Professional Documents
Culture Documents
DB 250 PF Series
TECHNICAL DATA
0
DIAGNOSES
1
AUTOMATIC GEARBOXES
2
PROPELLER SHAFTS
3
ANGLE DRIVES
4
0145
CONTENTS 3
DB 250 PF Series
0145
3 TECHNICAL DATA
DB 250 PF Series Contents
CONTENTS
0
Page Date
2. DRIVE SHAFTS
2.1 General ............................................................................................. 2-1 .............. 0145
2.2 Tightening torques ............................................................................ 2-2 .............. 0145
2.3 Filling capacities .............................................................................. 2-2 .............. 0145
0145 1
TECHNICAL DATA 3
Contents DB 250 PF Series
2 0145
3 TECHNICAL DATA
DB 250 PF Series Automatic gearboxes
1. AUTOMATIC GEARBOXES
Engine type
Gearbox
Reductions
types
PE 160 PE 183
X(2)
Voith D854.3 5,20 - 0,77:1 X(2)
0145 1-1
TECHNICAL DATA 3
Automatic gearboxes DB 250 PF Series
1-2 0145
3 TECHNICAL DATA
DB 250 PF Series Automatic gearboxes
Driveline
Silent blocks on flywheel housing M16 10.9 260 ± 20 Nm
0
Silent blocks on angle drive M16 10.9 260 ± 20 Nm
Vibration damper on flywheel housing M10 10.9 60 ± 4 Nm
Reducing ring on flywheel housing (A) M10 10.9 60 ± 4 Nm
Angle drive on reducing ring (B) M10 8.8 46 ± 4 Nm
Automatic gearbox on angle drive (C) M10 10.9 60 ± 4 Nm
Plugs
Voith DIWA.3E
Drain plug oil sump (A) 50 Nm
Drain plug torq converter (B) 50 Nm
Cover (C) 25 Nm
Cover oil filter (D) 25 Nm
0145 1-3
TECHNICAL DATA 3
Automatic gearboxes DB 250 PF Series
Plugs
ZF HP500
0 Cover oil filter (A)
Drain plug (B)
25 Nm
50 Nm
1-4 0145
3 TECHNICAL DATA
DB 250 PF Series Drive shafts
2. DRIVE SHAFTS
2.1 GENERAL 0
Make: Gelenk Wellen Bau
Type: 2045 (Compact 2000 series)
- Drive flange
Type: KV (serrated flange)
Diameter (A) gearbox side: Æ 155 mm
Type: KV (serrated flange)
Diameter (B) rear axle side: Æ 180 mm
Angle of flex per universal joint (b): max. 25°
Length (LZ min.): 534 mm
Extension length: 90 mm
Spline diameter (W): Æ 68 mm
Inspection:
There must be no clearly noticeable play on universal joints and sliding joint.
Gelenk-Wellen-Bau
Balancing speed 3000 rpm-1
Radial play universal joints 0.01 - 0.05 mm
0145 2-1
TECHNICAL DATA 3
Drive shafts DB 250 PF Series
Serrated flanges
- M12 10.9 105-126 Nm
- M14 10.9 136-204 Nm
Plain flanges
- M12 10.9 113-127 Nm
- M14 10.9 178-202 Nm
- M16 10.9 281-309 Nm
Grease must be seen to protrude from the spider(s) and sliding sleeve.
2-2 0145
3 DIAGNOSIS
DB 250 PF Series Contents
CONTENTS
Pages Date 1
1. DRIVE SHAFTS ........................................................................................ 1-1 ............. 0145
0145 1
DIAGNOSIS 3
Contents DB 250 PF Series
2 0145
3 DIAGNOSIS
DB 250 PF Series Drive shafts
1. DRIVE SHAFTS
1. FAULT-FINDING TABLE
Excessive universal joint angle (for example, Check the universal joint angle
caused by excessive caster)
0145 1-1
DIAGNOSIS 3
Drive shafts DB 250 PF Series
1-2 0145
3 AUTOMATIC GEARBOXES
DB 250 PF Series Contents
ZF-ECOMAT Transmissions
1. REPAIR MANUAL ZF-ECOMAT 2 Stages 1-2 (4149 751 601) ........... 1-1................................... 0103
0145 1
AUTOMATIC GEARBOXES 3
Contents DB 250 PF Series
2 0145
3 AUTOMATIC GEARBOXES
DB 250 PF Series Servicing VOITH DIWA.3 Transmissions
0145 1-1
AUTOMATIC GEARBOXES 3
Servicing VOITH DIWA.3 Transmissions DB 250 PF Series
1-2 0145
4FSWJDJOH4DIFEVMF
LN
LN
5SBOTNJTTJPOT %*8"
%*8"
%*8"&
Monthly
Danger! Apply the parking brake before carrying out further maintenance
work on the bus, so that the vehicle cannot move on its own!
■ Press the N key and thus bring the transmission to its neutral position.
■ Withdraw the dipstick from its guide tube and clean it.
■ Insert the dipstick again briefly to prevent wrong oil level reading by splash
oil.
Note! For silumin heat exchangers: Only use anti-freeze and/or anti-corrosive agents in the cooling
water which do not attack light metal (see also "Technical Manuals").
With oil grades according to List of Lubricants 55.6335. ..* (G 607):
every 60 000 km, at least every 2 years, however.
With oil grades according to List of Lubricants 55.6336. ..* (G 1363):
every 120 000 km, at least every 3 years, however.
■ Remove the drain plug (1) for the oil in the oil pan (allen wrench 12 mm) and
drain the oil.
2
■ Remove the drain plug (2) for the converter oil and drain the oil. The plug is
accessible through the oil pan drain hole.
1
■ Install drain plugs with new copper seals. Tighten drain plug (2) to 50 Nm
and drain plug (1) to 120 Nm.
3
■ Remove the drain plug (4) for the filter oil (width across flats 13 resp. 10)
and drain the oil.
4
■ Unscrew (width across flats 13) and remove the cover (3).
5 ■ Replace gasket (7), oil filter element (8) and sealing ring (9). Install gasket
with coated side (white) toward the filter housing.
Note! If the used filter element is very dirty, unscrew the oil pan and check
the disks!
5
3 ■ Fit cover (3), washers B8.4, spring washers B8 and tighten nuts M8 (6) to
25 Nm.
4
■ Install drain plug (4) with new copper seal and tighten to 15 Nm.
6
■ Fill in transmission oil.
7
*Note! Only use oils tested by Voith and approved in the Lists of Lubri-
cants 55.6335. .. (G 607) and 55.6336. .. (G 1363), respectively!
Quantity: Approx. 21 - 23 liters (approx. 25 - 28 liters for first filling).
The dipstick reading counts in any case!
8
■ Measure the oil level, check transmission - especially oil filter - for leaks.
■ Check the oil hoses (5). Replace if found very porous, cracked or chafed.
9
With oil grades according to List of Lubricants 55.6335. ..* (G 607):
every 60 000 km, at least every 2 years, however.
With oil grades according to List of Lubricants 55.6336. ..* (G 1363):
every 120 000 km, at least every 3 years, however.
■ Remove the drain plug (11) for the oil in the oil pan (allen wrench 12 mm)
and drain the oil.
12
■ Remove the drain plug (12) for the converter oil and drain the oil. The plug
is accessible through the oil pan drain hole.
11
■ Install drain plugs with new copper seals. Tighten drain plug (12) to 50 Nm
and drain plug (11) to 120 Nm.
■ Unscrew and remove the access cover (10) of the oil pan (width across
flats 36).
■ Unscrew and remove the cover (15) of the integrated oil filter (14) (width
13 across flats 36).
14 ■ Install cover (15) with oil filter element (17) and sealing ring (18) and tighten
to 25 Nm.
15
16 ■ Install access cover (10) with new sealing ring (16) and tighten to 25 Nm.
■ Measure the oil level, check transmission - especially the cover (10) of the
oil pan - for leaks.
17
■ Check the oil hoses (13). Replace if found very porous, cracked or chafed.
18
15
Check load transmitter setting if necessary
for DIWA.2, DIWA.3, DIWA.3E
See leaflets "Fault finding".
3 AUTOMATIC GEARBOXES
DB 250 PF Series Trouble shooting VOITH DIWA.3 Transmissions
0145 2-1
AUTOMATIC GEARBOXES 3
Trouble shooting VOITH DIWA.3 Transmissions DB 250 PF Series
2-2 0145
3 AUTOMATIC GEARBOXES
DB 250 PF Series Fault finding VOITH DIWA.3 Transmissions
0145 3-1
AUTOMATIC GEARBOXES 3
Fault finding VOITH DIWA.3 Transmissions DB 250 PF Series
3-2 0145
'BVMU'JOEJOH
5SBOTNJTTJPOT %*8"
%*8"&
SYMPTOMS
CAUSES
REMEDIES
Important information
Additional notes
What is it for?
The manual serves the following purposes:
n Support for commissioning, maintenance and repair work,
n it lists the possible causes of faults in DIWA.3 and DIWA.3E transmissions and tasks for further testing,
fault finding and removal.
The following publications are available for transmission description, design, installation, the main tasks
of maintenance and repair, etc.:
for
Brochure Part No. Purpose
transmission
Function description of the transmissi-
55.6355. .. DIWA.3 on, transmission data, installation in-
Technical Manual
55.6357. .. DIWA.3E structions, design and dimensional
data for transmission assemblies
All
Servicing Schedule 55.6374. .. Maintenance of DIWA transmissions
DIWA
55.6335. .. All List of the lube oils that are approved
Lists of Lubricants
55.6336. .. DIWA by Voith for DIWA transmissions
DIWA.3, Brief description of transmission ope-
Driving Instructions 55.6291. ..
DIWA.3E ration for the bus driver
DIWA.3, Use of the Voith PC-based diagnostic
Diagnostic Manual 55.6264. ..
DIWA.3E program DIWAGNOSIS
55.6600. .. D 851.3E
55.6601. .. D 854.3E Illustration and designation of trans-
Spare Parts Catalogs
55.6602. .. D 863.3E mission parts for spare parts ordering
55.6603. .. D 864.3E
Detection of defective electrical com-
DIWA.3,
Trouble Shooting 55.6293. .. ponents or assemblies using the PC
DIWA.3E
diagnostic program
Description of transmission disas-
55.6320. .. DIWA.3
Repair Manual sembly and assembly of 3- and 4-
55.6704. .. DIWA.3E
speed transmissions
Technical Description
55.6309. .. DIWA.3 Representation of the oil circuits for
with Oil and Control Cir-
55.6311. .. DIWA.3E the various transmission gear shifts
cuit Diagrams
All of the above brochures are available from department "ant" or "anv".
Subject to change
Who is it for?
n Service technicians (e.g. testing, acceptance, etc.)
n Automobile mechanics and electricians
Read out the fault memory of the transmission control unit by means of the diagnostic
program DIWAGNOSIS:
Diagnostic Manual
Fault Finding
Diagnostic Manual
Tracing of possible faults in the electrical system of DIWA.3 and DIWA.3E transmissi-
ons:
Trouble Shooting
Repair Manual,
Spare Parts Catalogs
Page
In general, the symptoms are similar for both transmission variants. The statements
below therefore apply to both variants unless otherwise indicated.
2. The location of SK and WR solenoid valves in the valve block has been changed. TFFDIBQUFS
■ By means of the Voith diagnostic program. Its use is described in the Diagnostic
Manual.
■ wf the transmission does no longer shift to 2nd, 3rd or 4th gear, but operation in
1st gear is normal.
Causes:
– failure of the inductive pick-up,
– cable break or short.
■ by means of emergency control cable in 1st gear. Always note that connection of
the cable will engage 1st gear. Therefore:
Danger! Apply the parking brake when the bus is stopped to prevent that the
vehicle can move unintentionally!
Towing
Note! In order to prevent damage to the DIWA transmission when the vehicle is
towed, the following must be observed:
■ Set the transmission to neutral and screw off plug from the transmission or elec-
tronic control unit.
■ In case of transmission damage: remove cardan shaft or stub shaft of rear axle.
■ If there is no transmission damage the vehicle can be towed with the cardan shaft
installed, yet only up to a distance of 10 km. The maximum towing speed is
30 km/h.
'BVMUTXJUIWFIJDMFTUPQQFE
Danger! Apply the parking brake when the bus is stopped for repairing to pre-
vent that the vehicle can move unintentionally!
1. Inductive pick-up N2, connector or con- Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+
necting cable defective. and connecting cable, repair or re- 5S4IPPU
DIBQUFS
place, if required. JOEVDUJWFQJDLVQ/
2a. Control unit does not receive L0 signal. Check and adjust connection, if re- 4FFDIBQUFS
For VDO or Voith load transmitter: quired. %JBHOPTUJDTGVODUJPO&
connection between injection pump and load
transmitter set improperly.
