SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-47
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-58
Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-187
 SECTION 3 POWER TRAIN SYSTEM
GROUP 1 STRUCTURE AND OPERATION
1. POWER TRAIN COMPONENT OVERVIEW

Drive axle Transmission Steering axle

Propeller shaft Torque converter Engine
110D7EPT01

The power train consists of the following components :

ÂTorque converter
ÂTransmission
ÂPropeller shaft
ÂDrive axle
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged three speed forward, three speed reverse power shift type
transmission.
The transmission outputs through universal joints to drive axle assembly.
The power transmitted to front axle drives front wheels.

3-1
ÂH
Hydraulic circuit

KR K1 K3 KV K2

E 55 D 56 C 58 B 53 A 57
P1 F 60 P2 P3 P4 P5 P6
B D B D B D B D B D B D

Y1 NFS Y2 NFS Y3 Y4 Y5 Y6
NFS NFS NFS NFS

Pressure
Temp reducing
sensor valve
K 65
9 bar
Main pressure
Valve block control circuit valve 16+2.5bar

Converter

Back Filter
pressure
valve Con.
4.3+3 bar safety
valve
11+2 bar By pass valve
5.5 bar
Pump
16+2 bar

Lubrication
Oil sump Main oil circuit

D507PT31

Forward Reverse Positions No. of

Speed Neutral on the measuring
F1 F2 F3 R1 R2 R3 valve block points
Y1 - F 60
Y2 ú ú ú - E 55
Y3 ú ú - D 56
Y4 ú ú - C 58
Y5 ú ú ú - B 53
Y6 ú ú - A 57
Clutch
engaged KV, K1 KV, K2 KV, K3 KR, K1 KR, K2 KR, K3 - - -

NFS Follow-on slide P3 Proportional valve K1

D Vibration damper P4 Proportional valve K3
B Orifice P5 Proportional valve KV
P1 Not used P6 Proportional valve K2
P2 Proportional valve KR Y1~Y6 Pressure regulators

3-2
2. TORQUE CONVERTER

5 1 2 3 4

D503TM01

1 Turbine 3 Pump 5 Input shaft

2 Stator 4 Transmission pump

The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the
characteristics, and with it the favorable efficiency of a fluid clutch.
The converter will be defined according to the engine power so that the most favorable operating
conditions for each installation case are given.
The Torque converter is composed of 3 main components :
Pump wheel - turbine wheel - stator(Reaction member)
These 3 impeller wheels are arranged in such a ring-shape system that the fluid is streaming through the
circuit components in the indicated order.
Pressure oil is constantly streaming out of the transmission pump through the converter. In this way, the
converter can fulfill its task to multiply the torque of the engine, and at the same time, the heat created in
the converter is dissipated through the escaping oil.
The oil, escaping out of the pump wheel, enters the turbine wheel and is there inversed in the direction of
flow.
According to the rate of inversion, the turbine wheel and with it also the output shaft, receive a more or
less high reaction moment. The stator(Reaction member), following the turbine, has the task to inverse
again the oil which is escaping out of the turbine and to delivery it under the suitable discharge direction
to the pump wheel.
Due to the inversion, the stator receives a reaction moment.
The relation turbine moment/pump moment is called torque conversion. This is the higher the greater
the speed difference of pump wheel and turbine wheel will be.
Therefore, the maximum conversion is created at standing turbine wheel.
With increasing output speed, the torque conversion is decreasing. The adoption of the output speed to
a certain required output moment is infinitely variable and automatically achieved by the torque
converter.

3-3
If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the
turbine moment becomes equal to that of the pump moment.
From this point on, the converter is working similar to a fluid clutch.
A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the
conversion range the moment upon the housing, and is released in the coupling range.
In this way, the stator can rotate freely.

Function of a hydrodynamic torque converter(Schematic view)

TP = Torque of the pump wheel

TT = Torque of the turbine wheel
TR = Torque of the reaction member(Stator)

Pump wheel TR

Turbine wheel
From the engine
TT

TP

To the gearbox

Starting
condition 1 Reaction member nT = 0
1.5 2.5
(Stator) Machine stopped

Intermediate
condition 1 <1.5 <2.5 nT < n engine

Condition shortly
before the converter 1 1 nT = 0.8n engine
clutch is closed. 0

Turbine wheel is running with

about the same speed as
pump wheel.

D503TM02

3-4
3. TRANSMISSION
1) LAYOUT

2 4
Gearbox diagram
3

1
KR
8

KV K4

AN/PTO

K1
K2

K3/AB

6
7

180D7ETM03

1 Clutch shaft (lay shaft, K4) 5 Clutch shaft (KZ)

2 Clutch shaft (KV) 6 Clutch shaft / Output (K3/AB)
3 Input shaft / Power take-off (AN/PTO) 7 Clutch shaft (K1)
4 Clutch shaft (KR) 8 Electro-hydraulic control

3-5
 2) INSTALLATION VIEW

1 2 3 9 10 11 12

13
4

8 20

5
16 14

19

18 15
7
6 17 16

180D7EPT26

1 Electro - hydraulic control 11 Lifting lugs

2 Converter bell 12 Converter bell
3 Lifting lugs 13 Converter with diaphragm - direct mounting
4 Gearbox housing front and rear section 14 Converter with diaphragm
5 Oil level tube with oil dipstick (rear side) 15 Exchange filter with filter head
6 Transmission suspension holes M20 16 Transmission suspension holes M20
7 Plate 17 Oil drain plug M38Ý1.5
8 Converter with diaphragm - direct mounting 18 Type plate
9 Power take - off; coaxial, engine - dependent 19 Output flange
10 Gearbox housing front and rear section 20 Oil level tube with oil dipstick (rear side)

3-6
3) OPERATION OF TRANSMISSION
(1) Gearbox diagram
The multi-speed reversing transmission in counter shaft design is power shiftable by hydraulically
actuated multi-disk clutches.
All gears are constantly meshing and carried on anti-friction bearings.
The gear wheels, bearings and clutches are cooled and lubricated with oil.
The 3-speed reversing transmission is equipped with 5 multi-disk clutches.
At the shifting, the actual plate pack is compressed by a piston, movable in axial direction, which is
pressurized by pressure oil.
A compression spring takes over the pushing bask of the piston, thus the release of the plate
pack. As to the layout of the transmission as well as the specifications of the closed clutches in
the single speeds.

Gearbox diagram
K1

K4
KR
Converter
KV KV K4

AN PTO AN/PTO

KR K1
K2

K3/AB
K2

K3/AB

Legend Diagram Clutches

KV = Clutch forward Driving direction Speed Clutch

KR = Clutch reverse 1 KV/K1
K1 = Clutch 1st speed Forward 2 KV/K2
K2 = Clutch 2nd speed 3 KV/K3
K3/AB = Clutch 3rd speed / output 1 KR/K1
K4 = Clutch 4th speed(layshaft) Reverse 2 KR/K2
AN/PTO = INPUT / Power take-off 3 KR/K3

180D7EPT32

3-7
 (2) Forward
In forward, forward clutch and 1st, 2nd, 3rd clutch are engaged.
Forward clutch and 1st, 2nd, 3rd clutch are actuated by the hydraulic pressure applied to the
clutch piston.

Transmission diagram 1st speed-reverse

K1
KR

K4 KV K4

Converter
AN/PTO
KV

K1
AN K2
PTO
Opinion direction K3/AB
of rotation
KR

K2 Legend

KV = Clutch forward
KR = Clutch reverse
K3/AB
K1 = Clutch 1st speed
K2 = Clutch 2nd speed
K3/AB = Clutch 3rd speed / output
K4 = Clutch 4th speed(layshaft)
AN/PTO = INPUT / Power take-off

2nd speed-reverse 3rd speed-reverse

KR KR

KV K4 KV K4

AN/PTO AN/PTO

K1 K1
K2 K2

K3/AB K3/AB

180D7EPT33

3-8
 (3) Reverse
In reserve, reserve clutch and 1st, 2nd, 3rd clutch are engaged.
Reverse clutch and 1st, 2nd, 3rd are actuated by the hydraulic pressure applied to the clutch
piston.

