Group 20 M191en 05 2015 PDF

TRANSMISSION
- TRANSMISSION CHARACTERISTICS AND

SPECIFICATIONS
20
- TRANSMISSION SCHEMATIC DIAGRAMS
- TRANSMISSION COMPONENTS LOCATION
- TRANSMISSION CONTROL AND

ADJUSTMENT
- TRANSMISSION REMOVAL u10- ENGINE

- TRANSMISSION REFIT u10- ENGINE
- SPECIFIC TRANSMISSION TOOLING
- CHARACTERISTICS AND SPECIFICATIONS

l 647174
- COMPONENT DIAGRAMS AND CROSS
SECTIONS (Gearbox Series PS09)
- TROUBLESHOOTING
- SPECIFIC TOOLING
TRANSMISSION CHARACTERISTICS AND
20
SPECIFICATIONS
pages
PRINCIPLE OF OPERATION OF GEARBOX PS09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEARBOX PS09 TECHNOLOGIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
– «OVERLAP» . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– «LOCKUP» . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(17/05/2013) 20-01-M191FR
2 SPECIFICATIONS
PRINCIPLE OF OPERATION OF GEARBOX PS09
OPERATION
 Manual gear change from 1 to 5 by pressing +/- on the JSM (Rep. 1).
 Choice of max. automatic gear (2, 3, 4, or 5) or manual mode on control block (Rep.2).
20
In automatic mode the lowest gear engaged is the 2nd gear. However, when the forward gear
is selected, the user can “force” 1st gear by pressing button 1 (condition: speed < 5 km/h) and
reselect 2nd gear by pressing button 2 or return to neutral.
 Choice of highway driving or handling mode (max. 25km/h) on the control block (Item 3).
 Gearbox oil temperature indicator light (Item 4).
 Automatic gear change according to:

– the speed (gearbox sensor)
– the accelerator pedal position (Item 5)
– the load (automatic gear change according to the load = LSAS)
 Diagnostics and adjustment via the PAD or the APC214 (Item 6).
 Gearbox cooling circuit (Item 7).
 Negative brake circuit on gearbox (Item 8).
 In handling mode, during the braking with inching pedal phase (Item 9), the transmission is
gradually cut-off.
 "Inching" mode only works in 1st, 2nd and 3rd gears (forward and reverse).
20-01-M191FR (17/05/2013)
SPECIFICATIONS 3
OVERVIEW
20
7
AP 214
DIAG
6 APC 214
ECU Manimux
Power 1
Cluster
3
ECU Manimux
Power 2
2
Control
block
Key:
: Mechanical connection
: Hydraulic system
: Cooling circuit hot
: Cooling circuit cold
: CAN OPEN
: "Manimux" CAN A
: CAN B «J 1939»
: Electrical connections
(17/05/2013) 20-01-M191FR
4 SPECIFICATIONS
GEARBOX PS09 TECHNOLOGIES
“OVERLAP”
Clutch overlap during gear changes avoids loss of torque.

20
Oil pressure
Clutch 1 pressure
reduction
Clutch 2
«overlap» pressure
increase
Clutch filling
time
Start of gear End of gear

change phase change phase
“LOCKUP”
The PS09 transmission is equipped with a Lockup function that improves gearbox efficiency by
mechanically coupling the torque converter (Item 1). The Lockup forms a bridge between the converter
turbine and the engine. The Lockup function is represented by the "converter locking electrovalve"
i TRANSMISSION SCHEMATIC DIAGRAMS)
• Lockup is allowed by the Manimux system in 4th and 5th gears in on-road mode.
• Lockup is activated by the APC214 (gearbox ECU) according to the driving conditions (e.g.: high speed)
20-01-M191FR (17/05/2013)
TRANSMISSION SCHEMATIC DIAGRAMS
20
pages
TRANSMISSION DRIVE CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CONTROL LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
GEAR BOX DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
NEUTRAL GEAR SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1ST FORWARD GEAR SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2ND FORWARD GEAR SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3RD FORWARD GEAR SCHEMATIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4TH FORWARD GEAR SCHEMATIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5TH FORWARD GEAR SCHEMATIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1ST REVERSE GEAR SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2ND REVERSE GEAR SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3RD REVERSE GEAR SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
(06/05/2015) 20-02-M191EN
2 TRANSMISSION SCHEMATIC DIAGRAMS
TRANSMISSION DRIVE CHAIN
Front axle Rear axle
Clockwise
Engine
20
Torque
converter
Z1
Z6 Z8 Z4
Z3 Z2
Gear box Z23

Z7 Z11 Z9 Z5
Z13 Z22
Z14 Z12 Z10
Forward gear
Z24 Z25 Z26 Z24 Z25 Z26
Gear box Maximum speed (unladen)

Z1 45 teeth Forward gear ratio km/h
Z2 47 teeth 1 5
Z3 47 teeth 2 9.1
Z4 39 teeth 3 15.4
Z5 73 teeth 4 23.1
Z6 39 teeth 5 33
Z7 73 teeth ≤ 33 km/h : Verrouillage
38.9
convertisseur
Z8 50 teeth
Z9 37 teeth
Reverse gear ratio km/h
Z10 48 teeth
1 5
Z11 23 teeth
2 9.1
Z12 55 teeth
3 15.4
Z13 48 teeth
Z14 37 teeth
Front and rear axles

Z22 9 teeth
Z23 32 teeth
Z24 70 teeth
Z25 14 teeth
Z26 27 teeth
20-02-M191EN (06/05/2015)
TRANSMISSION SCHEMATIC DIAGRAMS 3
CONTROL LOGIC
20
Lockup
converter
electrovalve Steering proportional
electrovalve
High-speed forward gear
1st / 3rd gear proportional electrovalve
electrovalve
1st / 3rd gear proportional
Neutral / reverse gear High-speed forward electrovalve
electrovalve proportional electrovalve 2nd gear proportional
Low-speed forward / neutral Reverse gear electrovalve
gear electrovalve sensor
Low-speed forward
gear sensor
FORWARD GEARS
Proportional Proportional Proportional Proportional Low-speed

EV Lockup converter
SOLENOIDS electrovalve electrovalve High electrovalve electrovalve forward / neutral
1st / 3rd electrovalve
steering speed forward gear 2nd 1st / 3rd gear electrovalve
TYPES Proportional Proportional Proportional Proportional TOR TOR TOR
1st X X X X
FORWARD GEARS
2nd X X X X
3rd X X X
4th X X X X
5th X X X X
REVERSE GEARS
Proportional Proportional Proportional