2b. Control unit does not receive L0 signal. 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
For E-Gas systems: (compare transmission type to con-
faulty assignment of accelerator pedal positi- trol unit nameplate).
on and load transmitter level. 2. Check assignment. TFFDIBQUFSBOE
3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&
3a. No signal from pressure switch for ANS Check switch, connector or connect- %JBHOPTUJDTGVODUJPO)
activation (BS): switch, connector or con- ing cable and repair or replace, if re- 5S4IPPU
DIBQUFS
necting cable defective. quired. QSFTTTX"/4BDUJWBUJPO
3b. If provided: stop brake (HSB) relay, Check relay, switch, connector or %JBHOPTUJDTGVODUJPO)
switch, connector or connecting cable defec- connecting cable and repair or repla- 5S4IPPU
DIBQUFS
tive. ce, if required. TUPQCSBLF
3c. No signal from service (foot) brake switch Check switch at brake, connector or %JBHOPTUJDTGVODUJPO'
(FB): one of the 3 microswitches, connector connecting cable and repair or repla- 5S4IPPU
DIBQUFS
or connecting cable defective. ce, if required. CSBLFWBMWF
4. Pushbutton switch (TS), connector or con- Check switch, connector or connect- %JBHOPTUJDTGVODUJPO$
necting cable defective. ing cable and repair or replace, if re- 5S4IPPU
DIBQUFS
quired. QVTICVUUPOTXJUDI
Field coil or one of the spools of the EK sole- 1. Check oil pressure at EK connec- %JBHOPTUJDTGVODUJPOT(
*
noid valve, connector or connecting cable tion (measuring cover):
defective. pArequ’d = 0 bar.
2. Check solenoid valve, connector 5S4IPPU
DIBQUFS
and cable and repair or replace, if re- &,TPMFOPJE
quired.
Field coil or one of the spools of solenoid val- 1. Check operating resp. converter 'PSTFUQPJOUT
TFF
ves TB or RBK, connector or connecting ca- pressure at connections TB and RBK DIBQUFS
ble defective. (measuring cover).
2. Check solenoid valves, connec- %JBHOPTUJDTGVODUJPOT(
*
tors and cables and repair or replace, 5S4IPPU
DIBQUFS
if required. 5#PS3#,TPMFOPJE
'BVMUTPOFOHBHFNFOUPGHFBST
3.1 After engagement of a forward (F) or reverse gear (R) and re- $IFDLJTPOMZQPTTJCMFXIFO
leasing the parking brake, the vehicle does not move - engine FOHJOFJTSVOOJOH
revs up to max. speed when accelerating
Fuse 8A for line +UZ, connector or connect- Check fuse, connector and cable, re- %JBHOEJTQMBZDPNNVOJ
ing cable defective. pair or replace, if required. DBUJPOTOPUFTUBCMJTIFE
5S4IPPU
DIBQUFS
DPOUSPMVOJUWPMUBHF
dS relay "control", connector or connecting Check relay, connector and cable, %JBHOPTUJDTEJTQMBZ
cable defective. repair or replace, if required. E4SFMBZXJUIPVUWPMUBHF
5S4IPPU
DIBQU
WPMUBHF
2. Gear safety pressure switch (ABSICH) is Check switch, connector and cable, %JBHOPTUJDTGVODUJPO)
not activated for pressure > 3 bar, connector repair or replace, if required. 5S4IPPU
DIBQUFS
or connecting cable defective. HFBSTBGFUZQSFTTVSFTXJUDI
3. Field coil or one of the spools of the EK so- 1. Check oil pressure at EK connec- 'PSTFUQPJOUT
TFFBMTP
lenoid valve, connector or connecting cable tion (measuring cover): DIBQUFS
defective. pArequ’d ≥ 3.5 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable and repair or replace, if re- 5S4IPPU
DIBQUFS
quired. &,TPMFOPJE
4. Transmission with ANS activation: Check switch, connector and cable, %JBHOPTUJDTGVOUJPO)
pressure switch for ANS activation (BS), repair or replace, if required. 5S4IPPU
DIBQUFS
connector or connecting cable defective. Note! EK closes when load trans- QSFTTTX"/4BDUJWBUJPO
Note! Switch may only be closed when mitter operated!
the brake device is operated!
2. EK solenoid valves hard to move or stuck, 1. Check oil pressure at EK connec- 'PSTFUQPJOUT
TDIBQU
e.g. by soiling of a spool or the field coil. tion (measuring cover): %JBHOPTUJDTGVODUJPO(
pArequ’d ≥ 3.5 bar. 5S4IPPU
DIBQUFS
2. Repair or replace solenoid valve. &,TPMFOPJE
3. Oil pressure after EK solenoid valve too 1. Check pressure as discr. above.
low: oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.
4. EK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
Pushbutton switch, connector or connecting Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$
cable defective. repair or replace, if required. 5S4IPPU
DIBQUFS
QVTICVUUPOTXJUDI
1. Inductive pick-up N1 or N2, connector or Check inductive pick-up, connector 1. Diagnostics: function J,
connecting cable defective. and connecting cable and repair or 2. Tr. Shoot., chapter 2.1/2:
replace, if required. inductive pick-up N1 or N2
2. Field coil of solenoid valves RBG or RGK, Check solenoid valves, connectors %JBHOPTUJDTGVODUJPO(
connector or connecting cable defective. and cables and repair or replace, if 5S4IPPU
DIBQ
Note! if RBG is defective, the R gear is left required. 3#(PS3#,TPMFOPJE
after approx. 1 sec.!
2. Switch, connector or connecting cable de- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$
fective. repair or replace, if required. 5S4IPPU
DIBQUFS
QVTICVUUPOTXJUDI
Pushbutton switch, connector or connecting Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$
cable defective. repair or replace, if required. 5S4IPPU
DIBQUFS
QVTICVUUPOTXJUDI
RBG or RBK solenoid valve hard to move or 1. Check operating resp. converter 'PSTFUQPJOUT
TDI
stuck, e.g. by soiling of a spool or field coil. pressure at connections RBG and
RBK (measuring cover).
2. Check solenoid valves, connec- %JBHOPTUJDTGVODUJPO(
tors and cables and repair or replace, 5S4IPPU
DIBQU
if required. 3#(PS3#,TPMFOPJE
1. Field coil or one of the spools of the WR 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
solenoid valve, connector or connecting ca- measuring point (fig. 6/2): JOHQPJOU
TDIBQUFS
ble defective. pWrequ’d ≥ 2 bar.
2. Check solenoid valve, connector %BHOPTUJDTGVODUJPO(
and cable and repair or replace, if re- 5S4IPPU
DIBQUFS
quired. 83TPMFOPJE
2. One of the control spools of the converter If required, disassemble and repair 3FQBJS.BOVBM
outlet valve hard to move or stuck. converter outlet valve.
4. Only for DIWA.3E: The converter inlet val- 1. Check oil pressure at WP connec- 'PSTFUQPJOUT
TFFBMTP
ve hard to move or stuck, valve does not tion (measuring cover): DIBQUFS
open properly. pArequ’d ≥ 8.3 bar.
2. Check converter filling valve and 3FQBJS.BOVBM
repair or replace, if required.
5. Only for DIWA.3E: The breather valve 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
hard to move or stuck, valve does not close measuring point (fig. 6/2): JOHQPJOU
TDIBQUFS
properly. pWrequ’d ≥ 2 bar.
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.
3.3 After engaging the R gear and releasing the parking brake,
the bus e.g. first rolls forward, then backward or vice versa,
or no vehicle movement
2. RBG or RBK solenoid valve hard to move 1. Check operating resp. converter 'PSTFUQPJOUT
TFF
or stuck, e.g. by soiling of a spool or field coil. pressure at connections RBG and DIBQUFS
RBK (measuring cover).
2. Check solenoid valves, connec- %JBHOPTUJDTGVODUJPO(
tors and cables and repair or replace, 5S4IPPU
DIBQU
if required. 3#(PS3#,TPMFOPJE
3. Oil pressure after solenoid valve RBG or 1. Check pressure as disribed above.
RBK too low: oil supply reduced or interrup- 2. Check oil-supplying components 3FQBJS.BOVBM
ted. and repair or replace, if required.
4. RB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
1. One of the coils or spools of the EK sole- Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO(
noid valve, connector or connecting cable cable and repair or replace, if requi- 5S4IPPU
DIBQUFS
defective. red. &,TPMFOPJE
2. EK solenoid valve hard to move, e.g. due Repair or replace solenoid valve. 3FQBJS.BOVBM
to pollution of a spool or the field coil.
3. EK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
Field coil or one of the spools of solenoid val- 1. Check operating resp. converter 'PSTFUQPJOUT
ves TB or RBK, connector or connecting ca- pressure at connections TB and RBK TDIBQUFS
ble defective. (measuring cover).
2. Check solenoid valves, connec- %JBHOPTUJDTGVODUJPO(
tors and cables and repair or replace, 5S4IPPU
DIBQU
if required. 5#PS3#,TPMFOPJE
1. One of the control spools of the converter 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
outlet valve hard to move or stuck. measuring point (fig. 6/2): JOHQPJOU
TFFBMTPDIBQU
pWrequ’d ≥ 2 bar.
2. If required, disassemble and repair 3FQBJS.BOVBM
converter outlet valve.
3. Only for DIWA.3E: The converter filling Check converter filling valve and re- 3FQBJS.BOVBM
valve hard to move or stuck, valve does not pair or replace, if required.
open properly.
4. Only for DIWA.3E: The breather valve 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
hard to move or stuck, valve does not close measuring point (fig. 6/2): JOHQPJOU
TDIBQUFS
properly. pWrequ’d ≥ 2 bar.
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.
'BVMUTXIJMFESJWJOH
1a. For VDO or Voith load transmitter: Check and adjust connection, if re- 4FFDIBQUFS
connection between injection pump and load quired. %JBHOPTUJDTGVODUJPO&
transmitter set improperly.
1b. For E-Gas systems: 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
engine power restricted due to faulty assign- (compare transmission type to con-
ment of accelerator pedal position and load trol unit nameplate).
transmitter level. 2. Check assignment. TFFDIBQUFSBOE
3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&
4.2 Poor acceleration in 1st gear, but normal in 2nd and 3rd gear
1. One of the control spools of the converter 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
outlet valve hard to move or stuck. measuring point (fig. 6/2): JOHQPJOU
TFFBMTPDIBQU
pWrequ’d ≥ 2 bar.
2. If required, disassemble and repair 3FQBJS.BOVBM
converter outlet valve.
3. Only for DIWA.3E: The converter filling Check converter filling valve and re- 3FQBJS.BOVBM
valve hard to move or stuck, valve does not pair or replace, if required.
open properly.
4. Only for DIWA.3E: The breather valve 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
hard to move or stuck, valve does not close measuring point (fig. 6/2): JOHQPJOU
TDIBQUFS
properly. pWrequ’d ≥ 2 bar.
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.
Field coil or one of the spools of solenoid val- 1. Check operating resp. converter 'PSTFUQPJOUT
TFF
ve TB, connector or connecting cable defec- pressure at connection TB (measur- DIBQUFS
tive. ing cover).
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable and repair or replace, if re- 5S4IPPU
DIBQUFS
quired. 5#TPMFOPJE
2. TB solenoid valve hard to move or stuck, 1. Check operating resp. converter 'PSTFUQPJOUT
TDIBQ
e.g. by pollution of a spool or the field coil. pressure at connection TB (measur- %JBHOPTUJDTGVODUJPO(
ing cover). 5S4IPPU
DIBQUFS
2. Repair or replace solenoid valve. 5#TPMFOPJE
3. Oil pressure after TB solenoid valve too 1. Check pressure as discr. above.
low: oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.
4. TB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
2. One of the 3 sliding contacts in the hand Check hand brake switch, micro- %JBHOPTUJDTGVODUJPOT%
'
brake switch, one of the 3 microswitches in switch in service brake switch, con- 5S4IPPU
DIBQUFS
the service brake switch, connector or con- nector and cable, repair or replace, if IBOEPSTFSWJDFCSBLFTXJUDI
nect-ing cable defective. required.
3. Pushbutton switch (e.g. terminal S1 with- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$
out power), connector or connecting cable repair or replace, if required. 5S4IPPU
DIBQUFS
defective. QVTICVUUPOTXJUDI
4.5 Transmission does not shift to 2nd gear - operation only pos-
sible in 1st gear
2. Pushbutton switch (e.g. continuous cur- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$
rent terminal S1, although button 1 not pres- repair or replace, if required. 5S4IPPU
DIBQUFS
sed), connector or connecting cable defecti- QVTICVUUPOTXJUDI
ve.
