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SECTION 21 - TRANSMISSION 267

2.15 FAULT FINDING

Before attempting any fault finding ensure you have

a suitable multimeter for checking component conti-
nuity. When fault finding remember that with an elec-
trical concern it is often a minor fault that may have
occurred and could be as simple as:
Z Poor continuity between connector pins.
Z Condensation in the connectors.
Z Disconnected cables.
Z Damaged or broken wires all of which could result
in a no drive situation but easily remedied when
found and corrected.
It should also be remembered that mechanical prob-
lems could result in fault codes appearing on the F28292

LED display.

INDICATION OF FAULTS
In case a fault is present during normal operation
and is detected by the microprocessor, both the T-
LED and N-LED may be blinking in some way as
F N R T N
shown in the table below.

NOTE: on an open circuit or on a battery connection

(+), at the ON/OFF outputs, a detection is made only 1 2 3 4 5 6 7 8
when the corresponding output is in the OFF posi-
tion. 1 2 3 4
Also a short to ground is only detected while the out-
put is on.
F28358

LED - T LED - N CONDITION SITUATION

(Orange) (Red)
Off Off Normal operation -
Off On Normal operation - N selected -
Off Blinks Blinks Normal operation - N selected/speed -
too high
On Off Diagnostic mode was activated at power up -
On On Controller in RESET - malfunction Fault
On Blinks Self calibration in progress -
Blinks On Last fault currently shown on display Fault
Blinks Blinks slower Input fault detected Fault
Blinks Blinks in phase Non critical output fault detected Fault
Blinks Blinks faster Safety critical output fault detected Fault
Blinks fast Blinks out of phase System shutdown - Neutral till power down Fault
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268 SECTION 21 - TRANSMISSION

LED DISPLAYED FAULTS

If a fault is, or there have been (intermittent faults)
present, a detailed fault display can be selected by
placing: the Powershift lever in neutral position and
pressing the kickdown button. The indicated fault on
the LED display can then be localized by using the
table below, until power down.

FAULT GROUP
The faults are displayed using 2 LEDs on the 8 LED
display. Faults are displayed as 3 subgroups - F N R T N
Group A:

FAULT SUBGROUP A GROUP INDICATION

Input related LED 1 blinks red 1 2 3 4 5 6 7 8
Output related LED 2 blinks red
Other LED 3 blinks red

A B
Within each group several faults are possible. The F28359

second LED’s position - Group B, indicates the fault

area, where the colour indicates the fault type. Typi-
cally an open circuit condition is shown using an or-
ange LED where a short circuit condition is indicated
with a red LED. Once the fault code has been deter-
mined proceed to fault codes.

FAULT GROUP FAULT GROUP PROBLEM FAULT CODE

LED (A) LED (B)
None None No fault active -
1 Red 4 Orange Shift lever input fault F1
1 Red 5 Orange Speed sensor open circuit F2
1 Red 5 Red Speed sensor in short F3
1 Red 7 Green Battery over voltage F4
2 Red 4 Orange Open circuit on one or both direction outputs F5
2 Red 4 Red Direction output forced to plus - critical fault F6
2 Red 5 Orange Other output open circuit F7
2 Red 5 Red Red Other output short circuit F8
2 Red 6 Orange Modulation output open circuit F9
2 Red 6 Red Modulation output short circuit F10
3 Red 5 Red Start-up fault - limp home mode selected F11
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SECTION 21 - TRANSMISSION 269

SHIFT LEVER INPUT FAULT CODE F1

Perform input test

This test is used to verify operation of the shift lever F N R T N
and its inputs. Blinks Slower
Blink
In this mode driving is possible.
Blinks Blinks

NOTE: the gear position indicators on the micro-

1 2 3 4 5 6 7 8
processor top cover are used to display the test in-
formation.
1 2 3 4

F28360

INPUT TEST REQUIREMENTS: with the powershift

lever in forward position and set to upshift (keep the
lever in this position during start-up), start the ma-
chine. The microprocessor shifts to the input test
mode. As shown in the table below placing the shift
lever in different positions in this mode illuminates its
respective LED (only 2 at the same time).

IMPORTANT: self test modes can only be started

WHILE POWERING UP (ignition on). Leaving the
self test mode is done by switching OFF the power
of the Microprocessor (ignition off).

