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3 CONTENTS

DB 250 PF Series

TECHNICAL DATA
0
DIAGNOSES
1
AUTOMATIC GEARBOXES
2
PROPELLER SHAFTS
3
ANGLE DRIVES
4

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CONTENTS 3
DB 250 PF Series

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3 TECHNICAL DATA
DB 250 PF Series 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 1
TECHNICAL DATA 3
Contents DB 250 PF Series

2 0145
3 TECHNICAL DATA
DB 250 PF Series Automatic gearboxes

1. AUTOMATIC GEARBOXES

1.1 GEARBOX TYPES 0

Engine type
Gearbox
Reductions
types
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

0145 1-1
TECHNICAL DATA 3
Automatic gearboxes DB 250 PF Series

1.2 CAPACITIES, MASS, FITTING LENGTH

Oil capacity (in litres)


Type of gearbox Mass in kg(1) Fitting length in mm
after when
1e filling
extending changing oil

Voith D851.3 ca. 25-28 - ca. 23-26 ca. 305 796

Voith D854.3 ca. 25-28 - ca. 23-26 ca. 340 874

ZF 4HP500 ca. 30 ca. 20 ca. 15 ca. 259 693(2)

ZF 5HP500 ca. 30 ca. 20 ca. 15 ca. 269 693(2)

(1) Weight of transmission + oil cooler dry


(2) Depends on type of propeller shaft

1-2 0145
3 TECHNICAL DATA
DB 250 PF Series Automatic gearboxes

1.3 TIGHTENING TORQUES

Driveline
Silent blocks on flywheel housing M16 10.9 260 ± 20 Nm
0
Silent blocks on angle drive M16 10.9 260 ± 20 Nm
Vibration damper on flywheel housing M10 10.9 60 ± 4 Nm
Reducing ring on flywheel housing (A) M10 10.9 60 ± 4 Nm
Angle drive on reducing ring (B) M10 8.8 46 ± 4 Nm
Automatic gearbox on angle drive (C) M10 10.9 60 ± 4 Nm

Plugs
Voith DIWA.3E
Drain plug oil sump (A) 50 Nm
Drain plug torq converter (B) 50 Nm
Cover (C) 25 Nm
Cover oil filter (D) 25 Nm

0145 1-3
TECHNICAL DATA 3
Automatic gearboxes DB 250 PF Series

Plugs
ZF HP500
0 Cover oil filter (A)
Drain plug (B)
25 Nm
50 Nm

1-4 0145
3 TECHNICAL DATA
DB 250 PF Series Drive shafts

2. DRIVE SHAFTS

2.1 GENERAL 0
Make: “Gelenk Wellen Bau”
Type: 2045 (Compact 2000 series)
- Drive flange
Type: KV (serrated flange)
Diameter (A) gearbox side: Æ 155 mm
Type: KV (serrated flange)
Diameter (B) rear axle side: Æ 180 mm
Angle of flex per universal joint (b): max. 25°
Length (LZ min.): 534 mm
Extension length: 90 mm
Spline diameter (W): Æ 68 mm

Lubricant: 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 3000 rpm-1
Radial play universal joints 0.01 - 0.05 mm

0145 2-1
TECHNICAL DATA 3
Drive shafts DB 250 PF Series

0 2.2 TIGHTENING TORQUES

Serrated flanges
- M12 10.9 105-126 Nm
- M14 10.9 136-204 Nm

Plain flanges
- M12 10.9 113-127 Nm
- M14 10.9 178-202 Nm
- M16 10.9 281-309 Nm

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 0145
3 DIAGNOSIS
DB 250 PF Series Contents

CONTENTS

Pages Date 1
1. DRIVE SHAFTS ........................................................................................ 1-1 ............. 0145

0145 1
DIAGNOSIS 3
Contents DB 250 PF Series

2 0145
3 DIAGNOSIS
DB 250 PF Series Drive shafts

1. DRIVE SHAFTS

1. FAULT-FINDING TABLE

FAULT: DRIVE LINE VIBRATION AT LOW VEHICLE SPEED 1


Possible cause Remedy

Excessive universal joint angle (for example, Check the universal joint angle
caused by excessive caster)

Play in universal joints Replace universal joint

Play in sliding joint Replace drive shaft

Forks not in line Align forks

FAULT: DRIVE LINE VIBRATION AT HIGH VEHICLE SPEED

Possible cause Remedy

Drive shaft imbalance Balance or replace the drive shafts,


if necessary

0145 1-1
DIAGNOSIS 3
Drive shafts DB 250 PF Series

1-2 0145
3 AUTOMATIC GEARBOXES
DB 250 PF Series Contents

CONTENTS Page Date

VOITH DIWA.3 Transmissions

1. SERVICING ......................................................................................... 1-1................................... 0102

2. TROUBLE SHOOTING ........................................................................ 2-1................................... 0203

3. FAULT FINDING .................................................................................. 3-1................................... 0203 2

ZF-ECOMAT Transmissions

1. REPAIR MANUAL ZF-ECOMAT 2 Stages 1-2 (4149 751 601) ........... 1-1................................... 0103

0145 1
AUTOMATIC GEARBOXES 3
Contents DB 250 PF Series

2 0145
3 AUTOMATIC GEARBOXES
DB 250 PF Series Servicing VOITH DIWA.3 Transmissions

1. SERVICING SCHEDULE TRANSMISSIONS DIWA.3

0145 1-1
AUTOMATIC GEARBOXES 3
Servicing VOITH DIWA.3 Transmissions DB 250 PF Series

1-2 0145
4FSWJDJOH4DIFEVMF
 LN
LN
5SBOTNJTTJPOT %*8" 
%*8" 
%*8"&

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


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

Monthly

Check oil level

■ 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.

■ 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!

■ Press the N key and thus bring the transmission to its neutral position.

■ Start the engine and let it run at idle speed.

■ Withdraw the dipstick from its guide tube and clean it.

■ Insert the dipstick again briefly to prevent wrong oil level reading by splash
oil.

■ 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 ■ Stop the engine.

■ Remove the drain plug (1) for the oil in the oil pan (allen wrench 12 mm) and
drain the oil.
2
■ Remove the drain plug (2) for the converter oil and drain the oil. The plug is
accessible through the oil pan drain hole.
1
■ Install drain plugs with new copper seals. Tighten drain plug (2) to 50 Nm
and drain plug (1) to 120 Nm.
3
■ Remove the drain plug (4) for the filter oil (width across flats 13 resp. 10)
and drain the oil.
4
■ Unscrew (width across flats 13) and remove the cover (3).

5 ■ Replace gasket (7), oil filter element (8) and sealing ring (9). Install gasket
with coated side (white) toward the filter housing.
Note! If the used filter element is very dirty, unscrew the oil pan and check
the disks!
5
3 ■ Fit cover (3), washers B8.4, spring washers B8 and tighten nuts M8 (6) to
25 Nm.
4
■ Install drain plug (4) with new copper seal and tighten to 15 Nm.
6
■ Fill in transmission oil.
7
*Note! Only use oils tested by Voith and approved in the Lists of Lubri-
cants 55.6335. .. (G 607) and 55.6336. .. (G 1363), respectively!
Quantity: Approx. 21 - 23 liters (approx. 25 - 28 liters for first filling).
The dipstick reading counts in any case!
8
■ Measure the oil level, check transmission - especially oil filter - for leaks.

■ Check the oil hoses (5). Replace if found very porous, cracked or chafed.

9
With oil grades according to List of Lubricants 55.6335. ..* (G 607):
every 60 000 km, at least every 2 years, however.
With oil grades according to List of Lubricants 55.6336. ..* (G 1363):
every 120 000 km, at least every 3 years, however.

Change oil and oil filter for DIWA.3E

10 Note! Drain oil at operating temperature only!

11 Danger! Scalding by hot oil!

■ Stop the engine.

■ Remove the drain plug (11) for the oil in the oil pan (allen wrench 12 mm)
and drain the oil.
12
■ Remove the drain plug (12) for the converter oil and drain the oil. The plug
is accessible through the oil pan drain hole.
11
■ Install drain plugs with new copper seals. Tighten drain plug (12) to 50 Nm
and drain plug (11) to 120 Nm.

■ Unscrew and remove the access cover (10) of the oil pan (width across
flats 36).

■ Unscrew and remove the cover (15) of the integrated oil filter (14) (width
13 across flats 36).

■ 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 ■ Install cover (15) with oil filter element (17) and sealing ring (18) and tighten
to 25 Nm.
15
16 ■ Install access cover (10) with new sealing ring (16) and tighten to 25 Nm.

10 ■ Fill in transmission oil.


*Note! Only use oils tested by Voith and approved in the Lists of Lubri-
cants 55.6335. .. (G 607) and 55.6336. .. (G 1363), respectively!
Quantity: Approx. 21 - 23 liters (approx. 25 - 28 liters for first filling).
The dipstick reading counts in any case!

■ Measure the oil level, check transmission - especially the cover (10) of the
oil pan - for leaks.
17
■ Check the oil hoses (13). Replace if found very porous, cracked or chafed.

18
15
Check load transmitter setting if necessary
for DIWA.2, DIWA.3, DIWA.3E
See leaflets "Fault finding".
3 AUTOMATIC GEARBOXES
DB 250 PF Series Trouble shooting VOITH DIWA.3 Transmissions

2. TROUBLE SHOOTING DIWA.3 TRANSMISSIONS

0145 2-1
AUTOMATIC GEARBOXES 3
Trouble shooting VOITH DIWA.3 Transmissions DB 250 PF Series

2-2 0145
3 AUTOMATIC GEARBOXES
DB 250 PF Series Fault finding VOITH DIWA.3 Transmissions

3. FAULT FINDING VOITH DIWA.3 TRANSMISSIONS

0145 3-1
AUTOMATIC GEARBOXES 3
Fault finding VOITH DIWA.3 Transmissions DB 250 PF Series

3-2 0145
'BVMU'JOEJOH
5SBOTNJTTJPOT %*8"
%*8"&
SYMPTOMS
CAUSES
REMEDIES

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 ser-


vice 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 infor-


mation 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 ser-
vice 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 envi-


ronmental pollution due to oil loss!