Inductive pick-up N2, connector or connect- Check inductive pick-up N2, connec- %JBHOPTUJDTGVODUJPO+
ing cable defective. tor and connecting cable and repair 5S4IPPU
DIBQUFS
or replace, if required. JOEVDUJWFQJDLVQ/
1a. For VDO or Voith load transmitter: Check connection and adjust, if re- 4FFDIBQUFS
connection between injection pump and load quired. %JBHOPTUJDTGVODUJPO&
transmitter set improperly.
1b. For E-Gas systems: 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
engine power restricted due to faulty assign- (compare transmission type to con-
ment of accelerator pedal position and load trol unit nameplate).
transmitter level. 2. Check assignment. TFFDIBQUFSBOE
3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&
Field coil or one of the spools of the PB sole- 1. Check oil pressure at PB connec- 'PSTFUQPJOUT
TFFBMTP
noid valve, connector or connecting cable tion (measuring cover): DIBQUFS
defective. pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 1#TPMFOPJE
2. PB solenoid valve hard to move or stuck, 1. Check oil pressure at PB connec- 'PSTFUQPJOUT
TDIBQU
e.g. by pollution of a spool or the field coil. tion (measuring cover): %JBHOPTUJDTGVODUJPO(
pArequ’d ≥ 8.3 bar. 5S4IPPU
DIBQUFS
2. Repair or replace solenoid valve. 1#TPMFOPJE
3. Oil pressure after PB solenoid valve too 1. Check pressure as discr. above.
low: oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.
4. PB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
4.7 Poor acceleration after shifting to 2nd gear, but normal in 1st
gear
Field coil or one of the spools of solenoid val- 1. Check oil pressure at TB connec- %JBHOPTUJDTGVODUJPO(
ve TB, connector or connecting cable defec- tion (measuring cover):
tive. pArequ’d = 0 bar.
2. Check solenoid valve, connector 5S4IPPU
DIBQUFS
and cable and repair or replace, if re- 5#TPMFOPJE
quired.
4.8 Transmission does not shift to 3rd gear - operation only pos-
sible in 1st and 2nd gear
2. Pushbutton switch, connector or connect- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$
ing cable defective. repair or replace, if required. 5S4IPPU
DIBQUFS
QVTICVUUPOTXJDI
Field coil or one of the spools of the DK sole- 1. Check oil pressure at DK connec- 'PSTFUQPJOUT
TDIBQ
noid valve, connector or connecting cable tion: pArequ’d ≥ 8.3 bar. %JBHOPTUJDTGVODUJPO(
defective. 2. Check solenoid valve, connector 5S4IPPU
DIBQUFS
and cable, repair or replace. %,TPMFOPJE
4.9 Poor acceleration after shifting to 3rd gear, but normal in 1st
and 2nd gear
2. DK solenod valve hard to move or stuck, 1. Check oil pressure at DK connec- 'PSTFUQPJOUT
TDIBQU
e.g. by pollutionof a spool or the field coil. tion (measuring cover): %JBHOPTUJDTGVODUJPO(
pArequ’d ≥ 8.3 bar. 5S4IPPU
DIBQUFS
2. Repair or replace solenoid valve. %,TPMFOPJE
3. Oil pressure after DK solenoid valve too 1. Check pressure as discr. above.
low: oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.
4. DK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
2. Pushbutton switch (e.g. continuous current Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$
terminal S3, although button 3 not pressed), repair or replace, if required. 5S4IPPU
DIBQUFS
connector or connecting cable defective. QVTICVUUPOTXJUDI
Field coil or one of the spools of solenoid valve 1. Check oil pressure at SK connec- 'PSTFUQPJOUT
TFFBMTP
DK, connector or connecting cable defective. tion (measuring cover): DIBQUFS
pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if re- 5S4IPPU
DIBQUFS
quired. 4,TPMFOPJE
4.11 Poor acceleration after shifting to 4th gear, but normal in 1st,
2nd, and 3rd gear
2. SK solenoid valve hard to move or stuck, 1. Check operating at SK connec- 'PSTFUQPJOUT
TDIBQU
e.g. by pollution of a spool or the field coil. tion (measuring cover): %JBHOPTUJDTGVODUJPO(
pArequ’d ≥ 8.3 bar. 5S4IPPU
DIBQUFS
2. Repair or replace solenoid valve. 4,TPMFOPJE
3. Oil pressure after SK solenoid valve too low: 1. Check pressure as discr. above.
oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.
4. SK disks damaged - possibly by used, pollu- Replace disks, replenish or change 3FQBJS.BOVBM
ted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
Kickdown switch, connector or connecting Check switch, connector and cable, %JBHOPTUJDTGVODUJPO&
cable defective. repair or replace, if required. 5S4IPPU
DIBQUFS
LJDLEPXOTXJUDI
1a. For VDO or Voith load transmitter: Check connection and adjust, if re- 4FFDIBQUFS
connection between injection pump and load quired. %JBHOPTUJDTGVODUJPO&
transmitter set improperly.
1b. For E-Gas systems: 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
engine power restricted due to faulty assign- (compare transmission type to con-
ment of accelerator pedal position and load trol unit nameplate).
transmitter level. 2. Check assignment. TFFDIBQUFSBOE
3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&
1. Coil or one of the spools of the WP soleno- 1. Check oil pressure at WP connec- 'PSTFUQPJOUT
TFFBMTP
id valve, connector or connecting cable de- tion (measuring cover): DIBQUFS
fective. pArequ’d ≥ 3.5 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 81TPMFOPJE
2. One of the control spools in the converter Disassemble converter outlet valve 3FQBJS.BOVBM
outlet valve hard to move or stuck. and replace, if required.
4.14 Transmission does not shift up, but back to 1st gear and
stays there
Inductive pick-up N2, connector or connec- Check inductive pick-up N2, connec- %JBHOPTUJDTGVODUJPO+
ting cable defective. tor and connecting cable and repair 5S4IPPU
DIBQUFS
or replace, if required. JOEVDUJWFQJDLVQ/
Fuse 8A for line +UZ, connector or connect- Check fuse, connector and cable, re- %JBHOEJTQMBZDPNNVOJ
ing cable defective. pair or replace, if required. DBUJPOTOPUFTUBCMJTIFE
5S4IPPU
DIBQUFS
DPOUSPMVOJUWPMUBHF
dS relay "control", connector or connecting Check relay, connector and cable, %JBHOPTUJDTEJTQMBZE4
cable defective. repair or replace, if required. SFMBZXJUIPVUWPMUBHF
5S4IPPU
DIBQUFS
TPMFOPJEWBMWFWPMUBHF
1. One of the field coils or spools of the PB Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO(
solenoid valve, connector or connecting ca- cable, repair or replace, if required. 5S4IPPU
DIBQUFS
ble defective. 1#TPMFOPJE
2. PB solenoid valve hard to move or stuck, Repair or replace solenoid valve. 3FQBJS.BOVBM
e.g. by pollution of a spool or the field coil.
3. PB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
4. Inductive pick-up N1, connector or con- Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+
necting cable defective. and connecting cable and repair or 5S4IPPU
DIBQUFS
replace, if required. JOEVDUJWFQJDLVQ/
1. One of the field coils or spools of the DK Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO(
solenoid valve, connector or connecting ca- cable, repair or replace, if required. 5S4IPPU
DIBQUFS
ble defective. %,TPMFOPJE
2. DK solenoid valve hard to move or stuck, Repair or replace solenoid valve. 3FQBJS.BOVBM
e.g. by pollution of a spool or the field coil.
3. DK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
4. Inductive pick-up N1, connector or con- Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+
necting cable defective. and connecting cable and repair or 5S4IPPU
DIBQUFS
replace, if required. JOEVDUJWFQJDLVQ/
4.18 For 4-gear transmissions: hard shifting from 3rd to 4th gear
1. One of the coils or spools of the SK sole- Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO(
noid valve, connector or connecting cable cable, repair or replace, if required. 5S4IPPU
DIBQUFS
defective. 4,TPMFOPJE
2. SK solenoid valve hard to move or stuck, Repair or replace solenoid valve. 3FQBJS.BOVBM
e.g. by pollution of a spool or the field coil.
3. SK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
4. Inductive pick-up N1, connector or con- Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+
necting cale defective. and connecting cable and repair or 5S4IPPU
DIBQUFS
replace, if required. JOEVDUJWFQJDLVQ/
'BVMUTXIJMFCSBLJOHXJUIUIFDPO
WFSUFSCSBLF
5.1 The converter brake (CB) does not operate in all F gears via
service (foot) and hand brake switch
1. ABS active.
2a. Control does not receive L0 signal. Check connection and adjust, if re- 4FFDIBQUFS
For VDO or Voith load transmitter: quired. %JBHOPTUJDTGVODUJPO&
connection between injection pump and load
transmitter set improperly.
2b. Control does not receive L0 signal. 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
For E-Gas systems: (compare transmission type to con-
engine power restricted due to faulty assign- trol unit nameplate).
ment of accelerator pedal position and load 2. Check assignment. TFFDIBQUFSBOE
transmitter level. 3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&
3. Field coil of solenoid valves PB, WP or Check solenoid valves, connectors %JBHOPTUJDTGVODUJPO(
RBK, connector or connecting cable defecti- and cables, repair or replace, if requi- 5S4IPPU
DIBQUFS
ve. red. TPMFOPJET
5.2 The converter brake does not operate in 1st gear via service
and hand brake switch
2. Converter brake was activated in 1st Converter brake must already have
gear (it is possible for some versions). been activated in 2nd, 3rd or 4th gear.
1. Coil or one of the spools of the TB sole- 1. Check operating resp. converter 'PSTFUQPJOUT
TFFBMTP
noid valve, connector or connecting cable pressure at TB connection (measuring DIBQUFS
defective. cover). %JBHOPTUJDTGVODUJPO(
2. Check solenoid valve, connector and 5S4IPPU
DIBQUFS
cable, repair or replace, if required. 5#TPMFOPJE
2. RBK solenoid valve hard to move or 1. Check operating resp. converter 'PSTFUQPJOUT
TFFBMTP
stuck, e.g. by pollution of a spool or the pressure at RBK connection (measur- DIBQUFS
field coil. ing cover). %JBHOPTUJDTGVODUJPO(
2. Check solenoid valve, connector and 5S4IPPU
DIBQUFS
cable, repair or replace, if required. 3#,TPMFOPJE
5.3 The converter brake does not operate in 1st, 2nd, 3rd and 4th
gear via service and hand brake switch
1. PB solenoid valve hard to move or stuck, 1. Check oil pressure at PB connection: 'PSTFUQPJOUT
TFFBMTP
e.g. by pollution of a spool or the field coil. pArequ’d ≥ 8.3 bar. DIBQUFS
2. Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO(
cable, repair or replace, if required. 5S4IPPU
DIBQUFS
1#TPMFOPJE
2. Coil or one of the spools of the RBG so- 1. Check operating resp. converter 'PSTFUQPJOUT
TFFBMTP
lenoid valve, connector or connecting ca- pressure at RBG connection (measur- DIBQUFS
ble defective. ing cover). %JBHOPTUJDTGVODUJPO(
*
2. Check solenoid valve, connector and 5S4IPPU
DIBQUFS
cable, repair or replace, if required. 3#(TPMFOPJE
5.4 One of the 3 or all brake stages of the converter brake does
not operate via service brake switch (brake pedal)
1. Converter brake deactivated by the OFF Indicator lamp (if installed) at the ma-
switch for activation by the brake pedal nual switch is not lit when the service
(FBAUS). brake switch is operated.
2. Switch, connector or connecting cable de- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO)
fective. repair or replace, if required. 5S4IPPU
DIBQUFS
DPOWFSUFSCBLF0''TXJUDI
3. One of the 3 microswitches in the service Check switch, connector and cable, %JBHOPTUJDTGVODUJPOT'
brake switch (FB), connector or connective repair or replace, if required. 5S4IPPU
DIBQUFS
cable defective. TFSWJDFCSBLFTXJUDI
5.5 One of the 3 or all brake stages of the converter brake does
not operate via the 3-stage hand brake switch (manual
switch)
One of the 3 sliding contacts in the hand bra- Check brake switch, connector and %JBHOPTUJDTGVODUJPOT%
ke switch (HB), connector or connecting ca- cable, repair or replace, if required. 5S4IPPU
DIBQUFS
ble defective. IBOECSBLFTXJUDI
Hand brake switch (HB), connector or con- Check brake switch, connector and %JBHOPTUJDTGVODUJPOT%
necting cable defective. cable, repair or replace, if required. 5S4IPPU
DIBQUFS
)#TXJUDI
TUBHF
5.7 For DIWA.3 in 2nd, 3rd, or 4th gear: hard activation of conver-
ter brake
1. WP solenoid valve hard to move or stuck, 1. Check oil pressure at WP connec- 'PSTFUQPJOUT
TFFBMTP
e.g. by pollution of a spool or the field coil. tion (measuring cover): DIBQUFS
pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 81TPMFOPJE
2. Oil pressure after WP solenoid valve too 1. Check pressure as discr. above.
low: WP oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.
