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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.
Mega 130
1003 and Up
Mega 160
1021 and Up
1001 and Up
2001 and Up
2001 and Up
1001 and Up
Mega 400-V
1001 and Up
Mega 500-V
2001 and Up
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
ADM (1 - 6)
AFP
CAN
LIS (1 and 2)
O.C.
Open Circuit
OP-Mode
OPeration Mode
S.C.
Short Circuit
TCU
VPS (1 and 2)
DISPLAY
Description
a, f
b, c, d, e
left
character
right
character
S
T
O
P
HBOE630L
Figure 1
Preselected Gear
S0607900C
Page 4
an
Meaning of Number
1 Hex
2 Hex
3 Hex
Speed Signal
4 Hex
5 Hex
6 Hex
7 Hex
8 Hex
9 Hex
A Hex
B Hex
C Hex
Logical Fault
D Hex
Power Supply
E Hex
F Hex
General Fault
S0607900C
Page 5
Meaning
1F, 1R
2F, 2R
3F, 3R
Remarks
---------------
4F
5F
6F
LF, LR
F or R, no gear
---------------
F or R flashing
Only 6WG.
---------------
**
*N
1 bar (special
symbol)
---------------
2 bars
---------------
3 bars
---------------
4 bars
---------------
4 bars and 2
arrows
Automatic mode.
---------------
Bars flashing
Fault code
---------------
WS
WR
WE
S0607900C
Page 6
Symbol
PN
Meaning
Direction F or R selected while
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
---------------
S0607900C
Page 7
S0607900C
Page 8
Clutch Pack
Mega 130
4WG-100
Mega 160
4WG-130
Mega 250-V
4WG-190
Mega 300-V
4WG-210
Mega 400-V
4WG-260
Mega 500-V
4WG-310
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
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.)
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.
TCU shifts
transmission to
neutral.
OP-Mode:
transmission shut
down.
Customer specific.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS1
(Function No. 1)
device.
S0607900C
Page 10
Fault
Code
(hex)
18 **
Reaction of the
TCU
Customer specific.
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.
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS1
(Function No. 1)
device.
Customer specific.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS1
(Function No. 1)
device.
Customer specific.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS2
(Function No. 2)
device.
S0607900C
Page 11
Fault
Code
(hex)
1B **
Reaction of the
TCU
Customer specific.
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.
Customer specific.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance of
Solenoid LIS2
(Function No. 2)
device.
No reaction,
TCU uses default
temperature.
OP-Mode: normal.
---------------
Check connectors.
Check temperature
sensor.
S0607900C
Page 12
Fault
Code
(hex)
26
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 connectors.
Check speed sensor.
OP-Mode: substitute
clutch control.
---------------
Check connectors.
Check speed sensor.
Cable / connector is
defective and is contacted to
vehicle ground.
Speed sensor has an
internal defect.
* 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 13
Fault
Code
(hex)
33
Reaction of the
TCU
OP-Mode: substitute
clutch control.
Possible Steps to
Repair
Check cable from
TCU to sensor.
Check connectors.
Remarks
Cable / connector is
defective and has bad
contact.
Speed sensor has an
internal defect.
Sensor gap is incorrect.
34
OP-Mode: substitute
clutch control.
If a failure is existing
at output speed,
Check connectors.
---------------
OP-Mode: substitute
clutch control.
If a failure is existing
at output speed,
Check connectors.
Cable / connector is
defective and is contacted to
vehicle ground.
---------------
OP-Mode: limp
home.
S0607900C
Page 14
Fault
Code
(hex)
36
Reaction of the
TCU
OP-Mode: substitute
clutch control.
If a failure is existing
at output speed,
Check connectors.
Cable / connector is
defective and has bad
contact.
Possible Steps to
Repair
Remarks
OP-Mode: limp
home.
OP-Mode: substitute
clutch control.
---------------
Check connectors.
Check speed sensor.
OP-Mode: substitute
clutch control.
---------------
Check connectors.
Check speed sensor.
Cable / connector is
defective and is contacted to
vehicle ground.
Speed sensor has an
internal defect.
* 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 15
Fault
Code
(hex)
39
Reaction of the
TCU
OP-Mode: substitute
clutch control.
Possible Steps to
Repair
Check cable from
TCU to sensor.
Check connectors.
