Group 3 - R

3
DB 250 PF Series
CONTENTS
TECHNICAL DATA DIAGNOSES AUTOMATIC GEARBOXES PROPELLER SHAFTS ANGLE DRIVES
0 1 2 3 4
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CONTENTS
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DB 250 PF Series
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DB 250 PF Series
TECHNICAL DATA
Contents
CONTENTS
0
Page Date
1. AUTOMATIC GEARBOXES ....................................................................... 1-1 .............. 0145 1.1 Gearbox types .................................................................................. 1-1 .............. 0145 1.2 Capacities, mass, fitting length ....................................................... 1-2 .............. 0145 1.3 Tightening torques ............................................................................ 1-3 .............. 0145 2. DRIVE SHAFTS 2.1 General ............................................................................................. 2-1 .............. 0145 2.2 Tightening torques ............................................................................ 2-2 .............. 0145 2.3 Filling capacities .............................................................................. 2-2 .............. 0145
0145
TECHNICAL DATA
Contents
DB 250 PF Series
0145
DB 250 PF Series
TECHNICAL DATA
Automatic gearboxes
1. AUTOMATIC GEARBOXES
1.1 GEARBOX TYPES
0
Engine type
Gearbox types
Reductions PE 160 PE 183
Voith D851.3
5,20 - 1,05:1
X(1)
X(1) X(2)
Voith D854.3
5,20 - 0,77:1
X(2)
ZF 4 HP 500
3,43 - 1,05:1
X(2)
X(2)
ZF 5 HP 500
3,43 - 0,83:1
X(2)
X(2)
(1) Standard version (2) Option
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1-1
TECHNICAL DATA
Automatic gearboxes
DB 250 PF Series
1.2
CAPACITIES, MASS, FITTING LENGTH
Oil capacity (in litres) Type of gearbox 1e filling Voith D851.3 Voith D854.3 ZF 4HP500 ZF 5HP500 ca. 25-28 ca. 25-28 ca. 30 ca. 30 after extending ca. 20 ca. 20 when changing oil ca. 23-26 ca. 23-26 ca. 15 ca. 15 Mass in kg(1) Fitting length in mm
ca. 305 ca. 340 ca. 259 ca. 269
796 874 693(2) 693(2)
(1) Weight of transmission + oil cooler dry (2) Depends on type of propeller shaft
1-2
0145
DB 250 PF Series
TECHNICAL DATA
Automatic gearboxes
1.3
TIGHTENING TORQUES M16 10.9 M16 10.9 M10 10.9 M10 10.9 M10 8.8 M10 10.9 260 20 Nm 260 20 Nm 60 4 Nm 60 4 Nm 46 4 Nm 60 4 Nm
Driveline Silent blocks on flywheel housing Silent blocks on angle drive Vibration damper on flywheel housing Reducing ring on flywheel housing (A) Angle drive on reducing ring (B) Automatic gearbox on angle drive (C)
Plugs Voith DIWA.3E Drain plug oil sump (A) Drain plug torq converter (B) Cover (C) Cover oil filter (D)
50 Nm 50 Nm 25 Nm 25 Nm
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1-3
TECHNICAL DATA
Automatic gearboxes
DB 250 PF Series
Plugs ZF HP500 Cover oil filter (A) Drain plug (B)
25 Nm 50 Nm
1-4
0145
DB 250 PF Series
TECHNICAL DATA
Drive shafts
2. DRIVE SHAFTS
2.1 GENERAL Make: Type: Drive flange Type: Diameter (A) gearbox side: Type: Diameter (B) rear axle side: Angle of flex per universal joint (b): Length (LZ min.): Extension length: Spline diameter (W): Lubricant: Gelenk Wellen Bau 2045 (Compact 2000 series) KV (serrated flange) 155 mm KV (serrated flange) 180 mm max. 25 534 mm 90 mm 68 mm High-temperature grease. -25 to +80 C Specifications according to STANDARD 4006 -005 and Material STD 2953 DIN/ISO-Bez. KP 2N-20 / KP 2P-30 / KP 2P-20
Inspection: There must be no clearly noticeable play on universal joints and sliding joint. Gelenk-Wellen-Bau Balancing speed Radial play universal joints 3000 rpm-1 0.01 - 0.05 mm
0145
2-1
TECHNICAL DATA
Drive shafts
DB 250 PF Series
2.2 TIGHTENING TORQUES Serrated flanges M12 10.9 M14 10.9 Plain flanges M12 10.9 M14 10.9 M16 10.9 105-126 Nm 136-204 Nm 113-127 Nm 178-202 Nm 281-309 Nm The thread must be lightly oiled when fitting the flange bolts. 2.3 FILLING CAPACITIES Grease must be seen to protrude from the spider(s) and sliding sleeve.
2-2
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3
DB 250 PF Series
DIAGNOSIS
Contents
CONTENTS
Pages
Date
1. DRIVE SHAFTS ........................................................................................ 1-1 ............. 0145
0145
DIAGNOSIS
Contents
3
DB 250 PF Series
0145
3
DB 250 PF Series
DIAGNOSIS
Drive shafts
1. DRIVE SHAFTS
1. FAULT-FINDING TABLE
FAULT: DRIVE LINE VIBRATION AT LOW VEHICLE SPEED Possible cause Excessive universal joint angle (for example, caused by excessive caster) Play in universal joints Play in sliding joint Forks not in line Remedy Check the universal joint angle
Replace universal joint Replace drive shaft Align forks
FAULT: DRIVE LINE VIBRATION AT HIGH VEHICLE SPEED Possible cause Drive shaft imbalance Remedy Balance or replace the drive shafts, if necessary
0145
1-1
DIAGNOSIS
Drive shafts
3
DB 250 PF Series
1-2
0145
3
DB 250 PF Series
AUTOMATIC GEARBOXES
Contents
CONTENTS
VOITH DIWA.3 Transmissions 1. 2. 3.
Page
Date
SERVICING ......................................................................................... 1-1................................... 0102 TROUBLE SHOOTING ........................................................................ 2-1................................... 0203 FAULT FINDING .................................................................................. 3-1................................... 0203
ZF-ECOMAT Transmissions 1. REPAIR MANUAL ZF-ECOMAT 2 Stages 1-2 (4149 751 601) ........... 1-1................................... 0103
0145
AUTOMATIC GEARBOXES
Contents
3
DB 250 PF Series
0145
3
DB 250 PF Series
AUTOMATIC GEARBOXES
Servicing VOITH DIWA.3 Transmissions
1. SERVICING SCHEDULE TRANSMISSIONS DIWA.3
0145
1-1
AUTOMATIC GEARBOXES
Servicing VOITH DIWA.3 Transmissions
3
DB 250 PF Series
1-2
0145
4FSWJDJOH 4DIFEVMF LN LN 5SBOTNJTTJPOT %*8" %*8" %*8"&
Voith. 55.6374.20 (G 1362e) / 2001-02
Transmissions DIWA.2, DIWA.3, DIWA.3E
Monthly Check oil level

I Bring the transmission to operating temperature, i.e. the oil temperature
must then be at least 60 C ( = 140 F). Note! The transmission oil temperature is about the same as the cooling water temperature. The cooling water temperature indicator can therefore be used for determining the transmission oil temperature.
I Place the vehicle in horizontal position.

Danger! Apply the parking brake before carrying out further maintenance work on the bus, so that the vehicle cannot move on its own!
I Press the N key and thus bring the transmission to its neutral position. I Start the engine and let it run at idle speed.
I Withdraw the dipstick from its guide tube and clean it. I Insert the dipstick again briefly to prevent wrong oil level reading by splash
oil.
I Read the oil level.

The two nominal marks max. and min. are important. The difference in quantity between "min." and "max." is about 2.5 l. Note! Too little oil: Transmission malfunction. Consequence: e.g. disk damage! Too much oil: Consequences: e.g. higher fuel consumption, oil escapes at the breather!
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.
Change oil and oil filter for DIWA.2, DIWA.3

Note! Drain oil at operating temperature only! Danger! Scalding by hot oil! 1
I Stop the engine. I Remove the drain plug (1) for the oil in the oil pan (allen wrench 12 mm) and
drain the oil.
I Remove the drain plug (2) for the converter oil and drain the oil. The plug is
accessible through the oil pan drain hole.
I Install drain plugs with new copper seals. Tighten drain plug (2) to 50 Nm
and drain plug (1) to 120 Nm. 3
I Remove the drain plug (4) for the filter oil (width across flats 13 resp. 10)
and drain the oil. 4
I Unscrew (width across flats 13) and remove the cover (3).
5
I 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 4
I Fit cover (3), washers B8.4, spring washers B8 and tighten nuts M8 (6) to
25 Nm.
I Install drain plug (4) with new copper seal and tighten to 15 Nm.
6 7
I Fill in transmission oil.

Only use oils tested by Voith and approved in the Lists of Lubricants 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!
*Note!
I Measure the oil level, check transmission - especially oil filter - for leaks. I Check the oil hoses (5). Replace if found very porous, cracked or chafed.
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.
Change oil and oil filter for DIWA.3E

10 11 Note! Drain oil at operating temperature only! Danger! Scalding by hot oil!
I Stop the engine. I Remove the drain plug (11) for the oil in the oil pan (allen wrench 12 mm)
and drain the oil. 12
I Remove the drain plug (12) for the converter oil and drain the oil. The plug
is accessible through the oil pan drain hole.
11
I Install drain plugs with new copper seals. Tighten drain plug (12) to 50 Nm
and drain plug (11) to 120 Nm.
I Unscrew and remove the access cover (10) of the oil pan (width across
flats 36).
I Unscrew and remove the cover (15) of the integrated oil filter (14) (width
13 across flats 36).
I Replace oil filter element (17) and sealing ring (18).

Note! If the used filter element is very dirty, unscrew the oil pan and check the disks! 14 15 16 10
I Install cover (15) with oil filter element (17) and sealing ring (18) and tighten
to 25 Nm.
I Install access cover (10) with new sealing ring (16) and tighten to 25 Nm. I Fill in transmission oil.
Only use oils tested by Voith and approved in the Lists of Lubricants 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!
*Note!
I Measure the oil level, check transmission - especially the cover (10) of the
oil pan - for leaks. 17
I 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
DB 250 PF Series
AUTOMATIC GEARBOXES
Trouble shooting VOITH DIWA.3 Transmissions
2. TROUBLE SHOOTING DIWA.3 TRANSMISSIONS
0145
2-1
AUTOMATIC GEARBOXES
Trouble shooting VOITH DIWA.3 Transmissions
3
DB 250 PF Series
2-2
0145
3
DB 250 PF Series
AUTOMATIC GEARBOXES
Fault finding VOITH DIWA.3 Transmissions
3. FAULT FINDING VOITH DIWA.3 TRANSMISSIONS
0145
3-1
AUTOMATIC GEARBOXES
Fault finding VOITH DIWA.3 Transmissions
3
DB 250 PF Series
3-2
0145
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SYMPTOMS CAUSES REMEDIES
Voith. 55.6303.22 / 2002-03
Important safety instructions!

It is your responsibility to familiarize yourself with the warnings and precautions described in this manual. Danger! in conjunction with the symbol on the right is used if personal injury or danger to life may result if work is not carried out carefully. This manual only contains the most important information, however. It is impossible to describe all conceivable mistakes and danger conditions. Therefore, everybody who performs installation, repair or service work must very carefully ensure that his personal safety or that of other persons is not at risk.
Important information
Note! in conjunction with the symbol on the right denotes information that is particularly important.
Additional notes
When replacing parts, always pay attention to the instructions in the spare parts catalog! Design improvements which should be taken into account during transmission overhauls are described in detail in the "Customer service letters". Furthermore, all work must be performed in accordance with Voith requirements to prevent damage to parts and tools.
Consequences of oil loss, treatment of used oil

Danger! If oil leaks because to piping, seals or O-rings are not properly installed or have become leaky over time, accidents may occur. In conjunction with the symbol on the right: be aware of environmental pollution due to oil loss! Used oil must be disposed of in accordance with environmental regulations.
Voith. Fault Finding DIWA.3, DIWA.3E
'BVMU 'JOEJOH
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. Additionel DIWA.3 and DIWA.3E documentation The following publications are available for transmission description, design, installation, the main tasks of maintenance and repair, etc.: Brochure Part No. for transmission DIWA.3 DIWA.3E All DIWA All DIWA DIWA.3, DIWA.3E DIWA.3, DIWA.3E D 851.3E D 854.3E D 863.3E D 864.3E DIWA.3, DIWA.3E DIWA.3 DIWA.3E DIWA.3 DIWA.3E Purpose Function description of the transmission, transmission data, installation instructions, design and dimensional data for transmission assemblies Maintenance of DIWA transmissions List of the lube oils that are approved by Voith for DIWA transmissions Brief description of transmission operation for the bus driver Use of the Voith PC-based diagnostic program DIWAGNOSIS Illustration and designation of transmission parts for spare parts ordering Detection of defective electrical components or assemblies using the PC diagnostic program Description of transmission disassembly and assembly of 3- and 4speed transmissions Representation of the oil circuits for the various transmission gear shifts
Technical Manual
55.6355. .. 55.6357. ..
Servicing Schedule Lists of Lubricants Driving Instructions Diagnostic Manual
55.6374. .. 55.6335. .. 55.6336. .. 55.6291. .. 55.6264. .. 55.6600. .. 55.6601. .. 55.6602. .. 55.6603. .. 55.6293. ..
Spare Parts Catalogs
Trouble Shooting
Repair Manual
55.6320. .. 55.6704. ..
Technical Description 55.6309. .. with Oil and Control Cir55.6311. .. cuit Diagrams
All of the above brochures are available from department "ant" or "anv". This documentation is protected by copyright Subject to change Who is it for? n Service technicians (e.g. testing, acceptance, etc.) n Automobile mechanics and electricians
II Voith. Fault Finding DIWA.3, DIWA.3E
Procedure for finding faults in DIWA.3 and DIWA.3E transmissions

If transmission malfunctions occur, fault may be present in a) the control unit records, b) in the electrical or c) mechanical part of electromechanical or d) purely mechanical components. In the case of faults in a) and b), use of "Diagnostic Manual" and "Trouble Shooting", if required, alone may be sufficient for repair. However, since malfunctions in c) and d) are not detected by the control or diagnosis, it is recommended to refer to the appropriate Voith documentation and programs for transmission malfunction repairs in the following order, for example: Read out the fault memory of the transmission control unit by means of the diagnostic program DIWAGNOSIS: Diagnostic Manual
Analysis of malfunctions and list of remedies, including, perhaps, information about transmission design and operation in the "Technical Manuals" and "Technical Descriptions with Oil Control Diagrams" for DIWA.3 and DIWA.3E:
Fault Finding
Use of the diagnostic program for fault tracing:
Diagnostic Manual
Tracing of possible faults in the electrical system of DIWA.3 and DIWA.3E transmissions: Trouble Shooting
Transmission repair and spare parts ordering: Repair Manual, Spare Parts Catalogs
III
5BCMF PG DPOUFOUT
Page Differences concerning the symptoms of transmission malfunctions in DIWA.3E and DIWA.3 1. General recommendations ...................................................................................................................... 1 First check in case of faults.................................................................................................................. 1 Continued operation possible............................................................................................................... 1 Emergency operation possible............................................................................................................. 1 Towing.................................................................................................................................................. 1 2. Faults with vehicle stopped ..................................................................................................................... 3 ANS activation without effect ............................................................................................................... 3 3. Faults on engagement of gears .............................................................................................................. 5 3.1 After engagement of a forward (V) or reverse gear (R) and releasing the parking brake, the vehicle does not move - engine revs up to max. speed when accelerating......................... 5 3.2 After engagement of the R gear and releasing the parking brake, the vehicle does not move- but transmission function is normal when engaging a F gear........ 6 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............. 7 3.4 Vehicle jerks after engagement of neutral - 1st gear or neutral - R gear ................................... 8 8.3 When starting uphill: after engaging of a F gear, release of parking brake and accelerating, the bus rolls backward ........................................... 8 4. Faults while driving................................................................................................................................ 11 4.1 Poor acceleration in all gears................................................................................................... 11 4.2 Poor acceleration in 1st gear, but normal in 2nd and 3rd gear ................................................ 11 4.3 Transmission shifts to 2nd gear with button 1 pressed............................................................ 12 4.4 Braking too strong with accelerator pedal released ................................................................. 12 4.5 Transmission does not shift to 2nd gear - operation only possible in 1st gear ........................ 13 4.6 Transmission shifts to 2nd gear, but no power transmission ................................................... 13 4.7 Poor acceleration after shifting to 2nd gear, but normal in 1st gear ........................................ 14 4.8 Transmission does not shift to 3rd gear - operation only possible in 1st and 2nd gear ........... 14 4.9 Poor acceleration after shifting to 3rd gear, but normal in 1st and 2nd gear ........................... 15 4.10 For 4-gear transmissions: transmission does not shift to 4th gear, operation only possible in 1st, 2nd and 3rd gear ..................................................................... 15 4.11 Poor acceleration after shifting to 4th gear, but normal in 1st, 2nd and 3rd gear .................... 16 4.12 Kickdown shifting not possible ................................................................................................. 16 4.13 Engine stalls in reverse gear.................................................................................................... 17 4.14 Transmission does not shift up, but back to 1st gear and stays there ..................................... 17 4.15 Transmission shifts to neutral while driving ............................................................................. 17 4.16 Hard shifting from 1st to 2nd gear............................................................................................ 18 4.17 Hard shifting from 2nd to 3rd gear ........................................................................................... 18 4.18 For 4-gear transmissions: hard shifting from 3rd to 4th gear ................................................... 19
IV
5. Faults while braking with the converter brake ....................................................................................... 21 5.1 The converter brake does not operate in all F gears via service (foot) and hand brake switch ................................................................................. 21 5.2 The converter brake does not operate in 1st gear via service and hand brake switch........................................................................................... 22 5.3 The converter brake does not operate in 1st, 2nd, 3rd and 4th gear via service and hand brake switch........................................................................................... 22 5.4 One of the 3 or all brake stages of the converter brake does not operate via service brake switch (brake pedal)..................................................................................... 23 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) ................................................................. 23 5.6 For one-stage hand brake switch (manual switch): stage 2 or 3 of the converter brake does not operate.............................................................. 23 5.7 For DIWA.3: In 2nd, 3rd or 4th gear: hard activation of converter brake ................................. 24 5.8 For DIWA.3: In 2nd, 3rd or 4th gear: brake force in stage I too high ....................................... 25 5.9 For DIWA.3: In 2nd, 3rd or 4th gear: brake force in brake stage II or III too low or too high ................................................................................................................... 25 5.10 For DIWA.3E: In 2nd, 3rd or 4th gear: hard activation of converter brake............................... 26 5.11 For DIWA.3E: In 2nd, 3rd or 4th gear: brake force in stage I too high..................................... 27 5.12 For DIWA.3E: In 2nd, 3rd or 4th gear: brake force in brake stage II or III too low or too high ................................................................................................................... 27 5.13 In 1st gear drive range: brake force in brake stage II or III too low or too high........................ 28 6. Faults in warning lamps, relays or switches.......................................................................................... 29 6.1 The central warning lamp (ZW) does not light after turning on the ignition ............................. 29 6.2 The pushbutton lighting (TL) does not light after turning on the ignition.................................. 29 6.3 The warning lamp tranmission oil temprature (TOEL) does not light after turning on the ignition ...................................................................................................... 29 6.4 Consumer via relays - converter brake (dW), reversing lamp (dR) or speed (dN) - cannot be activated........................................................ 29 7. Measuring devices ................................................................................................................................ 31 8. Checking oil pressures.......................................................................................................................... 33 8.1 Operating pressure .................................................................................................................. 33 8.2 Converter pressure .................................................................................................................. 34 9. Testing the motor control / transmission interface ................................................................................ 35 9.1 Engine idle speed .................................................................................................................... 35 9.2 Test: load transmitter signals as function of accelerator pedal position .................................. 35 9.3 Test: rated engine torque as function of load stage or engine speed...................................... 37 10. Appendices .......................................................................................................................................... 39 1 hydraulic control diagram DIWA.3, 1 hydraulic control diagram DIWA.3E, 1 circuit diagram DIWA.3, 1 circuit diagram DIWA.3E
Differences concerning the symptoms of transmission malfunctions in DIWA.3E and DIWA.3