3. One of the control spools in converter out- Disassemble converter outlet valve 3FQBJS.BOVBM
let valve hard to move or stuck. and repair, if required.
1. RBK solenoid valve hard to move or stuck, 1. Check operating resp. converter 'PSTFUQPJOUT
TFFBMTP
e.g. by pollution of a spool or the field coil. pressure at RBK connection (measu- DIBQUFS
ring cover).
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 3#,TPMFOPJE
2. RB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT
5.8 For DIWA.3 in 2nd, 3rd, or 4th gear: brake force in brake sta-
ge I too high
1. WP solenoid valve hard to move or stuck, 1. Check oil pressure at WP connec- 'PSTFUQPJOUT
TFFBMTP
e.g. by pollution of a spool or the field coil. tion (measuring cover): DIBQUFS
pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 81TPMFOPJE
2. Oil pressure after WP solenoid valve too 1. Check pressure as discr. above.
low: WP oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.
3. One of the control spools in converter out- Disassemble converter outlet valve 3FQBJS.BOVBM
let valve hard to move or stuck. and repair, if required.
5.9 For DIWA.3 in 2nd, 3rd, or 4th gear: brake force in brake sta-
ge II or III too low or too high
1a. Brake force too low: Field coil or one of 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
the spools of the WR solenoid valve, connec- measuring point (fig. 6/2). JOHQPJOU
TFFBMTPDIBQ
tor or connecting cable defective. 2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 83TPMFOPJE
1b. Brake force too low: Oil pressure after Check oil-supplying componets and 3FQBJS.BOVBM
WR solenoid valve too low because oil supp- repair or replace, if required.
ly is reduced or interrupted.
2a. Brake force too high: WP solenoid valve 1. Check oil pressure at WP connec- 'PSTFUQPJOUT
TFFBMTP
hard to move or stuck, e.g. by pollution of a tion (measuring cover): DIBQUFS
spool or the field coil. pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 81TPMFOPJE
2b. Brake force too high: Oil pressure after Check oil-supplying componets and 3FQBJS.BOVBM
WP solenoid valve too low because oil supp- repair or replace, if required.
ly is reduced or interrupted.
3. One of the control spools in converter out- Disassemble converter outlet valve 3FQBJS.BOVBM
let valve hard to move or stuck. and repair, if required.
5.10 For DIWA.3E in 2nd, 3rd, or 4th gear: hard activation of con-
verter brake
In 3rd and perhaps 4th gear and at high (”High speed” means: transmission 4FF0JMBOE$POUSPM$JSDVJU
speeds: Converter filling control (CFC) output speed is higher than the limit %JBHSBNTGPS%*8"&BCPVU
malfunction - converter pressure too set for activation of converter filling UIF$'$
high control, e. g. about 2000 to 2200 rev/
min in 4th gear).
1. WP solenoid valve hard to move or stuck, 1. Check oil pressure at WP connec- 'PSTFUQPJOUTBOENFBTVS
e.g. by pollution of a spool or the field coil tion (measuring cover): JOHQPJOU
TBMTPDIBQUFS
and doesn't close correcly. pArequ’d = 0 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 81TPMFOPJE
3. Breather valve hard to move or stuck and 1. Check converter pressure at 'PSTFUQPJOUTBOENFBTVS
doesn't open correcly. measur. point (6/2): pWrequ’d = 0 bar. JOHQPJOU
TBMTPDIBQUFS
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.
One of the control spools in converter outlet Disassemble converter outlet valve 3FQBJS.BOVBM
valve hard to move or stuck. and repair, if required.
1. RBK solenoid valve hard to move or 1. Check operating resp. converter 'PSTFUQPJOUT
TFFBMTP
stuck, e.g. by pollution of a spool or the field pressure at RBK connection (measur- DIBQUFS
coil. ing cover). %JBHOPTUJDTGVODUJPO(
2. Check solenoid valve, connector 5S4IPPU
DIBQUFS
and cable, repair or replace. 3#,TPMFOPJE
5.11 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake
stage I too high
One of the control spools in converter outlet Disassemble converter outlet valve 3FQBJS.BOVBM
valve hard to move or stuck. and repair, if required.
5.12 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake
stage II or III too low or too high
1a. Brake force too low: Field coil or one of 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
the spools of the WR solenoid valve, connec- measuring point (fig. 6/2). JOHQPJOU
TFFBMTPDIBQ
tor or connecting cable defective. 2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 83TPMFOPJE
1b. Brake force too low: Oil pressure after Check oil-supplying componets and 3FQBJS.BOVBM
WR solenoid valve too low because oil supp- repair or replace, if required.
ly is reduced or interrupted.
1c. Brake force too low: Converter filling val- 1. Check oil pressure at WP connec- 'PSTFUQPJOUT
TFFBMTP
ve hard to move or stuck and doesn’t open tion (measuring cover): DIBQUFS
correcly. pArequ’d ≥ 8.3 bar.
2. Check converter filling valve and 3FQBJS.BOVBM
repair or replace, if required.
1d. Brake force too low: Breather valve hard 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
to move or stuck and doesn’t close correcly. measuring point (fig. 6/2). JOHQPJOU
TBMTPDIBQUFS
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.
2. One of the control spools in converter out- Disassemble converter outlet valve 3FQBJS.BOVBM
let valve hard to move or stuck. and repair, if required.
5.13 In 1st gear range: brake force in brake stage II or II too low
or too high
1. RBK solenoid valve hard to move or 1. Check operating resp. converter 'PSTFUQPJOUT
TFFBMTP
stuck, e.g. by pollution of a spool or the field pressure at RBK connection (measu- DIBQUFS
coil. ring cover).
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU
DIBQUFS
red. 3#,TPMFOPJE
2. Oil pressure after RBK solenoid valve too 1. Check pressure as discr. above.
low: RBK oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.
1. Lamp defective.
2. If controlled through relays: relay, con- Check relay, connector and cable, re- %JBHOPTUJDTGVODUJPO(
nector or connecting cable defect. pair or replace, if required. 5S4IPPU
DIBQUFS
DFOUSBMXBSOJOHMBNQ
6.2 The pushbutton switch lighting (TL) does not light after
turning on the ignition
2. Pushbutton switch (e.g. terminal TL wit- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$
hout voltage), connector or connecting ca- repair or replace, if required. 5S4IPPU
DIBQUFS
ble defect. QVTICVUUPOTXJUDI
Lamp, connector or connecting cable de- Check lamp, connector and cable, re- %JBHOPTUJDTGVODUJPO(
fect. pair or replace, if required. 5S4IPPU
DIBQU
USBOTNJTTJPOPJMXBSOMBNQ
3. Relay dW, dR or dN, connector or con- Check relay, connector and cable, re- %JBHOPTUJDTGVODUJPO(
necting cable defect. pair or replace, if required. 5S4IPPU
DIBQUFS
SFMBZE8
E3PSE/
Pressure gauge
To measure the operating and con-
verter pressure.
Voith order no. 58.2748.11
Multimeter
To measure voltages and resi- 4FF5SPVCMF4IPPUJOH
stances.
Nominal value at idle speed (n ≥ approx. 500 - 600 rpm) pA ≥ 3.5 bar.
Measuring points
The operating pressure is usually
measured at the measuring point (fi-
gure 1/1).
The measuring points TB, RBG and RBK are each pressurized with the higher ope- 4FFDIBQUFS
rating or converter pressure.
Exceptions: The RBK pressure is set to
1. approx. 2.5 bar for converter pressure reduction WDA,
2. max. approx. 2 bar for braking in 1st gear range (chapters 5.4 and 5.6).
Danger! Connect pressure gauge, or change measuring cover, only with the en-
gine stopped, otherwise hot oil may result in scalding!
In particular in conjunction with electronic engine control units, it is frequently not pos-
sible to set the idle speed n in a simple manner. In addition, the settings are system-
dependent (guideline: n ≥ approx. 500 - 600 rpm with warm engine). On the other
hand, the idle speed must not be too high, because the input clutch, for example, will
not close: n ≤ 850 rpm (for gas engine: n ≤ 1000 rpm). %JBHOPTUJDTGVODUJPO*
During a function check, the speed can be measured by means of the diagnostic pro-
gram, for example.
Note! If the idle speed must be changed, contact the bus manufacturer, if requi-
red.
The following settings can be checked in a relatively simple manner with the bus stop-
ped by means of the diagnostic program: %JBHOPTUJDTGVODUJPO&
1. Load level L0 = "idle", accelerator pedal completely released.
2. Load level L6 = "full load", accelerator depressed to the stop (first, if any). Depend-
ent on the bus design, this accelerator pedal position may also be defined as L7 =
"kickdown", which is indicated by the diagnostic system.
3. Inf installed: load level L7 = "kickdown", accelerator pedal depressed beyond the
first and to the end stop against greater resistance.
4. Gradually depress the accelerator pedal from idle to full load and check that the %JBHOPTUJDTGVODUJPO*
"partial load" signals L2 to L5 are also displayed by the diagnostic system.
Note! For an accurate check of the load transmitter partial load signals as func-
tion of the accelerator pedal travel, documents from the bus manufacturer are
required.
Danger! When settings are made with the bus stopped, apply the parking brake
to prevent unintended rolling of the vehicle!
If the diagnostic system indicates load levels that do not correspond to the accelerator
pedal position, the following causes for faults may exist, apart from cable and connec-
tor defects:
1. Setting of accelerator pedal stops (idle, full load, kickdown, if installed).
2. With a VDO or Voith load transmitter: connection between load transmitter and in-
jection pump, see figures 7 and 8 on next page.
3. With electronic engine control units: connection between accelerator pedal and
load transmitter (setpoint switch), see figure 9 on next page.
4. Wrong control unit with data of the wrong load transmitter type (indicated by dia- %JBHOPTUJDTGVODUJPO"
gnostic system).
Note! the adjustment angles of the levers of injection pump and load transmit-
ter must be in proportion to each other! For example, if the injection pump lever
is moved by 1/3 of the angle between 0 and full load, the load transmitter lever
must also be move by 1/3 of its angle between 0 and full load!
