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(1) Normal
There's no failure detected in the transmission system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations. (See
following table)
(2) Substitute clutch control
TCU can't change the gears or the direction under the control of the normal clutch modulation.
TCU uses the substitute strategy for clutch control. All modulations are only time controlled.
(Comparable with EST 25)
(3) Limp-home
The detected failure in the system has strong limitations to transmission control. TCU can
engage only one gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator
must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector
into forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limphome gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home
gear of the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The
operator has to slow down the vehicle and must shift the gear selector into neutral position.
(4) Transmission-shutdown
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to neutral. The park brake will operate normally, also the other functions
which use ADM1 to ADM8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
(5) TCU-shutdown
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The
park brake will engage, also functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
Abbreviations
OC
: Open circuit
SC
: Short circuit
OP mode : Operating mode
TCU
: Transmission control unit
EEC
: Electronic engine controller
PTO
: Power take off
3-31
12
13
15
16
21
22
3-32
Fault code
(Hex)
23
24
25
26
27
OP mode : Normal
OP mode : Normal
3-33
Fault code
(Hex)
28
29
30
31
32
OP mode : Normal
3-34
Fault code
(Hex)
33
34
35
36
37
38
C
heck the cable from TCU to the
sensor
Check the connectors
Check the speed sensor
This fault is reset after power up of
TCU
Check the cable from TCU to the
sensor
Check the connectors
Check the speed sensor
Check the sensor gap
3-35
Fault code
(Hex)
39
3A
3B
3C
3D
3E
3-36
C
heck the cable from TCU to the
sensor
Check the connectors
Check the speed sensor
Fault code
(Hex)
71
73
O.C. at clutch K1
The measured resistance value of the
valve is out of limit
Cable/connector is defective and has no
contact to TCU
Regulator has an internal defect
74
C
heck the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
Check the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
Check the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
72
75
76
C
heck the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
Check the cable from TCU to the
TCU shifts to neutral
O.C. at clutch K2
gearbox
The measured resistance value of the OP mode : Limp home
If failure at another clutch Check the connectors from gearbox
valve is out of limit
Cable/connector is defective and has no is pending
to TCU
Check the regulator resistance*
contact to TCU
TCU shifts to neutral
Regulator has an internal defect
OP mode : TCU shutdown Check internal wire harness of the
gearbox
* See page 3-52
TCU shifts to neutral
OP mode : Limp home
If failure at another clutch
is pending
TCU shifts to neutral
OP mode : TCU shutdown
3-37
Fault code
(Hex)
77
C
heck the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
78
79
7A
7B
7C
7D
7E
3-38
Fault code
(Hex)
7F
81
82
83
84
85
O.C. at clutch K4
The measured resistance value of the
valve is out of limit
Cable/connector is defective and has
contact to TCU
Regulator has an internal defect
No reaction
OP mode : Normal
C
heck the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
C
heck the cable from TCU to the
engine derating device
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
Check the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
Check the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
3-39
C
heck the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
Fault code
(Hex)
86
O.C. at clutch KV
The measured resistance value of the
valve is out of limit
Cable/connector is defective and has
contact to TCU
Regulator has an internal defect
87
88
C
heck the cable from TCU to the
gearbox
Check the connectors from gearbox
to TCU
Check the regulator resistance*
Check internal wire harness of the
gearbox
* See page 3-52
Check the cable from TCU to the
TCU shifts to neutral
OP mode : Limp home
gearbox
If failure at another clutch Check the connectors from gearbox
is pending
to TCU
Check the regulator resistance*
TCU shifts to neutral
OP mode : TCU shutdown Check internal wire harness of the
gearbox
* See page 3-52
89
O.C. at clutch KR
The measured resistance value of the
valve is out of limit
Cable/connector is defective and has no
contact to TCU
Regulator has an internal defect
91
3-40
Fault code
(Hex)
92
93
94
95
96
No reaction
OP mode : Normal
No reaction
OP mode : Normal
No reaction
OP mode : Normal
C
heck the cable from TCU to the
stater interlock relay
Check the connectors from starter
interlock relay to TCU