Transmission diagram 1st speed-reverse

K1
KR

K4 KV K4

Converter
AN/PTO
KV

K1
AN K2
PTO
Opinion direction K3/AB
of rotation
KR

K2 Legend

KV = Clutch forward
KR = Clutch reverse
K3/AB
K1 = Clutch 1st speed
K2 = Clutch 2nd speed
K3/AB = Clutch 3rd speed / output
K4 = Clutch 4th speed(layshaft)
AN/PTO = INPUT / Power take-off

2nd speed-reverse 3rd speed-reverse

KR KR

KV K4 KV K4

AN/PTO AN/PTO

K1 K1
K2 K2

K3/AB K3/AB

180D7EPT34

3-9
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE

2 1 3

A A
Y6 Y1

Y5 Y2

B
Y4 Y3

3 6

2 6 1 4 11 9 10

Y5

8 7
SECTION A-A SECTION B-B

D507PT03

1 Pressure reducing valve(9bar) 7 Intermediate plate

2 Main pressure valve (16 + 2bar) 8 Duct plate
3 Housing 9 Vibration damper
4 Plug(cable harness) 10 Follow - on slide
5 Cover 11 Pressure regulator
6 Valve block

3-10
Transmission control, see schedule of measuring points, Oil circuit diagram and Electro-hydraulic
control unit see page 3-2, 3-10.
The transmission pump, necessary for the oil supply of the converter, and for the transmission
control, is sitting in the transmission on the engine-dependent input shaft.
The feed rate of the pump is
Q = 150˶/min, at nEngine = 2000 min -1
This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the fine filter -
the filter can also be fitted externally from the transmission - to the main pressure valve.
If because of contamination, respective damage, the through-flow through the fine filter is not
ensured, the oil will be directly conducted via a filter differential pressure valve(bypass valve Āp =
5.5+3bar) to the lubrication.
In this case, an error indication is shown on the display.

The five clutches of the transmission are selected via the 5 proportional valves P2 to P6.
The proportional valve(pressure regulator unit) is composed of pressure regulator(e.g. Y6), follow-
on slide and vibration damper.
The control pressure of 9+0.5bar for the actuation of the follow-on slides is created by pressure
reducing valve. The pressure oil(16+2bar) is directed via the follow-on slide to the respective clutch.
Due to the direct proportional selection with separated pressure modulation for each clutch, the
pressure to the clutches, which are engaged in the gear change, will be controlled. In this way, a
hydraulic intersection of the clutches to be engaged and disengaged becomes possible.
This is creating spontaneous shiftings without traction force interruption.
At the shifting, the following criteria will be considered :
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode(up-,down-, reverse shifting and speed engagement out of Neutral).
- Load condition(full and part load, traction, overrun inclusive consideration of load cycles during the
shifting).
The main pressure valve is limiting the max. control pressure to 16+2.5bar and releases the main
stream to the converter and lubrication circuit.
In the inlet to the converter, a converter safety valve is installed which protects the converter from
high internal pressures(opening pressure 11+2bar).
Within the converter, the oil serves to transmit the power according to the well-known hydrodynamic
principle(see Chapter torque converter page 3-3).
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by converter pressure back-up valve, rear-mounted to the converter, with an
opening pressure of at least 4.3+3bar.
The oil, escaping out of the converter, is directed to the oil cooler.
From the oil cooler, the oil is directed to the transmission and there to the lubricating oil circuit, so
that all lubricating points are supplied with cooled oil.
In the electrohydraulic control unit are 5 pressure regulators installed.

3-11
5) GEAR SELECTOR(DW-3)
The gear selector is designed for the mounting on the steering column left side. By a rotative
motion, the positions(speeds) 1 to 3 are selected by tilting the lever, the driving direction(Forward
(F) - Neutral(N) - Reverse(R)).
For the protection from unintended start off, a neutral interlock is installed :
Position "N" - Controller lever blocked in this position
Position "D" - Driving

Gear positions Type plate

F

N N N D

D507PT12

3-12
 Gear selector(DW-3)

LEVER FOR MECHANICAL

NEUTRAL INTERLOCK CODING GEAR SELECTOR

OUTPUT
FORWARD REVERSE NEUTRAL
SPEED
1 2 3 1 2 3 1 2 3
AD1 B1 ú ú ú
N D
AD2 B2
AD3 B3 ú ú ú ú ú ú
AD4 V ú ú ú
IN POSITION(NEUTRAL), ú ú ú
F-R NOT SWITCHABLE AD5 R
AD6 N ú ú ú

A B C D
A B C D

X2 X1

TYPE PLATE
CIRCUIT DIAGRAM SELECTOR
F GEAR POSITIONS

S5
F 2 1 SW A AD3(B3)
D
N N N

R
S4
2 1 BL C AD1(B1)
X1
R
RT A ED1(+/VP)
S1 1
F = FORWARD 3 2
GR D AD6(N)
N = NEUTRAL S2 1

2
R = REVERSE 3 GE
B AD4(FORWARD)
D = MECANICAL NEUTRAL INTERLOCK S3 1
3 2
1 = 1st SPEED RS
X2
C AD5(REVERSE)
2 = 2nd SPEED
3 = 3rd SPEED

CONNECTION DIAGRAM SELECTOR

(+)
K1 = RELAY STARTER INTERLOCK
K2 K2 = RELAY REVERSE LIGHTS
X2 : A
(+)
A1 = TCU(Transmission Control Unit)
B1 X1 : C A2 = CONTROLLER
B2
B3 X1 : A
A2 V X1 : B A1
R X1 : C
N X1 : D

K1

(-)

D507PT38

3-13
6) TRANSMISSION ERROR DISPLAY
(1) Function
The display can be used with the gear selector. It indicates speed and driving direction as well as
the activated inching.
When driving in the automatic mode, a bar indicator gives additionally also information about the
selected driving range; The automatic range is symbolized by arrows above and below the bar
indicator. In case of possible errors in the system, a wrench appears on the display, combined
with indication of the error number. Also sporadically occurring errors can be indicated.

f d Left side Right side

h S
T
O
P

b a c Central side g
D507CD33

a, f Automatic range(up and down shifting)

1 Bars
b, c, d, Preselected gear

2 Left side For the moment still without function

On the two alphanumeric 16-segment display, the electric control

Central and
3 unit issues the actual state of gear and driving direction. Besides, a
Right side
two digit error code will be indicated via these two segment
4 Spanner g Electronic control unit recognized an error, is flashing
5 Letters STOP h Immediate stop is required(At the moment not activated)

(2) Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off

3-14
 (3) Display during operation

Symbol Meaning Remarks

F, N, R Actual gear and direction

Central side shows actual gear
1, 2, 3 Right side shows actual direction
NN Not neutral, waiting for neutral To engage a gear, first move shift selector to
(Central and right side) after power up or a reverse fault neutral position and again to F to R position
1 bar Manual mode lst gear
2 bar Manual mode 2nd gear
3 bar Manual mode 3nd gear
3bars and 2 arrows Automatic mode a, f
Transmission neutral Cold start phase
Spanner flashing At least on fault active Select neutral to get fault code displayed
Changes between actual gear/direction while
Warning torque converter
WT driving, in neutral only displayed if no fault is
temperature
detected(spanner)
Changes between actual gear/direction while
WS Warning sump temperature driving, in neutral only displayed if no fault is
detected(spanner)
Changes between actual gear/direction while
WE Warning high engine speed driving, in neutral only displayed if no fault is
detected(spanner)
Transmission in neutral until parking brake is
Direction F or R selected while released.
PN parking brake engaged ö Machine starts to move after release of
parking brake.
Direction F or R selected while
F or R flashing turbine speed is to high ö Gear will engage when turbine speed drops