It may be necessary to determine the maximum possible engine torques in bus ope-
ration. Indirectly, they can be determined in a relatively simple manner by speed
measurements in the so-called stall point - e.g. by means of the diagnostic program. %JBHOPTUJDTGVODUJPO*
4H 4X 4V 4G 3H
1500
4F
1400
1300 3X
1200
1100 3V
Engine torque M1 (Nm)
1000
3G
900 3F
800
700
600
500
400
300
200
100
0
400 600 800 1000 1200 1400 1600 1800 2000 2200
Engine speed N1 (rpm)
10
9
8 DK
B
7
EK TB
A D 3rd gear x x x
E 4th gear
Braking 1st gear range x
x x
x
x
x x x1)
1st braking stage - 2nd gear x x x x x
2nd and 3rd brak. stage - 2nd gear x x x x2) x x
2nd and 3rd brak. stage - 3rd gear x x x x2) x x
10
pA DK
7
EK TB
B
A Converter drain valve (CDV)
B Converter filling valve (CFV)
C Operating pressure
PB RBG valve (OPV)
D Solenoid valves
E DIWA.3E transmission
F Gear pump
G Heat exchanger
WP RBK H Oil filter
A 1 2 3 D N R
221
202
238
221.1
+UB
+FB
20
38
2
-UB
EK
DK
19
55
37
119
137
221.3 -UB SK 118
21 18
-UB
39 54
a 3
REA0
RBG
36
117
17
240 FB1 22 -UB 153
53
204 KD 40 WR 135
35
204.1 KD -UB
4 16
-UB 152
23 52
241.1 DKV/PWM -UB
A b c 205.1
224.1
DKR
DKE
41
5
EKM
DKM
34
15
7
8
S1 S2 S3 S2/1 S2/2 S3/2 S3/3 24 51
SKM 3
D N R 42 33
PBM 6
2 D N R 6 14
200 TBM 4
1 2 D N R 25 50
1 2 3 D N R 43 32
207 HBA RBKM 5
226 7 13
HBB SENSE 1
244 26 49
HBC SENSE 2
44 31
S3/2
S2/1
S2/2
S3/3
208 +HB -UB
S1 227 227 S1 8 12
1 -UB 148
S2 245 245 27 48
2 S2 -UB
S3 209 209 S3 45 30
3 N1A 111
+V 228 228 +V 9 11
4 N1B 147
+R 246 246 +R 28 47
5 N2A 129
RS 230 210 46 29
6 /N N2B 110
+TS 229 10 10
7 229 +TS N3A 146
+TL 233 29 46
8 N3B 128
/N 210 47 28
9 211 FB2
-UB 221 11 9
10 230 RS
SSP 200 30 45
11 248 PU -UB
RF 256 48 27
12 212 BS TS+ 9
RS 12 8
13 231 FBAUS TS- 10
+R FB3 31 44
14 249 -UB
49 26
213 dS
13 7
dW
B C D
232
32 43
250 dN
50 25
214 dR IO9
14 6
233 +TL
33 42
251 ZW LGM 124
51 24
215 TOEL -LG 105
15 +LG 5 141
34 41
252 DIAGN-K IO3
52 23
252.1
216 DIAGN-L 4
16 40
227 -UB
z 0 1 2 3
S1
S2 245 1
227
245
216.1
WP
22
103
z 0 3 0 1 2 3 221.2 S3 209 2 209
235 ABSICH
ABS
35 -UB 3
221.2
y 0 1 2 3 228 3
253
53 39
y x +V 228 217 CAN-H RBK 121
T
4 17 21
+
4 244 4 244 11 19
HBA HBC 3 244 HBC 244 219.2
5 226 HBB 5 226 HBB 226 12 226
2
6 207 6 207 13 207
HBA 1 207 HBA
+HB 7 208 +HB 7 208 +HB 208 14 208
+
8 8 SSP 200 15 200
RF 256 16
17
18 219.2 +UZ
E F
221.3 -UB 1
252.1 DIAGN-K 2
216.1 DIAGN-L 8
10
S R
G
141 +LG
1
124 LGM
2
204 105 -LG
1 219 3
4
2 3 Q
128
146
152
153
147
111
110
129
135
137
119
102
103
121
117
120
101
118
9
148
4
3
1
10
2
6
5
KD 204 204
+UZ 219 1 219 A B C D E F G H J K L MN P R S T U V WX Y Z a b c d e f g h j
gn/ge FB1 240 2 240
240
1 3 249
bl 249 FB3 249
2 +FB 202 4 202
sw 202
3 5 211
br 211 FB2 211
4 6
7 + ws bl
P
4
ϑ
1 sw bl
8 -
H
2 3
9
bl
10
n1
ws
sw
2 bl
ws
sw n3
M
CAN-H 217 sw CAN-H 1
C
CAN-M 237 ge CAN-M
CAN-L B 236 CAN-L
A ws
sw n2
h i j k l m sw
2
br br
ge
2
sw
ge
WR SK
O
dS dW dR dN 4
gn bl
bl 3
rt bl rt
1 1
br
N
sw
2 ge
30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a ge
DK bl
rt
4
3
gn
bl
1
sw br br sw
J
2 ge ge 2
ge ge
EK bl
4 gn gn 4 bl TB
n rt 3
1
bl bl 3
1
rt
K
br
s st u sw
2
br
2
sw
q 61 D- D+
PB
ge
bl
4
ge
gn RBG
M 3
p v
238 +UB
rt
1
bl bl
1
rt
50e 50f D+ o 1
2
213 dS
sw br br sw
r w G 150
3
219.1 +UZ 2 ge 2 ge
RBK
t 4
214
232
dR
dW WP rt bl
gn
bl
4
3
bl
rt
5 251 ZW 1 1
6 253 ABS
7 250 dN
8 255 dNEUTR
9 252 DIAGN-K
10 216 DIAGN-L
11 200 SSP
DKR 12 205.1 DKR A Push-button switch L Switches and warning a Inhibitor switch for reverse gear m Relay for speed
13
DKE
DKV/PWM 14
224.1
241.1
DKE
DKV/PWM
B Connection cable for light transmission oil b Connections n Central warning light
15 204.1 KD push-button switch and M Engine control c Bridges o Fuse 8A
M 16
17
18
19
215
231
248
235
TOEL
FBAUS
PU
ABSICH
converter brake
C Cable 2
N Vehicle electrical system -
non-committal representation
d
e
Warning light transm. oil
Cut-out switch for conv. brake;
p
q
Relay for battery
Switch box
20 212 BS D E 200 control unit O Relays only for brake valve r Starter inhibitor relay
21 221.1 -UB
E Connection: level con- P CAN Bus f Pressure switch for s Starter
off
22
on
ABS verter and diagnostic PC Q Connection cable for gearshift inhibitor st Start button
P P
F Cable 1 brake valve and g Pressure switch for t Battery
d e f g G Load transmitter kickdown switch ANS activation u Overvoltage protection
H Speed and temperature R Kickdown switch h Relay for control unit v Generator
a 39
3
REA0
RBG
54
36 117
240 FB1 22 17 153
-UB
204 40 53 135
KD WR
204.1 KD 35
-UB
4 16 152
-UB
241.1 DKV/PWM 23 52
-UB
A b c 205.1
224.1
DKR
DKE
41
5
EKM
DKM
34
15
7
8
S1 S2 S3 S2/1 S2/2 S3/2 S3/3 24 51 3
D N R SKM
42 PBM 33 6
2 D N R 6 14
200 TBM 4
1 2 D N R 25 50
1 2 3 D N R 43 32
207 HBA RBKM 5
226 HBB 7 SENSE 13 1
244 HBC 26 SENSE 49 2
S3/2
S2/1
S2/2
S3/3
208 +HB 44 -UB 31
S1 227 8 12 148
1 227 S1 -UB
S2 245 27 48
2 245 S2 -UB
S3 209 45 30 111
3 209 S3 N1A
+V 228 9 11
4 228 +V N1B 147
+R 246 28 47 129
5 246 +R N2A
RS 230 46 29
6 210 /N N2B 110
+TS 229 10 10
7 229 +TS N3A 146
+TL 233 29 46 128
8 N3B
/N 210 FB2 47 28
9 211
-UB 221 230 11 9
10 RS
SSP 200 30 45
11 248 PU -UB
RF 256 BS 48 27 9
12 212 TS+
RS FBAUS 12 TS- 8
13 231 10
+R 249 FB3 31 -UB 44
14 26
213 dS 49
13 7
B C D
232 dW
32 43
250 dN
50 25
214 dR IO9
14 6
233 +TL
33 42 124
251 ZW LGM
51 24 105
215 TOEL -LG
15 +LG 5 141
41
252 DIAGN-K 34 IO3
52 23
252.1
216 DIAGN-L 4
227 16 -UB 40
S1 227 216.1
z 0 3 2
z 0 1 2 3 S2 245 1 245 235 ABSICH
22
103
221.2 0 1 3 221.2 S3 209 2 209 253 ABS
35 -UB 3
+
4 4 11 19
HBA 244 HBC 3 244 HBC 244 244 219.2
5 226 HBB 5 226 HBB 226 12 226
2
6 HBA 6 207 13 207
207 1 207 HBA
+HB 7 +HB 7 208 +HB 208 14 208
208
+
8 8 200 15
SSP 200
RF 256 16
17
18 219.2 +UZ
E
1
F
221.3 -UB
252.1 DIAGN-K 2
216.1 DIAGN-L 8
10
S R 141 +LG
G
1 124 LGM
204 2 105 -LG
1 219 3
4
2 3 Q
128
146
152
153
147
111
110
129
135
137
119
102
103
121
117
120
101
118
9
148
4
3
1
10
2
6
5
KD 204 204
+UZ 219 1 219 A B C D E F G H J K L MN P R S T U V WX Y Z a b c d e f g h j
gn/ge 240 FB1 2 240
240
bl 1 FB3 3 249
249 249
sw 2 202 +FB 4 202
202
br 3 211 FB2 5 211
211
4 6
7 + ws bl
ϑ 1
P
- 4 bl
8 sw
H
2 3
9
10 ws bl ws
n1 sw 2 bl sw
n3
M
CAN-H 217 sw CAN-H 1
C
CAN-M 237 ge CAN-M
CAN-L B 236 CAN-L
A ws
sw n2
h i j k l m sw
2
br br
2
sw
ge ge
dS dW dR dN 4
SK
O
gn
bl
rt 3
1
bl WR
bl rt
1
N
sw br
30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a ge 2 ge
4
DK bl
rt 3
gn
bl
1
sw br br sw
J
2 ge ge 2 ge
ge
n EK bl
rt
4
3
gn
bl
gn
bl
4
3
bl
rt
TB
1 1
K
br
s st u sw
2
br
2
sw
q PB
ge
4
ge
M
61 D- D+ bl
3
gn
bl RBG
p v o 1
238
213
+UB
dS
rt
1
bl
1
rt
50e 50f D+ 2 sw br
150 219.1
r w G 3 214
+UZ 2 br sw
t 4 232
dR
WP ge 2 ge
5
6
251
dW
ZW
rt
1
bl gn
bl
4
3
bl
rt
RBK
253 ABS 1
7 250 dN
8 255 dNEUTR
9 252 DIAGN-K
10 216 DIAGN-L
11
12
200 SSP A Push-button switch L Switches and warning a Inhibitor switch for reverse gear m Relay for speed
DKR 205.1 DKR
DKE 13 224.1 DKE B Connection cable for light transmission oil b Connections n Central warning light
14
DKV/PWM
15
241.1
204.1
DKV/PWM
KD
push-button switch and M Engine control c Bridges o Fuse 8A
M
16
17
215 TOEL converter brake N Vehicle electrical system - d Warning light transm. oil p Relay for battery
231 FBAUS
18 248 PU C Cable 2 non-committal representation e Cut-out switch for conv. brake; q Switch box
19
20
235
212
ABSICH D E 200 control unit O Relays only for brake valve r Starter inhibitor relay
BS
21 221.1 -UB E Connection: level con- P CAN Bus f Pressure switch for s Starter
off
on
22
verter and diagnostic PC Q Connection cable for gearshift inhibitor st Start button
ABS P P F Cable 1 brake valve and g Pressure switch for t Battery
G Load transmitter kickdown switch ANS activation u Overvoltage protection
d e f g H Speed and temperature R Kickdown switch h Relay for control unit v Generator
sensors S Brake valve i Relay for starter inhibitor w Regulator
L
inactive
J Solenoid valves T Manual switch for j Relay for centr. warn. light x Connections
K Connection cable converter brake k Relay for converter brake y Position Circuit diagram DIWA.3E
+ 24V for vehicle wiring U Switch for converter l Relay for reversing light z Stage no.
brake; stage no. 3 55.6168.10
Voith Turbo GmbH & Co. KG
Produktgruppe Nutzfahrzeuggetriebe
Alexanderstraße 2
D-89522 Heidenheim
Telephone (07321) 37-0
Telefax (07321) 37 7618
3 AUTOMATIC GEARBOXES
DB 250 PF Series ZF-ECOMAT 2 Transmissions
0145 1-1
AUTOMATIC GEARBOXES 3
ZF-ECOMAT 2 Transmissions DB 250 PF Series
1-2 0145
REPAIR MANUAL
011356
Copyright by ZF
These repair instructions are protected by copyright. Any reproduction and dissemination in whatever
form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or
electronic reproduction or as a storage in data-processing equipment or data networks without approval
by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.
Printed in Germany
Edition: 2001 - 03
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Instructions for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Arrangement of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cutaway views of Ecomat transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch and brake combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Page
3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
5
Important information HP 502 C / HP 592 C / HP 602 C
Companies repairing ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.
CAUTION
The transmission must NOT be hung by the input
shaft NOR by the output flange.
6
HP 502 C / HP 592 C / HP 602 C Instructions for repairs
In case of doubt always turn to the relevant depart- GASKETS, LOCKING PLATES
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed expertly Parts which cannot be removed without being damaged
and under clean conditions. must always be replaced with new parts (e.g. gaskets
Use specified tools to dismantle and assemble trans- and locking plates).
missions.
RE WO R K I N G
CLEANING PARTS
Rework may be carried out on seal contact surfaces
Remove remains of old gaskets on all seal-faces. using plunge-cut grinding only, never use an emery
Carefully remove burrs or similar patches of roughness cloth. Ensure that there are no traces of grinding or
using an oil-stone. riffling.
Lube bores and grooves must be free of anti-corrosion If rework is needed on distance washers, shims etc.
agents and foreign matter; check for perfect passage. because of clearance settings, ensure that the reworked
areas contain no face runout and have the same surface
Carefully cover opened transmissions to prevent foreign quality.
matter from entering.
TRANSMISSION ASSEMBLY
REUSING PARTS
Find a clean site to assemble the transmission. Gaskets
Parts such as ball or roller bearings, multi-discs, thrust are installed without the use of sealing compound or
washers etc., must be inspected by a competent person, grease. When measuring silicon-coated gaskets, take
who should decide whether or not they can be re-used. care not to include the silicon layer in the measure-
Replace parts which are damaged or have suffered from ment.
excessive wear. During assembly, comply with all adjustment data,
checking data and tightening torques in the Repair
Manual.