In general, the symptoms are similar for both transmission variants. The statements below therefore apply to both variants unless otherwise indicated. 1. A major difference between DIWA.3E and DIWA.3 transmissions is the converter filling control (CFC) which does not exist in DIWA.3. The purpose of converter inlet control is to improve application of the converter brake also at high vehicle speeds in 4th (and perhaps also 3rd) gear. Among other things, the hydraulic control includes two new valves: a converter inlet valve and a breather valve. The converter drain valve has been modified. Other parts, such as the turbine accumulator, have been dispensed with. Differences regarding the symptoms of transmission malfunctions can therefore be found in the chapters describing converter operation, i. e. the first gear (DIWA drive range), the reverse gear, and braking with the converter. 2. The location of SK and WR solenoid valves in the valve block has been changed. 3. There were some minor changes to the circuit diagram.
T DIBQU DIBQU DIBQU TFF DIBQUFS TFF BQQFOEJDFT JO DIBQUFS
VI
(FOFSBM SFDPNNFOEBUJPOT
First check in case of faults
I By means of the Voith diagnostic program. Its use is described in the Diagnostic Manual.
Continued operation possible,

I 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.
Emergency operation possible

I 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: I Set the transmission to neutral and screw off plug from the transmission or electronic control unit. I In case of transmission damage: remove cardan shaft or stub shaft of rear axle. I 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.
Possible cause
Check / remedy
Note / continue with
'BVMUT XJUI WFIJDMF TUPQQFE

Danger! Apply the parking brake when the bus is stopped for repairing to prevent that the vehicle can move unintentionally!
ANS activation without effect (ANS means Automatic Neutral at Standstill)

One of the conditions for ANS activation not met: driving speed less than 1 km/h, accelerator pedal in idle position, service (foot) brake switch (FB) and/or parking brake (HSB) operated (pcompr. air > 0.5 - 0.8 bar), forward gear engaged.
No release of ANS activation by control unit 1. Inductive pick-up N2, connector or connecting cable defective. 2a. Control unit does not receive L0 signal. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 2b. Control unit does not receive L0 signal. For E-Gas systems: faulty assignment of accelerator pedal position and load transmitter level. 3a. No signal from pressure switch for ANS activation (BS): switch, connector or connecting cable defective. 3b. If provided: stop brake (HSB) relay, switch, connector or connecting cable defective. 3c. No signal from service (foot) brake switch (FB): one of the 3 microswitches, connector or connecting cable defective. 4. Pushbutton switch (TS), connector or connecting cable defective. Check inductive pick-up, connector and connecting cable, repair or replace, if required. Check and adjust connection, if required. %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ / 4FF DIBQUFS %JBHOPTUJDT GVODUJPO &
1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. Check switch, connector or connecting cable and repair or replace, if required. Check relay, switch, connector or connecting cable and repair or replace, if required. Check switch at brake, connector or connecting cable and repair or replace, if required. Check switch, connector or connecting cable and repair or replace, if required.
%JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO ) 5S 4IPPU DIBQUFS QSFTT TX "/4 BDUJWBUJPO %JBHOPTUJDT GVODUJPO ) 5S 4IPPU DIBQUFS TUPQ CSBLF %JBHOPTUJDT GVODUJPO ' 5S 4IPPU DIBQUFS CSBLF WBMWF %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
Possible cause
Check / remedy
Input clutch (EK) does not open Field coil or one of the spools of the EK solenoid valve, connector or connecting cable defective. 1. Check oil pressure at EK connection (measuring cover): pArequd = 0 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required. %JBHOPTUJDT GVODUJPOT ( * 5S 4IPPU DIBQUFS &, TPMFOPJE
For ANS activation without stop brake (HSB): roll-back safety (simultaneous switching of turbine brake TB and reverse gear brake RB) without effect Field coil or one of the spools of solenoid valves TB or RBK, connector or connecting cable defective. 1. Check operating resp. converter pressure at connections TB and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required. 'PS TFUQPJOUT TFF DIBQUFS %JBHOPTUJDT GVODUJPOT ( * 5S 4IPPU DIBQUFS 5# PS 3#, TPMFOPJE
Possible cause
Check / remedy
'BVMUT PO FOHBHFNFOU PG HFBST

3.1 After engagement of a forward (F) or reverse gear (R) and releasing the parking brake, the vehicle does not move - engine revs up to max. speed when accelerating
$IFDL JT POMZ QPTTJCMF XIFO FOHJOF JT SVOOJOH
Control unit E 200 is not supplied with voltage - transmission remains in neutral Fuse 8A for line +UZ, connector or connecting cable defective. Check fuse, connector and cable, repair or replace, if required. %JBHO EJTQMBZ DPNNVOJ DBUJPOT OPU FTUBCMJTIFE 5S 4IPPU DIBQUFS DPOUSPM VOJU WPMUBHF
Solenoid valves without voltage dS relay "control", connector or connecting cable defective. Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT EJTQMBZ E4 SFMBZ XJUIPVU WPMUBHF 5S 4IPPU DIBQU WPMUBHF
Input clutch (EK) does not close 1. Idle speed N1 too high. 1. Check idle speed setpoint: n 850 rpm (for gas engine: n 1000). 2. If required, adjust idle speed. Check switch, connector and cable, repair or replace, if required. 1. Check oil pressure at EK connection (measuring cover): pArequd 3.5 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required. Check switch, connector and cable, repair or replace, if required. Note! EK closes when load transmitter operated! Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS PVUQVU E/&653 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO * %JBHOPTUJDT GVODUJPO ) 5S 4IPPU DIBQUFS HFBS TBGFUZ QSFTTVSF TXJUDI 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS &, TPMFOPJE %JBHOPTUJDT GVOUJPO ) 5S 4IPPU DIBQUFS QSFTT TX "/4 BDUJWBUJPO
2. Gear safety pressure switch (ABSICH) is not activated for pressure > 3 bar, connector or connecting cable defective. 3. Field coil or one of the spools of the EK solenoid valve, connector or connecting cable defective.
4. Transmission with ANS activation: pressure switch for ANS activation (BS), connector or connecting cable defective. Note! Switch may only be closed when the brake device is operated! 5. Bus with gas engine: relay dNEUTR, connector or connecting cable defective. Note! Idle seed is reached after the transmission was in neutral for some time!
Possible cause
Check / remedy
Disks of input clutch (EK) slip 1. Operating pressure too low. Check operating pressure: pArequd 3.5 bar. Adjust pressure, if required. 1. Check oil pressure at EK connection (measuring cover): pArequd 3.5 bar. 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT T DIBQU %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS &, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. EK solenoid valves hard to move or stuck, e.g. by soiling of a spool or the field coil.
3. Oil pressure after EK solenoid valve too low: oil supply reduced or interrupted. 4. EK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Pushbutton switch not ready to operate Pushbutton switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
3.2 After engagement of the R gear and releasing the parking brake, the vehicle does not move - but transmission function is normal when engaging a F gear
No release of reverse gear by the control unit 1. Inductive pick-up N1 or N2, connector or connecting cable defective. 2. Field coil of solenoid valves RBG or RGK, connector or connecting cable defective. Note! if RBG is defective, the R gear is left after approx. 1 sec.! Check inductive pick-up, connector and connecting cable and repair or replace, if required. Check solenoid valves, connectors and cables and repair or replace, if required. 1. Diagnostics: function J, 2. Tr. Shoot., chapter 2.1/2: inductive pick-up N1 or N2 %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQ 3#( PS 3#, TPMFOPJE
Possible cause
Check / remedy
Transmission with inhibiting switch for reverse gear (SPERR): switch not closed 1. Inhibiting switch not operated. 2. Switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
Pushbutton not ready to operate Pushbutton switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
Reverse gear brake (RB) does not close RBG or RBK solenoid valve hard to move or stuck, e.g. by soiling of a spool or field coil. 1. Check operating resp. converter pressure at connections RBG and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required. 'PS TFUQPJOUT T DI %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQU 3#( PS 3#, TPMFOPJE
Converter pressure too low 1. Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required. If required, disassemble and repair converter outlet valve. Check converter seal and repair, if required. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check converter filling valve and repair or replace, if required. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. Check breather valve and repair or replace, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T DIBQUFS %BHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 83 TPMFOPJE 3FQBJS .BOVBM $VTU 4FSW -FUUFS OP 3FQBJS .BOVBM 'PS TFUQPJOUT TFF BMTP DIBQUFS 3FQBJS .BOVBM 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T DIBQUFS 3FQBJS .BOVBM
2. One of the control spools of the converter outlet valve hard to move or stuck. 3. Converter leaks. 4. Only for DIWA.3E: The converter inlet valve hard to move or stuck, valve does not open properly.
5. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
Possible cause
Check / remedy
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
Disks of reverse gear brake (RB) slip 1. Operating pressure too low. Check operating pressure: pArequd 3.5 bar. Adjust pressure, if required. 1. Check operating resp. converter pressure at connections RBG and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required. 1. Check pressure as disribed above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT TFF DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQU 3#( PS 3#, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. RBG or RBK solenoid valve hard to move or stuck, e.g. by soiling of a spool or field coil.
3. Oil pressure after solenoid valve RBG or RBK too low: oil supply reduced or interrupted. 4. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Service (foot) brake switch (FB) for converter brake on unintentionally One of the 3 microswitches, connector or connecting cable defect. Check switch at brake, connector or connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO ' 5S 4IPPU DIBQUFS CSBLF WBMWF
3.4 Vehicle jerks after engagement of neutral - 1st gear or neutral - R gear
Input clutch (EK) closes too hard - oil pressure fault before EK 1. One of the coils or spools of the EK solenoid valve, connector or connecting cable defective. 2. EK solenoid valve hard to move, e.g. due to pollution of a spool or the field coil. 3. EK disks damaged - possibly by used, polluted, wrong or too little transmission oil. Check solenoid valve, connector and cable and repair or replace, if required. Repair or replace solenoid valve. Replace disks, replenish or change oil. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS &, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
Possible cause
Check / remedy
3.5 When starting uphill: after engaging of a F gear, release of parking brake and accelerating, the bus rolls backward
Insufficient tractive power Accelerator pedal not depressed enough.
Roll-back safety fails Field coil or one of the spools of solenoid valves TB or RBK, connector or connecting cable defective. 1. Check operating resp. converter pressure at connections TB and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required. 'PS TFUQPJOUT T DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQU 5# PS 3#, TPMFOPJE
Converter pressure too low 1. One of the control spools of the converter outlet valve hard to move or stuck. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. If required, disassemble and repair converter outlet valve. Check converter seal and repair, if required. Check converter filling valve and repair or replace, if required. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. Check breather valve and repair or replace, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU TFF BMTP DIBQU 3FQBJS .BOVBM $VTU 4FSW -FUUFS OP 3FQBJS .BOVBM 3FQBJS .BOVBM
2. Converter leaks. 3. Only for DIWA.3E: The converter filling valve hard to move or stuck, valve does not open properly. 4. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T DIBQUFS 3FQBJS .BOVBM
10
Possible cause
Check / remedy
'BVMUT XIJMF ESJWJOH

4.1 Poor acceleration in all gears
Wrong load transmitter signals or engine does not put out full power 1a. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 1b. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level. 2. Engine power. Check and adjust connection, if required. 1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 1. Measure speed at stall point. 2. Compare results to design values. 4FF DIBQUFS %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO & 4FF DIBQUFS
4.2 Poor acceleration in 1st gear, but normal in 2nd and 3rd gear
Converter pressure too low - engine speed in 1st gear too high with respect to speed 1. One of the control spools of the converter outlet valve hard to move or stuck. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. If required, disassemble and repair converter outlet valve. Check converter seal and repair, if required. Check converter filling valve and repair or replace, if required. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. Check breather valve and repair or replace, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU TFF BMTP DIBQU 3FQBJS .BOVBM $VTU 4FSW -FUUFS OP 3FQBJS .BOVBM 3FQBJS .BOVBM
2. Converter leaks. 3. Only for DIWA.3E: The converter filling valve hard to move or stuck, valve does not open properly. 4. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T DIBQUFS 3FQBJS .BOVBM
11
Possible cause
Check / remedy
Turbine brake (TB) does not close - engine speed is greatly decreased Field coil or one of the spools of solenoid valve TB, connector or connecting cable defective. 1. Check operating resp. converter pressure at connection TB (measuring cover). 2. Check solenoid valve, connector and cable and repair or replace, if required. 'PS TFUQPJOUT TFF DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 5# TPMFOPJE
Turbine brake (TB) disks slip 1. Operating pressure too low. Check operating pressure: pArequd 8.3 bar. Adjust pressure, if required. 1. Check operating resp. converter pressure at connection TB (measuring cover). 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT T DIBQ %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 5# TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. TB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
3. Oil pressure after TB solenoid valve too low: oil supply reduced or interrupted. 4. TB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
4.3 Transmission shifts to 2nd gear with pushbutton 1 pressed

Inhibition for shifting 1-2 not active - inhibition 1-2 is released when converter brake is activated 1. Hand brake switch (HB) not in 0 position or service brake switch (FB) operated. 2. One of the 3 sliding contacts in the hand brake switch, one of the 3 microswitches in the service brake switch, connector or connect-ing cable defective. 3. Pushbutton switch (e.g. terminal S1 without power), connector or connecting cable defective. Check hand brake switch, microswitch in service brake switch, connector and cable, repair or replace, if required. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPOT % ' 5S 4IPPU DIBQUFS IBOE PS TFSWJDF CSBLF TXJUDI %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
12
Possible cause
Check / remedy
4.4 Braking too strong with accelerator pedal released

Converter brake turned on See chapter 4.3, items 1 and 2.
4.5 Transmission does not shift to 2nd gear - operation only possible in 1st gear
Automatic shift from 1st to 2nd gear inhibited 1. Pushbutton 1 (5 or 6-pushbutton switch) depressed. 2. Pushbutton switch (e.g. continuous current terminal S1, although button 1 not pressed), connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
No signal regarding vehicle speed Inductive pick-up N2, connector or connecting cable defective. Check inductive pick-up N2, connector and connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ /
Wrong power transmitter signals - engine does not reach full power 1a. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 1b. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level. Check connection and adjust, if required. 1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 4FF DIBQUFS %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO &
13
Possible cause
Check / remedy
4.6 Transmission shifts to 2nd gear, but without power transmission

Pump brake (PB) does not close Field coil or one of the spools of the PB solenoid valve, connector or connecting cable defective. 1. Check oil pressure at PB connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 1# TPMFOPJE
Pump brake (PB) disks slip - engine speed is greatly reduced 1. Operating pressure too low. Check operating pressure: pArequd 8.3 bar. Adjust pressure. 1. Check oil pressure at PB connection (measuring cover): pArequd 8.3 bar. 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT T DIBQU %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 1# TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. PB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
3. Oil pressure after PB solenoid valve too low: oil supply reduced or interrupted. 4. PB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
4.7 Poor acceleration after shifting to 2nd gear, but normal in 1st gear
TB solenoid valve does not open - turbine brake remains closed. Field coil or one of the spools of solenoid valve TB, connector or connecting cable defective. 1. Check oil pressure at TB connection (measuring cover): pArequd = 0 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 5# TPMFOPJE
14
Possible cause
Check / remedy
4.8 Transmission does not shift to 3rd gear - operation only possible in 1st and 2nd gear
Automatic shifting from 2nd to 3rd gear inhibited 1. Pushbutton 2 (4, 5 or 6-pushbutton switch) depressed. 2. Pushbutton switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJDI
Lock-up clutch (DK) does not close Field coil or one of the spools of the DK solenoid valve, connector or connecting cable defective. 1. Check oil pressure at DK connection: pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace. 'PS TFUQPJOUT T DIBQ %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS %, TPMFOPJE
4.9 Poor acceleration after shifting to 3rd gear, but normal in 1st and 2nd gear
Lock-up clutch (DK) disks slip 1. Operating pressure too low. Check operating pressure: pArequd 8.3 bar. Adjust pressure, if required. 1. Check oil pressure at DK connection (measuring cover): pArequd 8.3 bar. 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT T DIBQU %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS %, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. DK solenod valve hard to move or stuck, e.g. by pollutionof a spool or the field coil.
3. Oil pressure after DK solenoid valve too low: oil supply reduced or interrupted. 4. DK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
15
Possible cause
Check / remedy
4.10 For 4-gear transmissions: transmission does not shift to 4th gear, operation only possible in 1st, 2nd and 3rd gear
Automatic shifting from 3rd to 4th gear inhibited 1. Pushbutton 3 of 6-pushbutton switch depressed. 2. Pushbutton switch (e.g. continuous current terminal S3, although button 3 not pressed), connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
Fast gear clutch (SK) does not close Field coil or one of the spools of solenoid valve DK, connector or connecting cable defective. 1. Check oil pressure at SK connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 4, TPMFOPJE
4.11 Poor acceleration after shifting to 4th gear, but normal in 1st, 2nd, and 3rd gear
Fast gear clutch (SK) disks slip 1. Operating pressure too low. Check operating pressure: pArequd 8.3 bar. Adjust pressure, if required. 1. Check operating at SK connection (measuring cover): pArequd 8.3 bar. 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT T DIBQU %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 4, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. SK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
3. Oil pressure after SK solenoid valve too low: oil supply reduced or interrupted. 4. SK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
16
Possible cause
Check / remedy
4.12 Kickdown shifting not possible

No signal for separate kickdown switch (KD) Kickdown switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO & 5S 4IPPU DIBQUFS LJDLEPXO TXJUDI
No load transmitter signal - load transmitter stage L7 is not reached 1a. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 1b. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level. Check connection and adjust, if required. 1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 4FF DIBQUFS %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO &
4.13 Engine stalls in reverse gear

Converter pressure is not controlled for seed over 1 km/h (= 30 Hz) 1. Coil or one of the spools of the WP solenoid valve, connector or connecting cable defective. 1. Check oil pressure at WP connection (measuring cover): pArequd 3.5 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. Disassemble converter outlet valve and replace, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM
2. One of the control spools in the converter outlet valve hard to move or stuck.
4.14 Transmission does not shift up, but back to 1st gear and stays there
No signal regarding vehicle speed Inductive pick-up N2, connector or connecting cable defective. Check inductive pick-up N2, connector and connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ /
17
Possible cause
Check / remedy
4.15 Transmission shifts to neutral while driving

Control unit E 200 is not supplied with voltage Fuse 8A for line +UZ, connector or connecting cable defective. Check fuse, connector and cable, repair or replace, if required. %JBHO EJTQMBZ DPNNVOJ DBUJPOT OPU FTUBCMJTIFE 5S 4IPPU DIBQUFS DPOUSPM VOJU WPMUBHF
Solenoid valves without voltage dS relay "control", connector or connecting cable defective. Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT EJTQMBZ E4 SFMBZ XJUIPVU WPMUBHF 5S 4IPPU DIBQUFS TPMFOPJE WBMWF WPMUBHF
4.16 Hard shifting from 1st to 2nd gear

Pump brake (PB) closes too hard - oil pressure fault before PB 1. One of the field coils or spools of the PB solenoid valve, connector or connecting cable defective. 2. PB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 3. PB disks damaged - possibly by used, polluted, wrong or too little transmission oil. 4. Inductive pick-up N1, connector or connecting cable defective. Check solenoid valve, connector and cable, repair or replace, if required. Repair or replace solenoid valve. Replace disks, replenish or change oil. Check inductive pick-up, connector and connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 1# TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ /
18
Possible cause
Check / remedy
4.17 Hard shifting from 2nd to 3rd gear