Remarks
Cable / connector is
defective and has bad
contact.
Speed sensor has an
internal defect.
Sensor gap is incorrect.
3A
OP-Mode: substitute
clutch control.
Check connectors.
---------------
If a failure is existing
at turbine speed,
TCU shifts to neutral.
OP-Mode: limp
home.
OP-Mode: substitute
clutch control.
Check connectors.
Cable / connector is
defective and is contacted to
vehicle ground.
If a failure is existing
at turbine speed,
---------------
S0607900C
Page 16
Fault
Code
(hex)
3C
Reaction of the
TCU
Possible Steps to
Repair
OP-Mode: substitute
clutch control.
Check connectors.
Cable / connector is
defective and has bad
contact.
Speed sensor has an
internal defect.
If a failure is existing
at turbine speed,
Remarks
OP-Mode: substitute
clutch control.
If a failure is existing
at turbine speed,
OP-Mode: limp
home.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
S0607900C
Page 17
Fault
Code
(hex)
72
OP-Mode: limp
home.
Cable / connector is
defective and has contact to
vehicle ground.
Regulator has an internal
defect.
73
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
OP-Mode: limp
home.
Cable / connector is
defective and has no contact
to TCU.
If failure at another
clutch is pending.
Reaction of the
TCU
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.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
OP-Mode: limp
home.
Cable / connector is
defective and has contact to
vehicle ground.
Regulator has an internal
defect.
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
S0607900C
Page 18
Fault
Code
(hex)
76
OP-Mode: limp
home.
Cable / connector is
defective and has no contact
to TCU.
If failure at another
clutch is pending.
Reaction of the
TCU
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.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
OP-Mode: limp
home.
Cable / connector is
defective and has contact to
vehicle ground.
Regulator has an internal
defect.
79
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
OP-Mode: limp
home.
Cable / connector is
defective and has no contact
to TCU.
If failure at another
clutch is pending.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
S0607900C
Page 19
Fault
Code
(hex)
7D
Reaction of the
TCU
Engine derating will
be on until TCU
power down even if
fault vanishes (loose
connection).
OP-Mode: normal.
No reaction.
OP-Mode: normal.
Cable / connector is
defective and is contacted to
battery voltage.
Check connectors
from engine derating
device to TCU.
Remarks
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35. (Only Mega
500-V)
Check connectors
from backup alarm
device to TCU.
7F
Check resistance 1)
of engine derating
device.
Possible Steps to
Repair
Check resistance 1)
of backup alarm
device.
No reaction.
OP-Mode: normal.
Check resistance 1)
of engine derating
device.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35. (Only Mega
500-V)
Connector has no
connection to TCU.
81
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
S0607900C
Page 20
Fault
Code
(hex)
82
OP-Mode: limp
home.
Cable / connector is
defective and has contact to
vehicle ground.
Regulator has an internal
defect.
83
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
OP-Mode: limp
home.
Cable / connector is
defective and has no contact
to TCU.
If failure at another
clutch is pending.
Reaction of the
TCU
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.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Cable / connector is
defective and has contact to
another regulator output of
TCU.
Regulator has an internal
defect.
85
OP-Mode: limp
home.
Cable / connector is
defective and has contact to
vehicle ground.
Regulator has an internal
defect.
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
S0607900C
Page 21
Fault
Code
(hex)
86
OP-Mode: limp
home.
Cable / connector is
defective and has no contact
to TCU.
If failure at another
clutch is pending.
Reaction of the
TCU
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.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Cable / connector is
defective and has contact to
another regulator output of
TCU.
Regulator has an internal
defect.
88
OP-Mode: limp
home.
Cable / connector is
defective and has contact to
vehicle ground.
Regulator has an internal
defect.
89
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
OP-Mode: limp
home.
Cable / connector is
defective and has no contact
to TCU.
If failure at another
clutch is pending.
1) See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
S0607900C
Page 22
Fault
Code
(hex)
91 **
Reaction of the
TCU
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.
No reaction.
OP-Mode: normal.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance 1)
of backup alarm
device.
No reaction.
OP-Mode: normal.
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 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 23
Fault
Code
(hex)
94 **
Reaction of the
TCU
No reaction.
OP-Mode: normal.
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.
No reaction.
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.
No reaction.
OP-Mode: normal.
1)
See
Measurement of
Resistance at
Actuator/sensors
and Cable on page
35.