Used oil must be disposed of in accordance with environmental


regulations.

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


'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.:

for
Brochure Part No. Purpose
transmission
Function description of the transmissi-
55.6355. .. DIWA.3 on, transmission data, installation in-
Technical Manual
55.6357. .. DIWA.3E structions, design and dimensional
data for transmission assemblies
All
Servicing Schedule 55.6374. .. Maintenance of DIWA transmissions
DIWA
55.6335. .. All List of the lube oils that are approved
Lists of Lubricants
55.6336. .. DIWA by Voith for DIWA transmissions
DIWA.3, Brief description of transmission ope-
Driving Instructions 55.6291. ..
DIWA.3E ration for the bus driver
DIWA.3, Use of the Voith PC-based diagnostic
Diagnostic Manual 55.6264. ..
DIWA.3E program DIWAGNOSIS
55.6600. .. D 851.3E
55.6601. .. D 854.3E Illustration and designation of trans-
Spare Parts Catalogs
55.6602. .. D 863.3E mission parts for spare parts ordering
55.6603. .. D 864.3E
Detection of defective electrical com-
DIWA.3,
Trouble Shooting 55.6293. .. ponents or assemblies using the PC
DIWA.3E
diagnostic program
Description of transmission disas-
55.6320. .. DIWA.3
Repair Manual sembly and assembly of 3- and 4-
55.6704. .. DIWA.3E
speed transmissions
Technical Description
55.6309. .. DIWA.3 Representation of the oil circuits for
with Oil and Control Cir-
55.6311. .. DIWA.3E the various transmission gear shifts
cuit Diagrams

All of the above brochures are available from department "ant" or "anv".

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 ap-
propriate 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 Des-
criptions 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 transmissi-
ons:

Trouble Shooting

Transmission repair and spare parts ordering:

Repair Manual,
Spare Parts Catalogs

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


5BCMFPGDPOUFOUT

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


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

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


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 TDIBQU  DIBQU 
drive range), the reverse gear, and braking with the converter. DIBQU

2. The location of SK and WR solenoid valves in the valve block has been changed. TFFDIBQUFS

3. There were some minor changes to the circuit diagram. TFFBQQFOEJDFT


JODIBQUFS

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


 (FOFSBMSFDPNNFOEBUJPOT

First check in case of faults

■ By means of the Voith diagnostic program. Its use is described in the Diagnostic
Manual.

Continued operation possible,

■ 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

■ by means of emergency control cable in 1st gear. Always note that connection of
the cable will engage 1st gear. Therefore:

Danger! Apply the parking brake when the bus is stopped to prevent that the
vehicle can move unintentionally!

Towing

Note! In order to prevent damage to the DIWA transmission when the vehicle is
towed, the following must be observed:

■ Set the transmission to neutral and screw off plug from the transmission or elec-
tronic control unit.

■ In case of transmission damage: remove cardan shaft or stub shaft of rear axle.

■ If there is no transmission damage the vehicle can be towed with the cardan shaft
installed, yet only up to a distance of 10 km. The maximum towing speed is
30 km/h.

Voith. Fault Finding DIWA.3, DIWA.3E 1


2 Voith. Fault Finding DIWA.3, DIWA.3E
Possible cause Check / remedy Note / continue with

 'BVMUTXJUIWFIJDMFTUPQQFE

Danger! Apply the parking brake when the bus is stopped for repairing to pre-
vent 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 con- Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+
necting cable defective. and connecting cable, repair or re- 5S4IPPU DIBQUFS
place, if required. JOEVDUJWFQJDLVQ/

2a. Control unit does not receive L0 signal. Check and adjust connection, if re- 4FFDIBQUFS 
For VDO or Voith load transmitter: quired. %JBHOPTUJDTGVODUJPO&
connection between injection pump and load
transmitter set improperly.

2b. Control unit does not receive L0 signal. 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
For E-Gas systems: (compare transmission type to con-
faulty assignment of accelerator pedal positi- trol unit nameplate).
on and load transmitter level. 2. Check assignment. TFFDIBQUFSBOE
3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&

3a. No signal from pressure switch for ANS Check switch, connector or connect- %JBHOPTUJDTGVODUJPO) 
activation (BS): switch, connector or con- ing cable and repair or replace, if re- 5S4IPPU DIBQUFS
necting cable defective. quired. QSFTTTX"/4BDUJWBUJPO

3b. If provided: stop brake (HSB) relay, Check relay, switch, connector or %JBHOPTUJDTGVODUJPO) 
switch, connector or connecting cable defec- connecting cable and repair or repla- 5S4IPPU DIBQUFS
tive. ce, if required. TUPQCSBLF

3c. No signal from service (foot) brake switch Check switch at brake, connector or %JBHOPTUJDTGVODUJPO' 
(FB): one of the 3 microswitches, connector connecting cable and repair or repla- 5S4IPPU DIBQUFS
or connecting cable defective. ce, if required. CSBLFWBMWF

4. Pushbutton switch (TS), connector or con- Check switch, connector or connect- %JBHOPTUJDTGVODUJPO$ 
necting cable defective. ing cable and repair or replace, if re- 5S4IPPU DIBQUFS
quired. QVTICVUUPOTXJUDI

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


Possible cause Check / remedy Note / continue with

Input clutch (EK) does not open

Field coil or one of the spools of the EK sole- 1. Check oil pressure at EK connec- %JBHOPTUJDTGVODUJPOT( *
noid valve, connector or connecting cable tion (measuring cover):
defective. pArequ’d = 0 bar.
2. Check solenoid valve, connector 5S4IPPU DIBQUFS
and cable and repair or replace, if re- &,TPMFOPJE
quired.

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 val- 1. Check operating resp. converter 'PSTFUQPJOUT TFF
ves TB or RBK, connector or connecting ca- pressure at connections TB and RBK DIBQUFS
ble defective. (measuring cover).
2. Check solenoid valves, connec- %JBHOPTUJDTGVODUJPOT( *
tors and cables and repair or replace, 5S4IPPU DIBQUFS
if required. 5#PS3#,TPMFOPJE

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


Possible cause Check / remedy Note / continue with

 'BVMUTPOFOHBHFNFOUPGHFBST

3.1 After engagement of a forward (F) or reverse gear (R) and re- $IFDLJTPOMZQPTTJCMFXIFO
leasing the parking brake, the vehicle does not move - engine FOHJOFJTSVOOJOH
revs up to max. speed when accelerating

Control unit E 200 is not supplied with


voltage - transmission remains in neutral

Fuse 8A for line +UZ, connector or connect- Check fuse, connector and cable, re- %JBHOEJTQMBZDPNNVOJ
ing cable defective. pair or replace, if required. DBUJPOTOPUFTUBCMJTIFE 
5S4IPPU DIBQUFS
DPOUSPMVOJUWPMUBHF

Solenoid valves without voltage

dS relay "control", connector or connecting Check relay, connector and cable, %JBHOPTUJDTEJTQMBZ
cable defective. repair or replace, if required. E4SFMBZXJUIPVUWPMUBHF 
5S4IPPU DIBQU
WPMUBHF

Input clutch (EK) does not close

1. Idle speed N1 too high. 1. Check idle speed - 'PSTFUQPJOUT TFFBMTP


setpoint: n ≤ 850 rpm DIBQUFS
(for gas engine: n ≤ 1000).
2. If required, adjust idle speed. %JBHOPTUJDTGVODUJPO*

2. Gear safety pressure switch (ABSICH) is Check switch, connector and cable, %JBHOPTUJDTGVODUJPO) 
not activated for pressure > 3 bar, connector repair or replace, if required. 5S4IPPU DIBQUFS
or connecting cable defective. HFBSTBGFUZQSFTTVSFTXJUDI

3. Field coil or one of the spools of the EK so- 1. Check oil pressure at EK connec- 'PSTFUQPJOUT TFFBMTP
lenoid valve, connector or connecting cable tion (measuring cover): DIBQUFS
defective. pArequ’d ≥ 3.5 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable and repair or replace, if re- 5S4IPPU DIBQUFS
quired. &,TPMFOPJE

4. Transmission with ANS activation: Check switch, connector and cable, %JBHOPTUJDTGVOUJPO) 
pressure switch for ANS activation (BS), repair or replace, if required. 5S4IPPU DIBQUFS
connector or connecting cable defective. Note! EK closes when load trans- QSFTTTX"/4BDUJWBUJPO
Note! Switch may only be closed when mitter operated!
the brake device is operated!

5. Bus with gas engine: Check relay, connector and cable,


relay dNEUTR, connector or connecting ca- repair or replace, if required.
ble defective. %JBHOPTUJDTGVODUJPO(
Note! Idle seed is reached after the trans- 5S4IPPU DIBQUFS
mission was in neutral for some time! PVUQVUE/&653

Voith. Fault Finding DIWA.3, DIWA.3E 5


Possible cause Check / remedy Note / continue with

Disks of input clutch (EK) slip

1. Operating pressure too low. Check operating pressure: 'PSTFUQPJOUT TFFBMTP


pArequ’d ≥ 3.5 bar. DIBQUFS 
Adjust pressure, if required.

2. EK solenoid valves hard to move or stuck, 1. Check oil pressure at EK connec- 'PSTFUQPJOUT TDIBQU
e.g. by soiling of a spool or the field coil. tion (measuring cover): %JBHOPTUJDTGVODUJPO(
pArequ’d ≥ 3.5 bar. 5S4IPPU DIBQUFS
2. Repair or replace solenoid valve. &,TPMFOPJE

3. Oil pressure after EK solenoid valve too 1. Check pressure as discr. above.
low: oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.