EE flashing
No communication with display
(central and right side)

3-15
 (4) Transmission error codes

Fault code Meaning of the fault code

(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

11 Logical error at gear range signal TCU shifts transmission to  Check the cables from TCU to
TCU detected a wrong signal combination neutral shift lever
for the gear range OP-mode : Transmission  Check signal combinations of shift
ÂCable from shift lever to TCU is broken shutdown lever positions for gear range
ÂCable is defective and is contacted to ö Failure cannot be detected in
battery voltage or vehicle ground systems with DW2/DW3 shift lever.
ÂShift lever is defective Fault is taken back if TCU detects
a valid signal for the position
12 Logical error at direction select signal TCU shifts transmission to  Check the cables from TCU to
TCU detected a wrong signal combination neutral shift lever
for the direction OP-Mode : Transmission  Check signal combinations of shift
ÂCable from shift lever to TCU is broken shutdown lever positions F-N-R
ÂCable is defective and is contacted to ö Fault is taken back if TCU detects
battery voltage or vehicle ground a valid signal for the direction at
ÂShift lever is defective the shift lever
13 Logical error at engine derating device After selecting neutral, TCU Â Check engine derating device
TCU detected no reaction of engine while change to OP mode limp ö This fault is reset after power up of
derating device active home TCU
15 Logical error at direction select signal 2 TCU shifts transmission to  Check the cables from TCU to
shift lever neutral if selector active shift lever 2
TCU detected a wrong signal combination OP mode : Transmission  Check signal combinations of shift
for the direction shutdown if elector lever positions F-N-R
ÂCable from shift lever 2 to TCU is broken active ö Fault is taken back if TCU detects
ÂCable is defective and is contacted to a valid neutral signal for the
battery voltage or vehicle ground direction at the shift lever
ÂShift lever is defective
16 Logical error at axle connection OP mode : Normal  Check the cables from TCU to
Feedback axle connection measured by TCU feedback axle connection switch
and output signal axle connection don't fit  Check signals of the feedback
ÂAxle can't be connected or disconnected axle connection switch
due to mechanical problem
ÂOne of the cables from feedback axle
connection switch to TCU is broken
21 S.C. to battery voltage at clutch cut off Clutch cut off function is  Check the cable from TCU to the
input disabled sensor
The measured voltage is too high: OP mode : Normal  Check the connectors
ÂCable is defective and is contacted to  Check the clutch cut off sensor
battery voltage
ÂClutch cut off sensor has an internal
defect
ÂConnector pin is contacted to battery
voltage
22 S.C. to ground or O.C. at clutch cut off Clutch cut off function is  Check the cable from TCU to the
input disabled sensor
The measured voltage is too low: OP mode : Normal  Check the connectors
ÂCable is defective and is contacted to  Check the clutch cut off sensor
vehicle ground
ÂCable has no connection to TCU
ÂClutch cut off sensor has an internal
defect
ÂConnector pin is contacted to vehicle
ground or is broken

3-16
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

23 S.C. to battery voltage at load sensor Retarder function is affected  Check the cable from TCU to the
input TCU uses default load sensor
The measured voltage is too high: OP mode : Normal  Check the connectors
ÂCable is defective and is contacted to  Check the load sensor
battery voltage  Check the assembly tolerances of
ÂLoad sensor has an internal defect load sensor
ÂConnector pin is contacted to battery ö Availability of retarder depends on
voltage default load
24 S.C. to ground or O.C. at load sensor Retarder function is affected  Check the cable from TCU to the
input TCU use default load sensor
The measured voltage is too low: OP mode : Normal  Check the connectors
ÂCable is defective and is contacted to  Check the load sensor
vehicle ground  Check the assembly tolerances of
ÂCable has no connection to TCU load sensor
ÂLoad sensor has as internal defect ö Availability of retarder depends on
ÂConnector pin is contacted to vehicle default load
ground or is broken
25 S .C. to battery voltage or O.C. at No reaction, TCU use default  Check the cable from TCU to the
transmi-ssion sump temperature sensor temperature sensor
input OP mode : Normal  Check the connectors
The measured voltage is too high: Â Check the temperature sensor
ÂCable is defective and is contacted to
battery voltage
ÂCable has no connection to TCU
ÂTemperature sensor has an internal
defect
ÂConnector pin is contacted to battery
voltage or is broken
26 S .C. to battery voltage or O.C. at No reaction, TCU uses default  Check the cable from TCU to the
transmi-ssion sump temperature sensor temperature sensor
input OP mode : Normal  Check the connectors
The measured voltage is too low: Â Check the temperature sensor
ÂCable is defective and is contacted to
vehicle ground
ÂTemperature sensor has an internal
defect
ÂConnector pin is contacted to vehicle
ground
27 S .C. to battery voltage or O.C. at No reaction, TCU uses default  Check the cable from TCU to the
retarder temperature sensor input temperature sensor
The measured voltage is too high: OP mode : Normal  Check the connectors
ÂCable is defective and is contacted to  Check the temperature sensor
battery voltage
ÂCable has no connection to TCU
ÂTemperature sensor has an internal
defect
ÂConnector pin is contacted to battery
voltage or is broken

3-17
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

28 S.C. to ground at retarder temperature No reaction, TCU uses default  Check the cable from TCU to the
sensor input temperature sensor
The measured voltage is too low: OP mode : Normal  Check the connectors
ÂCable is defective and is contacted to  Check the temperature sensor
vehicle ground
ÂTemperature sensor has an internal
defect
ÂConnector pin is contacted to vehicle
ground
29 S .C. to battery voltage or O.C. at No reaction, TCU uses default  Check the cable from TCU to the
converter output temperature sensor temperature sensor
input OP mode : Normal  Check the connectors
The measured voltage is too high: Â Check the temperature sensor
ÂCable is defective and is contacted to
battery voltage
ÂCable has no connection to TCU
ÂTemperature sensor has an internal
defect
ÂConnector pin is contacted to battery
voltage or is broken
30 S .C. to ground at converter output No reaction, TCU uses default  Check the cable from TCU to the
temperature sensor input temperature sensor
The measured voltage is too low: OP mode : Normal  Check the connectors
ÂCable is defective and is contacted to  Check the temperature sensor
vehicle ground
ÂTemperature sensor has an internal
defect
ÂConnector pin is contacted to vehicle
ground
31 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch  Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than  Check the connectors
7.00V at speed input pin  Check the speed sensor
ÂCable is defective and is contacted to
battery voltage
ÂCable has no connection to TCU
ÂSpeed sensor has an internal defect
ÂConnector pin is contacted to battery
voltage or has no contact
32 S.C. to ground at engine speed input OP mode : Substitute clutch  Check the cable from TCU to the
TCU measures a voltage less than 0.45V at control sensor
speed input pin  Check the connectors
ÂCable/connector is defective and is  Check the speed sensor
contacted to vehicle ground
ÂSpeed sensor has an internal defect