Neutral / reverse EV
SOLENOIDS electrovalve electrovalve electrovalve
gear electrovalve 1st / 3rd
steering 2nd 1st / 3rd
TYPES Proportional Proportional Proportional TOR TOR
1st X X X X
REVERSE GEARS
2nd X X X X
3nd X X X
(06/05/2015) 20-02-M191EN
GEAR BOX DIAGRAM
82
20
31
37
12 32
16
11
2 71
13
38
73 81
80
Components
Item Designation
1 Main pressure regulator
2 Safety valve
11 Converter output towards transmission oil coolant
12 Transmission oil coolant return
45 13 Coolant filter inlet
46
16 Coolant filter return
41 31 Main pressure regulator pressure test port
43
32 Lubricant pressure test port
44
39 37 Converter inlet pressure test port
40 38 Converter outlet pressure test port
42 39 Lockup converter pressure test port

40 Lockup converter control pressure test port
41 1st gear pressure test port
42 2nd gear pressure test port
43 3rd gear pressure test port
44 High-speed forward clutch pressure test port
45 Low-speed forward clutch pressure test port
46 Reverse clutch pressure test port
71 Converter outlet oil temperature sensor
73 Oil sump temperature sensor
80 Turbine speed sensor
81 Gearbox output speed sensor
82 Pressure sensor
20-02-M191EN (06/05/2015)
NEUTRAL GEAR SCHEMATIC DIAGRAM

Control electrovalves
20
Lockup
converter Steering proportional
electrovalve electrovalve
EV High-speed forward gear
1st/3rd proportional electrovalve
Neutral / reverse gear 1st / 3rd gear proportional
electrovalve High-speed forward electrovalve
Low-speed forward / proportional electrovalve 2nd gear proportional
neutral gear electrovalve Reverse gear electrovalve
sensor
Low-speed forward
gear sensor
15
37 Torque converter
38 32 71 GEAR BOX
AA
Safety Fan speed control
valve: 9 bar relief valve
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
Lockup CONTROL ELECTROVALVES
converter
electrovalve 40
Pressure switch
16
Hose High-speed Steering 2nd gear 1st / 3rd gear
forward gear EV N/R 1st / 3rd gear
31 proportional proportional
electrovalve
Low-speed N / F electrovalve proportional proportional
electrovalve
electrovalve
15 electrovalve electrovalve
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Analog Analog Analog
pressure pressure pressure
switch switch switch
Pump 44 45 46 42 41 43
73 High-Speed Low-Speed Reverse 2nd 1st 3rd

Forward Gear Forward Gear Gear
Suction strainer
Breather
Oil tank
(06/05/2015) 20-02-M191EN
Analog
pressure
switch
1ST FORWARD GEAR SCHEMATIC DIAGRAM

Activated electrovalve controls
EV 1st / 3rd gear
Low-speed N / F electrovalve
20
Steering 1st / 3rd gear

proportional proportional
15
37 Torque converter
38 32 71 GEAR BOX
AA
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
Pressure electrovalve 40
switch
16
31 forward gear
Low-speed N / F
electrovalve
N/R
electrovalve
1st / 3rd gear
electrovalve
15 electrovalve electrovalve electrovalve electrovalve
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Pump 44 45 46 42 41 43

Suction strainer
Breather
Oil tank
20-02-M191EN (06/05/2015)
Analog
pressure
switch
2nd FORWARD GEAR SCHEMATIC DIAGRAM

EV
Low-speed N / F
20
Steering 2nd gear
15
37 Torque converter
38 32 71 GEAR BOX
AA
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
electrovalve 40
Pressure switch
16
Hose High-speed Steering N/R 2nd gear 1st / 3rd gear
31 forward gear
proportional proportional EV
Low-speed N / F
electrovalve proportional
electrovalve
proportional 1st / 3rd gear
electrovalve
15 electrovalve electrovalve electrovalve
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Analog Analog
pressure pressure
switch switch
Pump 44 45 46 42 41 43

Suction strainer
Breather
Oil tank
(06/05/2015) 20-02-M191EN
3rd FORWARD GEAR SCHEMATIC DIAGRAM

EV
Low-speed N / F
20

15
37 Torque converter
38 32 71 GEAR BOX
AA
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
switch
16
31 forward gear
proportional proportional EV
Low-speed N / F
N/R
electrovalve
proportional proportional 1st / 3rd gear
electrovalve
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Pump 44 45 46 42 41 43

Suction strainer
Breather
Oil tank
20-02-M191EN (06/05/2015)
4th FORWARD GEAR SCHEMATIC DIAGRAM

20
High-speed forward 2nd gear
gear proportional proportional
15
37 Torque converter
38 32 71 GEAR BOX
AA
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
Pressure electrovalve
switch
40
16
Hose High-speed
Steering N/R 2nd gear 1st / 3rd gear 1st / 3rd gear
31 forward gear
EV
Low-speed N / F electrovalve proportional proportional
electrovalve
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Pump 44 45 46 42 41 43

Suction strainer
Breather
Oil tank
(06/05/2015) 20-02-M191EN
5th FORWARD GEAR SCHEMATIC DIAGRAM

20
High-speed forward 1st / 3rd gear

gear proportional proportional
15
37 Torque converter
38 32 71 GEAR BOX
AA
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
switch
16
Hose High-speed Steering
EV
2nd gear 1st / 3rd gear 1st / 3rd gear
31 forward gear proportional N/R proportional
proportional Low-speed N / F electrovalve proportional electrovalve
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Pump 44 45 46 42 41 43

Suction strainer
Breather
Oil tank
20-02-M191EN (06/05/2015)
1st REVERSE GEAR SCHEMATIC DIAGRAM

1st / 3rd gear
N / R electrovalve electrovalve
20
15
37 Torque converter
38 32 71 GEAR BOX
AA
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
switch
16
Hose High-speed Steering EV N/R 2nd gear 1st / 3rd gear
1st / 3rd gear
31
forward gear
proportional proportional Low-speed N / F proportional proportional
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Pump 44 45 46 42 41 43

Suction strainer
Breather
Oil tank
(06/05/2015) 20-02-M191EN
2nd REVERSE GEAR SCHEMATIC DIAGRAM