4. EK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

Pushbutton switch not ready to operate

Pushbutton switch, connector or connecting Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$ 
cable defective. repair or replace, if required. 5S4IPPU DIBQUFS
QVTICVUUPOTXJUDI

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 Check inductive pick-up, connector 1. Diagnostics: function J,
connecting cable defective. and connecting cable and repair or 2. Tr. Shoot., chapter 2.1/2:
replace, if required. inductive pick-up N1 or N2

2. Field coil of solenoid valves RBG or RGK, Check solenoid valves, connectors %JBHOPTUJDTGVODUJPO( 
connector or connecting cable defective. and cables and repair or replace, if 5S4IPPU DIBQ
Note! if RBG is defective, the R gear is left required. 3#(PS3#,TPMFOPJE
after approx. 1 sec.!

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


Possible cause Check / remedy Note / continue with

Transmission with inhibiting switch for


reverse gear (SPERR): switch not closed

1. Inhibiting switch not operated.

2. Switch, connector or connecting cable de- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$ 
fective. repair or replace, if required. 5S4IPPU DIBQUFS
QVTICVUUPOTXJUDI

Pushbutton not ready to operate

Pushbutton switch, connector or connecting Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$ 
cable defective. repair or replace, if required. 5S4IPPU DIBQUFS
QVTICVUUPOTXJUDI

Reverse gear brake (RB) does not close

RBG or RBK solenoid valve hard to move or 1. Check operating resp. converter 'PSTFUQPJOUT TDI
stuck, e.g. by soiling of a spool or field coil. pressure at connections RBG and
RBK (measuring cover).
2. Check solenoid valves, connec- %JBHOPTUJDTGVODUJPO( 
tors and cables and repair or replace, 5S4IPPU DIBQU
if required. 3#(PS3#,TPMFOPJE

Converter pressure too low

1. Field coil or one of the spools of the WR 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
solenoid valve, connector or connecting ca- measuring point (fig. 6/2): JOHQPJOU TDIBQUFS 
ble defective. pWrequ’d ≥ 2 bar.
2. Check solenoid valve, connector %BHOPTUJDTGVODUJPO( 
and cable and repair or replace, if re- 5S4IPPU DIBQUFS
quired. 83TPMFOPJE

2. One of the control spools of the converter If required, disassemble and repair 3FQBJS.BOVBM
outlet valve hard to move or stuck. converter outlet valve.

3. Converter leaks. Check converter seal and repair, if $VTU4FSW-FUUFSOP 


required. 3FQBJS.BOVBM

4. Only for DIWA.3E: The converter inlet val- 1. Check oil pressure at WP connec- 'PSTFUQPJOUT TFFBMTP
ve hard to move or stuck, valve does not tion (measuring cover): DIBQUFS
open properly. pArequ’d ≥ 8.3 bar.
2. Check converter filling valve and 3FQBJS.BOVBM
repair or replace, if required.

5. Only for DIWA.3E: The breather valve 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
hard to move or stuck, valve does not close measuring point (fig. 6/2): JOHQPJOU TDIBQUFS 
properly. pWrequ’d ≥ 2 bar.
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.

Voith. Fault Finding DIWA.3, DIWA.3E 7


Possible cause Check / remedy Note / continue with

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: 'PSTFUQPJOUT TFFBMTP


pArequ’d ≥ 3.5 bar. DIBQUFS 
Adjust pressure, if required.

2. RBG or RBK solenoid valve hard to move 1. Check operating resp. converter 'PSTFUQPJOUT TFF
or stuck, e.g. by soiling of a spool or field coil. pressure at connections RBG and DIBQUFS 
RBK (measuring cover).
2. Check solenoid valves, connec- %JBHOPTUJDTGVODUJPO( 
tors and cables and repair or replace, 5S4IPPU DIBQU
if required. 3#(PS3#,TPMFOPJE

3. Oil pressure after solenoid valve RBG or 1. Check pressure as disribed above.
RBK too low: oil supply reduced or interrup- 2. Check oil-supplying components 3FQBJS.BOVBM
ted. and repair or replace, if required.

4. RB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

Service (foot) brake switch (FB) for con-


verter brake on unintentionally

One of the 3 microswitches, connector or Check switch at brake, connector or %JBHOPTUJDTGVODUJPO' 


connecting cable defect. connecting cable and repair or repla- 5S4IPPU DIBQUFS
ce, if required. CSBLFWBMWF

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 sole- Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO( 
noid valve, connector or connecting cable cable and repair or replace, if requi- 5S4IPPU DIBQUFS
defective. red. &,TPMFOPJE

2. EK solenoid valve hard to move, e.g. due Repair or replace solenoid valve. 3FQBJS.BOVBM
to pollution of a spool or the field coil.

3. EK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

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


Possible cause Check / remedy Note / continue with

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 val- 1. Check operating resp. converter 'PSTFUQPJOUT 
ves TB or RBK, connector or connecting ca- pressure at connections TB and RBK TDIBQUFS
ble defective. (measuring cover).
2. Check solenoid valves, connec- %JBHOPTUJDTGVODUJPO(
tors and cables and repair or replace, 5S4IPPU DIBQU
if required. 5#PS3#,TPMFOPJE

Converter pressure too low

1. One of the control spools of the converter 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
outlet valve hard to move or stuck. measuring point (fig. 6/2): JOHQPJOU TFFBMTPDIBQU
pWrequ’d ≥ 2 bar.
2. If required, disassemble and repair 3FQBJS.BOVBM
converter outlet valve.

2. Converter leaks. Check converter seal and repair, if $VTU4FSW-FUUFSOP


required. 3FQBJS.BOVBM

3. Only for DIWA.3E: The converter filling Check converter filling valve and re- 3FQBJS.BOVBM
valve hard to move or stuck, valve does not pair or replace, if required.
open properly.

4. Only for DIWA.3E: The breather valve 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
hard to move or stuck, valve does not close measuring point (fig. 6/2): JOHQPJOU TDIBQUFS 
properly. pWrequ’d ≥ 2 bar.
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.

Voith. Fault Finding DIWA.3, DIWA.3E 9


10 Voith. Fault Finding DIWA.3, DIWA.3E
Possible cause Check / remedy Note / continue with

 'BVMUTXIJMFESJWJOH

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: Check and adjust connection, if re- 4FFDIBQUFS 
connection between injection pump and load quired. %JBHOPTUJDTGVODUJPO&
transmitter set improperly.

1b. For E-Gas systems: 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
engine power restricted due to faulty assign- (compare transmission type to con-
ment of accelerator pedal position and load trol unit nameplate).
transmitter level. 2. Check assignment. TFFDIBQUFSBOE
3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&

2. Engine power. 1. Measure speed at stall point. 4FFDIBQUFS


2. Compare results to design values.

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 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
outlet valve hard to move or stuck. measuring point (fig. 6/2): JOHQPJOU TFFBMTPDIBQU
pWrequ’d ≥ 2 bar.
2. If required, disassemble and repair 3FQBJS.BOVBM
converter outlet valve.

2. Converter leaks. Check converter seal and repair, if $VTU4FSW-FUUFSOP 


required. 3FQBJS.BOVBM

3. Only for DIWA.3E: The converter filling Check converter filling valve and re- 3FQBJS.BOVBM
valve hard to move or stuck, valve does not pair or replace, if required.
open properly.

4. Only for DIWA.3E: The breather valve 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
hard to move or stuck, valve does not close measuring point (fig. 6/2): JOHQPJOU TDIBQUFS 
properly. pWrequ’d ≥ 2 bar.
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.

Voith. Fault Finding DIWA.3, DIWA.3E 11


Possible cause Check / remedy Note / continue with

Turbine brake (TB) does not close - engi-


ne speed is greatly decreased

Field coil or one of the spools of solenoid val- 1. Check operating resp. converter 'PSTFUQPJOUT TFF
ve TB, connector or connecting cable defec- pressure at connection TB (measur- DIBQUFS 
tive. ing cover).
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable and repair or replace, if re- 5S4IPPU DIBQUFS
quired. 5#TPMFOPJE

Turbine brake (TB) disks slip

1. Operating pressure too low. Check operating pressure: 'PSTFUQPJOUT TFFBMTP


pArequ’d ≥ 8.3 bar. DIBQUFS 
Adjust pressure, if required.

2. TB solenoid valve hard to move or stuck, 1. Check operating resp. converter 'PSTFUQPJOUT TDIBQ
e.g. by pollution of a spool or the field coil. pressure at connection TB (measur- %JBHOPTUJDTGVODUJPO( 
ing cover). 5S4IPPU DIBQUFS
2. Repair or replace solenoid valve. 5#TPMFOPJE

3. Oil pressure after TB solenoid valve too 1. Check pressure as discr. above.
low: oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.

4. TB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

4.3 Transmission shifts to 2nd gear with pushbutton 1 pressed

Inhibition for shifting 1-2 not active - inhi-


bition 1-2 is released when converter bra-
ke 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 Check hand brake switch, micro- %JBHOPTUJDTGVODUJPOT% '
brake switch, one of the 3 microswitches in switch in service brake switch, con- 5S4IPPU DIBQUFS
the service brake switch, connector or con- nector and cable, repair or replace, if IBOEPSTFSWJDFCSBLFTXJUDI
nect-ing cable defective. required.

3. Pushbutton switch (e.g. terminal S1 with- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$ 
out power), connector or connecting cable repair or replace, if required. 5S4IPPU DIBQUFS
defective. QVTICVUUPOTXJUDI

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


Possible cause Check / remedy Note / continue with

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 pos-
sible in 1st gear

Automatic shift from 1st to 2nd gear inhi-


bited

1. Pushbutton 1 (5 or 6-pushbutton switch)


depressed.