3-18
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

33 Logical error at engine speed input OP mode : Substitute clutch  Check the cable from TCU to the
TCU measures a engine speed over a control sensor
threshold and the next moment the  Check the connectors
measured speed is zero  Check the speed sensor
ÂCable/connector is defective and has  Check the sensor gap
bad contact ö This fault is reset after power up of
ÂSpeed sensor has an internal defect TCU
ÂSensor gap has the wrong size
34 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch  Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than If a failure is existing at output  Check the connectors
7.00V at speed input pin speed, Â Check the speed sensor
ÂCable is defective and is contacted to TCU shifts to neutral
vehicle battery voltage OP mode : Limp home
ÂCable has no connection to TCU
ÂSpeed sensor has an internal defect
ÂConnector pin is contacted to battery
voltage or has no contact
35 S.C. to ground at turbine speed input OP mode : Substitute clutch  Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin If a failure is existing at output  Check the connectors
ÂCable/connector is defective and is speed, Â Check the speed sensor
contacted to vehicle ground TCU shifts to neutral ö This fault is reset after power up of
ÂSpeed sensor has an internal defect OP mode : Limp home TCU
36 Logical error at turbine speed input OP mode : Substitute clutch  Check the cable from TCU to the
TCU measures a turbine speed over a control sensor
threshold and at the next moment the If a failure is existing at output  Check the connectors
measured speed is zero speed, Â Check the speed sensor
ÂCable/connector is defective and has TCU shifts to neutral  Check the sensor gap
bad contact OP mode : Limp home
ÂSpeed sensor has an internal defect
ÂSensor gap has the wrong size
37 S .C. to battery voltage or O.C. at OP mode : Substitute clutch  Check the cable from TCU to the
internal speed input control sensor
TCU measures a voltage higher than  Check the connectors
7.00V at speed input pin  Check the speed sensor
ÂCable is defective and is contacted to
vehicle battery voltage
ÂCable has no connection to TCU
ÂSpeed sensor has an internal defect
ÂConnector pin is contacted to battery
voltage or has no contact
38 S.C. to ground at turbine speed input OP mode : Substitute clutch  Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin  Check the connectors
ÂCable/connector is defective and is  Check the speed sensor
contacted to vehicle ground
ÂSpeed sensor has an internal defect

3-19
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

39 Logical error at internal speed input OP mode : Substitute clutch  Check the cable from TCU to the
TCU measures a internal speed over a control sensor
threshold and at the next moment the  Check the connectors
measured speed is zero  Check the speed sensor
ÂCable/connector is defective and has  Check the sensor gap
bad contact ö This fault is reset after power up of
ÂSpeed sensor has an internal defect TCU
ÂSensor gap has the wrong size
3A S.C. to battery voltage or O.C. at output Special mode for gear selection  Check the cable from TCU to the
speed input OP mode : Substitute clutch sensor
TCU measures a voltage higher than control  Check the connectors
12.5V at speed input pin If a failure is existing at turbine  Check the speed sensor
ÂCable is defective and is contacted to speed,
battery voltage TCU shifts to neutral
ÂCable has no connection to TCU OP mode : lamp home
ÂSpeed sensor has an internal defect
ÂConnector pin is contacted to battery
voltage or has no contact
3B S.C. to ground at output speed input Special mode for gear selection  Check the cable from TCU to the
TCU measures a voltage less than 1.00V OP mode : Substitute clutch sensor
at speed input pin control  Check the connectors
ÂCable/connector is defective and is If a failure is existing at turbine  Check the speed sensor
contacted to vehicle ground speed,
ÂSpeed sensor has an internal defect TCU shifts to neutral
OP mode : lamp home
3C Logical error at output speed input Special mode for gear selection  Check the cable from TCU to the
TCU measures a turbine speed over a OP mode : Substitute clutch sensor
threshold and at the next moment the control  Check the connectors
measured speed is zero If a failure is existing at turbine  Check the speed sensor
ÂCable/connector is defective and has speed, Â Check the sensor gap
bad contact TCU shifts to neutral ö This fault is reset after power up of
ÂSpeed sensor has an internal defect OP mode : lamp home TCU
ÂSensor gap has the wrong size
3D Turbine speed zero doesn't fit to other - ö Not used
speed signals
3E Output speed zero doesn't fit to other Special mode for gear selection  Check the sensor signal of output
speed signals OP mode : Substitute clutch speed sensor
If transmission is not neutral and the control  Check the sensor gap of output
shifting has finished, If a failure is existing at turbine speed sensor
TCU measures output speed zero and speed, Â Check the cable from TCU to the
turbine speed or internal speed not equal TCU shifts to neutral sensor
to zero. OP mode : lamp home ö This fault is reset after power up of
ÂSpeed sensor has an internal defect TCU
ÂSensor gap has the wrong size

3-20
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

71 S.C. to battery voltage at clutch K1 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K1 valve is too If failure at another clutch is  Check the connectors from TCU
high pending to the gearbox
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown  Check internal wire harness of the
ÂCable/connector is defective and has gearbox
contact to another regulator output of the * See page 3-36
TCU
ÂRegulator has an internal defect
72 S.C. to ground at clutch K1 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K1 valve is too If failure at another clutch is  Check the connectors from
low pending gearbox to TCU
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown  Check internal wire harness of the
ÂRegulator has an internal defect gearbox
* See page 3-36
73 O.C. at clutch K1 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch is  Check the connectors from
ÂCable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral  Check the regulator resistance*
ÂRegulator has an internal defect OP mode : TCU shutdown  Check internal wire harness of the
gearbox
* See page 3-36
74 S.C. to battery voltage at clutch K2 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit, the voltage at K2 valve If failure at another clutch is  Check the connectors from
is too high pending gearbox to TCU
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown  Check internal wire harness of the
ÂCable/connector is defective and has gearbox
contact to another regulator output of the * See page 3-36
TCU
ÂRegulator has an internal defect
75 S.C. to ground at clutch K2 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K2 valve is too If failure at another clutch is  Check the connectors from
low pending gearbox to TCU
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown  Check internal wire harness of the
ÂRegulator has an internal defect gearbox
* See page 3-36
76 O.C. at clutch K2 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch is  Check the connectors from
ÂCable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral  Check the regulator resistance*
ÂRegulator has an internal defect OP mode : TCU shutdown  Check internal wire harness of the
gearbox
* See page 3-36

3-21
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

77 S.C. to battery voltage at clutch K3 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit, the voltage at K3 valve If failure at another clutch is  Check the connectors from
is too high pending gearbox to TCU
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown  Check internal wire harness of the
ÂCable/connector is defective and has gearbox
contact to another regulator output of the * See page 3-36
TCU
ÂRegulator has an internal defect
78 S.C. to ground at clutch K3 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K3 valve is too If failure at another clutch is  Check the connectors from
low pending gearbox to TCU
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown  Check internal wire harness of the
ÂRegulator has an internal defect gearbox
* See page 3-36
79 O.C. at clutch K2 TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch is  Check the connectors from
Cable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral  Check the regulator resistance*
Regulator has an internal defect OP mode : TCU shutdown  Check internal wire harness of the
gearbox
* See page 3-36
7A S .C. to battery voltage at converter - -
clutch
7B S.C. to ground at converter clutch - -
7C O.C. at converter clutch - ö Not used
7D S.C. ground at engine derating device Engine derating will be on until  Check the cable from TCU to the
ÂCable is defective and is contacted to TCU power down even if fault engine derating device
vehicle ground vanishes(Loose connection) Â Check the connectors from engine
ÂEngine derating device has an internal OP mode : Normal derating device to TCU
defect  Check the resistance* of engine
ÂConnector pin is contacted to vehicle derating device
ground ö Not used
* See page 3-36
7E S.C. battery voltage at engine derating No reaction  Check the cable from TCU to the
device OP mode : Normal engine derating device
ÂCable/connector is defective and is  Check the connectors from
contacted to battery voltage backup alarm device to TCU
ÂEngine derating device has an internal  Check the resistance* of backup
defect alarm device
* See page 3-36

3-22
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

7F O.C. at engine derating device No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal engine derating device
output pin, that looks like a O.C. for this  Check the connectors from engine
output pin derating device to TCU
ÂCable is defective and has no  Check the resistance* of engine
connection to TCU derating device
ÂEngine derating device has an internal * See page 3-36
defect
ÂConnector has no connection to TCU
85 S.C. to ground at clutch KV TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K4 valve is too If failure at another clutch is  Check the connectors from
low pending gearbox to TCU
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown  Check internal wire harness of the
ÂRegulator has an internal defect gearbox
* See page 3-36