N / R electrovalve
20
Steering 2nd gear

15
37 Torque converter
38 32 71 GEAR BOX
AA
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
switch
16
Hose High-speed Steering EV N/R
31
forward gear proportional
proportional proportional Low-speed N / F proportional electrovalve
electrovalve
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Pump 44 45 46 42 41 43

Suction strainer
Breather
Oil tank
20-02-M191EN (06/05/2015)
3rd REVERSE GEAR SCHEMATIC DIAGRAM

N/R
electrovalve
20
15
37 Torque converter
38 32 71 GEAR BOX
AA
12
Hose Cooler Hose

Lubrication
Relief valve:
19,5 - 22 bar
39
switch
16
Hose High-speed
forward gear
Steering EV N/R
31 proportional proportional
electrovalve
Low-speed N / F electrovalve
proportional
electrovalve
proportional electrovalve
Valve
By-pass
Filter
3,44 -
3,94 bar
14
Hose
13
Pump 44 45 46 42 41 43

Suction strainer
Breather
Oil tank
(06/05/2015) 20-02-M191EN
20
20-02-M191EN (06/05/2015)
TRANSMISSION COMPONENTS LOCATION
20
pages
CIRCUIT TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(09/01/2012) 20-03-M191FR
2 TRANSMISSION COMPONENTS LOCATION
TRANSMISSION SYSTEM
20
Rear drive axle
Gear box
Gear box filter

Front axle
20-03-M191FR (09/01/2012)
TRANSMISSION CONTROL AND ADJUSTMENT
20
pages
TRANSMISSION TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PRESSURE TEST PORT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PRESSURE TEST PORT VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
GEAR BOX OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
GEARBOX ECU REPLACEMENT (APC 214) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
GEAR BOX CALIBRATION (APC 214) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
– APC 214 PRESENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– CALIBRATION PROCEDURE WITH APC 214. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– CALIBRATION PROCEDURE WITH THE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
(03/09/2015) 20-04-M191EN
TRANSMISSION CONTROL AND
2 ADJUSTMENT
20
20-04-M191EN (03/09/2015)
ADJUSTMENT 3
TRANSMISSION TIGHTENING TORQUES
Ch
as
sis
20
Ch
as
sis
480 N.m ±4.8

62 N.m ±6
MLT 1040 L 137 ST3B

MLT-X 1040 L 137 ST3A
95 N.m ±9.5 (Tilting corrector)
95 N.m ±9.5
95 N.m ±9.5
340 N.m ±34
45 N.m ±4.5
62 N.m ±6
340 N.m ±34
33.9 ±4.1
31 N.m ±3
62 N.m ±6
95 N.m ±9.5
(03/09/2015) 20-04-M191FR
4 ADJUSTMENT
PRESSURE TEST PORT LOCATION

20
PP-42
180°
PP-32
PP-40
PP-44
PP-39 PP-45
PP-43
PP-41
PP-46
P2
PP-37
P3
P1
PP-38 PP-31
20-04-M191FR (03/09/2015)
ADJUSTMENT 5
PRESSURE TEST PORT VALUES
Pressure test Values (bar)(±0.3 bar)

Module Correspondence
port no. Min. Max.
PP-31 Main pressure regulator 18 21
PP-32 Lubricating pressure 0,5 2
PP-37 Converter inlet pressure 2 5
20
PP-38 Converter outlet pressure 2 5
PP-39 Non-interlocked lockup converter pressure (< 35 km/h) 18 21
PP-40 Interlocked lockup converter pressure switch (> 35 km/h) 18 21

Gear box
PP-41 1st gear pressure 18 21
PP-42 2nd gear pressure 18 21
PP-43 3rd gear pressure 18 21
PP-44 High-speed forward clutch pressure 18 21
PP-45 Low-speed forward clutch pressure 18 21
PP-46 Reverse clutch pressure 18 21
Note:
For PP-38 to PP-46 pressure sockets, use M10 X 1 O-ring connections (ISO 6149)
The three pressure switches P1, P2 and P3 on the electrovalve enable the Pad tool to display high-speed
Forward (PP-44), low-speed Forward (PP-45) and Reverse (PP-46) clutch pressures.
GEAR BOX OIL LEVEL
For lower machines s / n 933 278:
To facilitate control, it was noted on the dipstick into the following phases oil level:
 A cold, engine stopped (after a stop night): 16 mm above the Maxi
 A warm, engine stopped (after 1 minute): 5 mm above the Maxi
b Please note during this check, please have done well to heat the oil (50-80 ° c). The goal is to
open the oil calorstat and complete filling of the cooling system of the gearbox.
For machines above the s / n 933278:
The oil level control can be performed in the normal way l NI 647269.
GEARBOX ECU REPLACEMENT (APC 214)
The gearbox APC 214 ECU replacement procedure can be found in the PAD Diagnostic menu
e "ECU replacement"
(03/09/2015) 20-04-M191EN
6 ADJUSTMENT
GEAR BOX CALIBRATION (APC 214)
APC 214 PRESENTATION
• Digital LED display

• 3 LED states
 D = Yellow, Diagnostic modes
 E = Yellow, Error
20
 F = Red; fault or APC 200 reset

• 2 buttons
 M = Information group
 S = Item in the group
Display menu
M
M M
S S S
(FIX)
S
(FLASH)
S
END
Display Designation
GPOS Selected gear
VSPD Speed in KM/H or MPH
DIST Distance traveled
(Note: the distance can be reset to zero by pressing "s" for 3 seconds.)
OPER Number of hours operation
CPOS Position of JSM (+/-)
ESPD Engine speed in RPM
TSPD Turbine speed in RPM
OSPD Output speed in RPM
SRAT Speed ratio ( Tspd / Espd ),
TQ i Torque at gearbox input in Nm
TTMP Tank temperature
CTMP Converter outlet temperature
50 on LCD < 120° C ; 150 on LCD >120° C
Err Stored (Flash) and current (Fixed) error codes
20-04-M191EN (03/09/2015)
ADJUSTMENT 7
Transmission calibration must be performed:

• At the end of production
• After 2000 hours of operation (forward or reverse)
• After transmission maintenance
• After transmission repair or replacement
• After changing the gear box
• After changing a valve
• After changing an ECU
• After installing new software
20
PURPOSE:
To ensure correct operation of the transmission at all times
CALIBRATION PROCEDURE WITH APC 214
STEP 1
Place the machine in the following conditions:

 Transmission oil temperature > 60°C (i Step 2 for increasing the temperature)
 Engine idling (800 rpm ±200)
 In neutral
STEP 2
Press the S button, switch on the ignition and hold down S during 15 seconds to display
• If the temperature is higher than 60°C proceed to step 3.