POWERSHIFT LEVER POSITIONS - WITH UP LED - LED COLOUR - DISPLAYED = Ok

AND DOWNSHIFT SELECTION NUMBER
Neutral 2 RED
Neutral and upshift 3 RED
Neutral and downshift 1 RED
Forward 2 GREEN
Forward and upshift 3 GREEN
Forward and downshift 1 GREEN
Reverse 2 ORANGE
Reverse and upshift 3 ORANGE
Reverse and downshift 1 ORANGE
Operate disconnect button on loader lever 5 (*) (**) GREEN
Operate 4WD switch on instrument panel 6 (*) (**) GREEN
Foot brake test + 4WD 6 (**) GREEN
Foot brake test + 4WD 7 (*) RED
Transmission in automatic mode 7 (*) RED
Temperature and speed sensor: to test disconnect 8 RED
lead on the sensor and short to ground

*= Auto transmission only

**= Auto/Manual override
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270 SECTION 21 - TRANSMISSION

Key on power
YES
T-LED Blinks No input fault
N-LED Blinks Slower NO
YES
Select neutral and push kickdown
button:
= LED 1 red
= LED 4 orange NO Other input fault

YES YES
Input fault: forward/reverse Check through
Replace the powershift lever unit F2, F3, F4 or F11

YES
Test with new powershift
lever unit fitted
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SECTION 21 - TRANSMISSION 271

SPEED SENSOR / FAULT CODE F2 AND F3

A fault indication on the display is given to warn of
this problem.
F N R T N
If a speed sensor fault is detected the microproces-
Blinks Slower
sor will modify its behaviour in the following areas: Blinks
Blink

Z no upshifts will be allowed above second gear. Blinks 5

Z direction change while in F3 or F4: the actual re-
versal is preceded by a downshift sequence until 1 2 3 4 5 6 7 8
second gear is obtained.
Z 4WD braking remains operative. 1 2 3 4
NOTE: that the system response in this case is iden-
tical to the response in case of a power supply over- F28361

voltage.

Speed sensor test using the turbine speed dis-

play Turbine rpm LED
0 1 blinks
NOTE: a lamp test is performed prior to the speed
sensor test and monitors all LEDs are operational. 0 - 249 1 on
250 - 499 2 on
SPEED SENSOR TEST REQUIREMENTS: power-
shift lever to be in reverse position, twist to upshift 500 - 749 3 on
(keep the shift lever in this position during power up) 750 - 999 4 on
turn the ignition on and start the engine.
With engine running return Powershift lever to neu- 1000 - 1249 5 on
tral position and then place lever in forward and twist 1250 - 1499 6 on
to upshift. Increase engine speed and compare with
the table opposite. 1500 - 1749 7 on
1750 - 1999 8 on
IMPORTANT: self test modes can only be started
WHILE POWERING UP (ignition on). Leaving the above 2000 8 blinks
self test mode is done by switching OFF the power
to the Microprocessor (ignition off).

In this mode driving is possible.

The LED corresponding with the table opposite illu-
minates to indicate the torque converter turbine
speed and increases with engine revs.

NOTE: application of the foot brakes during this test

will reduce the turbine speed to zero.
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272 SECTION 21 - TRANSMISSION

Speed sensor test okay NO Key on power

YES YES

End T-LED Blinks

NO No input fault
N-LED Blinks Slower
YES
Select neutral and push kickdown
button:
= LED 1 red
= LED 1 red Other input fault
= LED 5 orange (F2) NO NO
= LED 5 red (F3)
YES YES YES
Check wires from speed sensor CV pin A to Powershift Refer to F1, F4
Repair NO lever unit pin A or CV pin J to pin U, and continuity test. or F11
Does it test OK?

YES
Check speed sensor has it failed
NO

Change lever unit CV15 (A) CV07 (J)

NO
100 Ω
If static is 0.6 - 0.8 V
or 1.3 - 1.5 V
+ 12 V

YES F28371

Replace sensor
If static is not 0.6 - 0.8 V or
1.3 - 1.5 V

F28370
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SECTION 21 - TRANSMISSION 273

FAULT CODE F4 / BATTERY OVERVOLTAGE

(17 V +)

Over voltage F N R T N
Even power supply levels up to 30 V will not damage Blinks Slower
Blink
system components.
Above a power supply of 17 Vdc: Blinks
Blinks
Group Fault 1 - Fault code 7.
1 2 3 4 5 6 7 8
NOTE: the speed sensor system will not operate
when an overvoltage is present. 1 2 3 4

F28362

Above a power supply of 24 Vdc:

the analogue signals are not reliable to convert any
more.
Over voltage: when the voltage exceeds 17 Vdc. F N R T N
Action of the Microprocessor:
Z no upshifts above second gear.
Z direction change while in Forward 3 or Forward 4:
the actual reversal is preceded by a downshift se- 1 2 3 4 5 6 7 8
quence until second gear is obtained.
1 2 3 4

+ 24 VDC F28363

Z brake switch activation always engages 4WD.