86 O.C. at clutch KV TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch is  Check the connectors from
ÂCable/connector is defective and has pending gearbox to TCU
contact to TCU TCU shifts to neutral  Check the regulator resistance*
ÂRegulator has an internal defect OP mode : TCU shutdown  Check internal wire harness of the
gearbox
* See page 3-36
87 S.C. to battery voltage at clutch KR TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit, the voltage at KR valve is If failure at another clutch is  Check the connectors from
too high pending gearbox to TCU
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown  Check internal wire harness of the
ÂCable/connector is defective and has gearbox
contact to another regulator output of the * See page 3-36
TCU
ÂRegulator has an internal defect

3-23
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

88 S.C. to ground at clutch KR TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at KR valve is too If failure at another clutch is  Check the connectors from
low pending gearbox to TCU
ÂCable/connector is defective and has TCU shifts to neutral  Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown  Check internal wire harness of the
ÂRegulator has an internal defect gearbox
* See page 3-36
89 O.C. at clutch KR TCU shifts to neutral  Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch is  Check the connectors from
ÂCable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral  Check the regulator resistance*
ÂRegulator has an internal defect OP mode : TCU shutdown  Check internal wire harness of the
gearbox
* See page 3-36
91 S.C. to ground at relay reverse warning Backup alarm will be on until  Check the cable from TCU to the
alarm TCU power down even if fault backup alarm device
TCU detected a wrong voltage at the vanishes(Loose connection) Â Check the connectors from
output pin, that looks like a S.C. to vehicle OP mode : Normal backup alarm device to TCU
ground  Check the resistance* of backup
ÂCable is defective and is contact to alarm device
vehicle ground * See page 3-36
ÂBackup alarm device has an internal
defect
ÂConnector pin is contacted to vehicle
ground
92 S.C. to battery voltage at relay reverse No reaction  Check the cable from TCU to the
warning alarm OP mode : Normal backup alarm device
TCU detected a wrong voltage at the  Check the connectors from
output pin, that looks like a S.C. to battery backup alarm device to TCU
voltage  Check the resistance* of backup
ÂCable is defective and is contacted to alarm device
battery voltage * See page 3-36
ÂBackup alarm device has an internal
defect
ÂConnector pin is contacted to battery
voltage

3-24
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

93 O.C. at relay reverse warning alarm No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal backup alarm device
output pin, that looks like a O.C. for this  Check the connectors from
output pin backup alarm device to TCU
ÂCable is defective and has no  Check the resistance* of backup
connection to TCU alarm device
ÂBackup alarm device has an internal * See page 3-36
defect
ÂConnector has no connection to TCU
94 S.C. to ground at relay starter interlock No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal stater interlock relay
output pin, that looks like a S.C. to vehicle  Check the connectors from starter
ground interlock relay to TCU
ÂCable is defective and is connection to  Check the resistance* of starter
vehicle ground interlock relay
ÂStarter interlock relay has an internal * See page 3-36
defect
ÂConnector pin is contacted to vehicle
ground
95 S.C. to battery voltage at relay starter No reaction  Check the cable from TCU to the
interlock OP mode : Normal starter interlock relay
TCU detected a wrong voltage at the  Check the connectors from starter
output pin, that looks like a S.C. to battery interlock relay to TCU
voltage  Check the resistance* of starter
ÂCable is defective and has no interlock relay
connection to battery voltage * See page 3-36
ÂStarter interlock relay has an internal defect
ÂConnector pin is contacted to battery
voltage
96 O.C. at relay starter interlock No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal starter interlock relay
output pin, that looks like a O.C. for this  Check the connectors from starter
output pin interlock relay to TCU
ÂCable is defective and has no  Check the resistance* of starter
connection to TCU interlock relay
ÂStarter interlock relay has an internal defect * See page 3-36
ÂConnector has no connection to TCU

3-25
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

97 S.C. to ground at park brake solenoid No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal park brake solenoid
output pin, that looks like a S.C. to vehicle  Check the connectors from park
ground brake solenoid to TCU
ÂCable is defective and is connection to  Check the resistance* of park
vehicle ground brake solenoid
ÂPark brake solenoid has an internal * See page 3-36
defect
ÂConnector pin is contacted to vehicle
ground
98 S .C. to battery voltage at park brake No reaction  Check the cable from TCU to the
solenoid Optional : (Some customers) park brake solenoid
TCU detected a wrong voltage at the TCU shifts to neutral caused  Check the connectors from park
output pin, that looks like a S.C. to battery by park brake feed back brake solenoid to TCU
voltage OP mode : Normal  Check the resistance* of park
ÂCable is defective and is connection to brake solenoid
battery voltage * See page 3-36
ÂPark brake solenoid has an internal
defect
ÂConnector pin is contacted to battery
voltage
99 O.C. at park brake solenoid No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the Optional : Some customers park brake solenoid
output pin, that looks like a O.C. for this TCU shifts to neutral caused  Check the connectors from park
output pin by park brake feed back brake solenoid to TCU
ÂCable is defective and has no OP mode : Normal  Check the resistance* of park
connection to TCU brake solenoid
ÂPark brake solenoid has an internal * See page 3-36
defect
ÂConnector has no connection to TCU
9A S .C. to ground at converter lock up No reaction  Check the cable from TCU to the
clutch solenoid OP mode : Normal converter clutch solenoid
TCU detected a wrong voltage at the  Check the connectors from
output pin, that looks like a S.C. to vehicle converter clutch solenoid to TCU
ground  Check the resistance* of park
ÂCable is defective and is contacted to brake solenoid
vehicle ground * See page 3-36
ÂConverter clutch solenoid has an
internal defect
ÂConnector pin is contacted to vehicle
ground
9B O .C. at converter lock up clutch Converter clutch always open, Â Check the cable from TCU to the
solenoid retarder not available converter clutch solenoid
TCU detected a wrong voltage at the OP mode : Normal  Check the connectors from
output pin, that looks like a O.C. for this converter clutch solenoid to TCU
output pin  Check the resistance* of park
ÂCable is defective and has no brake solenoid
connection to TCU * See page 3-36
ÂConverter clutch solenoid has an
internal defect
ÂConnector has no connection to TCU

3-26
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

9C S.C. to battery voltage at converter lock No reaction  Check the cable from TCU to the
up clutch solenoid OP mode : Normal converter clutch solenoid
TCU detected a wrong voltage at the  Check the connectors from
output pin, that looks like a S.C. to battery converter clutch solenoid to TCU
voltage  Check the resistance* of converter
ÂCable is defective and has no contacted clutch solenoid
to battery voltage * See page 3-36
ÂConverter clutch solenoid has an
internal defect
ÂConnector pin is contacted to battery
voltage
9D S.C. to ground at retarder solenoid No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal retarder solenoid
output pin, that looks like a S.C. to vehicle  Check the connectors from
ground retarder solenoid to TCU
ÂCable is defective and is contacted to  Check the resistance* of retarder
vehicle ground solenoid
ÂRetarder solenoid has an internal defect * See page 3-36
ÂConnector pin is contacted to vehicle
ground
9E O.C. at retarder solenoid No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal retarder solenoid
output pin, that looks like a O.C. for this  Check the connectors from
output pin retarder solenoid to TCU
ÂCable is defective and has no  Check the resistance* of retarder
connection to TCU solenoid
ÂRetarder solenoid has an internal defect * See page 3-36
ÂConnector has no connection to TCU
9F S .C. to battery voltage at retarder No reaction  Check the cable from TCU to the
solenoid OP mode : Normal retarder solenoid
TCU detected a wrong voltage at the  Check the connectors from
output pin, that looks like a S.C. to battery retarder solenoid to TCU
voltage  Check the resistance* of retarder
ÂCable is defective and has no solenoid
connection to battery voltage * See page 3-36
ÂRetarder solenoid has an internal defect
ÂConnector pin is contacted to battery
voltage