2. Pushbutton switch (e.g. continuous cur- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$ 
rent terminal S1, although button 1 not pres- repair or replace, if required. 5S4IPPU DIBQUFS
sed), connector or connecting cable defecti- QVTICVUUPOTXJUDI
ve.

No signal regarding vehicle speed

Inductive pick-up N2, connector or connect- Check inductive pick-up N2, connec- %JBHOPTUJDTGVODUJPO+
ing cable defective. tor and connecting cable and repair 5S4IPPU DIBQUFS
or replace, if required. JOEVDUJWFQJDLVQ/

Wrong power transmitter signals - engine


does not reach full power

1a. For VDO or Voith load transmitter: Check connection and adjust, if re- 4FFDIBQUFS 
connection between injection pump and load quired. %JBHOPTUJDTGVODUJPO&
transmitter set improperly.

1b. For E-Gas systems: 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
engine power restricted due to faulty assign- (compare transmission type to con-
ment of accelerator pedal position and load trol unit nameplate).
transmitter level. 2. Check assignment. TFFDIBQUFSBOE
3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&

Voith. Fault Finding DIWA.3, DIWA.3E 13


Possible cause Check / remedy Note / continue with

4.6 Transmission shifts to 2nd gear, but without power transmis-


sion

Pump brake (PB) does not close

Field coil or one of the spools of the PB sole- 1. Check oil pressure at PB connec- 'PSTFUQPJOUT TFFBMTP
noid valve, connector or connecting cable tion (measuring cover): DIBQUFS
defective. pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO(
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 1#TPMFOPJE

Pump brake (PB) disks slip - engine


speed is greatly reduced

1. Operating pressure too low. Check operating pressure: 'PSTFUQPJOUT TFFBMTP


pArequ’d ≥ 8.3 bar. DIBQUFS 
Adjust pressure.

2. PB solenoid valve hard to move or stuck, 1. Check oil pressure at PB connec- 'PSTFUQPJOUT TDIBQU
e.g. by pollution of a spool or the field coil. tion (measuring cover): %JBHOPTUJDTGVODUJPO(
pArequ’d ≥ 8.3 bar. 5S4IPPU DIBQUFS
2. Repair or replace solenoid valve. 1#TPMFOPJE

3. Oil pressure after PB solenoid valve too 1. Check pressure as discr. above.
low: oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.

4. PB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

4.7 Poor acceleration after shifting to 2nd gear, but normal in 1st
gear

TB solenoid valve does not open - turbine


brake remains closed.

Field coil or one of the spools of solenoid val- 1. Check oil pressure at TB connec- %JBHOPTUJDTGVODUJPO(
ve TB, connector or connecting cable defec- tion (measuring cover):
tive. pArequ’d = 0 bar.
2. Check solenoid valve, connector 5S4IPPU DIBQUFS
and cable and repair or replace, if re- 5#TPMFOPJE
quired.

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


Possible cause Check / remedy Note / continue with

4.8 Transmission does not shift to 3rd gear - operation only pos-
sible 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 connect- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$ 
ing cable defective. repair or replace, if required. 5S4IPPU DIBQUFS
QVTICVUUPOTXJDI

Lock-up clutch (DK) does not close

Field coil or one of the spools of the DK sole- 1. Check oil pressure at DK connec- 'PSTFUQPJOUT TDIBQ
noid valve, connector or connecting cable tion: pArequ’d ≥ 8.3 bar. %JBHOPTUJDTGVODUJPO( 
defective. 2. Check solenoid valve, connector 5S4IPPU DIBQUFS
and cable, repair or replace. %,TPMFOPJE

4.9 Poor acceleration after shifting to 3rd gear, but normal in 1st
and 2nd gear

Lock-up clutch (DK) disks slip

1. Operating pressure too low. Check operating pressure: 'PSTFUQPJOUT TFFBMTP


pArequ’d ≥ 8.3 bar. DIBQUFS 
Adjust pressure, if required.

2. DK solenod valve hard to move or stuck, 1. Check oil pressure at DK connec- 'PSTFUQPJOUT TDIBQU
e.g. by pollutionof a spool or the field coil. tion (measuring cover): %JBHOPTUJDTGVODUJPO( 
pArequ’d ≥ 8.3 bar. 5S4IPPU DIBQUFS
2. Repair or replace solenoid valve. %,TPMFOPJE

3. Oil pressure after DK solenoid valve too 1. Check pressure as discr. above.
low: oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.

4. DK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

Voith. Fault Finding DIWA.3, DIWA.3E 15


Possible cause Check / remedy Note / continue with

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 in-


hibited

1. Pushbutton 3 of 6-pushbutton switch de-


pressed.

2. Pushbutton switch (e.g. continuous current Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$ 
terminal S3, although button 3 not pressed), repair or replace, if required. 5S4IPPU DIBQUFS
connector or connecting cable defective. QVTICVUUPOTXJUDI

Fast gear clutch (SK) does not close

Field coil or one of the spools of solenoid valve 1. Check oil pressure at SK connec- 'PSTFUQPJOUT TFFBMTP
DK, connector or connecting cable defective. tion (measuring cover): DIBQUFS
pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if re- 5S4IPPU DIBQUFS
quired. 4,TPMFOPJE

4.11 Poor acceleration after shifting to 4th gear, but normal in 1st,
2nd, and 3rd gear

Fast gear clutch (SK) disks slip

1. Operating pressure too low. Check operating pressure: 'PSTFUQPJOUT TFFBMTP


pArequ’d ≥ 8.3 bar. DIBQUFS 
Adjust pressure, if required.

2. SK solenoid valve hard to move or stuck, 1. Check operating at SK connec- 'PSTFUQPJOUT TDIBQU
e.g. by pollution of a spool or the field coil. tion (measuring cover): %JBHOPTUJDTGVODUJPO( 
pArequ’d ≥ 8.3 bar. 5S4IPPU DIBQUFS
2. Repair or replace solenoid valve. 4,TPMFOPJE

3. Oil pressure after SK solenoid valve too low: 1. Check pressure as discr. above.
oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.

4. SK disks damaged - possibly by used, pollu- Replace disks, replenish or change 3FQBJS.BOVBM
ted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

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


Possible cause Check / remedy Note / continue with

4.12 Kickdown shifting not possible

No signal for separate kickdown switch


(KD)

Kickdown switch, connector or connecting Check switch, connector and cable, %JBHOPTUJDTGVODUJPO& 
cable defective. repair or replace, if required. 5S4IPPU DIBQUFS
LJDLEPXOTXJUDI

No load transmitter signal - load transmit-


ter stage L7 is not reached

1a. For VDO or Voith load transmitter: Check connection and adjust, if re- 4FFDIBQUFS 
connection between injection pump and load quired. %JBHOPTUJDTGVODUJPO&
transmitter set improperly.

1b. For E-Gas systems: 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
engine power restricted due to faulty assign- (compare transmission type to con-
ment of accelerator pedal position and load trol unit nameplate).
transmitter level. 2. Check assignment. TFFDIBQUFSBOE
3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&

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 soleno- 1. Check oil pressure at WP connec- 'PSTFUQPJOUT TFFBMTP
id valve, connector or connecting cable de- tion (measuring cover): DIBQUFS
fective. pArequ’d ≥ 3.5 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 81TPMFOPJE

2. One of the control spools in the converter Disassemble converter outlet valve 3FQBJS.BOVBM
outlet valve hard to move or stuck. and replace, if required.

4.14 Transmission does not shift up, but back to 1st gear and
stays there

No signal regarding vehicle speed

Inductive pick-up N2, connector or connec- Check inductive pick-up N2, connec- %JBHOPTUJDTGVODUJPO+
ting cable defective. tor and connecting cable and repair 5S4IPPU DIBQUFS
or replace, if required. JOEVDUJWFQJDLVQ/

Voith. Fault Finding DIWA.3, DIWA.3E 17


Possible cause Check / remedy Note / continue with

4.15 Transmission shifts to neutral while driving

Control unit E 200 is not supplied with


voltage

Fuse 8A for line +UZ, connector or connect- Check fuse, connector and cable, re- %JBHOEJTQMBZDPNNVOJ
ing cable defective. pair or replace, if required. DBUJPOTOPUFTUBCMJTIFE 
5S4IPPU DIBQUFS
DPOUSPMVOJUWPMUBHF

Solenoid valves without voltage

dS relay "control", connector or connecting Check relay, connector and cable, %JBHOPTUJDTEJTQMBZE4
cable defective. repair or replace, if required. SFMBZXJUIPVUWPMUBHF 
5S4IPPU DIBQUFS
TPMFOPJEWBMWFWPMUBHF

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 Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO(
solenoid valve, connector or connecting ca- cable, repair or replace, if required. 5S4IPPU DIBQUFS
ble defective. 1#TPMFOPJE

2. PB solenoid valve hard to move or stuck, Repair or replace solenoid valve. 3FQBJS.BOVBM
e.g. by pollution of a spool or the field coil.

3. PB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

4. Inductive pick-up N1, connector or con- Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+
necting cable defective. and connecting cable and repair or 5S4IPPU DIBQUFS
replace, if required. JOEVDUJWFQJDLVQ/

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


Possible cause Check / remedy Note / continue with

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 Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO(
solenoid valve, connector or connecting ca- cable, repair or replace, if required. 5S4IPPU DIBQUFS
ble defective. %,TPMFOPJE

2. DK solenoid valve hard to move or stuck, Repair or replace solenoid valve. 3FQBJS.BOVBM
e.g. by pollution of a spool or the field coil.