• If the temperature is lower than 60°C:
1 - Press M until appears then press S and increase the transmission temperature.
2 - When the temperature is above 75 °C press M until is displayed
STEP 3
On the screen, press S to access calibration
STEP 4
If all the conditions are met, the ECU will ask you to press the S key to start calibration. The screen will
then display .
Calibration is started when the ECU shows the following messages: ; ; ; etc.
STEP 5
Calibrated in completed when is displayed. Switch off the ignition until the ECU switches to
stand-by then re-start the engine.
(03/09/2015) 20-04-M191EN
8 ADJUSTMENT
CALIBRATION PROCEDURE WITH THE PAD
Select the transmission ECU (Item 1)

1
20
Select "calibration" (Item 2) then "calibration transmission"

(transmission calibration).
2 Validate the calibration.
Bring the engine oil temperature up to 65 °C (Item 3) by following

the instructions.
3
Validate then follow the instructions on the screen.
Calibration begins (time = between 15 and 20 minutes), follow the

instructions on the screen.
Calibration is finished when "Calibration effectuée"

(Calibration completed) appears on the screen.
20-04-M191EN (03/09/2015)
TRANSMISSION TROUBLESHOOTING
20
pages
ERROR CODES (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– GEARBOX CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
(04/06/2013) 20-08-M191EN
2 TRANSMISSION TROUBLESHOOTING
ERROR CODES (DTC)
GEARBOX
Error code
DANA (Hexadecimal) (Decimal) Components Description of error Cause of fault Repair
APC Error Fault Error Fault
214 code type code type
20
The measured value of analog

Analog input 5 - wire B04:
input 5 is higher than the
higher voltage than normal
15.03 7F015 03 520213 03 permitted maximum range. The
or short-circuit to positive
Converter input is definitely short-circuited
(SC+) - Check the wiring
outlet oil to the positive.
temperature The measured value of analog between APC 214 and the
sensor Analog input 5 - wire B04: device connected to this
input 5 is lower than the
lower voltage than normal analog input.
or short-circuit to negative
input is definitely short-circuited
(SC-) - Check the installation
to the ground (negative).
and the operation of the
The measured value of analog connected device.
Analog input 7 - wire A13:
input 7 is higher than the
higher voltage than normal
17.03 7F017 03 520215 03 permitted maximum range. The - Refer to the other errors
or short-circuit to positive
input is definitely short-circuited reported to identify the
(SC+)
Sump oil to the positive. analog input data value
temperature The measured value of analog concerned.
Analog input 7 - wire A13:
input 7 is lower than the
lower voltage than normal
input is definitely short-circuited
(SC-)
to the ground (negative).
The current measured in the

Speed input 0 - wire A22: speed sensor circuit is lower than
1A.05 7F01A 05 520218 05 lower current than normal normal. The input certainly has a
or open circuit loose connection or is short-
Turbine speed circuited to the positive. - Check the wiring
sensor between APC 214 and the
Speed input 0 - wire A22: speed sensor circuit is higher sensor connected to this
1A.06 7F01A 06 520218 06 higher current than normal than normal. The input is certainly speed input.
or grounded circuit short-circuited to the ground
(negative). - Check the installation
The current measured in the connected sensor.
Speed input 1 - wire A24: speed sensor circuit is lower than
1B.05 7F01B 05 520219 05 lower current than normal normal. The input certainly has a - Refer to the other errors
or open circuit loose connection or is short- reported to identify
Output speed circuited to the positive. the speed data value
sensor concerned.
Speed input 1 - wire A24: speed sensor circuit is higher
1B.06 7F01B 06 520219 06 higher current than normal than normal. The input is certainly
or grounded circuit short-circuited to the ground
(negative).
Power output 0 - wire A2- Dynamic monitoring of power
A3 : higher voltage than output 0 by the APC 214 has - Check the wiring
20.03 7F020 03 520224 03 between APC 214 and the
normal or short-circuit to detected that the output is short-
Forward/ positive (SC+) circuited to the positive. device connected to this
reverse power output.
proportional Dynamic monitoring of power
Power output 0 - wire A2-
electrovalve output 0 by the APC 214 has - Check the installation
A3 : lower voltage than
20.04 7F020 04 520224 04 detected that the output is and the operation of the
normal or short-circuit to
short-circuited to the ground connected actuator.
negative (SC-)
(negative).
20-08-M191EN (04/06/2013)
TRANSMISSION TROUBLESHOOTING 3
Error code

20.05 7F020 05 520224 05 A3: lower current than
normal or open circuit
Forward/ Dynamic monitoring of power

reverse output 0 by the APC 214 has
20.06 7F020 06 520224 06 A3: higher current than
proportional detected that the output is in
normal or grounded circuit
electrovalve open circuit (loose connection).
20
20.08 7F020 08 520224 08 A3: abnormal frequency,
pulse width or period

A5: higher voltage than output 1 by the APC 214 has
21.03 7F021 03 520225 03
positive (SC+) circuited to the positive.
Dynamic monitoring of power
output 1 by the APC 214 has
A5: lower voltage than
21.04 7F021 04 520225 04 detected that the output is
short-circuited to the ground
negative (SC-)
(negative).
Proportional Dynamic monitoring of power

electrovalve output 1 by the APC 214 has
1st/3rd detected that the output is in
normal, or open circuit
open circuit (loose connection).

normal or grounded circuit Dynamic monitoring of power
output 0 by the APC 214 has - Check the wiring
detected that the output is in between APC 214 and the
Power output 1 - wire A4- open circuit (loose connection). device connected to this
21.08 7F021 08 520225 08 A5: abnormal frequency, power output.
- Check the installation
Power output 2 - wire A6- Dynamic monitoring of power and the operation of the
A7: higher voltage than output 2 by the APC 214 has connected actuator.
22.03 7F022 03 520226 03
positive (SC+) circuited to the positive.
negative (SC-)
(negative).
Proportional Dynamic monitoring of power

2nd detected that the output is in

normal or grounded circuit Dynamic monitoring of power
detected that the output is in
Power output 2 - wire A6- open circuit (loose connection).