3-27
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

A1 S.C. to ground at difflock or axle No reaction  Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the  Check the connectors from difflock
output pin, that looks like a S.C. to vehicle solenoid to TCU
ground  Check the resistance* of difflock
ÂCable is defective and is contacted to solenoid
vehicle ground * See page 3-36
ÂDifflock solenoid has an internal defect
ÂConnector pin is contacted to vehicle
ground
A2 S.C. to battery voltage at difflock or axle No reaction  Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the  Check the connectors from difflock
output pin, that looks like a S.C. to battery solenoid to TCU
voltage  Check the resistance* of difflock
ÂCable is defective and has no solenoid
connection to battery voltage * See page 3-36
ÂDifflock solenoid has an internal defect
ÂConnector pin is contacted to battery
voltage
A3 O .C. at difflock or axle connection No reaction  Check the cable from TCU to the
solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the  Check the connectors from difflock
output pin, that looks like a O.C. for this solenoid to TCU
output pin  Check the resistance* of difflock
ÂCable is defective and has no solenoid
connection to TCU * See page 3-36
ÂDifflock solenoid has an internal defect
ÂConnector has no connection to TCU
A4 S.C. to ground at warning signal output No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a S.C. to vehicle  Check the connectors from
ground warning device to TCU
ÂCable is defective and is contacted to  Check the resistance* of warning
vehicle ground device
ÂWarning device has an internal defect * See page 3-36
ÂConnector pin is contacted to vehicle
ground
A5 O.C. voltage at warning signal output No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a O.C. for this  Check the connectors from
output pin warning device to TCU
ÂCable is defective and has no  Check the resistance* of warning
connection to TCU device
ÂWarning device has an internal defect * See page 3-36
ÂConnector has no connection to TCU
A6 S.C. to battery voltage at warning signal No reaction  Check the cable from TCU to the
output OP mode : Normal warning device
TCU detected a wrong voltage at the  Check the connectors from
output pin, that looks like a S.C. to battery warning device to TCU
voltage  Check the resistance* of warning
ÂCable is defective and has is contacted device
to battery voltage * See page 3-36
ÂWarning device has an internal defect
ÂConnector pin is contacted to battery
voltage

3-28
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

B1 Slippage at clutch K1 TCU shifts to neutral  Check pressure at clutch K1

TCU calculates a differential speed at OP mode : Limp home  Check main pressure in the
closed clutch K1. If this calculated value If failure at another clutch is system
is out of range, TCU interprets this as pending  Check sensor gap at internal
slipping clutch TCU shifts to neutral speed sensor
ÂLow pressure at clutch K1 OP mode : TCU shutdown  Check sensor gap at output speed
ÂLow main pressure sensor
ÂWrong signal at internal speed sensor  Check signal at internal speed
ÂWrong signal at output speed sensor sensor
ÂWrong size of the sensor gap  Check signal at output speed
ÂClutch is defective sensor
 Replace clutch
B2 Slippage at clutch K2 TCU shifts to neutral  Check pressure at clutch K2
TCU calculates a differential speed at OP mode : Limp home  Check main pressure in the
closed clutch K2. If this calculated value If failure at another clutch is system
is out of range, TCU interprets this as pending  Check sensor gap at internal
slipping clutch TCU shifts to neutral speed sensor
ÂLow pressure at clutch K2 OP mode : TCU shutdown  Check sensor gap at output speed
ÂLow main pressure sensor
ÂWrong signal at internal speed sensor  Check signal at internal speed
ÂWrong signal at output speed sensor sensor
ÂWrong size of the sensor gap  Check signal at output speed
ÂClutch is defective sensor
 Replace clutch
B3 Slippage at clutch K3 TCU shifts to neutral  Check pressure at clutch K3
TCU calculates a differential speed at OP mode : Limp home  Check main pressure in the
closed clutch K3. If this calculated value If failure at another clutch is system
is out of range, TCU interprets this as pending  Check sensor gap at internal
slipping clutch TCU shifts to neutral speed sensor
ÂLow pressure at clutch K3 OP mode : TCU shutdown  Check sensor gap at output speed
ÂLow main pressure sensor
ÂWrong signal at internal speed sensor  Check signal at internal speed
ÂWrong signal at output speed sensor sensor
ÂWrong size of the sensor gap  Check signal at output speed
ÂClutch is defective sensor
 Replace clutch

3-29
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

B5 Slippage at clutch KV TCU shifts to neutral  Check pressure at clutch KV

TCU calculates a differential speed at OP mode : Limp home  Check main pressure in the
closed clutch KV. If this calculated value If failure at another clutch is system
is out of range, TCU interprets this as pending  Check sensor gap at internal
slipping clutch TCU shifts to neutral speed sensor
ÂLow pressure at clutch KV OP mode : TCU shutdown  Check sensor gap at turbine
ÂLow main pressure speed sensor
ÂWrong signal at internal speed sensor  Check signal at internal speed
ÂWrong signal at turbine speed sensor sensor
ÂWrong size of the sensor gap  Check signal at turbine speed
ÂClutch is defective sensor
 Replace clutch
B6 Slippage at clutch KR TCU shifts to neutral  Check pressure at clutch KR
TCU calculates a differential speed at OP mode : Limp home  Check main pressure in the
closed clutch KR. If this calculated value If failure at another clutch is system
is out of range, TCU interprets this as pending  Check sensor gap at internal
slipping clutch TCU shifts to neutral speed sensor
ÂLow pressure at clutch KR OP mode : TCU shutdown  Check sensor gap at turbine
ÂLow main pressure speed sensor
ÂWrong signal at internal speed sensor  Check signal at internal speed
ÂWrong signal at turbine speed sensor sensor
ÂWrong size of the sensor gap  Check signal at turbine speed
ÂClutch is defective sensor
 Replace clutch
B7 Overtemp sump No reaction  Cool down machine
TCU measured a temperature in the oil OP mode : Normal  Check oil level
sump that is over the allowed threshold. Â Check temperature sensor
B8 Overtemp retarder TCU disables retarder  Cool down machine
TCU measured a temperature in the OP mode : Normal  Check oil level
retarder oil that is over the allowed  Check temperature sensor
threshold
B9 Overspend engine Retarder applies
-
OP mode : Normal
BA Differential pressure oil filter No reaction  Check oil filter
TCU measured a voltage at differential OP mode : Normal  Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
ÂOil filter is polluted  Check differential pressure
ÂCable/connector is broken or cable/ switch(Measure resistance)
connector is contacted to battery voltage
or vehicle ground
ÂDifferential pressure switch is defective

3-30
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

BB Slippage at converter lockup clutch - Â Check pressure at converter

TCU calculates a differential speed at lockup clutch
closed converter lockup clutch. If this  Check main pressure in the
calculated value is out of range, TCU system
interprets this as slipping clutch  Check sensor gap at engine
ÂLow pressure at converter lockup clutch speed sensor
ÂLow main pressure  Check sensor gap at turbine
ÂWrong signal at engine speed sensor speed sensor
ÂWrong signal at turbine speed sensor  Check signal at engine speed
ÂWrong size of the sensor gap sensor
ÂClutch is defective  Check signal at turbine speed
sensor
 Replace clutch
BD S.C. to ground at engine brake solenoid No reaction  Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal engine brake solenoid
output pin, that looks like a S.C. to vehicle  Check the connectors from engine
ground brake solenoid to TCU
ÂCable is defective and is contacted to  Check the resistance* of engine
vehicle ground brake solenoid
ÂEngine brake solenoid has an internal * See page 3-36
defect
ÂConnector pin is contacted to vehicle
ground
BE S.C. to battery voltage at engine brake No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal engine brake solenoid
output pin, that looks like a S.C. to battery  Check the connectors from engine
voltage brake solenoid to TCU
ÂCable is defective and is contacted to  Check the resistance* of engine
battery voltage brake solenoid
ÂEngine brake solenoid has an internal * See page 3-36
defect
ÂConnector pin is contacted to battery
voltage
BF O.C. at engine brake No reaction  Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal engine brake solenoid
output pin, that looks like a O.C. for this  Check the connectors from engine
output pin brake solenoid to TCU
ÂCable is defective and has no  Check the resistance* of engine
connection to TCU brake solenoid
ÂEngine brake solenoid has an internal * See page 3-36
defect
ÂConnector has no connection to TCU