3. DK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

4. Inductive pick-up N1, connector or con- Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+
necting cable defective. and connecting cable and repair or 5S4IPPU DIBQUFS
replace, if required. JOEVDUJWFQJDLVQ/

4.18 For 4-gear transmissions: hard shifting from 3rd to 4th gear

Fast gear clutch (SK) closes too hard - oil


pressure fault in front of SK

1. One of the coils or spools of the SK sole- Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO(
noid valve, connector or connecting cable cable, repair or replace, if required. 5S4IPPU DIBQUFS
defective. 4,TPMFOPJE

2. SK solenoid valve hard to move or stuck, Repair or replace solenoid valve. 3FQBJS.BOVBM
e.g. by pollution of a spool or the field coil.

3. SK disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

4. Inductive pick-up N1, connector or con- Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+
necting cale defective. and connecting cable and repair or 5S4IPPU DIBQUFS
replace, if required. JOEVDUJWFQJDLVQ/

Voith. Fault Finding DIWA.3, DIWA.3E 19


20 Voith. Fault Finding DIWA.3, DIWA.3E
Possible cause Check / remedy Note / continue with

 'BVMUTXIJMFCSBLJOHXJUIUIFDPO
WFSUFSCSBLF

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. Check connection and adjust, if re- 4FFDIBQUFS 
For VDO or Voith load transmitter: quired. %JBHOPTUJDTGVODUJPO&
connection between injection pump and load
transmitter set improperly.

2b. Control does not receive L0 signal. 1. Check control unit item number %JBHOPTUJDTGVODUJPO"
For E-Gas systems: (compare transmission type to con-
engine power restricted due to faulty assign- trol unit nameplate).
ment of accelerator pedal position and load 2. Check assignment. TFFDIBQUFSBOE
transmitter level. 3. Replace control unit, if required. %JBHOPTUJDTGVODUJPO&

3. Field coil of solenoid valves PB, WP or Check solenoid valves, connectors %JBHOPTUJDTGVODUJPO(
RBK, connector or connecting cable defecti- and cables, repair or replace, if requi- 5S4IPPU DIBQUFS
ve. red. TPMFOPJET

Voith. Fault Finding DIWA.3, DIWA.3E 21


Possible cause Check / remedy Note / continue with

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 Converter brake must already have
gear (it is possible for some versions). 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 sole- 1. Check operating resp. converter 'PSTFUQPJOUT TFFBMTP
noid valve, connector or connecting cable pressure at TB connection (measuring DIBQUFS
defective. cover). %JBHOPTUJDTGVODUJPO( 
2. Check solenoid valve, connector and 5S4IPPU DIBQUFS
cable, repair or replace, if required. 5#TPMFOPJE

2. RBK solenoid valve hard to move or 1. Check operating resp. converter 'PSTFUQPJOUT TFFBMTP
stuck, e.g. by pollution of a spool or the pressure at RBK connection (measur- DIBQUFS
field coil. ing cover). %JBHOPTUJDTGVODUJPO( 
2. Check solenoid valve, connector and 5S4IPPU DIBQUFS
cable, repair or replace, if required. 3#,TPMFOPJE

5.3 The converter brake does not operate in 1st, 2nd, 3rd and 4th
gear via service and hand brake switch

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, 1. Check oil pressure at PB connection: 'PSTFUQPJOUT TFFBMTP
e.g. by pollution of a spool or the field coil. pArequ’d ≥ 8.3 bar. DIBQUFS
2. Check solenoid valve, connector and %JBHOPTUJDTGVODUJPO( 
cable, repair or replace, if required. 5S4IPPU DIBQUFS
1#TPMFOPJE

2. Coil or one of the spools of the RBG so- 1. Check operating resp. converter 'PSTFUQPJOUT TFFBMTP
lenoid valve, connector or connecting ca- pressure at RBG connection (measur- DIBQUFS
ble defective. ing cover). %JBHOPTUJDTGVODUJPO( *
2. Check solenoid valve, connector and 5S4IPPU DIBQUFS
cable, repair or replace, if required. 3#(TPMFOPJE

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


Possible cause Check / remedy Note / continue with

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 Indicator lamp (if installed) at the ma-
switch for activation by the brake pedal nual switch is not lit when the service
(FBAUS). brake switch is operated.

2. Switch, connector or connecting cable de- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO) 
fective. repair or replace, if required. 5S4IPPU DIBQUFS
DPOWFSUFSCBLF0''TXJUDI

3. One of the 3 microswitches in the service Check switch, connector and cable, %JBHOPTUJDTGVODUJPOT'
brake switch (FB), connector or connective repair or replace, if required. 5S4IPPU DIBQUFS
cable defective. TFSWJDFCSBLFTXJUDI

5.5 One of the 3 or all brake stages of the converter brake does
not operate via the 3-stage hand brake switch (manual
switch)

One of the 3 sliding contacts in the hand bra- Check brake switch, connector and %JBHOPTUJDTGVODUJPOT%
ke switch (HB), connector or connecting ca- cable, repair or replace, if required. 5S4IPPU DIBQUFS
ble defective. IBOECSBLFTXJUDI

5.6 For one-stage hand brake switch: stage 2 or 3 of the conver-


ter brake does not operate

Hand brake switch (HB), connector or con- Check brake switch, connector and %JBHOPTUJDTGVODUJPOT%
necting cable defective. cable, repair or replace, if required. 5S4IPPU DIBQUFS
)#TXJUDI TUBHF

Voith. Fault Finding DIWA.3, DIWA.3E 23


Possible cause Check / remedy Note / continue with

5.7 For DIWA.3 in 2nd, 3rd, or 4th gear: hard activation of conver-
ter brake

Converter pressure uncontrolled or too


high

1. WP solenoid valve hard to move or stuck, 1. Check oil pressure at WP connec- 'PSTFUQPJOUT TFFBMTP
e.g. by pollution of a spool or the field coil. tion (measuring cover): DIBQUFS
pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 81TPMFOPJE

2. Oil pressure after WP solenoid valve too 1. Check pressure as discr. above.
low: WP oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.

3. One of the control spools in converter out- Disassemble converter outlet valve 3FQBJS.BOVBM
let valve hard to move or stuck. and repair, if required.

Reverse brake (RB) closes too hard - oil


pressure fault before RBK

1. RBK solenoid valve hard to move or stuck, 1. Check operating resp. converter 'PSTFUQPJOUT TFFBMTP
e.g. by pollution of a spool or the field coil. pressure at RBK connection (measu- DIBQUFS
ring cover).
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 3#,TPMFOPJE

2. RB disks damaged - possibly by used, pol- Replace disks, replenish or change 3FQBJS.BOVBM
luted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

3. Inductive pick-up N2 or N3, connector or Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+ 


connecting cable defective. and connecting cable and repair or 5S4IPPU DIBQUFS
replace, if required. JOEVDUJWFQJDLVQ/PS/

4. Wrong control unit. 1. Check item number of control unit %JBHOPTUJDTGVODUJPOT" *


(compare transmission type to con-
trol unit nameplate).
2. Check assignment.
3. Replace control unit, if required.

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


Possible cause Check / remedy Note / continue with

5.8 For DIWA.3 in 2nd, 3rd, or 4th gear: brake force in brake sta-
ge I too high

Converter pressure too high

1. WP solenoid valve hard to move or stuck, 1. Check oil pressure at WP connec- 'PSTFUQPJOUT TFFBMTP
e.g. by pollution of a spool or the field coil. tion (measuring cover): DIBQUFS
pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 81TPMFOPJE

2. Oil pressure after WP solenoid valve too 1. Check pressure as discr. above.
low: WP oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.

3. One of the control spools in converter out- Disassemble converter outlet valve 3FQBJS.BOVBM
let valve hard to move or stuck. and repair, if required.

5.9 For DIWA.3 in 2nd, 3rd, or 4th gear: brake force in brake sta-
ge II or III too low or too high

Converter pressure too high or too low

1a. Brake force too low: Field coil or one of 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
the spools of the WR solenoid valve, connec- measuring point (fig. 6/2). JOHQPJOU TFFBMTPDIBQ
tor or connecting cable defective. 2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 83TPMFOPJE

1b. Brake force too low: Oil pressure after Check oil-supplying componets and 3FQBJS.BOVBM
WR solenoid valve too low because oil supp- repair or replace, if required.
ly is reduced or interrupted.

2a. Brake force too high: WP solenoid valve 1. Check oil pressure at WP connec- 'PSTFUQPJOUT TFFBMTP
hard to move or stuck, e.g. by pollution of a tion (measuring cover): DIBQUFS
spool or the field coil. pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 81TPMFOPJE

2b. Brake force too high: Oil pressure after Check oil-supplying componets and 3FQBJS.BOVBM
WP solenoid valve too low because oil supp- repair or replace, if required.
ly is reduced or interrupted.

3. One of the control spools in converter out- Disassemble converter outlet valve 3FQBJS.BOVBM
let valve hard to move or stuck. and repair, if required.

4. Wrong control unit. 1. Check item number of control unit %JBHOPTUJDTGVODUJPOT" *


(compare transmission type to con-
trol unit nameplate).
2. Check assignment.
3. Replace control unit, if required.

Voith. Fault Finding DIWA.3, DIWA.3E 25


Possible cause Check / remedy Note / continue with

5.10 For DIWA.3E in 2nd, 3rd, or 4th gear: hard activation of con-
verter brake

In 3rd and perhaps 4th gear and at high (”High speed” means: transmission 4FF0JMBOE$POUSPM$JSDVJU
speeds: Converter filling control (CFC) output speed is higher than the limit %JBHSBNTGPS%*8"&BCPVU
malfunction - converter pressure too set for activation of converter filling UIF$'$
high control, e. g. about 2000 to 2200 rev/
min in 4th gear).

1. WP solenoid valve hard to move or stuck, 1. Check oil pressure at WP connec- 'PSTFUQPJOUTBOENFBTVS
e.g. by pollution of a spool or the field coil tion (measuring cover): JOHQPJOU TBMTPDIBQUFS
and doesn't close correcly. pArequ’d = 0 bar.
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 81TPMFOPJE

2. Converter filling valve hard to move or 1. Check pressure as discr. above.


stuck and doesn't close correcly. 2. Check converter filling valve and re- 3FQBJS.BOVBM
pair or replace, if required.