Lock-up clutch (DK) closes too hard - oil pressure fault before DK 1. One of the field coils or spools of the DK solenoid valve, connector or connecting cable defective. 2. DK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 3. DK disks damaged - possibly by used, polluted, wrong or too little transmission oil. 4. Inductive pick-up N1, connector or connecting cable defective. Check solenoid valve, connector and cable, repair or replace, if required. Repair or replace solenoid valve. Replace disks, replenish or change oil. Check inductive pick-up, connector and connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS %, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ /
4.18 For 4-gear transmissions: hard shifting from 3rd to 4th gear
Fast gear clutch (SK) closes too hard - oil pressure fault in front of SK 1. One of the coils or spools of the SK solenoid valve, connector or connecting cable defective. 2. SK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 3. SK disks damaged - possibly by used, polluted, wrong or too little transmission oil. 4. Inductive pick-up N1, connector or connecting cale defective. Check solenoid valve, connector and cable, repair or replace, if required. Repair or replace solenoid valve. Replace disks, replenish or change oil. Check inductive pick-up, connector and connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 4, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ /
19
20
Possible cause
Check / remedy
'BVMUT XIJMF CSBLJOH XJUI UIF DPO WFSUFS CSBLF

5.1 The converter brake (CB) does not operate in all F gears via service (foot) and hand brake switch
One of the conditions for activation of the converter brake not met: Accelerator pedal in idle position. service or hand brake switch operated.
No release of converter brake by control unit 1. ABS active. 2a. Control does not receive L0 signal. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 2b. Control does not receive L0 signal. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level. 3. Field coil of solenoid valves PB, WP or RBK, connector or connecting cable defective. Check connection and adjust, if required. 4FF DIBQUFS %JBHOPTUJDT GVODUJPO &
1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. Check solenoid valves, connectors and cables, repair or replace, if required.
%JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS TPMFOPJET
21
Possible cause
Check / remedy
5.2 The converter brake does not operate in 1st gear via service and hand brake switch
Converter brake not released by control unit 1. See chapter 5.1. 2. Converter brake was activated in 1st gear (it is possible for some versions). Converter brake must already have been activated in 2nd, 3rd or 4th gear.
Turbine (TB) or reverse gear brake (RB) does not close 1. Coil or one of the spools of the TB solenoid valve, connector or connecting cable defective. 1. Check operating resp. converter pressure at TB connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 5# TPMFOPJE 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 3#, TPMFOPJE
2. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
5.3 The converter brake does not operate in 1st, 2nd, 3rd and 4th gear via service and hand brake switch
Converter brake not released by control unit See chapter 5.1.
Pump (PB) or reverse gear brake (RB) does not close 1. PB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check oil pressure at PB connection: pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check operating resp. converter pressure at RBG connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 1# TPMFOPJE 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( * 5S 4IPPU DIBQUFS 3#( TPMFOPJE
2. Coil or one of the spools of the RBG solenoid valve, connector or connecting cable defective.
22
Possible cause
Check / remedy
5.4 One of the 3 or all brake stages of the converter brake does not operate via service brake switch (brake pedal)
Switch not operated or defective 1. Converter brake deactivated by the OFF switch for activation by the brake pedal (FBAUS). 2. Switch, connector or connecting cable defective. 3. One of the 3 microswitches in the service brake switch (FB), connector or connective cable defective. Indicator lamp (if installed) at the manual switch is not lit when the service brake switch is operated. Check switch, connector and cable, repair or replace, if required. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO ) 5S 4IPPU DIBQUFS DPOWFSUFS CBLF 0'' TXJUDI %JBHOPTUJDT GVODUJPOT ' 5S 4IPPU DIBQUFS TFSWJDF CSBLF TXJUDI
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 brake switch (HB), connector or connecting cable defective.
Check brake switch, connector and cable, repair or replace, if required.
%JBHOPTUJDT GVODUJPOT % 5S 4IPPU DIBQUFS IBOE CSBLF TXJUDI
5.6 For one-stage hand brake switch: stage 2 or 3 of the converter brake does not operate
Hand brake switch (HB), connector or connecting cable defective.
Check brake switch, connector and cable, repair or replace, if required.
%JBHOPTUJDT GVODUJPOT % 5S 4IPPU DIBQUFS )# TXJUDI TUBHF
23
Possible cause
Check / remedy
5.7 For DIWA.3 in 2nd, 3rd, or 4th gear: hard activation of converter brake
Converter pressure uncontrolled or too high 1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Disassemble converter outlet valve and repair, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
2. Oil pressure after WP solenoid valve too low: WP oil supply reduced or interrupted. 3. One of the control spools in converter outlet valve hard to move or stuck.
Reverse brake (RB) closes too hard - oil pressure fault before RBK 1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. Replace disks, replenish or change oil. Check inductive pick-up, connector and connecting cable and repair or replace, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 3#, TPMFOPJE 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ / PS / %JBHOPTUJDT GVODUJPOT " *
2. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil. 3. Inductive pick-up N2 or N3, connector or connecting cable defective. 4. Wrong control unit.
24
Possible cause
Check / remedy
5.8 For DIWA.3 in 2nd, 3rd, or 4th gear: brake force in brake stage I too high
Converter pressure too high 1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Disassemble converter outlet valve and repair, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
2. Oil pressure after WP solenoid valve too low: WP oil supply reduced or interrupted. 3. One of the control spools in converter outlet valve hard to move or stuck.
5.9 For DIWA.3 in 2nd, 3rd, or 4th gear: brake force in brake stage II or III too low or too high
Converter pressure too high or too low 1a. Brake force too low: Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective. 1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check solenoid valve, connector and cable, repair or replace, if required. Check oil-supplying componets and repair or replace, if required. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. Check oil-supplying componets and repair or replace, if required. Disassemble converter outlet valve and repair, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU TFF BMTP DIBQ %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 83 TPMFOPJE 3FQBJS .BOVBM
1b. Brake force too low: Oil pressure after WR solenoid valve too low because oil supply is reduced or interrupted. 2a. Brake force too high: WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM
2b. Brake force too high: Oil pressure after WP solenoid valve too low because oil supply is reduced or interrupted. 3. One of the control spools in converter outlet valve hard to move or stuck. 4. Wrong control unit.
3FQBJS .BOVBM %JBHOPTUJDT GVODUJPOT " *
25
Possible cause
Check / remedy
5.10 For DIWA.3E in 2nd, 3rd, or 4th gear: hard activation of converter brake
In 3rd and perhaps 4th gear and at high speeds: Converter filling control (CFC) malfunction - converter pressure too high 1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil and doesn't close correcly. (High speed means: transmission output speed is higher than the limit set for activation of converter filling control, e. g. about 2000 to 2200 rev/ min in 4th gear). 1. Check oil pressure at WP connection (measuring cover): pArequd = 0 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check pressure as discr. above. 2. Check converter filling valve and repair or replace, if required. 1. Check converter pressure at measur. point (6/2): pWrequd = 0 bar. 2. Check breather valve and repair or replace, if required. 4FF 0JM BOE $POUSPM $JSDVJU %JBHSBNT GPS %*8"& BCPVU UIF $'$
'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T BMTP DIBQUFS 3FQBJS .BOVBM
2. Converter filling valve hard to move or stuck and doesn't close correcly. 3. Breather valve hard to move or stuck and doesn't open correcly.
In 2nd, 3rd, and perhaps 4th gear and at all speeds: Converter pressure too high One of the control spools in converter outlet valve hard to move or stuck. Disassemble converter outlet valve and repair, if required. 3FQBJS .BOVBM
In 2nd, 3rd, and perhaps 4th gear and at all speeds: Reverse brake (RB) closes too hard - oil pressure fault before RBK 1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace. Replace disks, replenish or change oil. Check inductive pick-up, connector and connecting cable and repair or replace, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 3#, TPMFOPJE 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ / PS / %JBHOPTUJDT GVODUJPOT " *
2. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil. 3. Inductive pick-up N2 or N3, connector or connecting cable defective. 4. Wrong control unit.
26
Possible cause
Check / remedy
5.11 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake stage I too high
Converter pressure too high One of the control spools in converter outlet valve hard to move or stuck. Disassemble converter outlet valve and repair, if required. 3FQBJS .BOVBM
5.12 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake stage II or III too low or too high
Converter pressure too high or too low 1a. Brake force too low: Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective. 1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check solenoid valve, connector and cable, repair or replace, if required. Check oil-supplying componets and repair or replace, if required. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check converter filling valve and repair or replace, if required. 1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check breather valve and repair or replace, if required. Disassemble converter outlet valve and repair, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU TFF BMTP DIBQ %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 83 TPMFOPJE 3FQBJS .BOVBM
1b. Brake force too low: Oil pressure after WR solenoid valve too low because oil supply is reduced or interrupted. 1c. Brake force too low: Converter filling valve hard to move or stuck and doesnt open correcly.
'PS TFUQPJOUT TFF BMTP DIBQUFS 3FQBJS .BOVBM 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T BMTP DIBQUFS 3FQBJS .BOVBM 3FQBJS .BOVBM %JBHOPTUJDT GVODUJPOT " *
1d. Brake force too low: Breather valve hard to move or stuck and doesnt close correcly.
2. One of the control spools in converter outlet valve hard to move or stuck. 3. Wrong control unit.
27
Possible cause
Check / remedy
5.13 In 1st gear range: brake force in brake stage II or II too low or too high
RBK oil pressure too low or too high 1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 3#, TPMFOPJE 3FQBJS .BOVBM %JBHOPTUJDT GVODUJPOT " *
2. Oil pressure after RBK solenoid valve too low: RBK oil supply reduced or interrupted. 3. Wrong control unit.
28
Possible cause
Check / remedy
'BVMUT JO XBSOJOH MBNQT SFMBZT PS TXJUDIFT

6.1 The central warning lamp (ZW) does not light after turning on the ignition (ZW is energized a few seconds for test purposes)
1. Lamp defective. 2. If controlled through relays: relay, connector or connecting cable defect. Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS DFOUSBM XBSOJOH MBNQ
6.2 The pushbutton switch lighting (TL) does not light after turning on the ignition
1. For single pushbutton: lamp defective. 2. Pushbutton switch (e.g. terminal TL without voltage), connector or connecting cable defect. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
6.3 The warning lamp transmission oil temperature (TOEL) does not light after turning on the ignition (TOEL is energized a few seconds for test purposes)
Lamp, connector or connecting cable defect. Check lamp, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQU USBOTNJTTJPO PJM XBSO MBNQ
6.4 Consumer via relays - converter brake (dW), reversing lamp (dR) or speed (dN) - cannot be activated
1. Consumer not activated in record. 2. Consumer defective. 3. Relay dW, dR or dN, connector or connecting cable defect. Load correct record. Repair or replace consumer. Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS SFMBZ E8 E3 PS E/ %JBHOPTUJDT GVODUJPO ( %JBHOPTUJDT DIBQU
29
30
.FBTVSJOH EFWJDFT
The following equipment is required for troubleshooting if faults in DIWA.3 and DIWA.3E transmissions occur: PC or laptop with PC program Diwagnosis 59.2500. .. (latest version), level converter and connecting cable If the diagnostic program is used. Cable: Voith order no. 56.4219.10
%JBHOPTUJDT
Measuring cover (high design) To measure the oil pressures of clutches, brakes and valves of the transmission. Voith order no. 56.4218.10
Measuring cover (flat design) For restricted spaces in the transmission space. Voith order no. 56.4217.10
Pressure gauge To measure the operating and converter pressure. Voith order no. 58.2748.11
Multimeter To measure voltages and resistances.
4FF 5SPVCMF 4IPPUJOH
31
32
$IFDLJOH PJM QSFTTVSFT

8.1 Operating pressure
The uniform nominal value for the operating pressure is: pA = 8.5 bar (tolerance 0.2 bar). Measure the pressure only at an oil temperature of 80 - 90 C (= 176 - 194 F), immediately after shifting to 2nd gear (engine speed approx. 1500 rpm). 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 (figure 1/1).
If a measuring cover (figs. 2 and 3) is used, pressures which must correspond to the operating pressure are measured at the measuring points for the clutches resp. brakes DK, EK, PB, WP and SK. Fig. 2: Meas. points for DIWA.3 Fig. 3: Meas. points for DIWA.3E
2
Note! The WR oil pressure is cycled and therefore variable over time, its amount in addition depending on the relevant operating state (during braking or reversing). Therefore, simple pressure measurements by means of pressure gauges are not adequate for more thorough troubleshooting.
3
The measuring points TB, RBG and RBK are each pressurized with the higher operating 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 engine stopped, otherwise hot oil may result in scalding!
4FF DIBQUFS
33
If the measuring points mentioned are not accessible, the operating pressure can also be measured for DIWA.3 transmissions at the intermediate flange (if installed) of the oil filter: If the pressure is measured before (4/1) or after (4/2) the filter, approx. 0.5 bar must be added as flow resistance to obtain the value for the operating pressure. Note! Only measure before the filter if the filter element is clean! The working pressure can be set at the threaded pin of the operating pressure valve (5/1) - only possible with special screwdriver and socket wrench through the oil filler! If the required operating pressure is not reached, check piping for leakage and sealing gaps of the gear pump.
POMZ GPS %*8"
TFF 3FQBJS .BOVBM
8.2 Converter pressure

The converter pressure must be: pW 2 bar at an oil temperature toil of approx. 80 - 90 C (= 176 - 194 F), with forward gear engaged, engine at idle speed (500 50 rpm) and parking brake applied. If this value is not reached, converter sealing must be improved. Measuring point Usually, the converter pressure is measured at measuring point (6/2). Converter pressure with WDA deactivation At toil of = 80 - 90 C (= 176 - 194 F), the converter pressure must be 0,7 < pW < 2 bar Converter pressure when converter filling control (CFC) is active pW = 0 bar Converter pressure during braking At toil of = 80 - 90 C (= 176 - 194 F), with 2nd gear engaged (3rd gear inhibited) and approx. 50 % of maximum speed for 2nd gear, the converter pressure pW must be: brake stage I: pW = 0.2 - 0.7 bar brake stage II: pW = 1.8 - 2.5 bar brake stage III: pW = 3.6 - 4.9 bar POMZ GPS %*8"
$VTU 4FSW -FUUFS OP 3FQBJS .BOVBM
POMZ GPS %*8"&
GPS %*8"& POMZ XIFO $'$ JT OPU BDUJWF
34
5FTUJOH UIF NPUPS DPOUSPM USBOT NJTTJPO JOUFSGBDF

9.1 Engine idle speed
In particular in conjunction with electronic engine control units, it is frequently not possible to set the idle speed n in a simple manner. In addition, the settings are systemdependent (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). During a function check, the speed can be measured by means of the diagnostic program, for example. Note! If the idle speed must be changed, contact the bus manufacturer, if required.
%JBHOPTUJDT GVODUJPO *
9.2 Test: load transmitter signals as function of accelerator pedal position