3-31
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

C3 Overtemp converter output No reaction  Cool down machine

TCU measured a oil temperature at the OP mode : Normal  Check oil level
converter output that is the allowed  Check temperature sensor
threshold
C4 S.C. to ground at joystick status No reaction  Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the  Check the connectors from
output pin, that looks like a S.C. to vehicle joystick status indicator to TCU
ground  Check the resistance* of joystick
ÂCable is defective and is contacted to status indicator
vehicle ground * See page 3-36
ÂJoystick status indicator has an internal
defect
ÂConnector pin is contacted to vehicle
ground
C5 S.C. to battery voltage at joystick status No reaction  Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the  Check the connectors from
output pin, that looks like a S.C. to battery joystick status indicator to TCU
voltage  Check the resistance* of joystick
ÂCable is defective and is contacted to status indicator
battery voltage * See page 3-36
ÂJoystick status indicator has an internal
defect
ÂConnector pin is contacted to battery
voltage
C6 O.C. at joystick status indicator No reaction  Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal joystick status indicator
output pin, that looks like a O.C. for this  Check the connectors from
output pin joystick status indicator to TCU
ÂCable is defective and has no  Check the resistance* of joystick
connection to TCU status indicator
ÂJoystick status indicator has an internal * See page 3-36
defect
ÂConnector pin has no connection to
TCU

3-32
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

D1 S.C. to battery voltage at power supply See fault codes No.21 to 2C Â Check cables and connectors to
for sensors sensors, which are supplied from
TCU measures more than 6V at the pin AU1
AU1 (5V sensor supply) Â Check the power supply at the pin
AU1(Should be appx. 5V)
ö Fault codes No.21 to No.2C may
be reaction of this fault
D2 S.C. to ground at power supply for See fault codes No.21 to 2C Â Check cables and connectors to
sensors sensors, which are supplied from
TCU measures less than 4V at the pin AU1
AU1 (5V sensor supply) Â Check the power supply at the pin
AU1(Should be appx. 5V)
ö Fault codes No.21 to No.2C may
be reaction of this fault
D3 Low voltage at battery Shift to neutral  Check power supply battery
Measured voltage at power supply is lower OP mode : TCU shutdown  Check cables from batteries to
than 18V(24V device) TCU
 Check connectors from batteries
to TCU
D4 High voltage at battery Shift to neutral  Check power supply battery
Measured voltage at power supply is OP mode : TCU shutdown  Check cables from batteries to
higher than 32.5V(24V device) TCU
 Check connectors from batteries
to TCU
D5 Error at valve power supply VPS1 Shift to neutral  Check fuse
TCU switched on VPS1 and measured OP mode : TCU shutdown  Check cables from gearbox to
VPS1 is off or TCU switched off VPS1 and TCU
measured VPS1 is still on  Check connectors from gearbox to
ÂCable or connectors are defect and are TCU
contacted to battery voltage  Replace TCU
ÂCable or connectors are defect and are
contacted to vehicle ground
ÂPermanent power supply KL30 missing
ÂTCU has an internal defect
D6 Error at valve power supply VPS2 Shift to neutral  Check fuse
TCU switched on VPS2 and measured OP mode : TCU shutdown  Check cables from gearbox to
VPS2 is off or TCU switched off VPS2 and TCU
measured VPS2 is still on  Check connectors from gearbox to
ÂCable or connectors are defect and are TCU
contacted to battery voltage  Replace TCU
ÂCable or connectors are defect and are
contacted to vehicle ground
ÂPermanent power supply KL30 missing
ÂTCU has an internal defect

3-33
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

E1 S.C. battery voltage at speedometer - ö Not used

output
E2 S.C. to ground or O.C at speedometer ö Not used
output -

E3 S.C. to battery voltage at display output No reaction  Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on  Check the connectors at the
the connector display
ÂCable or connectors are defective and  Change display
are contacted to battery voltage
ÂDisplay has an internal defect
E4 S.C. to ground at display output No reaction  Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on  Check the connectors at the
the connector display
ÂCable or connectors are defective and  Change display
are contacted to battery voltage
ÂDisplay has an internal defect
E5 Communication failure on DeviceNet Shift to neutral  Check Omron master
OP mode : TCU shutdown  Check wire of DeviceNet-Bus
 Check cable to Omron master
E5 DISPID1 timeout TCU select parameter set with  Check display controller
Timeout of CAN-massage DISPID1 from ID0 Â Check wire of CAN-Bus
display controller OP mode : Limp home  Check cable display controller
ÂInterference on CAN-Bus
ÂCAN wire/connector is defective
ÂCan wire/connector is defective and has
contact to vehicle ground or battery
voltage

3-34
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair

F1 General EEPROM fault No reaction  Replace TCU

TCU can't read non volatile memory OP mode : Normal ö Often shown together with fault
ÂTCU is defective code F2
F2 Configuration lost Transmission stay neutral  Reprogram the correct configurat-
TCU has lost the correct configuration and OP mode : TCU shutdown ion for the vehicle (e.g. with cluster
can't control the transmission controller,...)
ÂInterference during saving data on non
volatile memory
ÂTCU is brand new or from another
vehicle
F3 Application error Transmission stay neutral  Replace TCU
Something of this application is wrong OP mode : TCU shutdown ö This fault occurs only if an test
engineer did something wrong in
the application of the vehicle
F5 Clutch failure Transmission stay neutral  Check clutch
AEB was not able to adjust clutch filling OP mode : TCU shutdown ö TCU shows also the affected
parameters clutch on the display
ÂOne of the AEB-Values is out of limit
F6 Clutch adjustment data lost No reaction, Â Execute AEB
TCU was not able to read correct clutch Default values : 0 for AEB
adjustment parameters Offsets used
ÂInterference during saving data on non OP mode : Normal
volatile memory
ÂTCU is brand new

3-35
(5) Measuring of resistance at actuator/sensor and cable
Η Actuator

2 G
76043PT19

Open circuit R12 = R1G = R2G = â

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)

Θ Cable

UBat

P(Power supply)
TCU
1 2 Actuator/
Sensor

C(Chassis)

Ground
76043PT20

Open circuit R12 = R1P = R1C = R2P = R2C= â

Short cut to ground R12 = 0; R1C = R2C = 0, R1P = R2P = â
Short cut to battery R12 = 0; R1C = R2C = 0, R1P = R2P = 0

3-36
7) ELECTRONIC CONTROL FOR POWER TRANSMISSION
(1) Description of the basic functions
The powershift transmission is equipped with TCU.
ÂThe system is processing the desire of the driver according to the following criteria :
ÂGear determination depending on gear selector position, driving speed and load condition.
ÂProtection from operating error as far as necessary, is possible via electronic protect-
tion(programming).
ÂProtection from over-speeds(on the base of engine and turbine speed).
ÂElectronic inching.

