voltage at clutch cutoff input.
22
Short circuit to ground or open circuit at clutch cutoff input.
23
Short circuit to battery voltage at load sensor input.
Not used.
24
Short circuit to ground or open circuit at load sensor input.
Not used.
25
Short circuit to battery voltage or open circuit at temperature sensor

input.
26
Short circuit to ground at temperature sensor input.
31
Short circuit to battery voltage at engine speed input.
32
Short circuit to ground or open circuit at engine speed input.
33
Logical error at engine speed input.
34
Short circuit to battery voltage at turbine speed input.
35
Short circuit to ground or open circuit at turbine speed input.
36
Logical error at turbine speed input.
37
Short circuit to battery voltage at internal speed input.
38
Short circuit to ground or open circuit at internal speed input.
39
Logical error at internal speed input.
3A
Short circuit to battery voltage at output speed input.
3B
Short circuit to ground or open circuit at output speed input.
3C
Logical error at output speed input.
71
Short circuit to battery voltage at clutch K1.
72
Short circuit to ground at clutch K1.
73
Open circuit at clutch K1.
74
75
76
S0607900C
Page 32
Error Code
Number
Remarks
77
78
79
7A
Short circuit to battery voltage at converter clutch.
Not used.
7B
Short circuit to ground at converter clutch.
Not used.
7C
Open circuit at converter clutch.
Not used
81
Short circuit battery voltage at clutch K4.
82
83
84
Short circuit to battery voltage at clutch KV.
85
Short circuit to ground at clutch KV.
86
Open circuit at clutch KV.
87
Short circuit to battery voltage at clutch KR.
88
Short circuit to ground at clutch KR.
89
Open circuit at clutch KR.
91
Short circuit battery voltage at relay reverse warning alarm.
92
Short circuit to ground at relay reverse warning alarm.
93
Open circuit at relay reverse warning alarm.
94
Short circuit to battery voltage at relay starter interlock.
95
Short circuit to ground at relay starter interlock.
96
Open circuit at relay starter interlock.
97
Short circuit to battery voltage at park brake solenoid.
98
Short circuit ground at park brake solenoid.
99
Open circuit at park brake solenoid.
B1
B2
B3
B4
S0607900C
Page 33
Error Code
Number
Remarks
B5
Slippage at clutch KV.
B6
Slippage at clutch KR.
D1
Short circuit to battery voltage at power supply for sensors.
D2
Short circuit to ground at power supply for sensors.
D3
Low power at battery.
D4
High power at battery.
D5
Error at switch 1 for valve power supply.
D6
Error at switch 2 for valve power supply.
E1
Short circuit to battery at speedometer output.
Not used.
E2
Short circuit to ground or open circuit at speedometer output.
Not used.
E3
Short circuit to battery voltage at display output.
Not used.
E4
Short circuit to ground or open circuit at display output.
Not used.
E5
Error at communication on CAN.
F1
General EEPROM fault.
F2
Configuration lost.
F3
Application error.
S0607900C
Page 34
MEASUREMENT OF RESISTANCE AT ACTUATOR/

SENSORS AND CABLE
ACTUATOR
Open circuit:R12 R1G R2G
Short cut to ground:R12 R;R1G 0, R2G R or

R1G R, R2G 0(for S.C. to ground, G is
connected to vehicle ground)
Short cut to battery:R12 R;R1G 0, R2G R or
R1G R, R2G 0(for S.C. to battery, G is
connected to battery voltage.
G
HBOE640I
Figure 2
CABLE
UBat
open circuit:
R12 R1P R1C R2P R2C
short cut to ground:
P (power supply)
TCU
Actuator /
R12 0;R1C R2C 0,R1P R2P
short cut to battery:
Sensor
C (chassis)
R12 0,R1C R2C ,R1P R2P 0
Gnd
HBOE650I
Figure 3
S0607900C
Page 35
S0607900C
Page 36

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S0607900C

TRANSMISSION ERROR CODES (ZF)S0607900C

SERIAL NUMBER RANGE

Mega 200-V (Tier I & II)

Mega 250-V (Tier I)

1001 thru 2000

Mega 250-V (Tier II)

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

Mega 400-III PLUS

1001 thru 2000

Mega 500-V (Tier II)

Copyright 2002 Daewoo

Transmission Error Codes (ZF)

Transmission Error Codes (ZF)

Anti Blocking System

Ausgeschaltet Digital Minus

Automatic Filling Parameter

Controller Area Network

Load Isolation System

Transmission Control Unit

Variable Power Supply

If a fault is detected, the display shows a

Automatic Range (Upshifting

(special symbols a-h)

EST-37 has detected

This character will not be

Transmission Error Codes (ZF)

DESCRIPTION OF FAULT CODES

Digital Input Signal

Analog Input Signal

CAN Signal Error

CAN Signal Error

CAN Signal Error

Analog Current Output Signal

Analog Current Output Signal

Digital Output Signal

Digital Output Signal

Transmission Fault, Clutch Error

High Speed Signal

Transmission Error Codes (ZF)

DISPLAY DURING OPERATION

Actual gear and direction.

Left digit shows actual gear.

Right digit shows actual direction.

Limp home gear.

Clutch Cut Off.

Direction F or R selected while

Not neutral, waiting for neutral after

Go engage a gear, first move shift selector to

Oil temperature too low, no gear

Warm up engine / transmission.

Oil temperature low, only one gear

Warm up engine / transmission.

Manual mode 1. gear.

Manual mode 2. gear.

Manual mode 3. gear.

Manual mode 4. gear.

6 WG: converter lockup clutch

Difference of engine and turbine speed above

4 WG: Downshift mode active.

At least one fault active.