The life of DIWA transmissions to a considerable extent depends on proper pressures in front of the disk clutches and brakes during shifting. Along with the input and output speeds, the motor torque is important, which to a great extent is in turn affected by the accelerator pedal position resp. the appropriate load levels L0 - L6 (or L0 - L7). The associated electronic signals are provided to the transmission in a different manner dependent on the engine control system. The following settings can be checked in a relatively simple manner with the bus stopped by means of the diagnostic program: 1. Load level L0 = "idle", accelerator pedal completely released. 2. Load level L6 = "full load", accelerator depressed to the stop (first, if any). Dependent 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 "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 function 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 connector 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 injection 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 diagnostic system).
4FF 5FDIOJDBM .BOVBMT DIBQUFS JOUFSGBDFT %JBHOPTUJDT GVODUJPO &
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35
Adjusting the connection between load transmitter and injection pump
4FF 5FDIO .BOVBMT DIBQUFS JOUFSGBDFT
Injection pump
Connection
transmitter
Mark for 0 load position
Mark for full load position 7
If the injection pump lever is in 0 load position
the load transmitter lever must be on the 0 load mark too!
If the injection pump lever is in full load position
the load transmitter lever must be on the full load mark too!
Otherwise, move the fastening with the link accordingly. Then recheck the setting in 0 load position! Note! the adjustment angles of the levers of injection pump and load transmitter 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!
Example for load transmitter adjustment with electronic engine control unit
36
9.3 Test: rated engine torque as function of load stage or engine speed
It may be necessary to determine the maximum possible engine torques in bus operation. 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. First of all pay attention: Danger! Apply parking brake to prevent unintentional bus movement! After that as example for full load operation (= load level L6): 1. engage forward gear, 2. depress accelerator pedal to the full load stop, 3. enter the measured engine speed N1 (= stall speed) in the diagram below (figure 10). The intersection with the appropriate pump characteristic of the transmission - for pump design, check the transmission nameplate, for example shows the maximum possible engine torque with the bus stopped. Note! The latter torque may deviate significantly from the maximum possible engine torque while driving with electronic engine control units. These tests are performed during acceptance protocol measurements.
"QQMJDBUJPO *OJUJBM "DDFQUBODF
1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 400
4H
4X
4V 4G 3H 4F 3X 3V 3G 3F
Engine torque M1 (Nm)
600
800
1000
1200
1400
1600
1800
2000
2200
10
Engine speed N1 (rpm)
37
38
"QQFOEJDFT
1 hydraulic control diagram DIWA.3 1 hydraulic ccontrol diagram DIWA.3E 1 circuit diagram DIWA.3 1 circuit diagram DIWA.3E
39
C
WR SK
B
7
DK
EK
TB
pa
PB
RBG
A B C D E F G H J 1-6 7,8 9 10 11 12 13 14 15
WP
RBK
Converter drain valve (CDV) Operating pressure valve (OPV) Solenoid valves Relief valve Pressure accumulator TB DIWA.3 transmission Gear pump Heat exchanger Oil filter CDV spools OPV spools Shuttle valve Reverse gear brake RB Turbine brake TB Pump brake PB Step-up gear clutch SK Lock-up clutch DK Input clutch EK
pw
15
14 13
12
11
10
Shifting function
ANS activation
EK DK SK PB TB WP WR RBK RBG
x x x x x x x x x x x x x x
1)
x1) x x x x
6 5
G E J H F D
ANS activ. via parking brake 1st gear (DIWA drive range) Upshift 1st-2nd gear* 2nd gear 3rd gear 4th gear Braking 1st gear range 1st braking stage - 2nd gear 2nd and 3rd brak. stage - 2nd gear 2nd and 3rd brak. stage - 3rd gear 2nd and 3rd brak. stage - 4th gear Reverse gear < 1 km/h Reverse gear > 1 km/h * = Transition x x x x
x x x x x
x x x x x x
x x2) x2) x2) x x1,2)
x1) x x x x x x x x x x x x
= Valve regulated 2) = Valve oscilated
Drawn: Neutral position
Hydraulic control diagram DIWA.3 55.2059.12
C
8
D
SK WR
10
pA
DK
EK
TB
A B C D E F G H 1-6 7 8,9 10 11 12 13 14 15 16 17 Converter drain valve (CDV) Converter filling valve (CFV) Operating pressure valve (OPV) Solenoid valves DIWA.3E transmission Gear pump Heat exchanger Oil filter CDV spools CFV spool OPV spools Shuttle valve Reverse gear brake RB Turbine brake TB Breather valve Pump brake PB Step-up gear clutch SK Lock-up clutch DK Input clutch EK
PB
RBG
WP
RBK
pW
17
16 15
14
13
12
11
E
Shifting function
1st gear (DIWA drive range)
EK DK SK PB TB WP WR RBK RBG
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
1)
x x x x
6 5
Upshift 1st-2nd gear* 2nd gear 3rd gear 4th gear 3rd gear with converter filling control (CFC) 4th gear with CFC 1st, 2nd and 3rd brak. stage - 4th gear with CFC* 1st braking stage - 4th gear 2nd and 3rd brak. stage - 4th gear 2nd and 3rd brak. stage - 3rd gear
A H
4 3 2 1
x x x x x x x2) x2) x2) x x x x x x1) x1) x x x2) x x x x x x x x
2nd and 3rd brak. stage - 2nd gear
Braking 1st gear range ANS activation ANS activation via parking brake Reverse gear < 1 km/h Reverse gear > 1 km/h * = Transition
= Valve regulated 2) = Valve oscilated
Drawn: Rest position
Hydraulic control diagram DIWA.3E 55.5661.15
A
a
238 221 202 221.1 221.3
+UB +FB -UB
1 20 38 2 21 39 3 22 40
EK -UB DK SK -UB -UB WR -UB -UB -UB EKM DKM SKM PBM TBM RBKM SENSE SENSE -UB -UB -UB N1A N1B N2A N2B N3A N3B -UB TS+ TS-UB REA0 RBG
240 204 204.1 241.1 205.1 224.1 200 207 226 244 208 227 245 209 228 246 210 229 230 211 248 212 231 249
A
D 2 D 1 2 D 1 2 3 D N N N N R R R R
S1
S2
S3 S2/1 S2/2 S3/2 S3/3
S1 S2 S3 +V +R RS +TS +TL /N -UB SSP RF RS +R
1 2 3 4 5 6 7 8 9 10 11 12 13 14
227 245 209 228 246 230 229 233 210 221 200 256
B
221.2
C
S1 S2 S3 +V +R RS +TS +TL /N -UB 227 245 209 228 246 230 229 233 210 221 221.2 244 226 207 208 200 256
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
213 232 250 214 233 251 215 252 216
z x
HBC HBA +HB 244 226 207 208 -UB HBC HBB HBA +HB
0 3
U
HBC HBA +HB
y
0 0 1 1 1 1
z
221.2
1 2
1
0 0 1 1
3
3
1 1 1 1
x
6 5 4 1 2 3 4 5 6 7 8
y
HBC HBB HBA +HB
0
0 0 0 1
2
0 1 1 1
1 2 3 4 5 6 7 8
227 245 209 228 246 230 229 233 210 221 244 226 207 208 200
235 253 217 236
237 255 219 219.1
4 23 41 5 24 42 6 25 43 HBA 7 HBB 26 HBC 44 +HB 8 S1 27 S2 45 S3 9 +V 28 +R 46 /N 10 +TS 29 47 FB2 11 RS 30 PU 48 BS 12 FBAUS 31 FB3 49 dS 13 dW 32 dN 50 dR 14 +TL 33 ZW 51 TOEL 15 34 DIAGN-K 52 252.1 DIAGN-L 16 216.1 ABSICH 35 ABS 53 CAN-H 17 CAN-M 36 54 CAN-L 18 37 dNEUTR 55
FB1 KD KD
DKV/PWM DKR DKE
D
-UB -UB
IO9 LGM -LG +LG IO3
WP RBK PB -UB TB PA
19 55 37 18 54 36 17 53 35 16 52 34 15 51 33 14 50 32 13 49 31 12 48 30 11 47 29 10 46 28 9 45 27 8 44 26 7 43 25 6 42 24 5 41 23 4 40 22 3 39 21 2 38 20 1
119 137 118 117 153 135 152 7 8 3 6 4 5 1 2 148 111 147 129 110 146 128
S2/1
S2/2
S3/2
S3/3
9 10
124 105 141
103 121 102 120 101
3 2 1
244 226 207 208
-UB HBC HBB HBA +HB SSP RF
+UZ 219.2
19
219.2 221.3 252.1 216.1
+UZ -UB DIAGN-K DIAGN-L
1 2 8 10
E G
2
1 3 4
F
141 124 105 +LG LGM -LG
S
1 2 3
gn/ge bl sw br
1 2 3 4
R
204 219
152 153
147 111
110 129
128 146
135 137 119 102 103 121 117 120 101 118
240 249 202 211
KD +UZ FB1 FB3 +FB FB2
204 219 240 249 202 211
M
h i
j
dW
P
CAN-H CAN-M CAN-L
1 2 3 4 5 6 7 8 9 10 C B A
204 219 240 249 202 211
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
217 237 236
sw CAN-H ge CAN-M CAN-L
n1
+ 1 2
ws sw ws sw
4 3 2 1
bl bl bl bl ws sw ws sw
148 10 9 8 7 6 5 4 3 2 1
n3 n2
sw ge bl rt
k
dR
l
dN
m WR
85 87 87a
sw rt sw ge bl rt sw ge bl rt sw ge bl rt sw
br bl br ge gn bl br ge gn bl br ge gn bl br bl
N
s
M
O
n
dS
1 2 4 3 1 2 4 3 1 2 4 3 1 2
br ge gn bl
2 4 3 1
SK
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
DK
J K
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
EK PB
br ge gn bl br bl br ge gn bl
2 4 3 1 2
sw ge bl rt sw rt sw ge bl rt
TB RBG RBK
q p t
st
61 50e 50f D+
u
DD+
v w
150
DKR DKE DKV/PWM
M
ABS d
inactive
on off
238 213 219.1 214 232 251 253 250 255 252 216 200 205.1 224.1 241.1 204.1 215 231 248 235 212 221.1
+UB dS +UZ dR dW ZW ABS dN dNEUTR DIAGN-K DIAGN-L SSP DKR DKE DKV/PWM KD TOEL FBAUS PU ABSICH BS -UB
1 2 4 3 1
WP
rt
+ 24V
A Push-button switch B Connection cable for push-button switch and converter brake C Cable 2 D E 200 control unit E Connection: level converter and diagnostic PC F Cable 1 G Load transmitter H Speed and temperature sensors J Solenoid valves K Connection cable for vehicle wiring
L M N O P Q R S T U
Switches and warning light transmission oil Engine control Vehicle electrical system non-committal representation Relays CAN Bus Connection cable for brake valve and kickdown switch Kickdown switch Brake valve Manual switch for converter brake Switch for converter brake; stage no. 3
a b c d e f g h i j k l
Inhibitor switch for reverse gear Connections Bridges Warning light transm. oil Cut-out switch for conv. brake; only for brake valve Pressure switch for gearshift inhibitor Pressure switch for ANS activation Relay for control unit Relay for starter inhibitor Relay for centr. warn. light Relay for converter brake Relay for reversing light
m n o p q r s st t u v w x y z
Relay for speed Central warning light Fuse 8A Relay for battery Switch box Starter inhibitor relay Starter Start button Battery Overvoltage protection Generator Regulator Connections Position Stage no.
Circuit diagram DIWA.3 55.3705.20
A
a
R
221
238 202 221.1 221.3
+UB +FB -UB
1 20 38 2 21 39 3 22 40
EK -UB DK SK -UB -UB WR -UB -UB -UB EKM DKM SKM PBM TBM RBKM SENSE SENSE -UB -UB -UB N1A N1B N2A N2B N3A N3B -UB TS+ TS-UB REA0 RBG
240 204 204.1
A
D 2 D 1 2 D 1 2 3 D
S2/1 S2/2 S3/2 S3/3
S1 N N N N R R R R
S2
S3 S2/1 S2/2 S3/2 S3/3 200 207 226 244 208 227 245 209 228 246 210 229 230 211
241.1 DKV/PWM 205.1 DKR 224.1 DKE
S1 S2 S3 +V +R RS +TS +TL /N -UB SSP RF RS +R
1 2 3 4 5 6 7 8 9 10 11 12 13 14
227 245 209 228 246 230 229 233 210 221 200 256
249
248 212 231 213 232 250 214
B
221.2
C
S1 S2 S3 +V +R RS +TS +TL /N -UB 227 245 209 228 246 230 229 233 210 221 221.2 244 226 207 208 200 256
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
233 251 215 252 216
z x y
HBC HBA +HB -UB HBC HBB HBA +HB
U
HBC HBA +HB
1 2 3 4 5 6 7 8
0 0 1
1 1 1
221.2
z x y
HBC HBB HBA +HB -UB HBC HBB HBA +HB
0
0
0 0 0 1
1 2 3
1
0 0 1 1
2
0 1 1 1
3
1 1 1 1
6 5 4
244 226 207 208
3 2 1
1 2 3 4 5 6 7 8
227 245 209 228 246 230 229 233 210 221 244 226 207 208 200
217 236
235 253
237 219 255 219.1
4 23 41 5 24 42 6 25 43 HBA 7 HBB 26 HBC 44 +HB 8 S1 27 S2 45 S3 9 +V 28 +R 46 /N 10 +TS 29 47 FB2 11 RS 30 PU 48 BS 12 FBAUS 31 FB3 49 dS 13 dW 32 dN 50 dR 14 +TL 33 ZW 51 TOEL 15 DIAGN-K 34 52 252.1 DIAGN-L 16 216.1 ABSICH 35 ABS 53 CAN-H 17 CAN-M 36 54 18 CAN-L 37 dNEUTR 55
FB1 KD KD
19 55 37 18 54 36 17 53 35 16 52 34 15 51 33 14 50 32 13 49 31 12 48 30 11 47 29 10 46 28 9 45 27 8 44 26 7 43 25 6 42 24 5 41 23 4 40 22 3 39 21 2 38 20 1
119 137 118 117 153 135 152 7 8 3 6 4 5 1 2 148 111 147 129 110 146 128
9 10
D
-UB -UB
IO9 LGM -LG +LG IO3
124 105 141
103 121 102 120 101
RBK PB -UB TB WP
+UZ 219.2
244 226 207 208
19
SSP RF
219.2 221.3 252.1 216.1
+UZ -UB DIAGN-K DIAGN-L
1 2 8 10
E G
2
3 4 1
F
141 124 105 +LG LGM -LG
S
1 2 3
gn/ge bl sw br
1 2 3 4
R
204 219
128 146
152 153
147 111
110 129
135 137 119 102 103 121 117 120 101 118
240 249 202 211
KD +UZ FB1 FB3 +FB FB2
204 219 240 249 202 211
M
h i
j
dW
P
CAN-H CAN-M CAN-L
1 2 3 4 5 6 7 8 9 10 C B A
204 219 240 249 202 211
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
217 237 236
sw CAN-H ge CAN-M CAN-L
n1
1 2
+ -
ws sw ws sw
4 3 2 1
bl bl bl bl ws sw ws sw
148 10 9 8 7 6 5 4 3 2 1
n3 n2
sw
k
dR
l
dN
m SK
85 87 87a
N
s
M
O
n
dS
sw ge bl rt sw ge bl rt sw ge bl rt sw ge bl rt sw
2 4 3 1 2 4 3 1 2 4 3 1 2 4 3 1 2
br ge gn bl br ge gn bl br ge gn bl br ge gn bl br bl
br
bl
rt
WR
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
DK
J K
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
EK PB WP
br ge gn bl br bl br ge gn bl
2 4 3 1 2
sw ge bl rt sw rt sw ge bl rt
TB RBG RBK
q p t
st
61 50e 50f D+
u
DD+
v w
150
DKR DKE DKV/PWM
M
ABS d
inactive
on off
238 213 219.1 214 232 251 253 250 255 252 216 200 205.1 224.1 241.1 204.1 215 231 248 235 212 221.1
+UB dS +UZ dR dW ZW ABS dN dNEUTR DIAGN-K DIAGN-L SSP DKR DKE DKV/PWM KD TOEL FBAUS PU ABSICH BS -UB
1 2 4 3 1
rt
+ 24V
A Push-button switch B Connection cable for push-button switch and converter brake C Cable 2 D E 200 control unit E Connection: level converter and diagnostic PC F Cable 1 G Load transmitter H Speed and temperature sensors J Solenoid valves K Connection cable for vehicle wiring
L M N O P Q R S T U
Switches and warning light transmission oil Engine control Vehicle electrical system non-committal representation Relays CAN Bus Connection cable for brake valve and kickdown switch Kickdown switch Brake valve Manual switch for converter brake Switch for converter brake; stage no. 3
a b c d e f g h i j k l
Inhibitor switch for reverse gear Connections Bridges Warning light transm. oil Cut-out switch for conv. brake; only for brake valve Pressure switch for gearshift inhibitor Pressure switch for ANS activation Relay for control unit Relay for starter inhibitor Relay for centr. warn. light Relay for converter brake Relay for reversing light
m n o p q r s st t u v w x y z
Relay for speed Central warning light Fuse 8A Relay for battery Switch box Starter inhibitor relay Starter Start button Battery Overvoltage protection Generator Regulator Connections Position Stage no.
Circuit diagram DIWA.3E 55.6168.10
Voith Turbo GmbH & Co. KG Produktgruppe Nutzfahrzeuggetriebe Alexanderstrae 2 D-89522 Heidenheim Telephone (07321) 37-0 Telefax (07321) 37 7618
3
DB 250 PF Series
AUTOMATIC GEARBOXES
ZF-ECOMAT 2 Transmissions
1. REPAIR MANUAL ZF-ECOMAT 2 STAGES 1-2
0145
1-1
AUTOMATIC GEARBOXES
ZF-ECOMAT 2 Transmissions
3
DB 250 PF Series
1-2
0145
REPAIR MANUAL
011356
HP 502 C / HP 592 C / HP 602 C EST 46 C / EST 47 C Stages 1-2

4149 751 601e
Subject to alterations in design
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
4149 751 601e
HP 502 C / HP 592 C / HP 602 C
Contents
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutaway views of Ecomat transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch and brake combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 6 7 9 11 12 15 19 20 22
1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level when cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level with engine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level on versions with heat exchanger higher than center line of transmission . . . . . . . . . . . Changing oil at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-4
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.7 2.8 2.9 2.10 2.11 2.12 2.13
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing retarder solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing accumulator solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing output sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing retarder resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and fitting oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing turbine sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing complete hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing complete oil level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing impulse sensor for speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing output flange and/or radial seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 2-1 2-3 2-4 2-5 2-6 2-7 2-11 2-13 2-17 2-23 2-28 2-32 2-33 2-37
Contents
HP 502 C / HP 592 C / HP 602 C

Page
3. 3.1 3.2 3.3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal tester concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test instructions for test cable 1 PO1 138 153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annex Description/menus for ZF Testman
3-1 3-1 3-2
4.
Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Hydraulic circuit diagram without NBS 4149 700 026 / 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Hydraulic circuit diagram with NBS 4149 700 026 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Connection diagram 6029 729 041 / 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Electrical circuit diagram n 6029 729 040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Pin pattern 6029 729 072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
HP 502 C / HP 592 C / HP 602 C
Preface
This repair manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF product in accordance with the state of development on the date of issue. However, due to continuing development of the product, repair work might require work practices and test or adjustment data not contained in this manual. We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training centers. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually trained personnel 2. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out conscientiously and with utmost care. Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case. ZF FRIEDRICHSHAFEN AG C.V ./Special Transmissions Service Plant 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726 Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.
Important information
SAFETY NOTICE Companies repairing ZF units are responsible for their own work safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations. Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.
HP 502 C / HP 592 C / HP 602 C

GENERAL INFORMATION Read this manual carefully before starting any tests or repair work.
CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings and components are not to scale. Conclusions about size and weight should not be drawn (even within a complete illustration). Always follow the working steps as described in the text.
The following safety instructions appear in this manual:
After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly.
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.
THREATS TO THE ENVIRONMENT ! Lubricants and cleaning agents must not be allowed to enter the soil, ground water or sewage system. Ask your local environment agency for safety information on the relevant products and adhere to their requirements. Collect used oil in a suitably large container. Dispose of used oil, dirty filters, lubricants and cleaning agents in accordance with environmental protection guidelines. When working with lubricants and cleaning agents always refer to the manufacturers instructions.
CAUTION The transmission must NOT be hung by the input shaft NOR by the output flange.
HP 502 C / HP 592 C / HP 602 C

In case of doubt always turn to the relevant department within ZF After-Sales Services for advice. All work on transmissions is to be performed expertly and under clean conditions. Use specified tools to dismantle and assemble transmissions. After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening. Pay particular attention to the projections and recesses of housings and covers when cleaning. Parts joined with Loctite are easier to separate if warmed with a fan heater.
Instructions for repairs

GASKETS, LOCKING PLATES Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).
SHAFT SEALS Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition.
RE WO R K I N G CLEANING PARTS Remove remains of old gaskets on all seal-faces. Carefully remove burrs or similar patches of roughness using an oil-stone. Lube bores and grooves must be free of anti-corrosion agents and foreign matter; check for perfect passage. Carefully cover opened transmissions to prevent foreign matter from entering. Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or riffling. If rework is needed on distance washers, shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality.
TRANSMISSION ASSEMBLY REUSING PARTS Parts such as ball or roller bearings, multi-discs, thrust washers etc., must be inspected by a competent person, who should decide whether or not they can be re-used. Replace parts which are damaged or have suffered from excessive wear. Find a clean site to assemble the transmission. Gaskets are installed without the use of sealing compound or grease. When measuring silicon-coated gaskets, take care not to include the silicon layer in the measurement. During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual.
Instructions for carrying out repairs

BEARINGS If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet). Temperature should be at ca. 85 C and must not exceed 120 C. Each mounted bearing must be oiled with operating oil.
HP 502 C / HP 592 C / HP 602 C

d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.
e) Fill the gap between the sealing lips so it is 60% filled with grease (e.g. produced by Aral such as Aralub HL2 or by DEA such as Spectron FO 20). f) If possible, heat shaft seal bores to between 40 and 50 C (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.
SEALING If a specific sealing agent* is to be used for sealing, comply with the manufacturers directions for use. Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing to enter oil ducts and bores. On oil-carrying ducts and bores, wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the surfaces are sealed.
R E TAI NI NG AG E NT S Retaining agents* may only be used in places as specified in the parts list. Always comply with manufacturers directions for use when using retaining agents (e.g. Loctite). During assembly, comply with all adjustment data, checking data and tightening torques.
SHAFT SEALS a) Apply a light coat of sealing agent* on outer edge of shaft seals with steel surround. TRANSMISSION OIL b) Never apply sealing agent to shaft seals with rubber surround, but apply a thin coat of Vaseline 8420 to the outer edge or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g. Pril, Coin, Palmolive). c) Shaft seals with steel and rubber surrounds should be treated on the outer edge of the rubber surround as described above in section b). After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques.
* refer to expendable material
HP 502 C / HP 592 C / HP 602 C

Tightening torques for nuts and bolts, extract from ZFN 148 This standard applies to bolts acc. to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934. This Standard contains data on tightening torques (MA) for bolts and nuts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12.
Tightening torques
Surface condition of bolts: thermally blackened and oiled or galvanized and oiled or galvanized, chrome-plated and oiled. Tighten screws with a calibrated torque spanner. NOTE Irregular tightening torques are listed separately in the Repair Manual.
Regular screw thread Size Bolt Nut M 4 M 5 M 6 M 7 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 Tightening torque MA (Nm) for 8.8 10.9 8 10 2.8 5.5 9.5 15 23 46 79 125 195 280 390 530 670 1000 1350 4.1 8.1 14 23 34 68 115 185 280 390 560 750 960 1400 1900
Fine screw thread Size 12.9 12 4.8 9.5 16.5 28 40 79 135 215 330 460 650 880 1100 1650 2250 Bolt Nut M 8x1 M 9x1 M 10 x 1 M 10 x 1.25 M 12 x 1.25 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 18 x 2 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 24 x 2 M 27 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 Tightening torque MA (Nm) for 8.8 10.9 8 10 24 36 52 49 87 83 135 205 310 290 430 580 760 730 1100 1050 1550 1500 36 53 76 72 125 122 200 300 440 420 620 820 1100 1050 1600 1500 2200 2100
12.9 12 43 62 89 84 150 145 235 360 520 490 720 960 1250 1200 1850 1800 2550 2500
Edition: August 1991 / checked 1997 9
Tightening torques
Screw plugs DIN 908, 910 and 7604 The screw plug tightening torques MA were determined according to DIN 7604 for screwing into steel, grey cast and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. The values for the tightening torque MA apply analogously for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical. General rule: Screw/bolt class 5, ZFN 148-1 Screw/bolt material: steel acc. to DIN 7604. Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled. Screw plugs (DIN 908, 910, 7604) Dimensions Tightening torque screwed into steel/gray cast Al alloy 20 25 / 30* 35 35 40 50 55 60 / 80* 70 80 / 105* 80 100 / 130* 95 120 130 140 150 145 160 150 170 160 180 195 205 10 15 / 20* 25 25 30 35 45 50 / 65* 60 70 / 90* 70 90 / 130* 85 110 115 120 130 125 140 130 145 135 150 165 175
HP 502 C / HP 592 C / HP 602 C