3. Breather valve hard to move or stuck and 1. Check converter pressure at 'PSTFUQPJOUTBOENFBTVS
doesn't open correcly. measur. point (6/2): pWrequ’d = 0 bar. JOHQPJOU TBMTPDIBQUFS
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.

In 2nd, 3rd, and perhaps 4th gear and at


all speeds: Converter pressure too high

One of the control spools in converter outlet Disassemble converter outlet valve 3FQBJS.BOVBM
valve hard to move or stuck. and repair, if required.

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 1. Check operating resp. converter 'PSTFUQPJOUT TFFBMTP
stuck, e.g. by pollution of a spool or the field pressure at RBK connection (measur- DIBQUFS
coil. ing cover). %JBHOPTUJDTGVODUJPO( 
2. Check solenoid valve, connector 5S4IPPU DIBQUFS
and cable, repair or replace. 3#,TPMFOPJE

2. RB disks damaged - possibly by used, Replace disks, replenish or change 3FQBJS.BOVBM


polluted, wrong or too little transmission oil. oil. 4FSWJDJOH4DIFEVMF
-JTUTPG-VCSJDBOUT

3. Inductive pick-up N2 or N3, connector or Check inductive pick-up, connector %JBHOPTUJDTGVODUJPO+ 


connecting cable defective. and connecting cable and repair or re- 5S4IPPU DIBQUFS
place, if required. JOEVDUJWFQJDLVQ/PS/

4. Wrong control unit. 1. Check item number of control unit %JBHOPTUJDTGVODUJPOT" *


(compare transmission type to control
unit nameplate).
2. Check assignment.
3. Replace control unit, if required.

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


Possible cause Check / remedy Note / continue with

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 Disassemble converter outlet valve 3FQBJS.BOVBM
valve hard to move or stuck. and repair, if required.

5.12 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake
stage II or III too low or too high

Converter pressure too high or too low

1a. Brake force too low: Field coil or one of 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
the spools of the WR solenoid valve, connec- measuring point (fig. 6/2). JOHQPJOU TFFBMTPDIBQ
tor or connecting cable defective. 2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 83TPMFOPJE

1b. Brake force too low: Oil pressure after Check oil-supplying componets and 3FQBJS.BOVBM
WR solenoid valve too low because oil supp- repair or replace, if required.
ly is reduced or interrupted.

1c. Brake force too low: Converter filling val- 1. Check oil pressure at WP connec- 'PSTFUQPJOUT TFFBMTP
ve hard to move or stuck and doesn’t open tion (measuring cover): DIBQUFS
correcly. pArequ’d ≥ 8.3 bar.
2. Check converter filling valve and 3FQBJS.BOVBM
repair or replace, if required.

1d. Brake force too low: Breather valve hard 1. Check converter pressure pW at 'PSTFUQPJOUTBOENFBTVS
to move or stuck and doesn’t close correcly. measuring point (fig. 6/2). JOHQPJOU TBMTPDIBQUFS
2. Check breather valve and repair or 3FQBJS.BOVBM
replace, if required.

2. One of the control spools in converter out- Disassemble converter outlet valve 3FQBJS.BOVBM
let valve hard to move or stuck. and repair, if required.

3. Wrong control unit. 1. Check item number of control unit %JBHOPTUJDTGVODUJPOT" *


(compare transmission type to con-
trol unit nameplate).
2. Check assignment.
3. Replace control unit, if required.

Voith. Fault Finding DIWA.3, DIWA.3E 27


Possible cause Check / remedy Note / continue with

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 1. Check operating resp. converter 'PSTFUQPJOUT TFFBMTP
stuck, e.g. by pollution of a spool or the field pressure at RBK connection (measu- DIBQUFS
coil. ring cover).
2. Check solenoid valve, connector %JBHOPTUJDTGVODUJPO( 
and cable, repair or replace, if requi- 5S4IPPU DIBQUFS
red. 3#,TPMFOPJE

2. Oil pressure after RBK solenoid valve too 1. Check pressure as discr. above.
low: RBK oil supply reduced or interrupted. 2. Check oil-supplying components 3FQBJS.BOVBM
and repair or replace, if required.

3. Wrong control unit. 1. Check item number of control unit %JBHOPTUJDTGVODUJPOT" *


(compare transmission type to control
unit nameplate).
2. Check assignment.
3. Replace control unit, if required.

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


Possible cause Check / remedy Note / continue with

 'BVMUTJOXBSOJOH MBNQT SFMBZTPS


TXJUDIFT
6.1 The central warning lamp (ZW) does not light after turning on
the ignition (ZW is energized a few seconds for test purpo-
ses)

1. Lamp defective.

2. If controlled through relays: relay, con- Check relay, connector and cable, re- %JBHOPTUJDTGVODUJPO( 
nector or connecting cable defect. pair or replace, if required. 5S4IPPU DIBQUFS
DFOUSBMXBSOJOHMBNQ

6.2 The pushbutton switch lighting (TL) does not light after
turning on the ignition

1. For single pushbutton: lamp defective.

2. Pushbutton switch (e.g. terminal TL wit- Check switch, connector and cable, %JBHOPTUJDTGVODUJPO$ 
hout voltage), connector or connecting ca- repair or replace, if required. 5S4IPPU DIBQUFS
ble defect. QVTICVUUPOTXJUDI

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 de- Check lamp, connector and cable, re- %JBHOPTUJDTGVODUJPO( 
fect. pair or replace, if required. 5S4IPPU DIBQU
USBOTNJTTJPOPJMXBSOMBNQ

6.4 Consumer via relays - converter brake (dW), reversing lamp


(dR) or speed (dN) - cannot be activated

1. Consumer not activated in record. Load correct record. %JBHOPTUJDTGVODUJPO(


%JBHOPTUJDTDIBQU

2. Consumer defective. Repair or replace consumer.

3. Relay dW, dR or dN, connector or con- Check relay, connector and cable, re- %JBHOPTUJDTGVODUJPO(
necting cable defect. pair or replace, if required. 5S4IPPU DIBQUFS
SFMBZE8 E3PSE/

Voith. Fault Finding DIWA.3, DIWA.3E 29


30 Voith. Fault Finding DIWA.3, DIWA.3E
 .FBTVSJOHEFWJDFT
The following equipment is required for troubleshooting if faults in DIWA.3 and DI-
WA.3E transmissions occur:

PC or laptop with PC program Di-


wagnosis 59.2500. .. (latest versi-
on), level converter and connec-
ting cable
If the diagnostic program is used. %JBHOPTUJDT
Cable: Voith order no. 56.4219.10

Measuring cover (high design)


To measure the oil pressures of clut-
ches, brakes and valves of the
transmission.
Voith order no. 56.4218.10

Measuring cover (flat design)


For restricted spaces in the trans-
mission space.
Voith order no. 56.4217.10

Pressure gauge
To measure the operating and con-
verter pressure.
Voith order no. 58.2748.11

Multimeter
To measure voltages and resi- 4FF5SPVCMF4IPPUJOH
stances.

Voith. Fault Finding DIWA.3, DIWA.3E 31


32 Voith. Fault Finding DIWA.3, DIWA.3E
 $IFDLJOHPJMQSFTTVSFT
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), imme-
diately 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 (fi-
gure 1/1).

If a measuring cover (figs. 2 and 3)


is used, pressures which must cor-
respond 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

Note! The WR oil pressure is cy-


cled and therefore variable over
time, its amount in addition de-
pending on the relevant operating
state (during braking or rever-
sing). Therefore, simple pressure
measurements by means of pres-
sure gauges are not adequate for
more thorough troubleshooting.
3

The measuring points TB, RBG and RBK are each pressurized with the higher ope- 4FFDIBQUFS
rating or converter pressure.
Exceptions: The RBK pressure is set to
1. approx. 2.5 bar for converter pressure reduction WDA,
2. max. approx. 2 bar for braking in 1st gear range (chapters 5.4 and 5.6).

Danger! Connect pressure gauge, or change measuring cover, only with the en-
gine stopped, otherwise hot oil may result in scalding!

Voith. Fault Finding DIWA.3, DIWA.3E 33


If the measuring points mentioned
are not accessible, the operating
pressure can also be measured for
DIWA.3 transmissions at the inter- POMZGPS%*8"
mediate 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 resi-
stance to obtain the value for the
operating pressure.
Note! Only measure before the fil-
4 ter if the filter element is clean!

The working pressure can be set at TFF3FQBJS.BOVBM


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 leaka-
ge and sealing gaps of the gear
pump.

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. $VTU4FSW-FUUFSOP
3FQBJS.BOVBM
Measuring point
Usually, the converter pressure is
measured at measuring point (6/2).

Converter pressure with WDA de- POMZGPS%*8"


activation
At toil of = 80 - 90 °C (= 176 - 194 °F),
the converter pressure must be
0,7 < pW < 2 bar

Converter pressure when conver- POMZGPS%*8"&


ter filling control (CFC) is active
pW = 0 bar

Converter pressure during bra-


king
At toil of = 80 - 90 °C (= 176 - 194 °F),
6 with 2nd gear engaged (3rd gear in-
hibited) and approx. 50 % of maxi-
mum speed for 2nd gear, the con-
verter pressure pW must be:
brake stage I: pW = 0.2 - 0.7 bar GPS%*8"&POMZXIFO$'$JT
brake stage II: pW = 1.8 - 2.5 bar OPUBDUJWF
brake stage III: pW = 3.6 - 4.9 bar

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


 5FTUJOH UIF NPUPS DPOUSPM  USBOT
NJTTJPOJOUFSGBDF

9.1 Engine idle speed

In particular in conjunction with electronic engine control units, it is frequently not pos-
sible to set the idle speed n in a simple manner. In addition, the settings are system-
dependent (guideline: n ≥ approx. 500 - 600 rpm with warm engine). On the other
hand, the idle speed must not be too high, because the input clutch, for example, will
not close: n ≤ 850 rpm (for gas engine: n ≤ 1000 rpm). %JBHOPTUJDTGVODUJPO*
During a function check, the speed can be measured by means of the diagnostic pro-
gram, for example.
Note! If the idle speed must be changed, contact the bus manufacturer, if requi-
red.