A9: higher voltage than output 3 by the APC 214 has
23.03 7F023 03 520227 03
High-speed positive (SC+) circuited to the positive.
forward gear
proportional Dynamic monitoring of power
negative (SC-)
(negative).
(04/06/2013) 20-08-M191EN
Error code

High-speed
forward gear Power output 3 - wire A8-
23.06 7F023 06 520227 06 proportional A9: higher current than
electrovalve normal or grounded circuit Dynamic monitoring of power
20

Power output 3 - wire A8- open circuit (loose connection).
Power output 4 - wire B01: Dynamic monitoring of power

higher voltage than normal output 4 by the APC 214 has
24.03 7F024 03 520228 03
or short-circuit to positive detected that the output is short-
(SC+) circuited to the positive.
Power output 4 - wire B01:
24.04 7F024 04 520228 04 Locking detected that the output is
selector short-circuited to the ground
(SC-)
(negative).

Power output 4 - wire B01:
24.05 7F024 05 520228 05 lower current than normal
or open circuit
Power output 5 - wire B03: Dynamic monitoring of power

25.03 7F025 03 520229 03
- Check the wiring
Power output 5 - wire B03: between APC 214 and the
lower voltage than normal device connected to this
25.04 7F025 04 520229 04 Disconnection detected that the output is
or short-circuit to negative power output.
(SC-)
(negative).
- Check the installation
Dynamic monitoring of power and the operation of the
Power output 5 - wire B03: connected actuator.
or open circuit
Power output 7 - wire A10: Dynamic monitoring of power

27.03 7F027 03 520231 03
Power output 7 - wire A10:
27.04 7F027 04 520231 04 Forward gear detected that the output is
(SC-)
(negative).

or open circuit

28.03 7F028 03 520232 03
28.04 7F028 04 520232 04 Reverse gear detected that the output is
(SC-)
(negative).

or open circuit
20-08-M191EN (04/06/2013)
Error code
29.03 7F029 03 520233 03
(SC+) circuited to the positive. - Check the wiring
Dynamic monitoring of power between APC 214 and the
output 8 by the APC 214 has device connected to this
29.04 7F029 04 520233 04 1st/3rd gear detected that the output is power output.
(SC-)
20
(negative). - Check the installation
Dynamic monitoring of power connected actuator.
or open circuit
Check the wiring between

Power output Power output ground: fault APC 214 and the device
2F.1F 7F02F 1F 520239 31 Overvoltage detected.
ground condition exists connected to this power
output.
The expected value for the Check the source signal

Input data declutch request input data item of the CAN message
30.13 7F030 13 520240 19 item: declutch received by the corresponding containing the declutch
request CAN message contains an invalid request input data item to
or unavailable value. request a valid value.
Input The expected value for the Check the source signal
data item: automatic/manual gear change of the CAN message
automatic/ request input data item received containing the automatic/
31.13 7F031 13 520241 19
manual by the corresponding CAN manual gear change
gear change message contains an invalid or request input data item to
request unavailable value. request a valid value.
The expected value for the forced Check the source signal
Input data
downshift request input data item of the CAN message
item: forced
32.13 7F032 13 520242 19 received by the corresponding containing the downshift
downshift
CAN message contains an invalid request input data item to
request

Input data
inching mode activation request of the CAN message
item: inching
input data item received by the containing the inching
36.13 7F036 13 520246 19 mode
corresponding CAN message mode activation request
activation
contains an invalid or unavailable input data item to request
request Incorrect valve from CAN value. a valid value.
bus
Input data
inching mode selection request of the CAN message
item: inching
input data item received by the containing the inching
37.13 7F037 13 520247 19 mode
corresponding CAN message mode selection request
selection
contains an invalid or unavailable input data item to request
request
value. a valid value.
forced parking brake request of the CAN message
Input data
input data item received by the containing the parking
39.13 7F039 13 520249 19 item: parking
corresponding CAN message brake request input data
brake request
contains an invalid or unavailable item to request a valid
value. value.
The expected value for the Check the source
Input disconnection request input signals of the CAN
data item: data item received by the message containing the
3B.13 7F03B 13 520251 19
disconnection corresponding CAN message disconnection request
request contains an invalid or unavailable input data item to request
value. a valid value.
Input redundant neutral switch input of the CAN message
data item: data item received by the containing the redundant
3D.13 7F03D 13 520253 19
redundant corresponding CAN message neutral switch input data
neutral switch contains an invalid or unavailable item to request a valid
value. value.
(04/06/2013) 20-08-M191EN
Error code

Input data locking request input data item of the CAN message
Incorrect value from CAN
45.13 7F045 13 520261 19 item: locking received by the corresponding containing the locking
bus
request CAN message contains an invalid request input data item to
- Check whether the CAN

20
message containing the

The CAN message containing gear lever data value was
Abnormal update the gear lever data value was not correctly sent to the CAN
5F.09 7F05F 09 520287 09
frequency received within the expected bus.
timescale. - Check whether the CAN
Input data message repetition rate is
item: gear sufficiently fast.
lever request
The expected value for the gear Check the source signal
lever request input data item of the CAN message
5F.13 7F05F 13 520287 19 received by the corresponding containing the locking
CAN message contains an invalid request input data item to

Input accelerator pedal request input of the CAN message
data item: Incorrect value from CAN data item received by the containing the accelerator
60.13 7F060 13 520288 19
accelerator bus corresponding CAN message pedal request input data
pedal request contains an invalid or unavailable item to request a valid
value. value.
The expected value for the brake Check the source signal
Input data pedal request input data item of the CAN message
61.13 7F061 13 520289 19 item: brake received by the corresponding containing the brake pedal
pedal request CAN message contains an invalid data item to request a
or unavailable value. valid value.
Input data item:

The transmission housing
transmission housing
temperature has exceeded
temperature request: valid
62.00 7F062 00 520290 00 the alarm limit, probably due
data but above the normal
Input to extremely intensive vehicle
operating range - More
data item: operation.
serious
transmission
housing Input data item:
temperature transmission housing The transmission housing
request temperature request: temperature has exceeded the
62.10 7F062 10 520290 16
valid data but above the warning limit, probably due to - Probably no servicing
normal operating range - very intensive vehicle operation. action required, simply a
Moderately serious temporary reduction of
intensity of operation to
enable the transmission
The transmission cooler inlet to cool.
Input data item:
temperature has exceeded
transmission cooler inlet
the alarm limit, probably due - If the problem persists,
63.00 7F063 00 520291 00 temperature: valid data but
to extremely intensive vehicle check the operation of the
above the normal operating
operation or a problem with the transmission cooler.
Input range - More serious
hydraulic cooling system.
data item:
transmission
cooler inlet
temperature The transmission cooler inlet
Input data item:
temperature has exceeded the
transmission cooler inlet
warning limit, probably due to
63.10 7F063 10 520291 16 temperature: valid data but
very intensive vehicle operation
or a problem with the hydraulic
range - Moderately serious
cooling system.
The expected value for the engine Check the source signal
Speed sensor Speed sensor input data
speed signal received by the of the CAN message
input data item: engine speed:
7A.13 7F07A 13 520314 19 corresponding CAN message containing the engine
item: engine incorrect value from CAN
contains an invalid or unavailable speed signal to request a
speed bus
value. valid value.
20-08-M191EN (04/06/2013)
Error code
Transmission ratio: valid

data but above the normal - Check the oil level
80.00 7F080 00 520320 00
operating range - More - Check the transmission
serious system pressure
The transmission ratio calculated
- Check the clutch pressure
from the measured speed signals
of all the clutches with
Transmission exceeds the anticipated value for
different gears selected
ratio the selected gear.
Transmission ratio: valid - Check the stalling speed
20
Uncontrolled slippage of one of
data but below the normal with different gears
80.01 7F080 01 520320 01 more clutches may occur.
operating range - More selected
serious - Check the speed signals
from all spied sensors
APC uninterruptible power

supply line - wire A1: valid APC uninterruptible power supply
90.00 7F090 00 520336 00 data but above the normal has exceeded the alarm limit.
APC serious
uninterruptible
power supply APC uninterruptible power
supply line - wire A1: valid APC uninterruptible power supply
90.01 7F090 01 520336 01 data but below the normal has fallen below the alarm limit.
serious Check whether the power
supply presents abnormal
APC switched power supply values
line - wire A27: valid data APC uninterruptible power supply
91.00 7F091 00 520337 00 but above the normal has exceeded the alarm limit.
serious
APC switched
power supply
APC switched power supply
line - wire A27: valid data
APC uninterruptible power supply
91.01 7F091 01 520337 01 but below the normal
has fallen below the alarm limit.
serious
APC 5V sensor reference

power supply line - wire B2: The reference power supply
92.00 7F092 00 520338 00 valid data but above the of the APC external sensor has
normal operating range - exceeded the alarm limit. - Refer to the other errors
APC 5V sensor More serious reported to identify the
reference analog input functions
power supply APC 5V sensor reference The reference power supply of the concerned.
power supply line - wire B2: APC external sensor has dropped
92.01 7F092 01 520338 01 valid data but below the below the alarm limit. - Check that the maximum
normal operating range - Generally, the load o this supply current of this supply line
More serious line is too high. is not exceeded (excessive
load).
The reference of the APC internal
APC 8 V internal sensor sensor has exceeded the alarm - Check the wiring
reference: valid data but limit. between the APC 214 and
93.00 7F093 00 520339 00 all devices connected to
above the normal operating The correct measurement of the
APC 8 V range - More serious APC 214 input signals can no this supply line.
internal longer be guaranteed.
sensor The reference of the APC internal - Check the installation
reference APC 8 V internal sensor sensor has dropped below the and operation of all
reference: valid data but alarm limit. connected devices.
93.01 7F093 01 520339 01
below the normal operating The correct measurement of the
range - More serious APC 214 input signals can no
longer be guaranteed.
(04/06/2013) 20-08-M191EN
Error code
- Download a valid,
During initialization, the APC 214
compatible data file (APT
detected that the application
APC file) with the correct
APC application flash section of the flash memory is
application corresponding DANA tool.
9B.1F 7F09B 1F 520347 31 memory damaged: fault damaged.
flash memory - If the problem persists,
condition exists The APC 214 remains blocked
damaged the flash memory in the
in shutdown mode until the
APC 214 is faulty: replace
problem is resolved
the APC 214.
20
During initialization, the APC 214 If the problem persists,

APC flash or APC flash or RAM memory
detected that the internal, the APC 214 is irreversibly
9D.0C 7F09D 0C 520349 12 RAM memory problem: faulty component
external or system RAM or the damaged: replace the APC
problem or smart device
flash memory is damaged. 214.
- Download a valid,
compatible microprogram
file (XML file) with the
detected that the microprogram
Configuration Configuration correct corresponding
present is not compatible with
error: error : incompatible DANA tool.
A0.1F 7F0A0 1F 520352 31 this APC 214.
incompatible microprogram: existence of - If the problem persists,
The APC 214 remains blocked
microprogram a fault condition the program and/or flash
memory in the APC 214
problem is resolved
is faulty: replace the APC
214.
- Download a valid,
During initialization, the
compatible data file (APT
APC 214 detected that the data
file) with the correct
file present is incompatible
Configuration error: Configuration error: corresponding DANA tool.
with the expectations of the
A1.1F 7F0A1 1F 520353 31 incompatible incompatible data file: fault - If the problem persists,
microprogram.
data file condition exists the program and/or flash
The APC 214 remains blocked
memory in the APC 214
is faulty: replace the APC
problem is resolved
214.
- Check whether the