Check the resistance* of starter
interlock relay
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to the
starter interlock relay
Check the connectors from starter
interlock relay to TCU
Check the resistance* of starter
interlock relay
* See page 3-52
No reaction
O.C. at relay starter interlock
TCU detected a wrong voltage at the OP mode : Normal
output pin, that looks like a O.C. for this
output pin
C a b l e i s d e fe c t i ve a n d h a s n o
connection to TCU
Starter interlock relay has an internal
defect
Connector has no connection to TCU
3-41
Fault code
(Hex)
97
98
99
9A
9B
C
No reaction
heck the cable from TCU to the
Optional : Some
park brake solenoid
Check the connectors from park
customers
TCU shifts to neutral
brake solenoid to TCU
caused by park brake feed Check the resistance* of park brake
back
solenoid
OP mode : Normal
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to the
converter clutch solenoid
C h e ck t h e c o n n e c t o r s f r o m
converter clutch solenoid to TCU
Check the resistance* of park brake
solenoid
* See page 3-52
3-42
Fault code
(Hex)
9C
9D
9E
9F
No reaction
OP mode : Normal
C
heck the cable from TCU to the
converter clutch solenoid
C h e ck t h e c o n n e c t o r s f r o m
converter clutch solenoid to TCU
Check the resistance* of converter
clutch solenoid
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to the
retarder solenoid
Check the connectors from retarder
solenoid to TCU
Check the resistance* of retarder
solenoid
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to the
retarder solenoid
Check the connectors from retarder
solenoid to TCU
Check the resistance* of retarder
solenoid
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to the
retarder solenoid
Check the connectors from retarder
solenoid to TCU
Check the resistance* of retarder
solenoid
* See page 3-52
3-43
Fault code
(Hex)
A1
A2
A3
A4
A5
A6
No reaction
OP mode : Normal
C
heck the cable from TCU to the
difflock solenoid
Check the connectors from difflock
solenoid to TCU
Check the resistance* of difflock
solenoid
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to the
difflock solenoid
Check the connectors from difflock
solenoid to TCU
Check the resistance* of difflock
solenoid
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to the
difflock solenoid
Check the connectors from difflock
solenoid to TCU
Check the resistance* of difflock
solenoid
* See page 3-52
No reaction
OP mode : Normal
No reaction
OP mode : Normal
C
heck the cable from TCU to the
warning device
Check the connectors from warning
device to TCU
Check the resistance* of warning
device
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to the
warning device
Check the connectors from warning
device to TCU
Check the resistance* of warning
device
* See page 3-52
3-44
Fault code
(Hex)
B1
Slippage at clutch K1
TCU calculates a differential speed at
closed clutch K1. If this calculated value
is out of range, TCU interprets this as
slipping clutch
Low pressure at clutch K1
Low main pressure
Wrong signal at internal speed sensor
Wrong signal at output speed sensor
Wrong size of the sensor gap
Clutch is defective
Slippage at clutch K2
TCU calculates a differential speed at
closed clutch K2. If this calculated value
is out of range, TCU interprets this as
slipping clutch
Low pressure at clutch K2
Low main pressure
Wrong signal at internal speed sensor
Wrong signal at output speed sensor
Wrong size of the sensor gap
Clutch is defective
Slippage at clutch K3
TCU calculates a differential speed at
closed clutch K3. If this calculated value
is out of range, TCU interprets this as
slipping clutch
Low pressure at clutch K3
Low main pressure
Wrong signal at internal speed sensor
Wrong signal at output speed sensor
Wrong size of the sensor gap
Clutch is defective
Slippage at clutch K4
TCU calculates a differential speed at
closed clutch K4. If this calculated value
is out of range, TCU interprets this as
slipping clutch
Low pressure at clutch K4
Low main pressure
Wrong signal at internal speed sensor
Wrong signal at turbine speed sensor
Wrong size of the sensor gap
Clutch is defective
B2
B3
B4
3-45
Fault code
(Hex)
B5
Slippage at clutch KV
TCU calculates a differential speed at
closed clutch KV. If this calculated value
is out of range, TCU interprets this as
slipping clutch
Low pressure at clutch KV
Low main pressure
Wrong signal at internal speed sensor
Wrong signal at turbine speed sensor
Wrong size of the sensor gap
Clutch is defective
Slippage at clutch KR
TCU calculates a differential speed at
closed clutch KR. If this calculated value
is out of range, TCU interprets this as
slipping clutch
Low pressure at clutch KR
Low main pressure
Wrong signal at internal speed sensor
Wrong signal at turbine speed sensor
Wrong size of the sensor gap
Clutch is defective
Overtemp sump
TCU measured a temperature in the oil
sump that is over the allowed threshold.