7
Instructions for carrying out repairs HP 502 C / HP 592 C / HP 602 C
8
HP 502 C / HP 592 C / HP 602 C Tightening torques
This standard applies to bolts acc. to DIN 912, DIN 931, Surface condition of bolts: thermally blackened and
DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934. oiled or galvanized and oiled or galvanized, chrome-pla-
This Standard contains data on tightening torques (MA) ted and oiled.
for bolts and nuts in strength categories 8.8, 10.9 and
12.9 and nuts in strength categories 8, 10 and 12. Tighten screws with a calibrated torque spanner.
NOTE
Irregular tightening torques are listed separately in the
Repair Manual.
M 7 15 23 28 M 10 x 1.25 49 72 84
M 8 23 34 40 M 12 x 1.25 87 125 150
M 10 46 68 79 M 12 x 1.5 83 122 145
9
Tightening torques HP 502 C / HP 592 C / HP 602 C
Screw plugs DIN 908, 910 and 7604 Union screws DIN 7643
The screw plug tightening torques MA were determined The tightening torques MA were determined for
according to DIN 7604 for screwing into steel, grey cast screwing into steel, grey cast and aluminum alloys.
and aluminum alloys. The values are based on experience and are intended
The values are based on experience and are as reference values for the fitter.
intended as reference values for the fitter. General rule: screw/bolt class 5, ZFN 148-1
The values for the tightening torque MA apply analo- Material: 9SMnPb28K acc. to DIN 1651
gously for screw plugs according to DIN 908 and Surface condition: as manufactured
DIN 910, as the thread geometries are almost identical. (without surface protection) and lightly
General rule: Screw/bolt class 5, ZFN 148-1 oiled or galvanized, chromated and
Screw/bolt material: steel acc. to lightly oiled.
DIN 7604. Surface condition: as manufac-
tured (without surface protection) and
lightly oiled or galvanized, chromated and
lightly oiled.
10
HP 502 C / HP 592 C / HP 602 C Expendables
NOTE: Inquire about the size of bundles that can be delivered before placing any orders!
11
Adjustment data HP 502 C / HP 592 C / HP 602 C
01. Internal resistance of R = approx. 67 ohm Ohmmeter and test Resistance rises with tempe-
solenoid valves for at 68 °F cable 1P01 138 153 rature to approx. 74 Ohm
clutches and brakes in (20 °C) or terminal tester when transmission at
transmission 6008 006 002 operating temperature.
03. Tightening torque for 26 ft-lbs Torque wrench Renew copper sealing ring.
M14x1.5 temperature 35 Nm
sensor
04. Tightening torque for 37 ft-lbs Torque wrench Renew copper sealing ring.
M22x1.5 oil drain plug in 50 Nm
oil pan
05. Clearance between induc- 0.02 - 0.027" Depth gauge, slider Adjust clearance with shims
tive sensor - output and 0.5 - 0.7 mm gauge 1X56 138 149
face end gears on plane- /1X56 138 150
tary carrier
06. Clearance between induc- 0.024 - 0.03" Depth gauge, slider Adjust clearance with shims
tive sensor - turbine and 0.6 - 0.8 mm gauge 1X56 138 149 /
pulse sensor ring 1X56 138 150
08. Clearance between speedo 0.027 - 0.055" Depth gauge Clearance is supplied,
sensor and toothedring on 0.7 - 1.4 mm check value.
output
10. Insertion depth of shaft 0.55 - 0.59" Use to 1X56 136 824
seal in output cover 14 - 15 mm This gives correct insertion
depth.
12
HP 502 C / HP 592 C / HP 602 C Adjustment data
12. Tightening torque for M12 44 ft-lbs Torque wrench Secure with lock plate
hex bolts at output flange 60 Nm Use to 1X56 136 471
13
14
HP 502 C / HP 592 C / HP 602 C Special tools
Tool
1 for lock plate on output flange
Tool
2 for fitting radial seal in
output flange
Lifting attachment
5 for transmission
15
Special tools HP 502 C / HP 592 C / HP 602 C
Measuring rod
6 to determine distance between
inductive sensor and pulse sensor on
turbine and output (in connection
with test fixture 1X56 138 150)
Test fixture
7 to determine distance between
inductive sensor and pulse sensor on
turbine and output (in connection
with measuring rod 1X56 138 149)
Gripper
8 to mount output flange
(in connection with mounting fixture
1X56 136 512)
Mounting fixture
9 to mount output flange (in connec-
tion with gripper 1X56 103 755)
16
HP 502 C / HP 592 C / HP 602 C Special tools
Test cable
11 for testing solenoid valves
Diagnostic software
14 Testman
Diagnose - Software
6008 308 014
for Ecomat 2
17
Special tools HP 502 C / HP 592 C / HP 602 C
EPD1 for
16 Simple programming device ZF-Service
only
18
Arrangement of
HP 502 C / HP 592 C / HP 602 C peripheral equipment
N R
3 D
1 2
013190
Key to drawing
1 Transmission electrical power plug 10 Pedal brake valve for actuation of service brake and
2 EST 46C / EST 47C plug continuous retarder actuation via CAN
3 Retarder plug 11 Accelerator pedal
4 Accumulator plug 12 Retarder switch OFF - ON
5 Temperature sensor plug 13 Vehicle power supply
6 Kickdown switch 14 Pressure switch for NBS
7 MOBiDIG connection plug 15 EST 46 C / EST 47 C electronic control unit
8 Speed range selector (Push-button switch) 16 Electric retarder hand lever
9 Dipstick (Oil level check, oil condition) 17 Speedometer pulse sensor
19
Cutaway view HP 502 C / HP 592 C / HP 602 C
ZF Ecomat transmission,
4-speed version
1 2 4 5 6 7 9 10 11 12 13
26 25 24 23 22 21 20 19 18 17 16 15 14
013468
Key to drawing
20
HP 502 C / HP 592 C / HP 602 C Cutaway view
ZF Ecomat transmission,
5 & 6-speed version
1 2 4 5 6 7 8 9 10 11 12 13
26 25 24 23 22 21 20 19 18 17 16 15 14
013467
Key to drawing
21
Clutch combination HP 502 C / HP 592 C / HP 602 C
22
HP 502 C / HP 592 C / HP 602 C Maintenance
1. Maintenance
1.1 Oil change intervals
NOTE : The suction filter must be renewed at every oil change. Before changing the filter, drain off the oil
(while still hot). The complete filter kit (filter and sealing rings) is available with order No. 4139 298 936.
*Average speed < 15 miles/h (25 km/h) and vehicle weight > 23 t.
The above quantities are reference quantities; the exact amount must always be found by measuring with the dipstick.
DANGER
011576
Insufficent oil can cause partial or regular retarder
failure: i.e. reduced or zero braking action.
NOTE
Before the oil level is checked, the transmission
oil must have reached an operating temperature of
180 - 195°F (80 - 90 °C).
9'2
Conditions:
Hot range } 80-90°C
• Vehicle standing level
• Speed range selector at “N” (Neutral)
• Engine idling (approx. 2 minutes)
• Transmission oil 80 - 90°C / 180 - 195°F
1-2
HP 502 C / HP 592 C / HP 602 C Maintenance
Conditions:
011577
Conditions:
011577
Conditions:
1-3
Maintenance HP 502 C / HP 592 C / HP 602 C
– Unscrew filter cover and renew suction filter (see filter cover
Section 2.1).
– Screw in drain plug (37 ft-lbs/50 Nm) and fit filter bolts (23 Nm)
cover (17 ft-lbs/23 Nm), see Section 2.1.
CAUTION
When working on a transmission with a converter
drain valve, always use genuine oil drain plug. The
drain plug controls and closes the converter drain oil drain plug 37 ft-lbs (50 Nm)
valve. 009871
011576
011577
1-4
HP 502 C / HP 592 C / HP 602 C Overhaul
2. Overhaul
DANGER
Collect used oil in a large enough container and dis-
pose of this in strict accordance with environmental 1
protection legislation. Refer to general notes on
threats to the environment.
011578
NOTE 1
Check filter for contamination.
DANGER
Dispose of contaminated filters in strict accordance
with environmental protection legislation. Refer to
general notes on threats to the environment.
011579
008513
2-1
Overhaul HP 502 C / HP 592 C / HP 602 C
010483
011578
2-2
HP 502 C / HP 592 C / HP 602 C Overhaul
011580
011581
011580
2-3
Overhaul HP 502 C / HP 592 C / HP 602 C
011583
5 Fit valve.
011584
011585
2-4
HP 502 C / HP 592 C / HP 602 C Overhaul
011584
011587
011588
2-5
Overhaul HP 502 C / HP 592 C / HP 602 C
011589
011590
011591
2-6
HP 502 C / HP 592 C / HP 602 C Overhaul
011592
CAUTION
Use suitable pliers and pull on the plugs - not on the
cables! 2
011775
1 2 3
011776
2-7
Overhaul HP 502 C / HP 592 C / HP 602 C
011598
012901
011778
2-8
HP 502 C / HP 592 C / HP 602 C Overhaul
011779
Measuring formula:
c-b=d
d+a= thickness "S" of spacer
Measuring example:
Dimension "c" = 52.6 mm
Dimension "b" = 51.3 mm
Dimension "a" = 0.6 mm (0.5 to 0.7 mm) 011780
Calculation example:
52.6 mm - 51.3 mm = 1.3 mm 2 3
1.3 mm + 0.6 mm = 1.9 mm
011620
2-9
Overhaul HP 502 C / HP 592 C / HP 602 C
4 3 1
011776
011775
011592
2-10
HP 502 C / HP 592 C / HP 602 C Overhaul
CAUTION
Each resistor is assigned to the relevant transmission
by checking the type of retarder fitted. Each is identi-
fied by an item number. This item number should be
read since you may only install a new resistor which
has an item number which is identical to the old one.
012902
NOTE
The resistor has a ten digit item number. Eight of
these digits (6029 201 6) can be found on the face
surfaces of the resistor (1). The two other item
number digits (2) are located, as is shown, on its 2
circumference.
2-11
Overhaul HP 502 C / HP 592 C / HP 602 C
011775
2-12
HP 502 C / HP 592 C / HP 602 C Overhaul
011578
DANGER
Beware of any oil remaining in the oil pan.
Ensure that the oil pan is well supported so that it 1
cannot fall over.
CAUTION 011579
016072
2-13
Overhaul HP 502 C / HP 592 C / HP 602 C
016073
016072
011601
2-14
HP 502 C / HP 592 C / HP 602 C Overhaul
011603
CAUTION
When working on a transmission with a converter
drain valve, always use genuine oil drain plug. The
drain plug controls and closes the converter drain
valve.
011579
011605
2-15
Overhaul HP 502 C / HP 592 C / HP 602 C
2-16
HP 502 C / HP 592 C / HP 602 C Overhaul
011579
011607
011608
2-17
Overhaul HP 502 C / HP 592 C / HP 602 C
1 2 3
011776
011783
CAUTION
It is important to measure onto a raised point on the
induction ring, otherwise the sensor will be damaged
by the raised points on the ring when the engine is
started.
011622
2-18
HP 502 C / HP 592 C / HP 602 C Overhaul
011784
011785
011778
2-19
Overhaul HP 502 C / HP 592 C / HP 602 C
011779
Measuring formula:
c-b=d
d + a = thickness “S” of spacer
Measuring example:
Dimension “c” = 52.6 mm
Dimension “b” = 50.9 mm 011780
Calculation example:
1 2 4
52.6 mm – 50.9 mm = 1.7 mm
1.7 mm + 0.7 mm = 2.4 mm
2-20
HP 502 C / HP 592 C / HP 602 C Overhaul
4 3 1
011776
011610
011607
2-21
Overhaul HP 502 C / HP 592 C / HP 602 C
CAUTION
When working on a transmission with a converter
drain valve, always use genuine oil drain plug. The
drain plug controls and closes the converter drain
valve.
011578
2-22
HP 502 C / HP 592 C / HP 602 C Overhaul
CAUTION
Before unscrewing cable harness from transmission,
remove any dirt and dust from the area around the
cable harness connector.
013480
011624
011579
2-23
Overhaul HP 502 C / HP 592 C / HP 602 C
015825
2
1
015826
DANGER
When the control module is released, oil will spurt
out. Protect yourself and especially your eyes from
the oil. Let the oil continue to drip out and be sure to
catch all of it.
DANGER
The shift control module weighs approx. 40 lbs. (18 kg).
Ensure it is well supported so that it cannot fall and
injure you or other persons under the vehicle.
015827
2-24
HP 502 C / HP 592 C / HP 602 C Overhaul
CAUTION
Take care that cable connectors on shift control
module do not get caught in the transmission, or they
may be torn off.
NOTE
Images, drawings and parts shown do not always
represent originals simply the process. Hex bolts
e.g. on the shift control unit are replaced by Torx
bolts.
011630
NOTE
Kostal socket (arrow) must be inserted in the seat
of the transmission housing.