Union screws DIN 7643 The tightening torques MA were determined for screwing into steel, grey cast and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. General rule: screw/bolt class 5, ZFN 148-1 Material: 9SMnPb28K acc. to DIN 1651 Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled.
Union screws (DIN7643) Pipe outer diameter 4-5 6 8 10 12 15 18 22 28 35 Thread Tightening torque MA in Nm 20 - 25 25 - 35 30 - 40 35 - 40 45 50 60 90 130 140
M 8x1 M 10 x 1 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 26 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 M 33 x 2 M 36 x 1.5 M 38 x 1.5 M 42 x 1.5 M 42 x 2 M 45 x 1.5 M 45 x 2 M 48 x 1.5 M 48 x 2 M 52 x 1.5 M 60 x 2 M 64 x 2
* DIN 7604 Form C
M8x1 M 10 x 1 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 22 x 1.5 M 26 x 1.5 M 30 x 1.5 M 38 x 1.5
Status: October 1995
10
HP 502 C / HP 592 C / HP 602 C
Expendables
Description ZF reference no. Grease 0750 199 001
Name
Approx. quantity
Application
Remarks
for example: Spectron FO 20
General assembly aid
Sealing compound 0666 790 017 Grease 0671 190 016 Transmission oil
WEVO-L100
Screwing connection on output flange General assembly aid
Industrial grade Vaseline 8420 refer to TE-ML14 List of Lubricants
General assembly aid
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
Description 01. Internal resistance of solenoid valves for clutches and brakes in transmission
Dimension R = approx. 67 ohm at 68 F (20 C)
Measurement device Ohmmeter and test cable 1P01 138 153 or terminal tester 6008 006 002
Remarks Resistance rises with temperature to approx. 74 Ohm when transmission at operating temperature.
02. Internal resistance of inductive sensors (speed sensors) nT and nOut
R = 1080 40 ohm at 68 F (20 C)
Ohmmeter
Resistance rises with temperature to approx. 1350 Ohm when transmission at operating temperature. Renew copper sealing ring.
03. Tightening torque for M14x1.5 temperature sensor 04. Tightening torque for M22x1.5 oil drain plug in oil pan
26 ft-lbs 35 Nm
Torque wrench
37 ft-lbs 50 Nm
Torque wrench
Renew copper sealing ring.
05. Clearance between inductive sensor - output and face end gears on planetary carrier 06. Clearance between inductive sensor - turbine and pulse sensor ring 07. Tightening torque for M6 fixing bolts on inductive sensor 08. Clearance between speedo sensor and toothedring on output 09. Tightening torque for speedo sensor 10. Insertion depth of shaft seal in output cover
0.02 - 0.027" 0.5 - 0.7 mm
Depth gauge, slider gauge 1X56 138 149 /1X56 138 150
Adjust clearance with shims
0.024 - 0.03" 0.6 - 0.8 mm
Depth gauge, slider gauge 1X56 138 149 / 1X56 138 150 Torque wrench
Adjust clearance with shims
7 ft-lbs 9.5 Nm
Do not overtighten
0.027 - 0.055" 0.7 - 1.4 mm
Depth gauge
Clearance is supplied, check value.
26 ft-lbs 35 Nm 0.55 - 0.59" 14 - 15 mm
Torque wrench
Do not overtighten.
Use to 1X56 136 824 This gives correct insertion depth.
12
HP 502 C / HP 592 C / HP 602 C
Adjustment data
Description 11. Tightening torque for M6 hex nuts on inductive sensor cover-output
Dimension 5 ft-lbs 6 Nm
Measurement device Torque wrench
Remarks Do not overtighten
12. Tightening torque for M12 hex bolts at output flange
44 ft-lbs 60 Nm
Torque wrench
Secure with lock plate Use to 1X56 136 471
13. Tightening torque for M42x2 screw plug in duct plate
67 - 74 ft-lbs 90 - 100 Nm
Torque wrench
14. Tightening torque for M10x1 screw plugs on the pressure measuring points
9 ft-lbs 12 Nm
Torque wrench
Do not overtighten
13
14
HP 502 C / HP 592 C / HP 602 C
Special tools
Fig. no.
Special tools
Order no.
Application
Qty.
Remarks
1X56 136 471 Tool for lock plate on output flange
1X56 136 824 Tool for fitting radial seal in output flange
1P01 136 670 Pressure test gauge 0 - 25 bar with M10x1 connectors
1P01 137 856 Pressure test gauge 0 - 10 bar with M10x1 connectors
1X56 137 126 Lifting attachment for transmission
15
Special tools
HP 502 C / HP 592 C / HP 602 C
Fig. no.
Special tools
Order no.
Application
Qty.
Remarks
1X56 138 149 Measuring rod to determine distance between inductive sensor and pulse sensor on turbine and output (in connection with test fixture 1X56 138 150)
1X56 138 150 Test fixture to determine distance between inductive sensor and pulse sensor on turbine and output (in connection with measuring rod 1X56 138 149)
1X56 103 755 Gripper to mount output flange (in connection with mounting fixture 1X56 136 512)
1X56 136 512 Mounting fixture to mount output flange (in connection with gripper 1X56 103 755)
1X56 136 513 (220V) or 1X56 137 575 (110V) 10 Hot air blower to heat various parts.
Options available: for 220 Volts or for 110 Volts
16
HP 502 C / HP 592 C / HP 602 C
Special tools
Fig. no.
Special tools
Order no.
Application
Qty.
Remarks
1P01 138 153 Test cable for testing solenoid valves
11
6008 006 002 68-pin terminal tester for electrical troubleshooting
12
6008 208 003 3 4 Testman Diagnostic System (for Windows 95, 98 and NT) Complete system without PC. Contains: 6008 308 901 Testman software on disc (1) 6008 308 600 DPA 04 I adapter (2) 5 1 6008 308 601 RS 232-cable(3) 0501 211 103 ISO cable (4) 1
Complete system for Windows 95, 98 and NT without PC
2 13
Optionally 6008 208 004 or 6008 208 003 but also with 0501 211 104 SAE cable (5).
6008 308 114 Diagnostic software Testman for Ecomat 2
14
Diagnose - Software 6008 308 014
17
Special tools
HP 502 C / HP 592 C / HP 602 C
Fig. no.
Special tools
Order no.
Application
Qty.
Remarks
6008 307 001 Diagnostic system MobiDig 2001 Complete system in portable case
1 for ZF-Service only
15
0501 301 068 EPD1 Simple programming device
16
6008 298 029 Plug-In memory card for EPD1
17
0501 211 103 ISO cable for EPD1
18
0501 211 648 SAE cable for EPD1
19
18
HP 502 C / HP 592 C / HP 602 C

Arrangement of peripheral equipment
Arrangement of peripheral equipment
N R 3 D 1 2

013190
Key to drawing 1 2 3 4 5 6 7 8 9 Transmission electrical power plug EST 46C / EST 47C plug Retarder plug Accumulator plug Temperature sensor plug Kickdown switch MOBiDIG connection plug Speed range selector (Push-button switch) Dipstick (Oil level check, oil condition) 10 11 12 13 14 15 16 17 Pedal brake valve for actuation of service brake and continuous retarder actuation via CAN Accelerator pedal Retarder switch OFF - ON Vehicle power supply Pressure switch for NBS EST 46 C / EST 47 C electronic control unit Electric retarder hand lever Speedometer pulse sensor
19
Cutaway view
HP 502 C / HP 592 C / HP 602 C

ZF Ecomat transmission, 4-speed version
10
11
12
13
26
25
24
23
22
21
20
19
18
17
16
15
14
013468
Key to drawing 1 2 4 5 6 7 9 10 11 12 13 14 Input Cover plate Control element Oil feed flange Clutch A Clutch B Housing Planet gear set I Planet gear set II Planet gear set III Speedo sensor Output 15 16 17 18 19 20 21 22 23 24 25 26 Inductive sensor output Brake F Brake E Brake D Control unit Inductive sensor Turbine Oil pan Retarder Primary pump Converter Torque converter WK Turbine shaft
20
HP 502 C / HP 592 C / HP 602 C

ZF Ecomat transmission, 5 & 6-speed version
Cutaway view
10
11
12
13
26
25
24
23
22
21
20
19
18
17
16
15
14
013467
Key to drawing 1 2 4 5 6 7 8 9 10 11 12 13 14 Input Cover plate Control element Oil feed flange Clutch A Clutch B Clutch C Housing Planet gear set I Planet gear set II Planet gear set III Speedo sensor Output 15 16 17 18 19 20 21 22 23 24 25 26 Inductive sensor Output Brake F Brake E Brake D Control unit Inductive sensor Turbine Oil pan Retarder Primary pump Converter Torque converter WK Turbine shaft
21
Clutch combination
Clutch and brake combinations
HP 502 C / HP 592 C / HP 602 C
No. of speeds 4-speed 4-speed 5-speed 5-speed 6-speed
HP 502 4149 002 . . . 4149 006 . . . 4149 001 . . . 4149 003 . . . 4149 004 . . .
Transmission model and Parts List No. HP 592 HP 602 4149 052 . . . 4149 062 . . . 4149 056 . . . 4149 066 . . . 4149 051 . . . 4149 061 . . . 4149 053 . . . 4149 063 . . . 4149 054 . . . 4149 064 . . .
Ratio range 2.81 - 1.00 3.43 - 1.00 2.81 - 0.80 3.43 - 0.83 3.43 - 0.59
Ecomat 2 without NBS Clutch / brake 4 speed Reverse Neutral 1st gear 2nd gear 3rd gear 4th gear A B1 B2 D E F1 F2 Clutch / brake 4 speed
Ecomat 2 with NBS A B1 B2 D E F 1 F2
i = 2.81 to 1.00 i= 3.43 to 1.00
i = 2.81 to 1.00 i = 3.43 to 1.00
Reverse Neutral Neutral NBS 1st gear 2nd gear 3rd gear 4th gear
* *
Ecomat 2 without NBS Clutch / brake 5-speed and 6-speed Reverse Neutral 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear A B2 C D E F1 F2 Clutch / brake 5-speed and 6-speed
Ecomat 2 with NBS A B2 C D E F1 F 2
i = 2.81 to 0.80 i = 3.43 to 0.83 i = 3.43 to 0.59
i = 2.81 to 0.80 i = 3.43 to 0.83 i = 3.43 to 0.59
Reverse Neutral Neutral NBS 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear
* *
B1 = inner piston face, clutch B B2 = outer piston face, clutch B F1 = outer piston face, brake F F2 = inner piston face, brake F
*
= reduced pressure (only for transissions with NBS)
22
HP 502 C / HP 592 C / HP 602 C

1. 1.1 Maintenance Oil change intervals
Maintenance
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. Transmission oil change Oil change following transmission repair. Mileage 600 miles (1,000 km) Operating hours 50 h
Mineral oil-based ATFs in accordance with Group standard ZFN 13015. TE-ML 14 Lubricant class 14A / 14D: Oil change in normal operating conditions. Oil change in tough operating conditions*. Construction machinery or special vehicles mobile cranes, garbage trucks, etc. But at least once every year. Semi-synthetic ATFs in accordance with Group standard ZFN 13015. TE-ML 14 Lubricant class 14B: Oil change in normal operating conditions. Oil change in tough operating conditions*. Construction machinery or special vehicles mobile cranes, garbage trucks, etc. But at least once every 2 years Synthetic ATF in accordance with Group standard ZFN 13015. TE-ML 14 Lubricant class 14C: Oil change in normal operating conditions. Oil change in tough operating conditions*. Construction machinery or special vehicles mobile cranes, garbage trucks, etc. But at least once every 2 years *Average speed < 15 miles/h (25 km/h) and vehicle weight > 23 t. 1.2 Oil capacities First fill of dry transmission (with oil cooler) At oil changes Refilling after installing transmission in vehicle 75,000 miles (120,000 km) 56,000 miles (90,000 km) 3,000 h 37,000 miles (60,000 km) 28,000 miles (45,000 km) 2,000 h 18,000 miles (30,000 km) 12,000 miles (20,000 km) 1,000 h
8 gal. 31/2 - 41/2 gal. 51/2 gal.
(30 liters) (14-17 liters) (20 liters)
The above quantities are reference quantities; the exact amount must always be found by measuring with the dipstick. 1.3 Oil grade See ZF List of Lubricants TE-ML 14. This list can be requested from any ZF After-Sales Service point. 1-1
Maintenance
1.4 Checking oil level The oil level must be checked at least once every week. Vehicle must be standing level. Engine at idling speed. Before checking oil level, shift into Neutral.
HP 502 C / HP 592 C / HP 602 C
Oil measuring rod (check oil level / oil condition)
Oil pipe (oil filling up) CAUTION An electronic oil level display only provides information. Regular checks must be conducted on the oil dipstick at operating temperature. Always ensure that the correct oil level is maintained. Too little oil may cause malfunction or failure of the transmission. Too much oil may cause the transmission to overheat.
DANGER Insufficent oil can cause partial or regular retarder failure: i.e. reduced or zero braking action.
011576
1.5
Operating temperature The correct operating temperature at which to check the oil level can be seen on the gauge in the vehicle. NOTE Before the oil level is checked, the transmission oil must have reached an operating temperature of 180 - 195F (80 - 90 C).

1.6
Adding oil Pour in transmission oil through the same hole as is used for measuring with the dipstick.1 quart (1 liter) changes the oil level by approx. 0.4" (10 mm).
001683
1.7
Checking oil level at operating temperature Conditions: Hot range Vehicle standing level Speed range selector at N (Neutral) Engine idling (approx. 2 minutes) Transmission oil 80 - 90C / 180 - 195F The oil level must be between the upper and lower marks of the hot range. If the oil level is not between these marks, repeat check, ensuring that the cap of the dipstick is firmly located in the bayonet socket when the dipstick is inserted.
80-90C
011577
1-2
HP 502 C / HP 592 C / HP 602 C

1.8 Checking oil level when cold Conditions: Vehicle standing level Speed range selector at "N" (Neutral) Engine idling Transmission oil ca. 30C / 86F After 3 to 5 minutes running at idling speed, the oil level in the transmission must be between the upper and lower marks for the cold range. If the oil is below the lower mark, add oil immediately. Adjust the final oil level after checking again at operating temperature.
Maintenance
Cold range
approx. 30C
011577
1.9
Checking oil level with engine off Conditions: Vehicle on level ground Engine at standstill The oil level must be between the upper and lower level marks for the stationary range. If the oil level is slightly too high, do not drain off oil. This option is only available in transmissions which have a heat exchanger (attached directly) or those in which the heat exchanger is situated at a lower level than the transmission. Stationary range
(nEng = 0)
011577
1.10 Checking oil level on versions with heat exchanger higher than center line of transmission Conditions: Vehicle standing level Speed range selector in Neutral setting Run engine at 1200 to 1500 rpm for 15 to 20 seconds Then within 3 minutes, with engine idling, check oil level as described in "Checking oil level when cold" and recheck as described in "Checking oil level at operating temperature".
1-3
Maintenance
1.11 Changing oil at operating temperature Switch off engine. Drain oil through drain hole in oil pan. Unscrew filter cover and renew suction filter (see Section 2.1). Screw in drain plug (37 ft-lbs/50 Nm) and fit filter 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 valve. Pull out dipstick and pour in max. 2.65 gal. (10 liters) transmission oil. Start engine and immediately, with engine idling, slowly pour in 1 gal. (4 liters) transmission oil. Insert dipstick and check oil level as described in Checking oil level when cold (see Section 1.8). Adjust oil level if necessary.
HP 502 C / HP 592 C / HP 602 C
filter cover bolts (23 Nm)
oil drain plug 37 ft-lbs (50 Nm)

009871
011576
Run vehicle until transmission oil reaches operating temperature (180 - 195F / 80 - 90C). Check oil level at operating temperature (see Section 1.7) and adjust if necessary. Hot range
80-90C
011577
1-4
HP 502 C / HP 592 C / HP 602 C

2. 2.1 1 Overhaul Renewing filter Drain oil at oil drain plug (1) in acc. with description in Section 1.11.
Overhaul
DANGER Collect used oil in a large enough container and dispose of this in strict accordance with environmental protection legislation. Refer to general notes on threats to the environment. 2 Remove filter cover (2).
011578
Pull out old filter element (1). NOTE Check filter for contamination. 1
DANGER Dispose of contaminated filters in strict accordance with environmental protection legislation. Refer to general notes on threats to the environment.
011579
Insert new filter element (No. 0750 131 003). NOTE Filter must always be renewed. It must not be cleaned and reused.
Check that O-ring of filter (1) is still correctly seated and is undamaged. Smear O-ring with transmission oil.
008513
2-1
Overhaul
7 Renew O-ring (1) in filter cover (2).
HP 502 C / HP 592 C / HP 602 C
010483
8 9
Replace filter cover (1). Tighten four hex. bolts (2). Tightening torque: 17 ft-lbs (23 Nm) 1
011578
2-2
HP 502 C / HP 592 C / HP 602 C

2.2 1 Renewing retarder solenoid valve Disconnect cable connector (1) from solenoid valve. Unscrew two M8 hex bolts (2).
Overhaul
2 1
011580
Remove solenoid valve (1) and insert new solenoid valve with new O-ring (2).
1 2
011581
Tighten both M8x22 hex bolts. Tightening torque: 17 ft-lbs (23 Nm) Reconnect cable connector.
011580
2-3
Overhaul
2.3 1 Renewing accumulator solenoid valve Disconnect 2-core cable connector from solenoid valve. Disconnect air line. Unscrew both M8 hex bolts.
HP 502 C / HP 592 C / HP 602 C
2 3
011583
Smear new O-ring (1) with industrial grade Vaseline and insert into groove in solenoid valve. Fit valve.
011584
Tighten both M8x55 hex bolts (1) to 17 ft-lbs (23 Nm). Reconnect air line and cable connector.
011585
2-4
HP 502 C / HP 592 C / HP 602 C

2.4 1 Renewing accumulator Remove solenoid valve from accumulator (1) as described in Section 2.3. Unscrew two M8 hex bolts with nuts (2) from end of accumulator nearest transmission output.
Overhaul
011584
Remove two M8 socket-head bolts (1) from end of accumulator nearest transmission input.
011587
Smear new O-ring (1) with industrial grade Vaseline and insert into groove in accumulator. Insert accumulator. Screw in two M8x25 sockethead bolts with washers on input side and screw in two M8 hex bolts with washers on output side and tighten. Tightening torque: 17 ft-lbs (23 Nm) 1
011588
2-5
Overhaul
2.5 1 Renewing temperature sensor Release 2-core cable connector from temperature sensor. Unscrew temperature sensor.
HP 502 C / HP 592 C / HP 602 C
011589
Slide new copper sealing ring (1) onto temperature sensor. Screw in temperature sensor. Tightening torque 26 ft-lbs (35 Nm).
011590
Reconnect 2-core cable connector with marking TG(1). 1
011591
2-6
HP 502 C / HP 592 C / HP 602 C