9.2 Test: load transmitter signals as function of accelerator pe-


dal 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 man- 4FF5FDIOJDBM.BOVBMT 
ner dependent on the engine control system. DIBQUFSJOUFSGBDFT

The following settings can be checked in a relatively simple manner with the bus stop-
ped by means of the diagnostic program: %JBHOPTUJDTGVODUJPO&
1. Load level L0 = "idle", accelerator pedal completely released.
2. Load level L6 = "full load", accelerator depressed to the stop (first, if any). Depend-
ent on the bus design, this accelerator pedal position may also be defined as L7 =
"kickdown", which is indicated by the diagnostic system.
3. Inf installed: load level L7 = "kickdown", accelerator pedal depressed beyond the
first and to the end stop against greater resistance.
4. Gradually depress the accelerator pedal from idle to full load and check that the %JBHOPTUJDTGVODUJPO*
"partial load" signals L2 to L5 are also displayed by the diagnostic system.
Note! For an accurate check of the load transmitter partial load signals as func-
tion of the accelerator pedal travel, documents from the bus manufacturer are
required.

Danger! When settings are made with the bus stopped, apply the parking brake
to prevent unintended rolling of the vehicle!

If the diagnostic system indicates load levels that do not correspond to the accelerator
pedal position, the following causes for faults may exist, apart from cable and connec-
tor defects:
1. Setting of accelerator pedal stops (idle, full load, kickdown, if installed).
2. With a VDO or Voith load transmitter: connection between load transmitter and in-
jection pump, see figures 7 and 8 on next page.
3. With electronic engine control units: connection between accelerator pedal and
load transmitter (setpoint switch), see figure 9 on next page.
4. Wrong control unit with data of the wrong load transmitter type (indicated by dia- %JBHOPTUJDTGVODUJPO"
gnostic system).

Voith. Fault Finding DIWA.3, DIWA.3E 35


Adjusting the connection between load transmitter and injection pump 4FF5FDIO.BOVBMT
DIBQUFSJOUFSGBDFT

Injection Connection transmitter


pump

Mark for Mark for


0 load position full load position
7

If the injection pump lever the load transmitter lever must


is in 0 load position be on the 0 load mark too!

If the injection pump lever the load transmitter lever must


is in full load position 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 transmit-
ter must be in proportion to each other! For example, if the injection pump lever
is moved by 1/3 of the angle between 0 and full load, the load transmitter lever
must also be move by 1/3 of its angle between 0 and full load!

Example for load transmitter adjustment


with electronic engine control unit

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


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 ope-
ration. Indirectly, they can be determined in a relatively simple manner by speed
measurements in the so-called stall point - e.g. by means of the diagnostic program. %JBHOPTUJDTGVODUJPO*

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 trans-
mission - 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

4H 4X 4V 4G 3H
1500
4F
1400
1300 3X
1200
1100 3V
Engine torque M1 (Nm)

1000
3G
900 3F
800
700
600
500
400
300
200
100
0
400 600 800 1000 1200 1400 1600 1800 2000 2200
Engine speed N1 (rpm)
10

Voith. Fault Finding DIWA.3, DIWA.3E 37


38 Voith. Fault Finding DIWA.3, DIWA.3E
"QQFOEJDFT

1 hydraulic control diagram DIWA.3


1 hydraulic ccontrol diagram DIWA.3E
1 circuit diagram DIWA.3
1 circuit diagram DIWA.3E

Voith. Fault Finding DIWA.3, DIWA.3E 39


C
WR SK

9
8 DK
B
7

EK TB

A Converter drain valve (CDV)


pa B Operating pressure
PB RBG valve (OPV)
C Solenoid valves
D Relief valve
E Pressure accumulator TB
F DIWA.3 transmission
WP RBK G Gear pump
H Heat exchanger
J Oil filter

1-6 CDV spools


7,8 OPV spools
9 Shuttle valve
10 Reverse gear brake RB
pw
11 Turbine brake TB
12 Pump brake PB
15 14 13 12 11 10 13 Step-up gear clutch SK
14 Lock-up clutch DK
15 Input clutch EK

Shifting function EK DK SK PB TB WP WR RBK RBG


ANS activation x x1)
6
G ANS activ. via parking brake
1st gear (DIWA drive range) x
x
x x
Upshift 1st-2nd gear* x x
5 2nd gear x x x

A D 3rd gear x x x

E 4th gear
Braking 1st gear range x
x x
x
x
x x x1)
1st braking stage - 2nd gear x x x x x
2nd and 3rd brak. stage - 2nd gear x x x x2) x x
2nd and 3rd brak. stage - 3rd gear x x x x2) x x

J H F 2nd and 3rd brak. stage - 4th gear


Reverse gear < 1 km/h x
x x x x2)
x
x
x
x
x
3 2 1 Reverse gear > 1 km/h x x x1,2) x x
4 * = Transition 1) = Valve regulated
2)
= Valve oscilated

Drawn: Neutral position


Hydraulic control diagram
DIWA.3 55.2059.12
C 9
D
SK WR
8

10

pA DK

7
EK TB
B
A Converter drain valve (CDV)
B Converter filling valve (CFV)
C Operating pressure
PB RBG valve (OPV)
D Solenoid valves
E DIWA.3E transmission
F Gear pump
G Heat exchanger
WP RBK H Oil filter

1-6 CDV spools


7 CFV spool
8,9 OPV spools
10 Shuttle valve
11 Reverse gear brake RB
12 Turbine brake TB
pW
13 Breather valve
14 Pump brake PB
17 16 15 14 13 12 11 15 Step-up gear clutch SK
16 Lock-up clutch DK
17 Input clutch EK
E
Shifting function EK DK SK PB TB WP WR RBK RBG
1st gear (DIWA drive range) x x x
Upshift 1st-2nd gear* x x
6 F 2nd gear x x x
3rd gear x x x
4th gear x x x
5
3rd gear with converter filling control (CFC) x x
A 4th gear with CFC x x
1st, 2nd and 3rd brak. stage - 4th gear with CFC* x x x
1st braking stage - 4th gear x x x x x
2nd and 3rd brak. stage - 4th gear x x x x2) x x
2nd and 3rd brak. stage - 3rd gear x x x x2) x x

H 2nd and 3rd brak. stage - 2nd gear


Braking 1st gear range
x
x
x
x
x
x
x2)
x
x
x1)
x

G ANS activation x x1)


4 3 2 1 ANS activation via parking brake x
Reverse gear < 1 km/h x x x x
Reverse gear > 1 km/h x x x2) x x
* = Transition 1) = Valve regulated
2) = Valve oscilated

Drawn: Rest position


Hydraulic control diagram
DIWA.3E 55.5661.15
1

A 1 2 3 D N R
221
202
238

221.1
+UB
+FB
20
38
2
-UB
EK

DK
19
55
37
119

137
221.3 -UB SK 118
21 18
-UB
39 54
a 3
REA0
RBG
36
117
17
240 FB1 22 -UB 153
53
204 KD 40 WR 135
35
204.1 KD -UB
4 16
-UB 152
23 52
241.1 DKV/PWM -UB

A b c 205.1
224.1
DKR
DKE
41
5
EKM
DKM
34
15
7
8
S1 S2 S3 S2/1 S2/2 S3/2 S3/3 24 51
SKM 3
D N R 42 33
PBM 6
2 D N R 6 14
200 TBM 4
1 2 D N R 25 50
1 2 3 D N R 43 32
207 HBA RBKM 5
226 7 13
HBB SENSE 1
244 26 49
HBC SENSE 2
44 31

S3/2
S2/1

S2/2

S3/3
208 +HB -UB
S1 227 227 S1 8 12
1 -UB 148
S2 245 245 27 48
2 S2 -UB
S3 209 209 S3 45 30
3 N1A 111
+V 228 228 +V 9 11
4 N1B 147
+R 246 246 +R 28 47
5 N2A 129
RS 230 210 46 29
6 /N N2B 110
+TS 229 10 10
7 229 +TS N3A 146
+TL 233 29 46
8 N3B 128
/N 210 47 28
9 211 FB2
-UB 221 11 9
10 230 RS
SSP 200 30 45
11 248 PU -UB
RF 256 48 27
12 212 BS TS+ 9
RS 12 8
13 231 FBAUS TS- 10
+R FB3 31 44
14 249 -UB
49 26
213 dS
13 7
dW

B C D
232
32 43
250 dN
50 25
214 dR IO9
14 6
233 +TL
33 42
251 ZW LGM 124
51 24
215 TOEL -LG 105
15 +LG 5 141
34 41
252 DIAGN-K IO3
52 23
252.1
216 DIAGN-L 4
16 40
227 -UB
z 0 1 2 3
S1
S2 245 1
227
245
216.1
WP
22
103
z 0 3 0 1 2 3 221.2 S3 209 2 209
235 ABSICH
ABS
35 -UB 3
221.2
y 0 1 2 3 228 3
253
53 39
y x +V 228 217 CAN-H RBK 121

T
4 17 21

U x +R 246 246 236 CAN-M PB 102


HBC 0 0 0 1 230 5 230 36 -UB 2
RS
6 54 38
HBC 0 1 HBB 0 0 1 1 +TS 229 229 TB 120
7 20
HBA 0 1 6 HBA 0 1 1 1 +TL 233 233 237 CAN-L 18 PA 101
1 1 210 8 37 1
HBC +HB 1 1 5 +HB 1 1 1 1 /N 210 255 dNEUTR
2 2 221 9 55
4 -UB 221 219
3 3 -UB 221.2 10 +UZ
-UB 219.1