NOTE: with voltages below 8 Vdc, the microproces-

sor enters the reset mode. F N R T N

Intermittent power loss

After power is restored, the microprocessor goes
1 2 3 4 5 6 7 8
through the reset mode.

1 2 3 4

- 8 VDC F28364
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274 SECTION 21 - TRANSMISSION

Key on power
YES
T-LED Blinks No input fault
NO
N-LED Blinks Slower
YES

Select neutral and push kickdown Other input fault

button: NO Check through F1, F2, F3 or
1 red - 7 green F11
YES
Check battery voltage above
NO
17.7 Volts
YES
Check dual battery connection is Disconnect and
parallel and okay NO
reconnect correctly
YES YES

Repair or Check alternator output

NO is it correct
replace
YES
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SECTION 21 - TRANSMISSION 275

FAULT CODE F5 AND F6 / OPEN CIRCUIT

DIRECTION OUTPUTS

Direction selection related outputs (E06-Pin P, F N R T N

E07-Pin N): Blinks Faster
Blink
A short to plus is considered as a critical fault. Shorts
to plus usually result in being blocked in either For- Blinks Blinks

ward or Reverse. If both are on simultaneously, the

transmission Behaviour depends on the state of a 1 2 3 4 5 6 7 8
mechanical interlock inside the transmission.
1 2 3 4

F28365

In this case the Microprocessor normally turns on

the pressure modulator (E03-Pin T). This results in
immediate selection of neutral regardless of the ori-
1 2
gin of the fault. Indeed even in case the short to plus A
B M
is applied externally, this response effectively blocks
C N L
the transmission in neutral. P U
If however at the time the fault was detected a fault D V K
was also present on the pressure modulator, the mi- R T
croprocessor reverts to shutdown mode and re- E S J
mains this way until power is removed. Shutdown F H
G
mode is a state in which power is removed from the
microprocessor outputs by opening the internal re-
dundant shutdown path. F4288

This only helps if the fault was caused by the micro-

processor internally.
Additionally, during program execution, critical vari-
ables are continuously checked for contents integri-
ty.

Gearshifts
low/high solenoid:
inactive = forward high is selected
active = forward low is selected

SHIFT FORWARD REVERSE

DIAGRAM -
SOLENOIDS
1 2 3 4 12
reverse/n XX
forward/n
low/high XXXX
1st/2nd XX X
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276 SECTION 21 - TRANSMISSION

During the output test LEDs 1234567 one by one are used and by
colour identifies the possible component at fault. Green= No fault
Red = Short circuit NO
found
Yellow = open circuit or short to battery plus
YES YES
Identify component by LED Identify component by LED
1 - Forward solenoid 1 - Forward solenoid
2 - Reverse solenoid 2 - Reverse solenoid
3 - 1/2 Solenoid 3 - 1/2 Solenoid
4 - High/low forward travel solenoid 4 - High/low forward travel solenoid
5 - 4WD/RWD solenoid 5 - 4WD/RWD solenoid
6 - Direction modulation solenoid 6 - Direction modulation solenoid
7 - Range modulation solenoid 7 - Range modulation solenoid
YES YES
Example: LED 1(red) forward solenoid Example: LED 2 (orange) reverse
output shorted to ground or a solenoid output open circuit or shorted
component. to battery plus
Check component and continuity of the Check component and continuity of the
cables and connectors cables and connectors output test

Output test
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SECTION 21 - TRANSMISSION 277

OUTPUT FAULT - LED COLOUR

OUTPUT TEST REQUIREMENTS: powershift lever
to be in forward position, twist clockwise to downshift
and turn ignition on.
In this mode, driving is not possible, since all micro-
processor outputs remain off until the test mode is
left.
The colour and number of the LED indicates its sta-
tus:

COLOUR STATUS
GREEN Output OK
ORANGE Output not connected
or shorted to battery
plus
RED Output shorted to
ground (or to another
output)

Output test - Fault by LED Number

The LED numbers correspond to the connector out-

put wires as follows:
Example:
LED 1 = Forward solenoid - colour
Orange = (Output not connected or shorted to bat-
tery plus)