2.6 1 Renewing output sensor Remove cover (1) from inductive sensor.
Overhaul
011592
Disconnect cables (1) on inductive sensor. They have flat-pin plugs and are to be pulled out with a straight pull.
CAUTION Use suitable pliers and pull on the plugs - not on the cables!
Screw out TORX screw (2) and remove inductive sensor.
011775
Remove O-ring (1), spacers (2) and TORX screw (3) from inductive sensor (4).
3
011776
2-7
Overhaul
5 Turn output flange until gearing (1) on planet carrier in the center of the bore for the inductive sensor becomes visible.
HP 502 C / HP 592 C / HP 602 C
011598
Introduce measuring rod 1X56 138 149 (1) into the bore of the inductive sensor and screw-tighten (2). Tightening torque: 7 ft-lbs (9.5 Nm)
Introduce measuring sensor (3) until it abuts against face-end of gearing and secure by tightening the screw (4).
Screw out fixing bolt (2) of the measuring rod and carefully pull out the measuring rod.
012901
Measure distance from front end of measuring sensor to contact surface of measuring rod holder and note down as "dimension b". b
011778
2-8
HP 502 C / HP 592 C / HP 602 C

10 Insert new inductive sensor in test fixture 1X56 138 150 and screw-tighten. Tightening torque: 7 ft-lbs (9.5 Nm)
Overhaul
011779
11
Measure distance from contact surface of inductive sensor to contact surface of inductive sensor holder and note down as "dimension c".
Inductive sensor distance "dimension a" must be between 0.02 and 0.027" (0.5 and 0.7 mm). Adjust with spacers. 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) Calculation example: 52.6 mm - 51.3 mm = 1.3 mm 1.3 mm + 0.6 mm = 1.9 mm Determined thickness "S" of spacer = 1.9 mm Spacers WTB 0769 143 377 are available from 0.80 to 6.00 mm, in steps of 0.1 mm. 1 2 3 4 5 Gearing of planet carrier Output cover of housing Inductive sensor Spacers Fixing bolt of inductive sensor
011780
5
011620
2-9
Overhaul
12 Insert TORX screw (1) and washer in bore on inductive sensor (2). Slide spacers as determined (3) onto the TORX screw and secure with Oring (4).
HP 502 C / HP 592 C / HP 602 C
1
011776
13 14
Connect cable plug (1) with inductive sensor. Insert inductive sensor and tighten with TORX screw M6x45 (2). Tightening torque: 7 ft-lbs (9.5 Nm) 1
011775
15
Renew O-ring on cover and fasten cover using two M6 hex nuts and washers. Tightening torque: 5 ft-lbs (6 Nm)
011592
2-10
HP 502 C / HP 592 C / HP 602 C

2.6.1 Renewing retarder resistor 1 Remove cover on output inductive sensor in acc. with Section 2.6 Unfasten cable plug on resistor. This is a flat-pin plug which should be pulled out in a straight line. Take out resistor.
Overhaul
CAUTION Each resistor is assigned to the relevant transmission by checking the type of retarder fitted. Each is identified 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 circumference. Example: 6029 201 6(48) = resistance of 46.40 k OTK resistance = 1.96 - 150 kW Item number 6029 201 652 6029 201 651 6029 201 650 6029 201 649 6029 201 648 6029 201 647 6029 201 646 6029 201 645 6029 201 644 6029 201 643 6029 201 642 6029 201 641 6029 201 640 6029 201 639 6029 201 638 6029 201 637 6029 201 636 6029 201 635 6029 201 634 6029 201 633 Designation Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Check on retarder fitted 150.00 k 100.00 k 75.00 k 57.60 k 46.40 k 37.40 k 31.60 k 26.10 k 22.10 k 18.70 k 15.80 k 13.30 k 11.30 k 9.31 k 7.68 k 6.34 k 5.11 k 3.92 k 2.94 k 1.96 k
012903
2-11
Overhaul
4 Connect new resistor (item number must be identical to the old resistor) and install as is shown.
HP 502 C / HP 592 C / HP 602 C
011775
2-12
HP 502 C / HP 592 C / HP 602 C

2.7 1 Removing and fitting oil pan Drain out oil and remove oil filter as described in Section 2.1.
Overhaul
011578
2 3
Remove hex bolts (1) from oil pan. Release oil pan from sealing face by tapping lightly with plastic mallet.
DANGER Beware of any oil remaining in the oil pan. Ensure that the oil pan is well supported so that it cannot fall over.
Remove oil pan.
CAUTION If the transmission is fitted with a converter drain valve, do not damage the actuation bolt (1) for the converter drain valve when taking off the oil pan. 1
011579
016072
2-13
Overhaul
5 Before fitting the oil pan, check that indented ring ZA 5 (1) is safely snapped into the groove of the actuation bolt for the converter drain valve.
HP 502 C / HP 592 C / HP 602 C
016073
Check actuation bolt (1) for converter drain valve for ease of movement.
016072
7 8
Place new gasket onto oil pan. Place oil pan onto transmission housing, insert 2 hex bolts (with steel washers) at opposite points and tighten.
011601
2-14
HP 502 C / HP 592 C / HP 602 C

9 The two hex bolts (1) at the middle of the front end of the oil pan require copper washers. Use steel washers for the rest of the oil pan bolts.
Overhaul
1
011603
10
Tighten all M8x60 hex bolts on the oil pan. Tightening torque: 17 ft-lbs (23 Nm) Insert and tighten oil drain plug as described in Section 1.
11
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
12
Renew oil filter and fill transmission with oil as described in Section 1.
011605
2-15
Overhaul
HP 502 C / HP 592 C / HP 602 C
2-16
HP 502 C / HP 592 C / HP 602 C

2.8 1 Renewing turbine sensor Remove oil pan as described in Section 2.7.
Overhaul
011579
Remove M42x2 screw plug (1).
011607
Disconnect cable connectors (1) from sensor. These are blade connectors which should be pulled off straight. Unscrew socket-head bolt (2) and remove inductive sensor 2 1
011608
2-17
Overhaul
5 Remove O-ring (1), spacers (2) and socket-head bolt (3) from inductive sensor.
HP 502 C / HP 592 C / HP 602 C
3
011776
Using a large screwdriver or similar, turn the torque converter and at the same time use a small screwdriver to find the raised points on the sensor induction ring (1).
011783
When one of these raised points is in line with the bore for the sensor, measure gap a between the sensor (3) and a raised point on the induction ring (1).
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

8 Introduce measuring rod 1X56 138 149 into the bore of the inductive sensor and screwtighten (1). Tightening torque: 7 ft-lbs (9.5 Nm) 1
Overhaul
011784
Introduce measuring sensor (1) until it is firmly wedged against the raised section of the pulse sensor ring and secure by tightening the screw (2). Screw out fixing bolt (3) of the measuring rod and carefully pull out the measuring rod. 3 2
10
011785
11
Measure distance from front end of measuring sensor to contact surface of measuring rod holder and note down as dimension b. b
011778
2-19
Overhaul
12 Insert new inductive sensor in test fixture 1X56 138150 and screw-tighten. Tightening torque: 7 ft-lbs (9.5 Nm)
HP 502 C / HP 592 C / HP 602 C
011779
13
Measure distance from contact surface of inductive sensor to contact surface of inductive sensor holder and note down as dimension c.
Inductive sensor distance a must be 0.024 - 0.03" (0.6 - 0.8 mm).
Adjust with spacers. Measuring formula: c-b=d d + a = thickness S of spacer Measuring example: Dimension c = 52.6 mm Dimension b = 50.9 mm Dimension a = 0.7 mm (0.6 - 0.8 mm) Calculation example: 52.6 mm 50.9 mm = 1.7 mm 1.7 mm + 0.7 mm = 2.4 mm Determined thickness S of spacer = 2.4 mm Spacers OTK 0769 143 377 are available from 0.8 to 6 mm, in steps of 0.1 mm.
3 1 2 4
011780
1 2 3 4 5 2-20
Sensor induction ring Mounting plate Inductive sensor Shim washers Socket-head bolt
a
011622
HP 502 C / HP 592 C / HP 602 C

14 Insert TORX screw (1) and washer in bore on inductive sensor (2). Slide spacers as determined (3) onto the TORX screw and secure with Oring (4).
Overhaul
1
011776
15
Insert inductive sensor and tighten with M6x45 socket-head screw (1). Tightening torque: 7 ft-lbs (9.5 Nm) Connect cable plug (1) to inductive sensor.
16
011610
17
Screw M42x2 screw plug into duct plate and tighten. Tightening torque: 67 - 74 ft-lbs (90 - 100 Nm)
011607
2-21
Overhaul
18 19 Fit oil pan as described in Section 2.7. Screw in oil drain plugs as described in Section 1.9.
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. 20 Renew oil filter and fill transmission with oil as described in Section 1.
011578
2-22
HP 502 C / HP 592 C / HP 602 C

2.9 Renewing complete hydraulic control module
Overhaul
CAUTION Before unscrewing cable harness from transmission, remove any dirt and dust from the area around the cable harness connector.
Release cable harness connector by turning locking ring anti-clockwise.
013480
Unscrew the two M8 hex bolts (1) with washers from the KOSTAL socket.
011624
Remove oil pan as described in Section 2.7.
011579
2-23
Overhaul
4 Use a screwdriver to snap flat connector for inductive sensor output (1) and flat connector for retarder resistance (2) off valve body and disconnect from connector bush.
HP 502 C / HP 592 C / HP 602 C
5 NOTE The sump temperature sensor is integrated in the connector (3). Only remove if necessary.. 5 Guide cable for sump temperature sensor (4) out of protective sleeve (5). 4 2 3
015825
If the transmission is fitted with an oil level display, remove protective cap (1) from connector and disconnect connector (2) from oil level electronic unit. 2 1
015826
Loosen, but do not remove, the 39 M8 torx bolts which hold the shift control module in the transmission housing.
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

8 Fully unscrew the M8 torx screws and remove shift control module.
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
When installing the shift control module, follow the above instructions in reverse order, paying attention to the following points: 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
10
The sensor clearance only needs to be reset if the shift control module is renewed.
011611
2-25
Overhaul
11 The 39 M8 torx screws which hold the shift control module are of two different lengths: 30 M8x43 screws (1) 9 M8x35 screws (2) The 9 shorter torx screws are for the recessed areas. Tighten all M8 torx screws to 17 ft-lbs (23 Nm).
HP 502 C / HP 592 C / HP 602 C
015827
12
If the transmission is fitted with an oil level display, insert connector (1) into bush of oil level electronic unit. 1 3 2
CAUTION The oil level electronic unit (2) is very sensitive and must not be bent as the connector is inserted. Hold back rear of electronic unit when inserting connector.
13
Place protective cap (3) over connector on oil level electronic unit. NOTE Protective cap must be snapped into place.
015828
14
Connect flat connectors onto side of shift control unit as shown. 1 Inductive sensor output connector 2 Retarder resistance connector 3 Sump temperature sensor NOTE The sump temperature sensor is integrated in the connector (3). 1 2 3
5 4
15
Insert temperature sensor cable (4) in protective sleeve (5).
015825
2-26
HP 502 C / HP 592 C / HP 602 C

16 Insert connector socket into recess in housing and screw in both M8x20 hex bolts with washers. Tightening torque 17 ft-lbs (23 Nm).
Overhaul
011624
17
Measure sensor clearance as described in Section 2.8, screw in sensor with new shim washers and reconnect cables.
011607
18
Fit oil pan and new filter as described in Section 2.7.
011578
2-27
Overhaul
2.10 Changing complete oil level display Remove oil pan and transmission control unit in accordance with sections 2.7 and 2.9. Installation position of complete oil level display (1).
HP 502 C / HP 592 C / HP 602 C
015829
Unscrew two M6 Torx bolts (1) on oil level electronic unit.
CAUTION Handle oil level electronic unit with care. It is very sensitive to impact. 1
015830
Unscrew two M6 Torx bolts (1) and take out oil level indicator complete with retaining plate, sensor and oil level electronic unit. NOTE Do not unfasten M6 Torx bolt (2).
015831
2-28
HP 502 C / HP 592 C / HP 602 C

3 When installing a new oil level sensor (i.e. not yet set), straighten the retaining section (1) out from the retaining plate (2) and sensor (3).
Overhaul
2 3
015832
Insert new oil level sensor (i.e. not yet set and not secured) complete with retaining plate and use 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 connection are each fitted with two O-rings for damping. Check that O-rings are seated properly.
1 3 2 4
1 2 3 4 5 6 7
Torx bolt Washer 9x2.5 O-ring Retaining plate 14x2.5 O-ring Bush O-ring for fastening
5 6
Length X = 5.0 +3 mm
015834
2-29
Overhaul
5 Unfasten M6x16 Torx bolt (1).
HP 502 C / HP 592 C / HP 602 C
1 6 Correct setting length of oil level sensor between face end on sensor and housing sealing face.
015833
CAUTION Setting lengths are different depending on the parts list. Take the correct setting length from the parts list.
Example: Oil level indicator parts list 4149 043 005 Setting length X = 0.62 0.02" (15.7 0.5 mm) 7 Once the sensor is set, tighten the M6x16 Torx bolt (1) on the holder and secure correct installation position. Tightening torque: 7.5 ft-lbs (10 Nm)
015835
Length X
Remove complete oil level indicator again. Insert safety section (1) in suitable bore on holder and secure oil level sensor by bending the retaining section through 90. 2 1
015832
2-30
HP 502 C / HP 592 C / HP 602 C

9 Reinsert secured oil level sensor and use two M6x30 Torx bolts (1) to screw into place. Tightening torque: 7 ft-lbs (9.5 Nm) Check sensor installation length X again.
Overhaul
gt Len
hX
10
015831
11
Use two M6x30 Torx bolts (1) to screw oil level electronic unit into place as shown. Tightening torque: 7 ft-lbs (9.5 Nm)
CAUTION Handle oil level electronic unit with care. It is very sensitive to impact.
015830
2-31
Overhaul
2.11 Renewing pulse sensor 1 Unscrew pulse sensor (1).
HP 502 C / HP 592 C / HP 602 C
011635
Smear threads of new pulse sensor with transmission oil.
011636
Screw in new pulse sensor. Tightening torque: 26 ft-lbs (35 Nm)
011637
2-32
HP 502 C / HP 592 C / HP 602 C

2.12 Renewing output flange and/or shaft seal 1
Overhaul
Remove lock plate from output flange (1).
DANGER Wear eye protection, metal chips may fly out.
011638
Unscrew both M12 hex bolts from output shaft. NOTE When unscrewing bolts, use a suitable lever to prevent output flange from turning.
Remove clamping plate (1). If necessary, release by tapping with plastic mallet
011639
Pull off output flange using a standard 2-arm puller. NOTE Protect end of output shaft with a washer or similar.
011640
2-33
Overhaul
5 Pull shaft seal off input shaft using a suitable tool.
HP 502 C / HP 592 C / HP 602 C
CAUTION Take care not to damage seal bore while pulling out seal.
012273
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
Wet outer edge of shaft seal with lubricant (e.g. liquid detergent concentrate/washing-up liquid).
CAUTION Do not use grease or transmission oil on outside of seal or leaks may result. 8 Drive in shaft seal until tool abuts against bearing.
011643
2-34
HP 502 C / HP 592 C / HP 602 C

NOTE Correct seal insertion depth of 0.590.04 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. 9 Pack the space between the sealing lip and the dust lip with grease.
Overhaul
001654
10
Heat output flange to 210 to 230F (100 110C).
CAUTION Do not heat output flange over 230F (110C) or seal will be damaged.
DANGER Always wear protective gloves when handling hot output flange. NOTE Insert hex bolts before fitting flange if necessary. 11 Screw gripper 1X56 103 755 onto output shaft, attach output flange and use tightening tool 1X56 136 512 to tighten until firmly home.
011645
CAUTION Never knock output flange into place. 12 Coat sealing face (flat face without bevels) of pressure washer (1) with sealing compound (WEVO L100 produced by WEVOCHEMIE) and attach on flange.
011646
2-35
Overhaul
13 Smear bolt heads of the M12x30 hex bolts on their underside with sealing compound (WEVO-L100 produced by WEVOCHEMIE), screw in and tighten. Tightening torque: 44 ft-lbs (60 Nm) NOTE Always use new hex bolts here.
HP 502 C / HP 592 C / HP 602 C
011647
14
Drive lock plate over M12 hex bolts using tool 1X56 136 471 until lock plate is in firm contact with clamping plate.
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. 15 Reconnect propeller shaft. Tighten hex bolts in accordance with vehicle manufacturers instructions.
011649
2-36
HP 502 C / HP 592 C / HP 602 C

2.13 Pressure tests Pressure tests with transmission installed in vehicle: 1 Set up the pressure measurement connections intended for the test. Unfasten screw plug and screw in test pressure gauge. Test pressure gauge 1PO1 136 670 (up to 25 bar) Test pressure gauge 1PO1 137 856 (up to 10 bar) 1 = Main pressure PH 2 = Throttle pressure PD1 3 = Pressure before converter PD2 4 = Pressure after heat exchanger PD6 PD7* 5 = Retarder pressure PR3 6 = Retarder control pressure PRR3 * (4) for Retarder "ON" = PD6 * (4) for Retarder "OFF" = PD6 PD7 = Lubricating oil pressure
Overhaul
1 6
2
011650
2 3
Conduct pressure test in acc. with following table. After finishing pressure tests, remove test pressure gauges. Fit in screw plugs with new copper seal rings. Tightening torque: 9 ft-lbs (12 Nm)
011651
2-37
Overhaul
Pressure table: A = Normal main pressure B = Higher main pressure for engines more powerful than 1036 ft-lbs (1400 Nm) Pressure measurement: 1 = Main pressure PH 2 = Throttle pressure PD1 (PD1 = no current = 10 bar) Pressure table NORMAL MAIN PRESSURE
Load Idling Idling Full load Full load Idling Idling Full load Full load N N
Engaged
HP 502 C / HP 592 C / HP 602 C

3 = Pressure before converter PD2 4 = Pressure after heat exchanger PD6 PD7* * for Retarder "ON" = PD6 * for Retarder "OFF" = PD6 PD7 = Lubricating oil pressure 5 = Retarder pressure PR3 6 = Retarder control pressure PRR3 7 = Oil temperature toil neng = Engine speed WK = Lock-up clutch
1 M 10x1 toil (C)
20 - 40 20 - 40 20 - 40 20 - 40 80 - 90 80 - 90 80 - 90 80 - 90
2 M 10x1 PD1 (bar)

40,3 0.2 - 1.0 for 2 sec. 40,3 40,3 40,3 0.2 - 1.0 for 2 sec. 40,3 40,3
3 M 10x1 PD2 (bar)

4.0 - 5.5 4.0 - 5.5 6.0 - 8.5 6.0 - 8.5 3.0 - 4.5 3.0 - 4.5 6.0 - 8.5 6.0 - 8.5
4 M 10x1 PD6/D7 (bar)

0.8 - 1.8 0.8 - 1.8 1.8 - 2.5 1.8 - 2.8 0.1 - 0.8 0.1 - 0.8 1.8 - 2.5 1.8 - 2.5
5*/6*
M 10x1 PR3/PRR3 (bar)
Gear N D
WK
neng
(min-1)
PH (bar)
7 - 15 7 - 15 18 - 21 10 - 12 7 - 15 7 - 15 16 - 20 10 - 12
open open open closed open
700 550 2000-2500 2000-2500 700 550 2000-2500 2000-2500
N N
open open closed
Engaged
* 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.
Pressure table HIGHER MAIN PRESSURE

Load Idling Idling Full load Full load Idling Idling Full load Full load N N
Engaged
1 M 10x1
2 M 10x1 PD1 (bar)

40,3 0.2 - 1.5 for 2 sec. 40,3 40,3 40,3 0.2 - 1.5 for 2 sec. 40,3 40,3
3 M 10x1 PD2 (bar)