CAN message has been
CAN message CVC_to_ correctly sent to the CAN
The CAN message is not received
C1.09 7F0C1 09 520385 09 TC_1: abnormal update bus.
within the expected time limit.
CAN message frequency - Check whether the CAN
CVC_to_TC_1 message repetition rate is
sufficiently fast.
CAN message CVC_to_
Invalid content in the CAN Check the content of the
C1.13 7F0C1 13 520385 19 TC_1: incorrect value from
message CAN message
the CAN bus
- Check whether the
within the expected timescale.
sufficiently fast.
CAN message CVC_to_
Invalid content in the CAN Check the content of the
message CAN message
the CAN bus
- Check whether the
within the expected time limit.
sufficiently fast.
CAN message CVC_to_
the CAN bus Invalid content in the CAN Check the content of the
CAN message CVC_to_ message CAN message
CAN message
CVC_to_TC_4
the CAN bus
20-08-M191EN (04/06/2013)
Error code
- Check whether the
CAN message CAN message EEC1:
C5.09 7F0C5 09 520389 09 CAN message has been
EEC1 abnormal update frequency
correctly sent to the CAN
bus.
within the expected timescale.
CAN message CAN message EEC2: - Check whether the CAN
C6.09 7F0C6 09 520390 09 message repetition rate is
EEC2 abnormal update frequency
sufficiently fast.
CAN message CAN message peak load: Incoming CAN message overload
20
CA.1F 7F0CA 1F 520394 31 No action required
peak load fault condition exists to APC 214
Transmission calibration has

not yet been performed in the
Transmission calibration
APC 214. The corresponding
E0.0D 7F0E0 0D 520416 13 interval exceeded: out-of-
time interval exceeded code is
calibration
Transmission issued to inform the driver of this
calibration situation. Perform transmission
interval ‘The time interval for performing calibration.
exceeded Transmission calibration
transmission calibration has
interval exceeded: valid
expired. The corresponding
E0.0F 7F0E0 0F 520416 15 data but above the normal
time interval exceeded code is
operating range - Less
issued to inform the driver of this
serious
situation.
Vehicle speed for changing

Vehicle speed
direction exceeded: valid
for changing
E1.0F 7F0E1 0F 520417 15 data but above the normal
direction
operating range - Less
exceeded
serious
Vehicle Vehicle engine speed An operational limit has been

engine speed for changing direction exceeded under normal
E2.0F 7F0E2 0F 520418 15 for changing exceeded: valid data but operation. The corresponding
direction above the normal operating excess speed code is issued to
exceeded range - Less serious inform the driver of this situation.
None
Vehicle speed for downshift
Vehicle speed
exceeded: valid data but
E3.0F 7F0E3 0F 520419 15 for downshift
exceeded
range - Less serious
Max Max permitted torque

permitted exceeded in inching mode: The transmission has exceeded
E4.0F 7F0E4 0F 520420 15 torque valid data but above the the maximum torque in inching
exceeded in normal operating range - mode.
inching mode Less serious
F0.XX* 7F0F0 XX* 520432 XX* DANA configuration error

DANA An unexpected event occurred Note the error code
F1.XX* 7F0F1 XX* 520433 XX* - non-standard fault mode
configuration and was detected by the reported and contact a
indicator: DANA reserved
F2.XX* 7F0F2 XX* 520434 XX* error microprogram of the APC 214. DANA representative.
code
*XX: any value
(04/06/2013) 20-08-M191EN
Error code
detected that flash memory
APC flash memory partially group 0 is incomplete or partially
F3.00 7F0F3 00 520435 00 damaged: parameter damaged.
group 0 The APC 214 remains blocked
problem is resolved.
20

in shutdown mode until the - If this problem occurs
problem is resolved. immediately after an
During initialization, the APC 214 update of the APC 214
detected that flash memory microprogram, it may be
APC flash memory partially group 4 is incomplete or partially resolved by switching off
F3.04 7F0F3 04 520435 04 damaged: parameter damaged. the APC 214 in the normal
group 4 The APC 214 remains blocked way.
APC flash in shutdown mode until the
memory problem is resolved. - If the problem persists,
partially During initialization, the APC 214 download an APT file that
damaged detected that flash memory is compatible with the
APC flash memory partially group 5 is incomplete or partially active microprogram in
F3.05 7F0F3 05 520435 05 damaged: parameter damaged. the APC 214.
in shutdown mode until the - If the error code still
problem is resolved. persists, the flash memory
During initialization, the APC 214 may be damaged (contact
detected that flash memory Spicer Off-Highway)
20-08-M191EN (04/06/2013)
Error code
- If this problem occurs

APC flash memory partially immediately after an
F3.0A 7F0F3 0A 520435 10 damaged: parameter During initialization, the APC 214
update of the APC 214
group 10 detected that the logging part of
APC flash microprogram, it may be
the flash memory is damaged. All
memory resolved by switching off
functional logging data (such as
partially the APC 214 in the normal
distance traveled, etc.), as well as
damaged APC flash memory partially way.
the error logging data will be lost
- If the problem persists,
20
F3.0B 7F0F3 0B 520435 11 damaged: parameter and reset to zero.
group 11 contact Spicer Off-
Highway