LED OUTPUT OUTPUT

NUMBER WIRE FUNCTION 1 2
A
B M
1 E06 Forward solenoid
C N L
2 E07 Reverse solenoid P U
D V K
R T
E S J
F H
G

F4288
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278 SECTION 21 - TRANSMISSION

Key on power
YES
T-LED Blinks Safety critical
NO output
N-LED Blinks Faster
YES
Other output fault
Select neutral and push kickdown button forced to plus
(F5) open circuit: 2 red - 4 orange NO (F6) 2 red - 4 red NO

YES YES
All LEDs green Perform output test - fault Other LEDs are
NO NO
and OK found? orange
YES YES YES
Led 1 orange Led 2 orange Proceed to F7, F8,
YES YES F9 or F10
Check the forward cable Check the reverse cable
of the powershift lever: of the powershift lever: is
Repair or YES is it faulty? it faulty?
replace NO YES NO

Check forward travel solenoid Check reverse travel solenoid

Repair or YES resistance: is it faulty? resistance: is it faulty?
replace NO YES NO

Check internal wires in forward travel Check internal wires in reverse

Repair or YES solenoid: are they faulty? travel solenoid: are they faulty?
replace
NO YES NO

Replace the
powershift lever
unit

F28372
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SECTION 21 - TRANSMISSION 279

FAULT CODE F7 AND F8 / OUTPUT FAULT -

STATUS BY LED COLOUR
OUTPUT TEST REQUIREMENTS: powershift lever
to be in forward position, twist clockwise to downshift
F N R T N
Blinks Blinks
and turn ignition on. Blinks
in Phase

In this mode, driving is not possible, since all micro- Blinks 5

processor outputs remain off until the test mode is
left. 1 2 3 4 5 6 7 8
The colour and number of the LED indicates its sta-
tus: 1 2 3 4
COLOUR STATUS
F28367
GREEN Output OK
ORANGE Output not connected
or shorted to battery
plus
RED Output shorted to
ground (or to another
output)

Output test - Fault by LED Number

The LED numbers correspond to the connector out-
put wires as follows:
Example:
LED colour Red and numbered 3 = 1/2 solenoid out-
put shorted to ground.

LED OUTPUT OUTPUT

NUMBER WIRE FUNCTION 4 5
A
B M
3 E04 1/2 Solenoid
C N L
4 E05 High/low forward P U
travel solenoid D V K
R T
5 E09 AWD/RWD E S J
solenoid F H
G
3
F4293
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280 SECTION 21 - TRANSMISSION

Key on power
YES
T-LED Blinks
NO Non critical output
N-LED Blinks in phase
fault
YES

Select neutral and push kickdown button Other output fault

(F7) open circuit: 2 red - 5 orange NO (F8) short circuit 2 NO
red - 5 red
YES YES
All LEDs green
NO Perform output test - fault found? NO Other LEDs are
and OK
orange
YES YES YES YES
Led 3 orange or red Led 4 orange or Led 5 orange or Proceed to
red red F9 or F10
YES YES YES
Check 1/2 solenoid: is Check the AWD/RWD
YES it faulty? solenoid: is it faulty?
Repair or Check the high/
NO low solenoid: is it YES NO
replace
YES faulty?
NO

Check internal and

external wiring of
affected solenoids: are
Repair or
YES they faulty?
replace
NO

Replace the
powershift lever unit

5
F28373
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SECTION 21 - TRANSMISSION 281

FAULT CODE F9 AND F10 / DIRECTION

MODULATION OUTPUT SHORT OR OPEN
CIRCUIT
A fault on this output is considered as a problem po- F N R T N
Blinks Blinks
tentially reducing transmission life. in Phase
Blinks
For this reason while a fault is persistent, the allow-
able direction change speed limit is decreased grad-
Blinks 6
ually (10%) each time a direction change was 1 2 3 4 5 6 7 8
inhibited, down to a minimum of 20% of the maxi-
mum allowable shift speed.
1 2 3 4
After a while, this can result in a severely degraded
performance (only low speed reversals are possi-
ble), but it has the advantage that the driver cannot F28368

be surprised by a sudden performance loss, which

could constitute a safety hazard in itself.