Check resistance 1)
of starter interlock
relay.
No reaction.
OP-Mode: normal.
---------------
S0607900C
Page 24
Fault
Code
(hex)
96 **
Reaction of the
TCU
No reaction.
OP-Mode: normal.
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.
No reaction.
OP-Mode: normal.
Check the
connectors from
valve to TCU.
Cable/connector resistance
and has no contact to TCU.
Slippage at clutch K1.
OP-Mode: limp
home.
If failure at another
clutch is pending.
TCU shifts to neutral.
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
output speed sensor.
Check signal at
internal speed
sensor.
Check signal at
output speed sensor.
Replace clutch.
S0607900C
Page 25
Fault
Code
(hex)
B2
Reaction of the
TCU
OP-Mode: limp
home.
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
Clutch is defective.
TCU shifts to neutral.
OP-Mode: limp
home.
Check main
pressure in system.
Check sensor gap at
internal speed
sensor.
Check sensor gap at
output speed sensor.
Replace clutch.
---------------
Check signal at
output speed sensor.
Check pressure at
clutch K2.
Remarks
Check signal at
internal speed
sensor.
B3
Possible Steps to
Repair
If failure at another
clutch is pending.
TCU shifts to neutral.
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
output speed sensor.
Check signal at
internal speed
sensor.
Check signal at
output speed sensor.
Replace clutch.
S0607900C
Page 26
Fault
Code
(hex)
B4
Reaction of the
TCU
OP-Mode: limp
home.
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
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.
Check signal at
turbine speed
sensor.
Clutch is defective.
Replace clutch.
B5
OP-Mode: limp
home.
If failure at another
clutch is pending.
TCU shifts to neutral.
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.
S0607900C
Page 27
Fault
Code
(hex)
B6
Reaction of the
TCU
OP-Mode: limp
home.
If failure at another
clutch is pending.
TCU shifts to neutral.
OP-Mode: TCU shut
down.
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.
Check signal at
turbine speed
sensor.
Clutch is defective.
Replace clutch.
B7
D1
Overtemp sump.
No reaction.
OP-Mode: normal.
Check temperature
sensor.
D2
D3
---------------
Shift to neutral.
---------------
S0607900C
Page 28
Fault
Code
(hex)
D4
Reaction of the
TCU
Shift to neutral.
Possible Steps to
Repair
Check power supply
battery.
Remarks
---------------
D5
Shift to neutral.
Check fuse.
---------------
Check connectors
from gearbox to
TCU.
Replace TCU.
Shift to neutral.
Check fuse.
---------------
Check connectors
from gearbox to
TCU.
Replace TCU.
S0607900C
Page 29
Fault
Code
(hex)
E3
Reaction of the
TCU
No reaction.
OP-Mode: normal.
Possible Steps to
Repair
Check the cable from
TCU to the display.
Check the
connectors at the
display.
Change display.
Remarks
---------------
No reaction.
OP-Mode: normal.
Check the
connectors at the
display.
Change display.
---------------
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!
Check clutch.
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.
S0607900C
Page 30
Fault
Code
(hex)
F6 **
Reaction of the
TCU
No reaction,
Possible Steps to
Repair
Execute AFP.
Remarks
---------------
OP-Mode: normal.
S0607900C
Page 31
Remarks
11
12
21
22
23
Not used.
24
Not used.
25
26
31
32
33
34
35
36
37
38
39
3A
3B
3C
71
72
73
74
75
76
S0607900C
Page 32
Error Code
Number
Remarks
77
78
79
7A
Not used.
7B
Not used.
7C
Not used
81
82
83
84
85
86
87
88
89
91
92
93
94
95
96
97
98
99
B1
B2
B3
B4
S0607900C
Page 33
Error Code
Number
Remarks
B5
B6
D1
D2
D3
D4
D5
D6
E1
Not used.
E2
Not used.
E3
Not used.
E4
Not used.
E5
F1
F2
Configuration lost.
F3
Application error.
S0607900C
Page 34
G
HBOE640I
Figure 2
CABLE
UBat
open circuit:
R12 R1P R1C R2P R2C
short cut to ground:
P (power supply)
TCU
Actuator /
Sensor
C (chassis)
Gnd
HBOE650I
Figure 3
S0607900C
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S0607900C
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