APC flash memory detected that a critical part of
F4.00 7F0F4 00 520436 00 irreversibly damaged: flash memory 0 is damaged.
parameter group 0 The APC 214 remains blocked in
shutdown mode.
shutdown mode.
shutdown mode.
shutdown mode.
APC flash memory detected that a critical part of - Download an APT file
F4.04 7F0F4 04 520436 04 irreversibly damaged: flash memory 4 is damaged. that is compatible with the
parameter group 4 The APC 214 remains blocked in active microprogram in
APC flash
shutdown mode. the APC 200.
memory
irreversibly During initialization, the APC 214 - If the error code still
damaged APC flash memory detected that a critical part of persists, the flash memory
F4.05 7F0F4 05 520436 05 irreversibly damaged: flash memory 5 is damaged. may be damaged (contact
parameter group 5 The APC 214 remains blocked in Spicer Off-Highway)
shutdown mode.
shutdown mode.
shutdown mode.
shutdown mode.
shutdown mode.
(04/06/2013) 20-08-M191EN
GEARBOX CALIBRATION
The codes listed below are error codes that appear only during automatic calibration.
Calibration
Explanation
code
E.1.XX Contact pressure calibration
E.2.XX Optimize filling time
20
XX Explanation Controller action Driver action Cause of fault Repair
1->5, Unexpected Stop calibration of Log the fault The engine is not Continue calibration to identify whether all
7->9, response to the clutch XX. reported for responding to the target clutches suffer the same problem. Download
11->13, algorithm during Wait for “continue” clutch XX engine speed. The the correct parameter file and restart calibration.
15, calibration. request. and request vehicle began to move. Check whether the vehicle begins to move
17-> 24 calibration to Incorrect configuration of during calibration. Check the engine speed
continue. parameters. response.
06 During calibration, The controller The driver can The turbine speed does Measure the clutch pressure to detect a clutch
the turbine speed signals the fault and press button S not achieve a minimum leak
signal does abandons clutch on the APC200 value during the speed Check the speed sensor signal (may be
not achieve a calibration with the to continue change iteration process associated with 42.04 and/or 42.05 during
minimum value error code the calibration caused by clutch slippage normal operation and with E1.26 during contact
procedure or an incorrect turbine pressure calibration)
speed signal. Check the stalling speed to detect clutch
slippage
10 Transmission fault Calibration is Exit calibration Caused by the stop error Resolve the cause of the stop error code during
during calibration stopped code during calibration. calibration
E.g.: error code 20.60
during calibration
14 The turbine speed The controller The driver can The turbine speed Measure the clutch pressure to detect leakage
signal does not fall signals the fault and press button S does not fall due to an from the clutch
during calibration abandons clutch on the APC200 excessively large internal Check the speed sensor signal (should match
calibration with the to continue leak and/or clutch 42.04 and/or 42.05 during normal operation and
error code the calibration slippage E1.26 during contact pressure calibration)
procedure Incorrect turbine speed
signal
16 During calibration, The controller The driver can Faulty turbine speed Check the speed sensor signal (should match
the turbine speed signals the fault and press button S sensor 42.04 and/or 42.05 during normal operation and
signal is too low to abandons clutch on the APC200 A sticky or burnt clutch E1.25 during contact pressure calibration)
start calibration calibration with the to continue causes a drop in the
error code the calibration turbine speed before
procedure pressure is applied
25 Early detection The controller The driver can Excessive resistance due to Carry out automatic calibration at a higher
of contact during signals the fault and press button S thick oil. temperature (90-100 °C)
contact pressure abandons clutch on the APC200 A sticky or burnt clutch Check the speed sensor signal (should match
calibration. contact pressure to continue causes a drop in the 42.04 and/or 42.05 during normal operation)
Excessive calibration with the the calibration turbine speed before Check the VFS and replace if necessary
resistance error code procedure pressure is applied.
Speed sensor problem
Faulty VFS
26 No contact The controller The driver can Sticky clutch or excessively Measure the clutch pressure to detect clutch
detected during signals the fault and press button S large internal leak leakage
contract pressure abandons clutch on the APC200 Speed sensor problem Check the speed sensor signal (should match
calibration. contact pressure to continue Faulty VFS 42.04 and/or 42.05 during normal operation)
calibration with the the calibration Check the VFS and replace if necessary
error code procedure
20-08-M191EN (04/06/2013)
SPECIFIC TRANSMISSION TOOLING
20
pages
BASIC KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
DIGITAL MANOMETER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
(19/03/2012) 20-09-M191EN
2 SPECIFIC TRANSMISSION TOOLING
BASIC KIT
This box contains all the components required for measuring

pressure on all Manitou products.
20
2 3 5
1 3 4 5
Basis gauge kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549671
Consisting of:
1 - 1 gauge 1/9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549882

2 - 1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
3 - 2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
4 - 1 gauge 0/400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
5 - 2 gauge 0/600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
6 - 4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
7 - 2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
8 - 7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
20-09-M191EN (19/03/2012)
SPECIFIC TRANSMISSION TOOLING 3
DIGITAL MANOMETER SET
FUNCTIONS:
• Gauge function: the display allows the following combinations:
 The upstream pressure temperature at +/- 2°C

 The upstream temperature P1 with its mini and maxi (700 bar
20
in class 0.1)
 Downstream pressure P2 with its min. and max. (700 bar
in class 0.1)
 Differential pressure ΔP=P1-P
• Hold function: The user can freeze the screen display at any
time to take notes
• Unit function: The user can change the unit of measurement

at any time (bar, psi, kPa, mCe).
• Function Tare: Enables offset to zero
• Leak test function: Can measure a pressure variation over a

specified time
• Record function: A maximum of 16000 readings can be recorded.

The sampling period can be configured.
• Reset function: The 2 sensors are reset to zero
Digital Manometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662187
Consisting of:
1 - 1 digital gauge ΔP HP 700 bar

2 - 1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar
3 - 2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar
4 - 2 gauge adaptors 1620
(19/03/2012) 20-09-M191EN
4 SPECIFIC TRANSMISSION TOOLING
20
20-09-M191EN (19/03/2012)

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TRANSMISSION

- TRANSMISSION CHARACTERISTICS AND

- TRANSMISSION COMPONENTS LOCATION

- TRANSMISSION CONTROL AND

- TRANSMISSION REMOVAL u10- ENGINE

- CHARACTERISTICS AND SPECIFICATIONS

PRINCIPLE OF OPERATION OF GEARBOX PS09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PRINCIPLE OF OPERATION OF GEARBOX PS09

 Gearbox oil temperature indicator light (Item 4).

 Automatic gear change according to:

 Gearbox cooling circuit (Item 7).

 Negative brake circuit on gearbox (Item 8).

GEARBOX PS09 TECHNOLOGIES

Clutch overlap during gear changes avoids loss of torque.

Start of gear End of gear

TRANSMISSION DRIVE CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

TRANSMISSION DRIVE CHAIN

Front axle Rear axle

Gear box Z23

Z14 Z12 Z10

Z24 Z25 Z26 Z24 Z25 Z26

Gear box Maximum speed (unladen)

Front and rear axles

Proportional Proportional Proportional Proportional Low-speed

Proportional Proportional Proportional

GEAR BOX DIAGRAM

42 39 Lockup converter pressure test port

NEUTRAL GEAR SCHEMATIC DIAGRAM

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

6 TRANSMISSION SCHEMATIC DIAGRAMS

1ST FORWARD GEAR SCHEMATIC DIAGRAM

Steering 1st / 3rd gear

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

TRANSMISSION SCHEMATIC DIAGRAMS 7

2nd FORWARD GEAR SCHEMATIC DIAGRAM

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

3rd FORWARD GEAR SCHEMATIC DIAGRAM

Steering 1st / 3rd gear

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

4th FORWARD GEAR SCHEMATIC DIAGRAM

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

5th FORWARD GEAR SCHEMATIC DIAGRAM

High-speed forward 1st / 3rd gear

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

1st REVERSE GEAR SCHEMATIC DIAGRAM

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

2nd REVERSE GEAR SCHEMATIC DIAGRAM

Steering 2nd gear

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

3rd REVERSE GEAR SCHEMATIC DIAGRAM

Hose Cooler Hose

73 High-Speed Low-Speed Reverse 2nd 1st 3rd

Rear drive axle

Gear box filter