4.0 - 5.5 4.0 - 5.5 6.0 - 8.5 6.0 - 8.5 3.0 - 4.5 3.0 - 4.5 6.0 - 8.5 6.0 - 8.5
4 M 10x1 PD6/D7 (bar)

0.8 - 1.8 0.8 - 1.8 1.8 - 2.5 1.8 - 2.8 0.1 - 0.8 0.1 - 0.8 1.8 - 2.5 1.8 - 2.5
5*/6*
M 10x1 PR3/PRR3 (bar)
Gear N D
WK
neng
(min-1)
toil (C)
20 - 40 20 - 40 20 - 40 20 - 40 80 - 90 80 - 90 80 - 90 80 - 90
PH (bar)
13 -22 13 - 22 21 - 25 12 - 16 10 - 17 10 - 17 21 - 24 12 - 15
open open open closed open
700 550 2000-2500 2000-2500 700 550 2000-2500 2000-2500
N N
open open closed
Engaged
*Values are shown in the relevant parts list or may be obtained from ZF.
2-38
warm
cold
warm
cold
HP 502 C / HP 592 C / HP 602 C

3 3.1 Troubleshooting Terminal tester concept 25-, 55-, 68-pin EST electronic control unit
Troubleshooting
68-pin terminal tester 6008 006 002 (1) *6008 199 001 contains (1) (2) (3)
55-pin terminal tester 1P01 137 834
can no longer be supplied
68-pin - 55-pin reduction adapter cable *6008 004 024 (2) from vehicle power supply to Buka *6008 004 025 (3) from Buka to EST plug
55-pin - 25-pin reduction adapter cable
6008 004 026 bush 6008 004 027 plug
68-pin electronic control unit EST 31 EST 37 EST 45 EST 46 EST 47 AS Tronic WG T 7000 Ecomat 2 Ecomat 2
55-pin electronic control unit EST 14 AVS EST 15 Retarder EST 18 Ecomat
25-pin electronic control unit EST 32 Intarder
3-1
Troubleshooting
3.2 a)
!
HP 502 C / HP 592 C / HP 602 C
1PO1 138 153 test cable Insert Kostal plug of test cable into Kostal socket on transmission. CAUTION Do not apply voltage to emergency cut-off switch (yellow sockets) or to inductive sensor (green sockets), or the switch or sensor will be short-circuited and irreparably damaged. If the switch is damaged, the transmission must be removed from the vehicle
DANGER Only use test cable with vehicle stationary and engine off.
Table for checking model of retarder fitted Item number 6029 201 652 6029 201 651 6029 201 650 6029 201 649 6029 201 648 6029 201 647 6029 201 646 6029 201 645 6029 201 644 6029 201 643 6029 201 642 6029 201 641 6029 201 640 6029 201 639 6029 201 638 6029 201 637 6029 201 636 6029 201 635 6029 201 634 6029 201 633 Designation Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Retarder check 150.00 k W 100.00 k W 75.00 k W 57.60 k W 46.40 k W 37.40 k W 31.60 k W 26.10 k W 22.10 k W 18.70 k W 15.80 k W 13.30 k W 11.30 k W 9.31 k W 7.68 k W 6.34 k W 5.11 k W 3.92 k W 2.94 k W 1.96 k W CAUTION Each resistor is assigned to the relevant transmission by checking the type of retarder fitted. Each is identified 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.
3-2
HP 502 C / HP 592 C / HP 602 C

b) Resistance measurements: Measure resistance of solenoid valve coils and inductive sensors, see list below.
Troubleshooting
On solenoid valves the resistance value rises with rising temperature. On the temperature sensor B14 the resistance value drops with rising temperature. Ohmmeter Nominal readings approx. 67 4 W approx. 67 4 W approx. 67 4 W approx. 67 4 W approx. 67 4 W approx. 67 4 W approx. 67 4 W approx. 67 4 W approx. 67 4 W approx. 8,6 0,5 W
NOTE: Resistance values may change with rising or dropping temperatures.
Test specimen
Brakes, A4 Clutches, Inductive sensors, Marking Pin Resistance Clutch A Clutch B1 Clutch B2 Brake D Brake E Brake F Brake G / F2 Clutch WK Retarder D1 valve n Output Retarder recognition Oil level display Sump temperature n Turbine A B C D E F G WK RET D1 nAB RET.K Oil TG nT 13 12 11 22 24 19 6 9 8 10 2 18 23 4 1
Solenoid valve Y17 Solenoid valve Y16 Solenoid valve Y15 Solenoid valve Y14 Solenoid valve Y13 Solenoid valve Y12 Solenoid valve Y11 Solenoid valve Y18 Solenoid valve Y19 D1Prop.-solenoid Y20 Inductive sensor B11 Retarderresistor B16 Oil level sensor B15
at 20C at 20C at 20C at 20C at 20C at 20C at 20C at 20C at 20C at 20C
approx. 850 100 W at 20C * 1.96 to 150 kW ** PWM %, VPE 5 Volt approx. 125 5 kW at 20C approx. 850 100 W at 20C
Temp. sensor B14
Inductive sensor B12
Tolerance and characteristics temperature sensor see next page
Ground/earth Ground/earth Ground/earth
GM1 GM2 VM1 VM2
15 17 21 20
* see table for checking model of retarder fitted ** no resistance measurements must be carried out
3-3
Troubleshooting
Temperature sensor NTC - Sensor B14 Thermometrics DKS 4261 2 elements in series Table of tolerance - 20C bis 150C
HP 502 C / HP 592 C / HP 602 C

Temp. 2*Rt [C] [Ohm] -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 957796 720948 547652 419668 324282 252580,6 198235,8 156760,6 124765,8 99991 80649,2 65448,2 53425,2 43857 36197,6 30031,2 25040 20978,6 17657 14927,6 12674 10804,8 9248 7945,8 6852 5929,8 5149,4 4486,4 3921,6 3438 3023,2 2666,2 2357,8 2090,8 1858,8 2*Rt (min) 2*Rt (max) [Ohm] [Ohm] 896080,6 1023353,4 676412 768108 515240,8 581880,2 395880 444708 306690,8 342746 239476,2 266295,4 188407 208494 149700,6 164443,6 119130 130615,8 95685,8 104448 77343 84063,2 62896,4 68076,4 51446,4 55457,8 42316 45435,8 34992,8 37428,8 29086 30994,8 24296 25796,4 20391,2 21574 17192,4 18127 14559,2 15299,2 12381,4 12968,2 10572,4 11038,2 9063 9433 7775 8117 6694,8 7010 5785,4 6075,4 5017 5283,2 4365 4609,4 3810 4034,2 3336 3541,6 2929,8 3118,4 2580,6 2753,6 2279,4 2438,2 2018,8 2164,6 1792,8 1926,8
Characteristics Resistance/Temperature
100000 90000 80000 70000 60000 50000 40000 30000 20000 10000 0 20 30 40
2 elements in series DKS 4261 (2*in Reihe)

2*Rt [Ohm]
Resistance Widerstand [Ohm]
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
Installation and menus
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
6008 758 103
ZF-Diagnostic tool Testman
Contents
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents of the Testman diagnosis software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testman software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of the diagnosis software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting up a programming tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPA 04 I description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPA 04 I programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting a COM port .....................................................................
4 5 6 6 7 8 9 9 10 11 11 12 13 14 14 15 15 16
Starting the Testman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testman screen display Start-up logo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen display of the product menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents of the product menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen display of the repair aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents of the repair aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface

This manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF product in accordance with the state of development on the date of issue. However, due to continuing development of the product, repair work might require work practices and test or adjustment data not contained in this manual. We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training centers. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually trained personnel 2. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out conscientiously and with utmost care. Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case. ZF FRIEDRICHSHAFEN AG C.V ./Special Transmissions Service Plant 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726 Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.

SAFETY NOTICE
Safety notice
Companies repairing ZF units are responsible for their own work safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations. Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.
The following safety instructions appear in this manual:
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.
Contents of Testman / System components
ZF Testman electronic diagnosis
Aids to repair work
Diagnosis
Test inputs and outputs System check at standstill System check in motion Test equipment Analogue displays, speeds, currents etc.
Vehicle configuration
Telephone directory
Tightening torques Adjustment data Special tools/test equipment Maintenance Repairs Pressures Circuit diagrams Electrical measuring values
Reading error memory Deleting error memory Identification block
Viewing the vehicle data Copying vehicle data Modifying /extending vehicle data
Telephone directory of all people in the Technical Service, arranged by product
ZF Testman diagnostic tool Order numbers: Order number Designation Testman software on diskette DPA 04 I diagnostic adapter 6008 208 004 RS 232 cable Installation instructions ISO cable SAE cable Item number 6008 308 901 6008 308 600 6008 308 601 6008 758 703 0501 211 103 0501 211 104 6008 208 003 Order number
6008 308 900
Batch number for diagnosis software on diskette. You can obtain further information about the desired diagnosis software from your ZF Service Center.

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. 2. 3. 4. 5. 6. 7. Insert the Testman 1 diagnosis software in the disk drive (e.g. A). Use the Start symbol (Windows interface) and pull up the Run command. The Run window is opened. Use your mouse to click on Search. Select the drive (e.g. A). The contents of the diskette are now displayed. Select the Testman Setup program and follow the instructions in the software.
Testman software installation
1
015917
1 Testman software on diskettes Order No.: 6008 308 901
The Testman installation process is now complete. NOTE The Testman is available in English and German. These languages only have an effect on system reactions (not on the diagnosis software).
Additional settings
Start the Testman. The first time you open the program, ZF ISO Man Properties appears on screen. Here you should select the correct COM port on your PC and confirm 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.

NOTE Communication is not possible unless you have selected the correct COM port.
015911
1. 2.
Click on the Testman icon with your right mouse button. Select Properties.
3. 4.
Select the program and select Close on completion. Accept and confirm with OK.
015948

Installation of the diagnosis software 1. 2. 3. 4. 5. 6. 7. 8. Insert the diagnosis software in the disk drive (e.g. A). Use the Start symbol (Windows interface) and pull up the Run command. The Run window is opened. Use your mouse to click on Search. Select the drive (e.g. A). The contents of the diskette are now displayed. Depending on the drive, select Install or d. Use your mouse to click on OK. This installs the diagnosis software.
Installation of the diagnosis software Connecting up a programming tool
1
015916
1. Diagnosis software on diskette Order No. 6008 308 900 NOTE You can obtain more detailed information about your choice of diagnosis software from your nearest ZF Service Center.
The installation process is now complete.
Connecting up a programming tool 1. Connect COM port (1) and DPA 04 I adapter (3) using an RS 232 cable (2). Connect an ISO or SAE cable (4) to the appropriate port (ISO 9141 / SAE S1708) on the DPA 04 I adapter and connect to the electronic control unit in the vehicle. 1 3
2.
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
DPA 04 I description
Description of the DPA 04 I diagnosis and programming adapter The DPA 04 I features three interfaces, V-24, RS 232, ISO 9141 and SAE J1708. The RS 232 communicates between the DPA 04 I and a laptop computer. The ISO 9141 and SAE J1708 communicate between the DPA 04 I and the control unit. Appropriate adapter cables are required for the ISO and the SAE interfaces. The same adapter cables as the DPA 02/03 can be used (pins compatible with the ISO interface). Here are the three basic operating modes of the DPA 04 I: 4. 1. Data transmission via ISO interface and control unit. Data transmission via SAE interface and control unit. Interface converter between MobiDig 2001/200 and SAE control unit. 5. 2. Front panel 1.
LED L line Lights up whenever data have to be transferred on the L line. LED data Lights up whenever data have to be transferred on the K line. LED Ubatt Lights up when the vehicle circuit voltage lies between 12 24 V . NOTE: In SAE mode, dependent upon switch setting KL15ECU UPRG switch OFF setting: programming voltage not present ON setting: programming voltage present. NOTE Always ensure the Testman is in the OFF position when working on it.No communication is possible if the switch is in the wrong position. KL15ECU switch This switch is not relevant in ISO mode.
3.
2.
3.
10

The DPA 04 I has a Flash Prom which is supplied with Testman functions.
DPA 04 I programming Selecting COM port

In the event of the DPA 04 I drive losing data, proceed in accordance with the following instructions in order to restore Testman functionality.
015908
1. 2. 3.
Quit the Testman. Connect DPA 04 I to the laptop. Connect the DPA 04 I to the power supply using an ISO or SAE cable.
4. 5.
Select directory/folder GDS 3000 / dpaload using the drive (C or D). Start dpa4.bat batch processing. This loads the Testman functions for the DPA 04 I. This process lasts approximately 1 minute. Open the text editor from the Start bar. Open \GDS3000\dpaload\bload166.cfg. You can enter the correct COM port here (see arrow). Save and close.
NOTE The download software is usually set to COM 1 (i.e. default setting). If your laptop has a different COM port, adapt the setting as follows:
1. 2. 3. 4.
015947
11
Starting the Testman

Symbols and switch surfaces
End Testman
Selection of application

Help
Print Return System
Continue Start

012290/013809/013810/013811
Starting the Testman 1. 2. Double-click the Testman icon on your desktop to start the program. If the Testman has been started successfully, you will see a menu with 3 items: File - for exiting the Testman Pal2Application - for selecting the application Help To load an application, use the mouse to click on the "Pal2Application". A selection bar opens containing the menu item "Run". Click on "Run". The "Run Pal2Application" window is opened. Click on "Select".
8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
The "Open" window is opened. Select the transmission application. Click on "Open". The "Open" window is closed and the "Run PAL2Application" window is opened. Click on "Run". Now the Testman start-up logo "ZF Service" appears. Click on "Continue". The product menu appears. Use the mouse to select the menu item you want (line is highlighted). Press the "Enter" key on the PC or use the mouse to click on "Continue".
3. 4. 5. 6. 7.
12
Start-up logo

Continue

Select "Run" under RUN PAL2Application Press the "Enter" key on the PC or use the mouse to click on the symbol "continue"
The start-up logo "ZF Service" appears
The product menu appears
13
Product menu / Contents

Continue

Mark menu point using the mouse Press the "Enter" key on the PC or use the mouse to click on the symbol "Continue"
Menu point is marked Menu point appears
Maintenance, tightening torques, special tools / test equipment, repairs, circuit and wiring diagrams, pressures and electr. measuring values.
System check: vehicle in motion. Check of all system components which can be tested when vehicle is in motion. Errors are described on the screen when exiting the function test.
Test equipment. Product-specific. Product-specific. Reading/deleting error memory. Identification block. System check: Vehicle at standstill. Check of all system components which can be tested when vehicle is at standstill. Errors are described on the screen when exiting the function test. Vehicle-specific data. Such as customer sheets, vehicle data etc. ZF contacts. Telephone directory of all people in the Technical Service, arranged by product. Analogue display: Such as speeds, currents etc.
14
Repair aid / Contents

Continue

Mark menu point using the mouse Press the "Enter" key on the PC or use the mouse to click on the symbol "Continue"
Menu point is marked Menu point appears
Oil change intervals, types of oil (ZF list of lubricants), oil quantities, oil changes, oil fills (figure) and product-specific maintenance information. ZF standard 148 and product-specific tightening torques. Product-specific. All tools required for work on the vehicle are shown as pictures with their ZF nos. Product-specific. Example: Description of how to change the inductive sensor.
Product-specific. Product-specific. Product-specific. Example: Voltages and resistance. Previous menu is displayed.
15
Technical data
System prerequisites for your PC Windows 95 / 98 or Windows NT 4.0 Pentium RAM Free disk space Disk drive Serial port 90 MHz 16 MB / NT 4.0 32 MB 20 MB 3 1/2 COM 1 or COM 2 Electrostatic compatibility

Technical data for the DPA 04 I Operating voltage 12 24 volts
Operating temperature range 0 to 50 C Storage temperature range Humidity Electromagnetic compatibility -20 to +60 C 10 90% 801000 MHz AM 1kHz 80%
4 kV on contact, and 8 kV with no contact
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
DETAIL X
AUSFUEHRUNG HAUPTDRUCKVENTIL MIT DRUCKABSENKUNG 2 NEBENATRIEBE MOEGLICH PTO'S CAN BE FITTED WK D2 VERSION MAIN PRESSURE VALVE WITH PRESSURE REDUCER
4 GANG 4 GEAR
RUECKWAERTS REVERSE NEUTRAL 1. GANG 1st GEAR 2. GANG 2nd GEAR 3. GANG 3rd GEAR 4. GANG 4th GEAR
i = 2.81 BIS 1.0 3.43 BIS 1.0

TO
WK
B 1 = INNERE KOLBENFLAECHE KUPPLUNG B INNER PISTON FACE CLUTCH B B 2 = AEUSSERE KOLBENFLAECHE KUPPLUNG B OUTER PISTON FACE CLUTCH B F 1 = AEUSSERE KOLBENFLAECHE BREMSE F OUTER PISTON FACE BRAKE F B2 F 2 = INNERE KOLBENFLAECHE BREMSE F INNER PISTON FACE BRAKE F
B1
B2
F1
F2
5 - &. 6 GANG 5 - & 6 GEAR

C C WANDLERENTLEERVENTIL CONVERTERPURGE VALVE SPEICHER ACCUMULATOR A8 B2 RUECKWAERTS REVERSE NEUTRAL 1. GANG 1st GEAR 2. GANG 2nd GEAR 3. GANG 3rd GEAR 4. GANG 4th GEAR 5. GANG 5th GEAR 6. GANG 6th GEAR WAERMETAUSCHER OIL COOLER TEMP.MESSSTELLE TEMPERATUR SWITCH SENSOR SCHMIERDRUCKVENTIL LUBRICATING PRESSURE VALVE
i = 2.81 BIS 0.8 / 3.43 BIS 0.83 3.43 BIS 0.59 TO TO
WANDLERSICHERHEITSVENTIL CONVERTER SAFETY VALVE E D2 F1 F1-VENTIL F1 F X D2 F2-VENTIL F2 HAUPTDRUCKVENTIL MAIN PRESSURE VALVE RETARDERREGELVENTIL RETARDER CONTROL VALVE R3 RR3
WANDLERGEGENDRUCKVENTIL CONVERTER COUNTERPRESSURE VALVE
D4 R3
D6
D5
D7
KUEHLERUMSCHALTVENTIL COOLER CHANGEOVER VALVE
D8 D1 P
D8
R1
D9
R2
RETARDER
D1 A2
PRIMAERPUMPE PRIMARY PUMP
P DROSSELDRUCKVENTIL THROTTLE PRESSURE VALVE A1
SAUGFILTER SUCTION FILTER
011867
4-1
HP 502 C / HP 592 C / HP 602 C
Hydraulic circuit diagram with NBS 4149 700 026/2
A
NA DETAIL X AUSFUEHRUNG HAUPTDRUCKVENTIL MIT DRUCKABSENKUNG 2 NEBENABTRIEBE MOEGLICH PTO'S CAN BE FITTET WK D2 VERSION MAIN PRESSURE VALVE WITH PRESSURE REDUCER
B1 B2
F1 F2
4 GANG 4 GEAR
RUECKWAERTS REVERSE NEUTRAL NEUTRAL NBS 1. GANG 1st GEAR 2. GANG 2nd GEAR 3. GANG 3rd GEAR 4. GANG 4th GEAR
i = 2.81 BIS 1.0 3.43 BIS 1.0 TO

* *
WK
B1 = INNERE KOLBENFLAECHE KUPPLUNG B INNER PISTON FACE CLUTCH B B2 = AEUSSERE KOLBENFLAECHE KUPPLUNG B OUTER PISTON FACE CLUTCH B
B2 B1
F 1 = AEUSSERE KOLBENFLAECHE BREMSE F OUTER PISTON FACE BRAKE F