Direction Modulation Solenoid (E03) Pin T

The variable Current solenoid for direction modula-

tion is connected to the modulation Common Plus A
B M
(Pin K) at one side and to (Pin T) at the other side. 1
A programmable current is increased or reduced to C N L
P U
the solenoid controlling the modulating pressure. D V K
No current corresponds to maximum pressure. R T
S
2
Approximately 1 Amp corresponds with no pressure. E J
F H
G

F4296
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282 SECTION 21 - TRANSMISSION

Key on power
YES
T-LED Blinks
NO No fault
N-LED Blinks in phase
YES
Select neutral and push kickdown (F10)
Other non critical
button (F9) 2 red - 5 orange 2 red - 6
NO NO output fault, F7 or F8
red
YES YES
All LEDs green Direction modulator open Direction modulator short
NO
and OK circuit circuit
YES YES
Check solenoid Check solenoid resistance:
Repair or YES resistance: is it faulty? is it faulty?
replace NO YES NO

Repair or Check internal and external wiring of the direction

replace YES modulation solenoid: are they faulty?
NO

Replace the
powershift lever unit

F28374
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SECTION 21 - TRANSMISSION 283

FAULT CODE F11 / START UP FAULT LIMP

HOME SELECTED

Internal faults F N R T N
Blinks Slower
Blink
At power up a series of integrity checks is done.
If a fault is detected: Blinks
Blinks
Z and the fault prevent operation as a transmission
1 2 3 4 5 6 7 8
controller: the microprocessor locks itself in a reset
state.
Z and controlling the transmission is still possible: the 1 2 3 4
microprocessor reverts to limp home mode.
F28369
Limp Home mode

Defaulted to if an internal problem is detected at

power up.
This model automatically selected at power up if the
integrity tests show that EPROM parameters are cor-
rupt, but the microprocessor can still function as a
transmission controller (other component’s integrity
are intact).
In this mode the user can operate the transmission in
either direction in 1st and 2nd. There are no protec-
tions: all shifts are unmodulated.

Key on power
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES
Select neutral and push kickdown button Other output fault 2 red - 6 red
NO (F11) 3 red - 5 red Refer F1, F2, F3 or F4
NO
YES
Replace the
powershift lever unit
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284 SECTION 21 - TRANSMISSION

FAULTS OTHER F12

NOT IDENTIFIED BY THE LEDS
There may be situations when an individual compo-
nent develops a fault but it is not highlighted by the
LEDs. If a component is in doubt proceed to input
test as follows:

Perform Input test:

This test is used to verify the inputs.

In this mode driving is possible.

NOTE: the gear position indicators on the microproc-

essor top cover are used to display the test informa-
tion.

INPUT TEST REQUIREMENTS: the powershift le-

ver must be in forward position. Set it to upshift and
start the machine. The microprocessor shifts to the
input test mode.
As shown in the table below placing the shift lever in
different positions in this mode illuminates its respec-
tive LED.

IMPORTANT: selftest modes can only be started

WHILE POWERING UP (ignition on). Leaving the
selftest mode is done by switching OFF the power of
the microprocessor.

CHECKING OF INPUT REQUESTS LED - LED COLOUR -

NUMBER DISPLAYED
Confirm input test is okay (lever forward, neutral, reverse) and in order check as below:
1. Operate disconnect button on loader lever 5 GREEN = OKAY
2. Operate 4WD switch on instrument panel and foot brakes 6 GREEN = OKAY
3. Foot brake test on later models 7 RED = OKAY
4. Temperature and speed sensor: to test disconnect lead on 8 RED = OKAY
the sensor and short to ground
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SECTION 21 - TRANSMISSION 285

F12

Key on power
YES
Perform input test and analyse
faults if possible fault found

NO
Possible input switch faults:
4WD - Request
Repair or Brake - Request
replace YES
Declutch - Request
Direction - Request
Speed/Temp sensor

F13

Key on power
YES
Perform output test and check
range modulation LED 7 (wire
Repair or E08)
replace YES Green = Okay
Orange = Open circuit
Red = Short circuit
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286 SECTION 21 - TRANSMISSION

LIMP HOME LEAD

In the event of a total failure of the microprocessor
such as a serious cab or loom fire the vehicle can be
moved by using the limp home lead to by-pass the
microprocessor.
Tool No. - 380000715

Mounted to the left hand side and to the top of the

transmission is the microprocessor loom connector.
Disconnect the damaged loom and connect the limp 1
home lead in its place.

F11834

Connect the plug end into the 12 V auxiliary socket

or any available 12 V supply.

F11835

When seated in the cab, start the engine and make

sure that the personnel stays away from the ma-
chine. Select forward or reverse travel on the switch
and the machine will move accordingly.

NOTE: when using the limp home lead only second

gear (forward or reverse) is selectable no other
gearshift or modulation is available.