180D7EPT17

3-37
Legend
1 = Cable from angle sensor / Inch-sensor (option)
2 = Wiring
3 = Cable to temperature measuring point behind the converter "No. 63"
4 = Warning lamp
5 = Controller DW-3
6 = Cable to plug connection on the electrohydraulic control unit
7 = Cable to filter contamination switch
8 = Supply system connection
9 = Display
10 = Cable to inductive transmitter - speed engine
11 = Switch select auto/manual mode
12 = Switch neutral request
13 = Switch feetbeack parking brake
14 = Diagnosis Laptop with ZF-Diagnostic system Testmann
15 = CAN - Connection
16 = TCU
17 = Cable to speed sensor output and speedometer
18 = Cable to inductive transmitter - speed central gear train
19 = Cable to inductive transmitter - speed turbine
20 = Transmission

3-38
(2) Automatic calibration of the shifting elements (AEB)
The AEB serves to compensate tolerances (plate clearance and pressure level), which are in
fluencing the filling procedure of the clutches. For each clutch, the correct filling parameters for
* Period of the rapid - filling time
* Level of the filling equalizing pressure are defined in a test cycle.
The filling parameters are stored, together with the ABE-program and the driving program in the
transmission electronics. Because the electronics will be separately supplied, the AEB-cycle must
be started only after the installation of both components in the vehicle, thus ensuring the correct
mating (transmission and electronics).
ö At any rate, the AEB - cycle must be carried out at the vehicle manufacturer prior to the
commissioning of the vehicles.
It is imperative, to respect the following test conditions :

Shifting position neutral

Engine in idling speed

Praking brake applied

Transmission in operating temperature
ö After a replacement of the transmission the electrohydraulic control or the TCU in the vehicle the
AEB-cycle must be as well carried out again.
The AEB-cycle continues for about 3 to 4 minutes. The determined filling parameters are stored in
the EEPROM of the electronics. In this way, the error message F6 shown on the display will be
cancelled also at non - performed AEB.
ö For the start of the AEB-cycle there are principally two possibilities :

Η Start of the AEB by separate tools which are connected on the diagnostic port of the wiring.
Following tools for the AEB start will be offered by the ZF service ;

Testmann (see Diagnostic systems)

AEB Starter
Order - No. : ZGAQ-03870
The Special tool developped by the ZF can be used only for the
starting of the AEB. 180D7EPT18

Θ Start AEB by operating elements on the vehicle.

For it a CAN-communication between transmission and vehicle electronics is necessary.
ö Due to the operation of the transmission the paper friction linings installed in the ergopower
transmissions are settling, i.e. the plate clearance becomes greater.
Because these settling appearances can interfere the shifting quality, ZF recommends to repeat
the AEB-cycle at the Maintenance intervals.
ö The ZF recommends likewise at a reduced shifting quality as first measure to repeat the AEB-
cycle.

3-39
(3) Inching device
This function is especially suitable for lift trucks. It allows to reduce the driving speed infinitely
variable without modification of the engine speed in such a way that driving with a very low speed
will be possible. In his way, the driver can move the vehicle very exactly to a determined position.
At the same time and important part of the engine power for the output of the hydraulic system is
at disposal by the high engine speed.
Operation is carried out by a separate inching pedal, where an angle of rotation sensor is
mounted.
By means of the proportional valve technology the TCU regulates the pressure in the driving
direction clutch in such a way that the driving speed is adjusted in accordance with the inch
rotating angle sensor position. Clutch overloading is avoided thanks to the electronic protection.

3-40
4. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurement have to be carried out with hot transmission(about 80~95ÁC)

49 48 10 47 21 65 51 48 54

55
57

56
53

34
(See Detail-A) 63
(See Detail-B)

15

34 16

63
58

15

Detail-A Detail-B

180D7ETM04

·Pressure regulator under voltage

Engaged clutch
Driving direction Speed Y2 Y3 Y4 Y5 Y6
1 ● ● K1 KV
2 ● ● KV K2
Forward
3 ● ● K3 KV
1 ● ● KR K1
2 ● ● KR K2
Reverse
3 ● ● KR K3
Neutral
Engaged clutch KR K1 K3 KV K2
Position on valve block E D C B A
Consec. No. Of measuring points 55 56 58 53 57

3-41
1) OIL PRESSURE AND TEMPERATURE

Port Description Size

51 In front of converter - Opening pressure 11+2 bar M10x1
53 Clutch Forward 16 + 2 bar KV M10x1
55 Clutch reverse 16 + 2 bar KR M10x1
56 Clutch 16 + 2 bar K1 M10x1
57 Clutch 16 + 2 bar K2 M10x1
58 Clutch 16 + 2 bar K3 M10x1
63 Temperature sensor behind the converter M14x1.5
65 System pressure 16 + 2.5 bar M10x1

2) MEASURING POINTS FOR DELIVERY RATES

Port Description Size

15 Connection to the oil cooler M33x2
16 Connection from the oil cooler M33x2

3) INDUCTIVE TRANSMITTER - IMPURSE - SPEED SENSOR AND SWITCH

Port Description Size

21 Inductive transmitter n Turbine M18x1.5
34 Speed sensor n Output an speedometer -
47 Inductive transmitter n Central gear train M18x1.5
48 Inductive transmitter n Engine M18x1.5
54 Filter contamination switch M14x1.5

4) CONNECTIONS

Port Description Size

10 Breather -
49 Plug connection on electro-hydraulic control unit -

3-42
 5. DRIVE AXLE
1) STRUCTURE 1

413

412
411 419 528
415 539
408 406 540
403 414
405
533
409 402 425
417
536
406 538535
409 534
532
418 530 529 531
404
416
420
422 428
427
400 421 401 439
423
573
583
432
433
434
436
445
441
440
444

100D7DR02

400 Differential & carrier 412 Bearing bushing 422 Hexagon screw
401 Drive pinion 413 Hexagon screw 423 Hexagon screw
402 Ring gear 414 Hexagon screw 425 Hexagon screw
403 Differential housing 415 Tapered roller bearing 427 Screw plug
404 Differential housing 416 Tapered roller bearing 428 Sealing ring
405 Differential spider 417 Differential carrier 432 Tapered roller bearing
406 Differential side gear 418 Hexagon screw 436 Tapered roller bearing
408 Differential pinion 419 Setting ring 440 Radial seal ring
409 Disk 420 Setting ring 444 Drive flange
411 Thrust washer 421 Lock plate 445 Adjusting nut

3-43
 2) STRUCTURE 2

280
278 273
279 272
260

259
258
252 263
264

251
250 273
266 272
251
265
250 269
262

261
283

281
271
282

100D7DR03

250 Inner disk 263 O-ring 280 Bleeder valve

251 Outer disk 266 Hexagon screw 281 Pipe
252 Piston 269 Hex socket screw 282 Hexagon screw with flange
258 Gasket 271 Face seal 283 Compression spring
259 Gasket 272 Screw plug
260 Brake carrier 273 Sealing ring
261 Housing 278 Bleeding socket
262 O-ring 279 Sealing ring

3-44
 3) STRUCTURE 3

336

338
337

333
324
322

329

331
324

340
335
300
320

314

316

310
311
304

308 312
305 307
306
100D7DR04

300 Planetary housing 314 Sun gear 335 Ring gear

304 O-ring 316 Circlip 336 Ring gear carrier
306 Sealing ring 320 Thrust ring 337 Retainer
307 Screw plug 322 Planetary gear 338 Hexagon socket screw
308 Sealing ring 324 Thrust washer 340 O-ring
310 Adjusting screw 329 Needle bearing
311 Slotted nut 331 Planetary pin
312 Hexagon socket screw 333 Locking pin

4) OPERATION
Both sides of the housing are supported by the frame and the center is mounted on the
transmission case through propeller shaft.
The mast is installed on the front of the drive axle housing. The final deceleration and differential
device built in the housing guarantee accurate rotation and smooth operation.
The power from the transmission in transferred through the hypoid pinion, hypoid gear, differential
case, the pinion of the differential device and the side gear to the drive axle shaft by the side gear
spline and to the hub and wheel mounted on the shaft by high tension bolts.

3-45
6. TIRE AND WHEEL

D507AX68

1 Wheel rim 3 Lock ring 5 Valve assembly

2 Tire 4 Side ring 6 Wheel nut

1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work.

3-46