!DANGER
Look out for sharp edges.
The hydraulic control unit weighs approx. 40 lbs.
(18 kg).
CAUTION
Do not clamp on wiring.
011629
011611
2-25
Overhaul HP 502 C / HP 592 C / HP 602 C
015827
NOTE
Protective cap must be snapped into place.
015828
015825
2-26
HP 502 C / HP 592 C / HP 602 C Overhaul
011624
011607
011578
2-27
Overhaul HP 502 C / HP 592 C / HP 602 C
015829
CAUTION
Handle oil level electronic unit with care. It is very
sensitive to impact.
1
015830
NOTE
Do not unfasten M6 Torx bolt (2).
015831
2-28
HP 502 C / HP 592 C / HP 602 C Overhaul
2
3
015832
4 Insert new oil level sensor (i.e. not yet set and not
secured) complete with retaining plate and use 1
two M6x30 Torx bolts (1) to screw into place.
Tightening torque: 7 ft-lbs (9.5 Nm)
015833
CAUTION
The Torx bolts on the retaining plate screw connec- 1
tion are each fitted with two O-rings for damping.
Check that O-rings are seated properly. 3 2
4
1 Torx bolt
2 Washer 5
3 9x2.5 O-ring 6
4 Retaining plate
5 14x2.5 O-ring
6 Bush
7 O-ring for fastening 7 Length X =
5.0 +3 mm
015834
2-29
Overhaul HP 502 C / HP 592 C / HP 602 C
CAUTION
Setting lengths are different depending on the parts
list. Take the correct setting length from the parts list.
Example:
015832
2-30
HP 502 C / HP 592 C / HP 602 C Overhaul
015831
CAUTION
Handle oil level electronic unit with care. It is very
sensitive to impact. 1
015830
2-31
Overhaul HP 502 C / HP 592 C / HP 602 C
011635
011636
011637
2-32
HP 502 C / HP 592 C / HP 602 C Overhaul
DANGER
Wear eye protection, metal chips may fly out.
011638
NOTE
When unscrewing bolts, use a suitable lever to
1
prevent output flange from turning.
011639
NOTE
Protect end of output shaft with a washer or
similar.
011640
2-33
Overhaul HP 502 C / HP 592 C / HP 602 C
CAUTION
Take care not to damage seal bore while pulling
out seal.
012273
6 Place shaft seal (1) onto tool 1X56 136 824 with
sealing lip facing towards output cover.
CAUTION
Do not fit seal the wrong way round. The spring load
on the sealing lip must be visible when the seal is on
the tool.
011642
CAUTION
Do not use grease or transmission oil on outside of
seal or leaks may result.
011643
2-34
HP 502 C / HP 592 C / HP 602 C Overhaul
NOTE
Correct seal insertion depth of 0.59–0.04 in.
(15-1 mm), measured from the face of the bearing
inner ring to the face of the seal, is given by using
tool 1X56 136 824.
001654
CAUTION
Do not heat output flange over 230°F (110°C) or seal
will be damaged.
DANGER
Always wear protective gloves when handling hot out-
put flange.
NOTE
Insert hex bolts before fitting flange if necessary.
CAUTION
Never knock output flange into place.
011646
2-35
Overhaul HP 502 C / HP 592 C / HP 602 C
NOTE
Always use new hex bolts here.
011647
011648
DANGER
When the lock plate (1) has been driven in, you may
be left with a sharp edge. Carefully remove this edge
using a file or other suitable tool.
CAUTION
Maintain cleanliness. Carefully remove swarf and
other particles.
011649
2-36
HP 502 C / HP 592 C / HP 602 C Overhaul
1 = Main pressure PH 5 3
2 = Throttle pressure PD1
3 = Pressure before converter PD2
4 = Pressure after heat exchanger PD6 5 PD7*
1
5 = Retarder pressure PR3 6 2
6 = Retarder control pressure PRR3
011650
011651
2-37
Overhaul HP 502 C / HP 592 C / HP 602 C
0.2 - 1.0
cold
Idling N D open 550 20 - 40 7 - 15 4.0 - 5.5 0.8 - 1.8
for 2 sec.
Full load N open 2000-2500 20 - 40 18 - 21 4±0,3 6.0 - 8.5 1.8 - 2.5
Full load Engaged closed 2000-2500 20 - 40 10 - 12 4±0,3 6.0 - 8.5 1.8 - 2.8
Idling N open 700 80 - 90 7 - 15 4±0,3 3.0 - 4.5 0.1 - 0.8
0.2 - 1.0
warm
Idling N D open 550 80 - 90 7 - 15
for 2 sec.
3.0 - 4.5 0.1 - 0.8
Full load N open 2000-2500 80 - 90 ◆16 - 20 4±0,3 6.0 - 8.5 1.8 - 2.5
Full load Engaged closed 2000-2500 80 - 90 10 - 12 4±0,3 6.0 - 8.5 1.8 - 2.5
* Values are shown in the relevant parts list or may be obtained from ZF.
◆ If the pressure falls below this value: Please contact the relevant ZF service agency before removing the transmission.
0.2 - 1.5
Idling N D open 550 80 - 90 10 - 17 3.0 - 4.5 0.1 - 0.8
for 2 sec.
Full load N open 2000-2500 80 - 90 21 - 24 4±0,3 6.0 - 8.5 1.8 - 2.5
Full load Engaged closed 2000-2500 80 - 90 12 - 15 4±0,3 6.0 - 8.5 1.8 - 2.5
*Values are shown in the relevant parts list or may be obtained from ZF.
2-38
HP 502 C / HP 592 C / HP 602 C Troubleshooting
3 Troubleshooting
3.1 Terminal tester concept
25-, 55-, 68-pin EST electronic control unit
68-pin 55-pin
terminal tester terminal tester
68-pin - 55-pin
reduction adapter cable
3-1
Troubleshooting HP 502 C / HP 592 C / HP 602 C
3-2
HP 502 C / HP 592 C / HP 602 C Troubleshooting
b) Resistance measurements:
Measure resistance of solenoid valve coils and On solenoid valves the resistance value rises with rising
inductive sensors, see list below. temperature.
NOTE: Resistance values may change with rising or On the temperature sensor B14 the resistance value
dropping temperatures. drops with rising temperature.
Brakes, A4 Ohmmeter
Clutches,
Test specimen Nominal readings
Inductive sensors,
Resistance Marking Pin
D1-
Prop.-solenoid Y20
D1 valve D1 10 approx. 8,6 ± 0,5 W at 20°C
Oil level sensor B15 Oil level display Oil 23 ** PWM %, VPE 5 Volt
¨ Tolerance and
characteristics
Ground/earth GM1 15
temperature sensor
see next page Ground/earth GM2 17
VM1 21
Ground/earth
VM2 20
* see table for checking model of retarder fitted
** no resistance measurements must be carried out
3-3
Troubleshooting HP 502 C / HP 592 C / HP 602 C
Temperature sensor NTC - Sensor B14 Temp. 2*Rt 2*Rt (min) 2*Rt (max)
Thermometrics DKS 4261 [˚C] [Ohm] [Ohm] [Ohm]
2 elements in series
-20 957796 896080,6 1023353,4
-15 720948 676412 768108
Table of tolerance - 20°C bis 150°C -10 547652 515240,8 581880,2
-5 419668 395880 444708
0 324282 306690,8 342746
5 252580,6 239476,2 266295,4
10 198235,8 188407 208494
15 156760,6 149700,6 164443,6
20 124765,8 119130 130615,8
25 99991 95685,8 104448
30 80649,2 77343 84063,2
35 65448,2 62896,4 68076,4
40 53425,2 51446,4 55457,8
45 43857 42316 45435,8
50 36197,6 34992,8 37428,8
55 30031,2 29086 30994,8
60 25040 24296 25796,4
65 20978,6 20391,2 21574
70 17657 17192,4 18127
75 14927,6 14559,2 15299,2
80 12674 12381,4 12968,2
85 10804,8 10572,4 11038,2
90 9248 9063 9433
95 7945,8 7775 8117
100 6852 6694,8 7010
105 5929,8 5785,4 6075,4
110 5149,4 5017 5283,2
115 4486,4 4365 4609,4
120 3921,6 3810 4034,2
125 3438 3336 3541,6
130 3023,2 2929,8 3118,4
135 2666,2 2580,6 2753,6
140 2357,8 2279,4 2438,2
Characteristics
145 2090,8 2018,8 2164,6
Resistance/Temperature
150 1858,8 1792,8 1926,8
2 elements
DKS 4261 (2*in Reihe)in series
100000
90000
80000 2*Rt [Ohm]
Widerstand [Ohm]
70000
60000
Resistance
50000
40000
30000
20000
10000
0
20 30 40 50 60 70 80 90 100 110 120
Tem peratur [˚C]
Temperature
3-4
HP 502 C / HP 592 C / HP 602 C Annex
DIAGNOSTIC TOOL
015955
ZF FRIEDRICHSHAFEN AG
D-88038 Friedrichshafen, Service Werk 2
Telefon: (0 75 41) 77-0, Fax: (0 75 41) 77-5726
Internet: http://www.zf-group.de
6008 758 103
Subject to alterations in design
Copyright by ZF
These instructions are protected by copyright. Any reproduction and dissemination in whatever
form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or
electronic reproduction or as a storage in data-processing equipment or data networks without approval
by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.
Printed in Germany
Edition 2000 - 04
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contents of the “Testman” diagnosis software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testman software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation of the diagnosis software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting up a programming tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DPA 04 I description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DPA 04 I programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Selecting a COM port ..................................................................... 11
Starting the Testman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Testman screen display – Start-up logo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Screen display of the product menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Contents of the product menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Screen display of the repair aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contents of the repair aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preface ZF-Diagnostic tool “Testman”
4
ZF-Diagnostic tool “Testman” Safety notice
SAFETY NOTICE
NOTE
Refers to special processes, techniques, data, use
of auxiliary equipment, etc.
CAUTION
This is used when incorrect, unprofessional
working practices could damage the product.
! DANGER
This is used when lack of care could lead to
personal injury or death.
5
Contents of Testman / System components ZF-Diagnostic tool “Testman”
ZF Testman
electronic diagnosis
Test
Aids to Vehicle Telephone
Diagnosis inputs and
repair work configuration directory
outputs
Tightening torques Reading error System check at Viewing the Telephone direc-
memory standstill vehicle data tory of all people
Adjustment data in the Technical
Deleting error System check in Copying vehicle Service, arranged
Special tools/test memory motion data by product
equipment
Identification Test equipment Modifying /exten-
Maintenance block ding vehicle data
Analogue displays,
Repairs speeds, currents
etc.
Pressures
Circuit diagrams
Electrical measur-
ing values
Order numbers:
Batch number for diagnosis software on diskette. You can obtain further information
6008 308 900
about the desired diagnosis software from your ZF Service Center.
6
ZF-Diagnostic tool “Testman” Testman software installation
NOTE
This software will run using Windows 95,
Windows 98 and Windows NT. (Installation under
Windows NT only with administrator rights)
1. Insert the “Testman 1” diagnosis software in the
disk drive (e.g. “A”).
2. Use the “Start” symbol (Windows interface) and
pull up the ”Run” command.
3. The “Run” window is opened.
4. Use your mouse to click on “Search”.
5. Select the drive (e.g. “A”). 1
015917
6. The contents of the diskette are now displayed.
1 Testman software on diskettes
7. Select the Testman Setup program and follow the Order No.: 6008 308 901
instructions in the software.
The Testman installation process is now complete.
NOTE
The Testman is available in English and German.
These languages only have an effect on system reac-
tions (not on the diagnosis software).
7
Additional settings ZF-Diagnostic tool “Testman”
Start the Testman. The first time you open the program, NOTE
“ZF ISO Man Properties” appears on screen. Here you Communication is not possible unless you have selected
should select the correct COM port on your PC and con- the correct COM port.
firm this choice. If you need this function again at a later
point, double-click the “Z” symbol to the bottom right of
the task bar.
015911
1. Click on the Testman icon with your right mouse 3. Select the program and select “Close on
button. completion”.
2. Select “Properties”. 4. Accept and confirm with “OK”.
015948
8
Installation of the diagnosis software
ZF-Diagnostic tool “Testman” Connecting up a programming tool
4
015955
Key to drawing
1. Your PC – with appropriate system requirements
2. RS 232 cable Order No. 6008 308 601
3. DPA 04 I diagnosis adapter Order No. 6008 308 600
4. ISO cable Order No. 0501 211 103
or
SAE cable Order No. 0501 211 104
9
DPA 04 I description ZF-Diagnostic tool “Testman”
5. KL15ECU switch
This switch is not relevant in ISO mode.
10
DPA 04 I programming
ZF-Diagnostic tool “Testman” Selecting COM port
The DPA 04 I has a Flash Prom which is supplied with In the event of the DPA 04 I drive losing data, proceed in
Testman functions. accordance with the following instructions in order to
restore Testman functionality.