P
F 2 = INNERE KOLBENFLAECHE BREMSE F INNER PISTON FACE BRAKE F

* = REDUZIERTER DRUCK
A
C C B2
B2
F1 F2
5 - &. 6 GANG 5 - & 6 GEAR

WANDLERENTLEERVENTIL CONVERTERPURGE VALVE
SPEICHER ACCUMULATOR A8
i = 2.81 BIS 0.8 / 3.43 BIS 0.83 3.43 BIS 0.59 TO TO
RUECKWAERTS REVERSE NEUTRAL NEUTRAL NBS 1. GANG 1st GEAR 2. GANG 2nd GEAR 3. GANG 3rd GEAR 4. GANG 4th GEAR 5. GANG 5th GEAR 6. GANG 6th GEAR
*
*
WANDLERSICHERHEITSVENTIL CONVERTER SAFETY VALVE E D2
WANDLERGEGENDRUCKVENTIL CONVERTER COUNTERPRESSURE VALVE
WAERMETAUSCHER OIL COOLER
TEMP .MESSSTELLE TEMPERATUR SWITCH SENSOR
SCHMIERDRUCKVENTIL F1 VENTIL F1 F X D2 RETARDERREGELVENTIL RETARDER CONTROL VALVE R3 D4 R3 D6 D5 D7 LUBRICATING PRESSURE VALVE RR3
F2 VENTIL F2
HAUPTDRUCKVENTIL MAIN PRESSURE VALVE
D8 D1 P G P P D9 R2
D8
KUEHLERUMSCHALTVENTIL COOLER CHANGEOVER VALVE
R1
RETARDER
D1
PRIMAERPUMPE PRIMARY PUMP A2
P DROSSELDRUCKVENTIL THROTTLE PRESSURE VALVE A1
SAUGFILTER SUCTION FILTER
011938
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
015811
4-7
HP 502 C / HP 592 C / HP 602 C
015810
4-9
HP 502 C / HP 592 C / HP 602 C
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 2 3
,
Wandler Torque converter Momentomvandlare Koppelomvormer Retarder Retarder Retarder Retarder Wandler-Sicherheitsventil Torque converter safety valve Momentom-vandlarens Skerhetsventil Koppel-omvormerVeiligheidsventiel Druckspeicher Accumulator Ackumulator Drukreservoir Khler-Umschaltventil Cooler changeover valve Omkopplingsventil kylare Koeleromschakelventiel Wrmetauscher Heat exchanger Vrmevxlare Koeler Schaltgetriebe Planet gear train Automatvxellda Transmissie WK-Ventileinheit WK valve unit Ventilenhet WK WK-ventielunit Magnetventil Solenoid valve Magnetventil Magneetventiel Drucksteuerventil Pressure control valve Tryckregleringsventil Drukregelventiel Ausschaltventil Shutoff valve Urkopplingsventil Afschakelventiel Ventileinheit Kupplung/Bremse valve unit Clutches/Brakes Ventilenhet Lamellkoppling ventielunit Koppeling\Rem Magnetventil Solenoid valve Magnetventil Magneetventiel Drucksteuerventil Pressure control valve Tryckregleringsventil Drukregelventiel Ausschaltventil Shutoff valve Urkopplingsventil Afschakelventiel Kupplung/Bremse A, B, C, D, E, F, G Clutches/Brakes Lamellkoppling Koppeling\Rem Retarderregelventil Retarder control valve Retarderstyrventil Retarderregelventiel Hauptdruckventil Main pressure valve Huvudtryckventil Hoofddrukventiel Filter Filter Filter Filter Pumpe Pump Pump Pomp Schmierdruck Lubrication pressure Smrjoljetryck Smeerdruk Wandlergegendruck Converter counterpressure Momentomvandlarens mottrycksventil Koppelomvormertegendruk Drosseldruckventil Throttle pressure valve Tryckmoduleringsventil Modulatiedrukventiel Luft Air Luft Lucht
4 5
4 4
# #
)&
7 8
4!

2
289 4!
!
8.1 8.2 8.3
$
9 9.1
,&
22
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44!
%
& "
9.2 9.3 10 11 12
' ' '
&
& &
25+0
$
13 14 15
017 728
&!
'!
, 2
%
16 17 18
,
)&
Technische nderungen vorbehalten Subject to technical change without notice Rtt till tekniska ndrigar frbehlles Technische veranderingen voorbehouden
HYDRAULIC 2
Einschaltstellung Position locked Lge till Inschakelstand
ZF FRIEDRICHSHAFEN AG
4149 753 702 MC-C 08.2002
1 2 3
,
Wandler Torque converter Momentomvandlare Koppelomvormer Retarder Retarder Retarder Retarder Wandler-Sicherheitsventil Torque converter safety valve Momentom-vandlarens Skerhetsventil Koppel-omvormerVeiligheidsventiel Druckspeicher Accumulator Ackumulator Drukreservoir Khler-Umschaltventil Cooler changeover valve Omkopplingsventil kylare Koeleromschakelventiel Wrmetauscher Heat exchanger Vrmevxlare Koeler Schaltgetriebe Planet gear train Automatvxellda Transmissie WK-Ventileinheit WK valve unit Ventilenhet WK WK-ventielunit Magnetventil Solenoid valve Magnetventil Magneetventiel Drucksteuerventil Pressure control valve Tryckregleringsventil Drukregelventiel Ausschaltventil Shutoff valve Urkopplingsventil Afschakelventiel Ventileinheit Kupplung/Bremse valve unit Clutches/Brakes Ventilenhet Lamellkoppling ventielunit Koppeling\Rem Magnetventil Solenoid valve Magnetventil Magneetventiel Drucksteuerventil Pressure control valve Tryckregleringsventil Drukregelventiel Ausschaltventil Shutoff valve Urkopplingsventil Afschakelventiel Kupplung/Bremse A, B, C, D, E, F, G Clutches/Brakes Lamellkoppling Koppeling\Rem Retarderregelventil Retarder control valve Retarderstyrventil Retarderregelventiel Hauptdruckventil Main pressure valve Huvudtryckventil Hoofddrukventiel Filter Filter Filter Filter Pumpe Pump Pump Pomp Schmierdruck Lubrication pressure Smrjoljetryck Smeerdruk Wandlergegendruck Converter counterpressure Momentomvandlarens mottrycksventil Koppelomvormertegendruk Drosseldruckventil Throttle pressure valve Tryckmoduleringsventil Modulatiedrukventiel Luft Air Luft Lucht
4 5
4 4
# #
)&
7 8
4!

2
289
!
8.1 8.2 8.3
4! 44!
$
9 9.1
,&
22
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& "
9.2 9.3 10 11 12
% ' & ' '!

, 2
&
25+0
$
13 14 15
017 727
&!
%
16 17 18
,
)&
Technische nderungen vorbehalten Subject to technical change without notice Rtt till tekniska ndrigar frbehlles Technische veranderingen voorbehouden
HYDRAULIC 1
Ausschaltstellung Position opened Lge frn Uitschakelstand
ZF FRIEDRICHSHAFEN AG
4149 753 701 MC-C 08.2002
3
DB 250 PF Series
DRIVE SHAFTS
Contents
CONTENTS
Page
Date
1. GENERAL .................................................................................................. 1-1 .............. 0145 1.1 General information .......................................................................... 1-1 .............. 0145 1.2 Inspection ......................................................................................... 1-2 .............. 0145 2. REMOVAL AND INSTALLATION ............................................................... 2-1 .............. 0145 2.1 Drive shaft assembly ........................................................................ 2-1 .............. 0145 2.2 Drive flange ....................................................................................... 2-2 .............. 0145 2.3 Spider ............................................................................................... 2-3 .............. 0145
0145
DRIVE SHAFTS
Contents
3
DB 250 PF Series
0145
3
DB 250 PF Series
DRIVE SHAFTS
General
1. GENERAL
1.1 GENERAL INFORMATION Do not use high pressure when lubricating the lubrication points. The grease gun must be used evenly and smoothly. The drive shafts slip joint must not be cleaned using a high pressure hose or steam. If in doubt, the drive shaft should be lubricated after it has been cleaned. If no grease appears to escape from one or more bearings when lubricating the lubrication points, then the relevant spider must be replaced together with the bearings. The drive flanges on a new drive shaft have a protective coating. If this coating does not have any dirt on it, then it does not have to be removed before assembly. The drive flanges should be free of dirt before assembly. Only use a lubricant that satisfies the specifications given. Do not use any lubricant that contains Mos2. During anti-corrosion treatment, the slip joint must be completely covered.
0145
1-1
DRIVE SHAFTS
General
3
DB 250 PF Series
1.2 SERVICE The drive shaft should be inspected according to the intervals below. 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.
1.2.1 Small service 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 and are fitted correctly. Check whether the bearing/coupling components show signs of heating (discolouring of the material or burnt sealing rings). Check the O-rings on the bearing bushes and the slip joint visually and by seeing how much lubricant has been used. Check whether the grease nipples are still present. Check their condition. Check the visible plastic guide coating on the slip joint for damage. Check the drive shaft for rust, distortion and other damage. If there is excessive noise or vibrations when driving at a certain speed, check the balance plates on the drive shaft (unbalance). Check whether any play can be felt or seen by pulling the drive shaft and slip joint upwards. 1. 2. 3. 4. 5. 6. Drive shaft Yoke Balance plate Welded-up clamps (G.W.B.) Slip joint Drive shaft
3.
4.
5.
6.
7.
8.
9.
If any faults are found when carrying out the points above, the drive shaft should be replaced.
1-2
0145
3
DB 250 PF Series
DRIVE SHAFTS
General
1.2.2 Large service 1. Carry out the inspection given for the small service. 2. Remove the drive shaft (see Drive shaft removal and installation). Check the play on the universal joint bearings by laying the drive shaft flat on a table. Next, put one hand on the pipe of the drive shaft axle and, with the other hand, rotate the drive flange. No play must be felt. Do this for both 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). By hand, check the movement of the drive flanges. It must be possible to turn the drive flanges in a horizontal and vertical direction without any resistance (jarring) being felt. The drive flanges must not drop by themselves. If resistance can be felt, then the bearings must first be lubricated. If this does not have any effect, then the bearings and the spider must be replaced (see Spider removal and installation). Clean all the grease nipples and lubricate all the points. Use a suitable lubricant (see Technical information). MoS2 grease must not be used.
3.
4.
5.
Check whether lubricant escapes from all the universal joints bearings. If this does not happen, then one or more of the bearings are faulty. Replace the relevant spider and its bearings (see Spider removal and installation).
0145
1-3
DRIVE SHAFTS
General
3
DB 250 PF Series
6.
Check the slip joints radial and tangential play.

0,17 mm
a. b.
c.
Check for tangential play (play between the teeth). Secure the slip joints fixed pipe in a workbench with the yoke in a vertical direction. 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. Turn the yoke tangentially and measure the play on the splines. This must not be greater than 0.2 mm.
0,2 mm
02381B
7. a. b. c.
d. e.
f.
Check the slip joints radial play. Pull the slip joint out about 45 mm. Lay the drive shaft on a flat table with the fixed yokes touching the table. Place a suitable gauge indicator with a magnetic foot just behind the weld on the drive shafts pipe. Put the measuring pin just behind the weld on the yoke and zero the gauge. Lift the drive shaft up a little bit in the middle whilst making sure that the yokes remain touching the table. Check the play. It must not be greater than 0.17 mm.
The drive shaft must be replaced completely if the radial or tangential play is too large.
1-4
0145
3
DB 250 PF Series
DRIVE SHAFTS
General
8. -
Check the slip joints splines. Remove the grease nipple. Mark the position of both parts of the slip joint in relation to each other. Carefully pull the slip joint apart. Check the innermost and outermost splines for damage, signs of heating and wear. Check the O-ring for damage. If there are any faults, replace the O-ring or the complete drive shaft. If there is no damage, lubricate the O-ring and slip joint and push them together (beware of the alignment!). Fit the grease nipple and lubricate the slip joint.
Use a suitable lubricant (see Technical information). MoS2 grease must not be used.
0145
1-5
DRIVE SHAFTS
General
3
DB 250 PF Series
1-6
0145
3
DB 250 PF Series
DRIVE SHAFTS
Removal and installation
2. REMOVAL AND INSTALLATION

2.1 REMOVING AND INSTALLING THE DRIVE SHAFT ASSEMBLY When removing the drive shaft, make sure that you do not put yourself or others in danger. The drive shaft has components that could trap body parts. Always move and store the drive shaft in a horizontal position. This will prevent damage which would make the drive shaft become unbalanced. Only use original bolts that are of the correct type. Removal 1. Support the shaft in at least two places. 2. Remove the fixing bolts from the flanges. If necessary, push the drive shafts slip joint inwards a bit, so that the drive shaft can easily be reached between the rear axle and the gear box. Remove the drive shaft from underneath the vehicle. The drive shaft must always be moved and stored in a horizontal position. 4. When repairs have been carried out, or another drive shaft has been fitted, the yokes must be in line and all the universal joints must be lubricated.
3.
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
DB 250 PF Series
2.2 DRIVE FLANGE If a flange must be removed that is directly attached to a spider, see the instructions in 2.3. If a flange must be removed that is directly attached to the gear box or rear axle, see the instructions for the removal and installation of the drive flange for the relevant gear box or rear axle. It must be possible to move the flanges on the spiders by hand after assembly. They must not fall down by themselves.
2-2
0145
3
DB 250 PF Series
DRIVE SHAFTS
2.3 SPIDER Removal 1. Remove the complete drive shaft. See Drive shaft removal and installation. 2. Place the drive shaft on a strong, flat table using a bench vice. Remove all the circlips and grease nipples and throw them away. Mark both parts of the slip joint so that they can be put back in the correct way during assembly.
3.
4.
5.
Put the shaft on a bush under a press as shown (the inner diameter of the bush must be greater than the diameter of the bearing bush). Push the spider downwards, together with the bearings and flange, using a suitable punch until the spider touches the axles yoke.
6.
Remove the drive shaft from under the press and clamp the part of the bearing bush that has been pushed out in a bench vice. Work the yoke upwards using a tyre lever. This will make the bearing bush come completely loose so that it can be removed.
7.
0145
2-3
DRIVE SHAFTS
3
DB 250 PF Series
8.
Turn the shaft through 180. Put the shaft back onto the bush. Push the spider downwards again in the direction of the shafts yoke until the spider touches the yoke.
9.
10. The spider and the flange can be tilted out of shafts yoke.
3
11. Clamp the partly pushed out bearing bush in a bench vice. 12. Work the yoke upwards using a tyre lever. This will make the bearing bush come completely loose so that it can be removed.
13. Repeat points 5 to 12 to remove the flange from the spider. 14. Check the components that will be reused for cracks and damage. Always replace the spider together with the bearings.
2-4
0145
3
DB 250 PF Series
DRIVE SHAFTS
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. 2. 3. Press one bearing partly into the yoke. Fit the retaining rings to the spider with a bit of grease. Tilt the spider into the yoke so that the hole A (for the grease nipple) points towards the shaft.
4.
5.
Slide the spider a little bit into the bearing which has already been fitted. Place the whole thing on a bush under a press. The opposite bearing can now be pressed into the yoke using the spider as a guide. The spider must be able to move freely whilst pressing.
6.
Continue pressing the bearing in until the circlip can be fitted on the side that is being pressed. Fit the circlip.
0145
2-5
DRIVE SHAFTS
3
DB 250 PF Series
Next, press the opposite bearing further into the yoke and fit the circlip. 7. Repeat points 1 to 6 to fit the flange and the spider into the shafts yoke. Fit the grease nipple(s). Lubricate all the lubrication points using the correct grease (see Technical information) until grease escapes from all the bearings. Fit the drive shaft. See Drive shaft removal and installation.
8.
9.
2-6
0145
3
DB 250 PF Series
ANGLE DRIVES
Contents
CONTENTS
Page
Date
1. MAINTENANCE, REPAIR, SPARE PARTS ANGLE DRIVES W10, W13 FOR DIWA TRANSMISSIONS ................... 1-1 ............. 9901
2. REPAIR MANUAL SPRING COUPLING DIRECT-SEPERATE INSTALLATION ...................................................... 2-1 ............. 0201
0145
ANGLE DRIVES
Contents
3
DB 250 PF Series
0145
3
DB 250 PF Series
ANGLE DRIVES
Angle drives W10, W13
1. MAINTENANCE, REPAIR, SPARE PARTS ANGLE DRIVES W10, W13 FOR DIWA TRANSMISSIONS (G 1230e99)
0145
1-1
ANGLE DRIVES
Angle drives W10, W13
3
DB 250 PF Series
1-2
0145
3
DB 250 PF Series
ANGLE DRIVES
Spring coupling
2. REPAIR MANUAL SPRING COUPLING DIRECT-SEPERATE INSTALLATION (G 1051gb/2002)
0145
2-1
ANGLE DRIVES
Spring coupling
3
DB 250 PF Series
2-2
0145

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3

TECHNICAL DATA DIAGNOSES AUTOMATIC GEARBOXES PROPELLER SHAFTS ANGLE DRIVES

Reductions PE 160 PE 183

(1) Standard version (2) Option

CAPACITIES, MASS, FITTING LENGTH

ca. 305 ca. 340 ca. 259 ca. 269

796 874 693(2) 693(2)

Plugs ZF HP500 Cover oil filter (A) Drain plug (B)

1. DRIVE SHAFTS ........................................................................................ 1-1 ............. 0145

Replace universal joint Replace drive shaft Align forks

1. SERVICING SCHEDULE TRANSMISSIONS DIWA.3

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Voith. 55.6374.20 (G 1362e) / 2001-02

Transmissions DIWA.2, DIWA.3, DIWA.3E

Monthly Check oil level

I Place the vehicle in horizontal position.

I Read the oil level.

Change oil and oil filter for DIWA.2, DIWA.3

I Fill in transmission oil.

Change oil and oil filter for DIWA.3E

I Replace oil filter element (17) and sealing ring (18).

Check load transmitter setting if necessary for DIWA.2, DIWA.3, DIWA.3E

2. TROUBLE SHOOTING DIWA.3 TRANSMISSIONS

3. FAULT FINDING VOITH DIWA.3 TRANSMISSIONS

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Voith. 55.6303.22 / 2002-03

Important safety instructions!

Consequences of oil loss, treatment of used oil

Voith. Fault Finding DIWA.3, DIWA.3E

Servicing Schedule Lists of Lubricants Driving Instructions Diagnostic Manual

Spare Parts Catalogs

Procedure for finding faults in DIWA.3 and DIWA.3E transmissions

Use of the diagnostic program for fault tracing:

Voith. Fault Finding DIWA.3, DIWA.3E

Voith. Fault Finding DIWA.3, DIWA.3E

Voith. Fault Finding DIWA.3, DIWA.3E

Differences concerning the symptoms of transmission malfunctions in DIWA.3E and DIWA.3

Voith. Fault Finding DIWA.3, DIWA.3E

Continued operation possible,

Emergency operation possible

Voith. Fault Finding DIWA.3, DIWA.3E

Voith. Fault Finding DIWA.3, DIWA.3E

Note / continue with

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ANS activation without effect (ANS means Automatic Neutral at Standstill)

Voith. Fault Finding DIWA.3, DIWA.3E

Note / continue with

Voith. Fault Finding DIWA.3, DIWA.3E

Note / continue with

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Voith. Fault Finding DIWA.3, DIWA.3E

Note / continue with

Voith. Fault Finding DIWA.3, DIWA.3E

Note / continue with

Voith. Fault Finding DIWA.3, DIWA.3E

Note / continue with

Voith. Fault Finding DIWA.3, DIWA.3E

Note / continue with

Voith. Fault Finding DIWA.3, DIWA.3E

Voith. Fault Finding DIWA.3, DIWA.3E

Note / continue with

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Voith. Fault Finding DIWA.3, DIWA.3E

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POMZ GPS %*8"

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GPS %*8"& POMZ XIFO $'$ JT OPU BDUJWF

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