Overtemp retarder
TCU measured a temperature in the
retarder oil that is over the allowed
threshold
Overspend engine
B6
B7
B8
B9
BA
C
heck pressure at clutch KV
Check main pressure in the system
Check sensor gap at internal speed
sensor
Check sensor gap at turbine speed
sensor
Check signal at internal speed
sensor
C heck signal at turbine speed
sensor
Replace clutch
Check pressure at clutch KR
TCU shifts to neutral
OP mode : Limp home
Check main pressure in the system
If failure at another clutch Check sensor gap at internal speed
is pending
sensor
Check sensor gap at turbine speed
TCU shifts to neutral
OP mode : TCU shutdown
sensor
C heck signal at internal speed
sensor
Check signal at turbine speed
sensor
Replace clutch
Cool down machine
No reaction
Check oil level
OP mode : Normal
Check temperature sensor
Cool down machine
TCU disables retarder
Check oil level
OP mode : Normal
Check temperature sensor
TCU shifts to neutral
OP mode : Limp home
If failure at another clutch
is pending
TCU shifts to neutral
OP mode : TCU shutdown
Retarder applies
OP mode : Normal
No reaction
Differential pressure oil filter
TCU measured a voltage at differential OP mode : Normal
pressure switch out of the allowed range
Oil filter is polluted
Cable/connector is broken or cable/
connector is contacted to battery voltage
or vehicle ground
Differential pressure switch is defective
3-46
C
heck oil filter
C h e c k w i r i n g f r o m T C U t o
differential pressure switch
C h e ck d i f fe r e n t i a l p r e s s u r e
switch(Measure resistance)
Fault code
(Hex)
BB
BD
BE
BF
No reaction
OP mode : Normal
No reaction
OP mode : Normal
No reaction
OP mode : Normal
C
heck the cable from TCU to the
engine brake solenoid
Check the connectors from engine
brake solenoid to TCU
Check the resistance* of engine brake
solenoid
* See page 3-52
3-47
Fault code
(Hex)
C3
C4
C5
C6
No reaction
OP mode : Normal
No reaction
OP mode : Normal
No reaction
OP mode : Normal
C
heck the cable from TCU to
joystick status indicator
Check the connectors from joystick
status indicator to TCU
Check the resistance* of joystick
status indicator
* See page 3-52
No reaction
OP mode : Normal
C
heck the cable from TCU to
joystick status indicator
Check the connectors from joystick
status indicator to TCU
Check the resistance* of joystick
status indicator
* See page 3-52
3-48
Fault code
(Hex)
D1
D2
D3
D4
D5
D6
Shift to neutral
OP mode : TCU shutdown
Check fuse
Shift to neutral
OP mode : TCU shutdown Check cables from gearbox to TCU
Check connectors from gearbox to
TCU
Replace TCU
3-49
Fault code
(Hex)
E1
E2
E3
E4
E5
E6
No reaction
OP mode : Normal
No reaction
OP mode : Normal
C
heck the cable from TCU to the
display
Check the connectors at the display
Change display
3-50
Fault code
(Hex)
F1
F2
F3
F5
F6
Replace TCU
Often shown together with fault
code F2
Transmission stay neutral Reprogram the correct configuratOP mode : TCU shutdown
ion for the vehicle (e.g. with cluster
controller,...)
No reaction
OP mode : Normal
3-51
G
76043PT19
Open circuit
R12 = R1G = R2G =
Short cut to ground R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to ground, G is connected to vehicle ground)
Short cut to battery
R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to battery, G is connected to battery voltage)
(2) Cable
UBat
P(Power supply)
TCU
2 Actuator/
Sensor
C(Chassis)
Ground
76043PT20
Open circuit
Short cut to ground
Short cut to battery
3-52