015908
015947
11
Starting the Testman ZF-Diagnostic tool “Testman”
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012290/013809/013810/013811
12
ZF-Diagnostic tool “Testman” Start-up logo
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Select "Run" under RUN PAL2Application ☞ The start-up logo "ZF Service" appears ☞
Press the "Enter" key on the PC or use the
mouse to click on the symbol "continue" ☞ The product menu appears
13
Product menu / Contents ZF-Diagnostic tool “Testman”
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Test equipment.
Product-specific.
Analogue display:
Such as speeds, currents etc.
'LDJQRVLV
Product-specific. 9HKLFOHFRQILJXUDWLRQ
Reading/deleting error memory.
Vehicle-specific data.
Identification block.
Such as customer sheets, vehicle data etc.
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=)6HUYLFHWHOHSKRQHGLUHFWRU\
System check: Vehicle at standstill.
ZF contacts.
Check of all system components which can be
Telephone directory of all people in the Tech-
tested when vehicle is at standstill.
nical Service, arranged by product.
Errors are described on the screen when exit-
ing the function test.
14
ZF-Diagnostic tool “Testman” Repair aid / Contents
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6WDUW 7HVWPDQ'HYHORSPHQ
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Oil change intervals, types of oil (ZF list of lubri- Product-specific.
cants), oil quantities, oil changes, oil fills (figure)
and product-specific maintenance information.
3UHVVXUHV
Product-specific.
7LJKWHQLQJWRUTXHV
ZF standard 148 and product-specific tightening
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torques.
Product-specific.
Example: Voltages and resistance.
6SHFLDOWRROVWHVWHTXLSPHQW
Product-specific.
5HWXUQWRPHQX
All tools required for work on the vehicle are
shown as pictures with their ZF nos. Previous menu is displayed.
5HSDLUV
Product-specific.
Example: Description of how to change the
inductive sensor.
15
Technical data ZF-Diagnostic tool “Testman”
16
HP 502 C / HP 592 C / HP 602 C Hydraulic circuit diagram without NBS 4149 700 026/1
A B1 B2 D E F1 F2
NA
4 GANG i = 2.81 BIS 1.0
DETAIL X 3.43 BIS 1.0
4 GEAR TO
AUSFUEHRUNG RUECKWAERTS
HAUPTDRUCKVENTIL REVERSE
MIT DRUCKABSENKUNG
P NEUTRAL
2 NEBENATRIEBE MOEGLICH VERSION
PTO'S CAN BE FITTED MAIN PRESSURE VALVE
WITH PRESSURE REDUCER 1. GANG
1st GEAR
WK
2. GANG
2nd GEAR
D2 3. GANG
3rd GEAR
4. GANG
WK 4th GEAR
A B2 C D E F1 F2
F1-VENTIL R3
D4 D6 D5 D7
F1 RR3
X R3
F
D2
RETARDER-
F2-VENTIL REGELVENTIL
RETARDER KUEHLER-
HAUPTDRUCK- CONTROL VALVE UMSCHALT-
F2 VENTIL VENTIL
MAIN PRESSURE COOLER
VALVE CHANGEOVER
D8 D8 VALVE R1
D1
P
P D9 R2
RETARDER
PRIMAER-
PUMPE
D1 PRIMARY PUMP
A2
SAUGFILTER
P
SUCTION FILTER
011867
A1
DROSSELDRUCKVENTIL
THROTTLE PRESSURE
VALVE
4-1
HP 502 C / HP 592 C / HP 602 C Hydraulic circuit diagram with NBS 4149 700 026/2
A B1 B2 D E F1 F2
NA
4 GANG i = 2.81 BIS 1.0
DETAIL X 3.43 BIS 1.0
4 GEAR TO
AUSFUEHRUNG
RUECKWAERTS
HAUPTDRUCKVENTIL
MIT DRUCKABSENKUNG REVERSE
P NEUTRAL *
2 NEBENABTRIEBE MOEGLICH VERSION
PTO'S CAN BE FITTET MAIN PRESSURE VALVE
WITH PRESSURE REDUCER NEUTRAL NBS *
WK 1. GANG
1st GEAR
D2 2. GANG
2nd GEAR
3. GANG
WK 3rd GEAR
4. GANG
4th GEAR
A
B1 = INNERE KOLBENFLAECHE KUPPLUNG B
INNER PISTON FACE CLUTCH B
A B2 C D E F1 F2
SCHMIERDRUCK-
VENTIL
F1 VENTIL R3 LUBRICATING
PRESSURE VALVE
D4 D6 D5 D7
F1 RR3
X R3
F
D2
RETARDER-
REGELVENTIL
RETARDER
F2 VENTIL CONTROL VALVE KUEHLER-
HAUPTDRUCK-
VENTIL UMSCHALT-
VENTIL
F2
MAIN PRESSURE COOLER
VALVE CHANGEOVER
D8 D8 VALVE R1
D1
P
P P D9
R2
RETARDER
PRIMAER-
PUMPE
D1 PRIMARY PUMP
A2
SAUGFILTER
P
SUCTION FILTER 011938
A1
DROSSELDRUCKVENTIL
THROTTLE PRESSURE
VALVE
4-3
HP 502 C / HP 592 C / HP 602 C EST 46 C, Connection diagram 6029 729 041/1
015812
4-5
HP 502 C / HP 592 C / HP 602 C EST 46 C, Connection diagram 6029 729 041/2
015811
4-7
HP 502 C / HP 592 C / HP 602 C EST 47 C, Connection diagram 6029 729 041/3
015810
4-9
HP 502 C / HP 592 C / HP 602 C EST 47 C, Connection diagram 6029 729 041/4
015809
4-11
HP 502 C / HP 592 C / HP 602 C EST 46 / 47 C, Electrical circuit diagram 6029 729 040
015813
4-13
HP 502 C / HP 592 C / HP 602 C EST 46 / 47 C, Pin pattern 6029 729 072
015808
4-15
1 Wandler • Torque converter • Moment-
omvandlare • Koppelomvormer
2 Retarder • Retarder • Retarder • Retarder
3 Wandler-Sicherheitsventil • Torque converter
safety valve • Momentom-vandlarens
Säkerhetsventil • Koppel-omvormer-
Veiligheidsventiel
1 12 15 8.1
Ventilenhet WK • WK-ventielunit
Magnetventil • Solenoid valve • Magnetventil •
Magneetventiel
8.2 Drucksteuerventil • Pressure control valve •
Tryckregleringsventil • Drukregelventiel
8.3 Ausschaltventil • Shutoff valve •
Urkopplingsventil • Afschakelventiel
017 728
Momentomvandlarens mottrycksventil •
8.3 9.3 Koppelomvormertegendruk
17 Drosseldruckventil • Throttle pressure valve •
Tryckmoduleringsventil • Modulatiedrukventiel
Einschaltstellung
ZF FRIEDRICHSHAFEN AG
HYDRAULIC 2 Position locked
Läge till
Inschakelstand 4149 753 702 • MC-C • 08.2002
1 Wandler • Torque converter • Moment-
omvandlare • Koppelomvormer
2 Retarder • Retarder • Retarder • Retarder
3 Wandler-Sicherheitsventil • Torque converter
safety valve • Momentom-vandlarens
Säkerhetsventil • Koppel-omvormer-
Veiligheidsventiel
2 4 Druckspeicher • Accumulator • Ackumulator •
Drukreservoir
5 Kühler-Umschaltventil • Cooler changeover
valve • Omkopplingsventil kylare •
Koeleromschakelventiel
6 Wärmetauscher • Heat exchanger •
Värmeväxlare • Koeler
5 7 Schaltgetriebe • Planet gear train •
Automatväxellåda • Transmissie
8 WK-Ventileinheit • WK valve unit •
1 12 15
Ventilenhet WK • WK-ventielunit
8.1 Magnetventil • Solenoid valve • Magnetventil •
Magneetventiel
8.2 Drucksteuerventil • Pressure control valve •
Tryckregleringsventil • Drukregelventiel
8.3 Ausschaltventil • Shutoff valve •
Urkopplingsventil • Afschakelventiel
11
Koppeling\Rem
11
10
Retarderregelventil • Retarder control valve •
Retarderstyrventil • Retarderregelventiel
8.1
Huvudtryckventil • Hoofddrukventiel
9.1
13 Filter • Filter • Filter • Filter
14 Pumpe • Pump • Pump • Pomp
8.2 9.2 6 15 Schmierdruck • Lubrication pressure •
Smörjoljetryck • Smeerdruk
16
17 Wandlergegendruck • Converter counterpressure •
017 727
Momentomvandlarens mottrycksventil •
8.3 9.3 Koppelomvormertegendruk
17 Drosseldruckventil • Throttle pressure valve •
Tryckmoduleringsventil • Modulatiedrukventiel
18 Luft • Air • Luft • Lucht
Ausschaltstellung
ZF FRIEDRICHSHAFEN AG
HYDRAULIC 1 Position opened
Läge från
Uitschakelstand 4149 753 701 • MC-C • 08.2002
3 DRIVE SHAFTS
DB 250 PF Series Contents
CONTENTS
Page Date
3
1.2 Inspection ......................................................................................... 1-2 .............. 0145
0145 1
DRIVE SHAFTS 3
Contents DB 250 PF Series
2 0145
3 DRIVE SHAFTS
DB 250 PF Series General
1. GENERAL
0145 1-1
DRIVE SHAFTS 3
General DB 250 PF Series
1.2 SERVICE
Service intervals:
- There should be a small service every 50,000
km or every six months.
- There should be a large service every 200,000
km or every two years.
3
1. Inspect all the joints. Where necessary,
retighten the nuts and bolts using a torque
spanner.
2. Check whether all the circlips are still in place 1. Drive shaft
and are fitted correctly. 2. Yoke
3. Balance plate
3. Check whether the bearing/coupling 4. Welded-up clamps (G.W.B.)
components show signs of heating (discolou- 5. Slip joint
ring of the material or burnt sealing rings). 6. Drive shaft
1-2 0145
3 DRIVE SHAFTS
DB 250 PF Series General
3
sides. Bear in mind that the slip joint can
extend out a bit. If play can be felt, the spider
and the bearings must be replaced (see
“Spider removal and installation”).
0145 1-3
DRIVE SHAFTS 3
General DB 250 PF Series
0,17 mm
0,2 mm
- Check for tangential play (play between the
teeth).
a. Secure the slip joint’s fixed pipe in a
workbench with the yoke in a vertical direction.
b. Place a suitable gauge indicator on a flat part
and allow the measuring pin to rest against the
side of the yoke. Zero the gauge.
c. Turn the yoke tangentially and measure the
play on the splines. This must not be greater
3
than 0.2 mm.
02381B
1-4 0145
3 DRIVE SHAFTS
DB 250 PF Series General
3
the alignment!). Fit the grease nipple and
lubricate the slip joint.
0145 1-5
DRIVE SHAFTS 3
General DB 250 PF Series
1-6 0145
3 DRIVE SHAFTS
DB 250 PF Series Removal and installation
Removal
1. Support the shaft in at least two places.
Installation
1. Fit the drive shaft in the reverse order to its
removal.
Tighten all the bolts to the required torque (see
“Technical information”).
0145 2-1
DRIVE SHAFTS 3
Removal and installation DB 250 PF Series
3
down by themselves.
2-2 0145
3 DRIVE SHAFTS
DB 250 PF Series Removal and installation
2.3 SPIDER
Removal
1. Remove the complete drive shaft.
See “Drive shaft removal and installation”.
3
4. Mark both parts of the slip joint so that they
can be put back in the correct way during
assembly.
0145 2-3
DRIVE SHAFTS 3
Removal and installation DB 250 PF Series
2-4 0145
3 DRIVE SHAFTS
DB 250 PF Series Removal and installation
Installation
1. Remove the spider, bearing bush and oil
retainer rings from the repair kit.
Apply a thin layer of grease to the bearings so
that the needles remain in place.
3
(for the grease nipple) points towards the shaft.
0145 2-5
DRIVE SHAFTS 3
Removal and installation DB 250 PF Series
3
See “Drive shaft removal and installation”.
2-6 0145
3 ANGLE DRIVES
DB 250 PF Series Contents
CONTENTS
Page Date
0145 1
ANGLE DRIVES 3
Contents DB 250 PF Series
2 0145
3 ANGLE DRIVES
DB 250 PF Series Angle drives W10, W13
0145 1-1
ANGLE DRIVES 3
Angle drives W10, W13 DB 250 PF Series
1-2 0145
3 ANGLE DRIVES
DB 250 PF Series Spring coupling
0145 2-1
ANGLE DRIVES 3
Spring coupling DB 250 PF Series
2-2 0145