+
4 244 4 244 11 19
HBA HBC 3 244 HBC 244 219.2
5 226 HBB 5 226 HBB 226 12 226
2
6 207 6 207 13 207
HBA 1 207 HBA
+HB 7 208 +HB 7 208 +HB 208 14 208

+
8 8 SSP 200 15 200
RF 256 16
17
18 219.2 +UZ

E F
221.3 -UB 1
252.1 DIAGN-K 2
216.1 DIAGN-L 8
10

S R
G
141 +LG
1
124 LGM
2
204 105 -LG
1 219 3
4

2 3 Q

128
146
152
153

147
111

110
129

135
137
119
102
103
121
117
120
101
118

9
148

4
3

1
10

2
6
5
KD 204 204
+UZ 219 1 219 A B C D E F G H J K L MN P R S T U V WX Y Z a b c d e f g h j
gn/ge FB1 240 2 240
240
1 3 249
bl 249 FB3 249
2 +FB 202 4 202
sw 202
3 5 211
br 211 FB2 211
4 6
7 + ws bl

P
4
ϑ
1 sw bl
8 -

H
2 3
9
bl
10
n1
ws
sw
2 bl
ws
sw n3
M
CAN-H 217 sw CAN-H 1
C
CAN-M 237 ge CAN-M
CAN-L B 236 CAN-L
A ws
sw n2
h i j k l m sw
2
br br
ge
2
sw
ge
WR SK
O
dS dW dR dN 4
gn bl
bl 3
rt bl rt
1 1
br

N
sw
2 ge
30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a ge
DK bl
rt
4
3
gn
bl
1
sw br br sw

J
2 ge ge 2
ge ge
EK bl
4 gn gn 4 bl TB
n rt 3
1
bl bl 3
1
rt

K
br
s st u sw
2
br
2
sw

q 61 D- D+
PB
ge
bl
4
ge
gn RBG
M 3
p v
238 +UB
rt
1
bl bl
1
rt

50e 50f D+ o 1
2
213 dS
sw br br sw

r w G 150
3
219.1 +UZ 2 ge 2 ge
RBK
t 4
214
232
dR
dW WP rt bl
gn
bl
4
3
bl
rt
5 251 ZW 1 1
6 253 ABS
7 250 dN
8 255 dNEUTR
9 252 DIAGN-K
10 216 DIAGN-L
11 200 SSP
DKR 12 205.1 DKR A Push-button switch L Switches and warning a Inhibitor switch for reverse gear m Relay for speed
13
DKE
DKV/PWM 14
224.1
241.1
DKE
DKV/PWM
B Connection cable for light transmission oil b Connections n Central warning light
15 204.1 KD push-button switch and M Engine control c Bridges o Fuse 8A
M 16
17
18
19
215
231
248
235
TOEL
FBAUS
PU
ABSICH
converter brake
C Cable 2
N Vehicle electrical system -
non-committal representation
d
e
Warning light transm. oil
Cut-out switch for conv. brake;
p
q
Relay for battery
Switch box
20 212 BS D E 200 control unit O Relays only for brake valve r Starter inhibitor relay
21 221.1 -UB
E Connection: level con- P CAN Bus f Pressure switch for s Starter
off

22
on

ABS verter and diagnostic PC Q Connection cable for gearshift inhibitor st Start button
P P
F Cable 1 brake valve and g Pressure switch for t Battery
d e f g G Load transmitter kickdown switch ANS activation u Overvoltage protection
H Speed and temperature R Kickdown switch h Relay for control unit v Generator

L sensors S Brake valve i Relay for starter inhibitor w Regulator


inactive
J Solenoid valves T Manual switch for j Relay for centr. warn. light x Connections
K Connection cable converter brake k Relay for converter brake y Position Circuit diagram DIWA.3
+ 24V
for vehicle wiring U Switch for converter l Relay for reversing light z Stage no.
brake; stage no. 3
55.3705.20
A
1
20
238 +UB EK 119
1 2 3 D N R 202 +FB
38
-UB 19
221 221.1 2 55 137
DK
221.3 -UB 37 118
SK
21 -UB 18

a 39
3
REA0
RBG
54
36 117
240 FB1 22 17 153
-UB
204 40 53 135
KD WR
204.1 KD 35
-UB
4 16 152
-UB
241.1 DKV/PWM 23 52
-UB

A b c 205.1
224.1
DKR
DKE
41
5
EKM
DKM
34
15
7
8
S1 S2 S3 S2/1 S2/2 S3/2 S3/3 24 51 3
D N R SKM
42 PBM 33 6
2 D N R 6 14
200 TBM 4
1 2 D N R 25 50
1 2 3 D N R 43 32
207 HBA RBKM 5
226 HBB 7 SENSE 13 1
244 HBC 26 SENSE 49 2

S3/2
S2/1

S2/2

S3/3
208 +HB 44 -UB 31
S1 227 8 12 148
1 227 S1 -UB
S2 245 27 48
2 245 S2 -UB
S3 209 45 30 111
3 209 S3 N1A
+V 228 9 11
4 228 +V N1B 147
+R 246 28 47 129
5 246 +R N2A
RS 230 46 29
6 210 /N N2B 110
+TS 229 10 10
7 229 +TS N3A 146
+TL 233 29 46 128
8 N3B
/N 210 FB2 47 28
9 211
-UB 221 230 11 9
10 RS
SSP 200 30 45
11 248 PU -UB
RF 256 BS 48 27 9
12 212 TS+
RS FBAUS 12 TS- 8
13 231 10
+R 249 FB3 31 -UB 44
14 26
213 dS 49
13 7

B C D
232 dW
32 43
250 dN
50 25
214 dR IO9
14 6
233 +TL
33 42 124
251 ZW LGM
51 24 105
215 TOEL -LG
15 +LG 5 141
41
252 DIAGN-K 34 IO3
52 23
252.1
216 DIAGN-L 4
227 16 -UB 40
S1 227 216.1
z 0 3 2
z 0 1 2 3 S2 245 1 245 235 ABSICH
22
103
221.2 0 1 3 221.2 S3 209 2 209 253 ABS
35 -UB 3

y y 0 1 2 3 +V 228 3 228 217 CAN-H 53 RBK 39


121
x
T
4 17 21

U x +R 246 246 236 CAN-M PB 102


230 5 36 -UB 2
HBC 0 0 0 1 RS 230
229 6 54 38
HBC 0 1 HBB 0 0 1 1 +TS 229 TB 120
HBA 0 1 233 7 18 WP 20
6 HBA 0 1 1 1 +TL 233 237 CAN-L 101
1 1 8 37 1
HBC +HB 1 1 5 +HB 1 1 1 1 /N 210 210 255 dNEUTR
2 2 9 219 55
4 -UB 221 221
3 3 221.2 10 +UZ
-UB -UB 219.1

+
4 4 11 19
HBA 244 HBC 3 244 HBC 244 244 219.2
5 226 HBB 5 226 HBB 226 12 226
2
6 HBA 6 207 13 207
207 1 207 HBA
+HB 7 +HB 7 208 +HB 208 14 208
208

+
8 8 200 15
SSP 200
RF 256 16
17
18 219.2 +UZ

E
1

F
221.3 -UB
252.1 DIAGN-K 2
216.1 DIAGN-L 8
10

S R 141 +LG

G
1 124 LGM
204 2 105 -LG
1 219 3
4

2 3 Q

128
146
152
153

147
111

110
129

135
137
119
102
103
121
117
120
101
118

9
148

4
3

1
10

2
6
5
KD 204 204
+UZ 219 1 219 A B C D E F G H J K L MN P R S T U V WX Y Z a b c d e f g h j
gn/ge 240 FB1 2 240
240
bl 1 FB3 3 249
249 249
sw 2 202 +FB 4 202
202
br 3 211 FB2 5 211
211
4 6
7 + ws bl
ϑ 1

P
- 4 bl
8 sw

H
2 3
9
10 ws bl ws
n1 sw 2 bl sw
n3
M
CAN-H 217 sw CAN-H 1
C
CAN-M 237 ge CAN-M
CAN-L B 236 CAN-L
A ws
sw n2
h i j k l m sw
2
br br
2
sw
ge ge
dS dW dR dN 4
SK
O
gn
bl
rt 3
1
bl WR
bl rt
1

N
sw br
30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a ge 2 ge
4
DK bl
rt 3
gn
bl
1
sw br br sw

J
2 ge ge 2 ge
ge
n EK bl
rt
4
3
gn
bl
gn
bl
4
3
bl
rt
TB
1 1

K
br
s st u sw
2
br
2
sw
q PB
ge
4
ge

M
61 D- D+ bl
3
gn
bl RBG
p v o 1
238
213
+UB
dS
rt
1
bl
1
rt

50e 50f D+ 2 sw br
150 219.1
r w G 3 214
+UZ 2 br sw
t 4 232
dR
WP ge 2 ge
5
6
251
dW
ZW
rt
1
bl gn
bl
4
3
bl
rt
RBK
253 ABS 1
7 250 dN
8 255 dNEUTR
9 252 DIAGN-K
10 216 DIAGN-L
11
12
200 SSP A Push-button switch L Switches and warning a Inhibitor switch for reverse gear m Relay for speed
DKR 205.1 DKR
DKE 13 224.1 DKE B Connection cable for light transmission oil b Connections n Central warning light
14
DKV/PWM
15
241.1
204.1
DKV/PWM
KD
push-button switch and M Engine control c Bridges o Fuse 8A

M
16
17
215 TOEL converter brake N Vehicle electrical system - d Warning light transm. oil p Relay for battery
231 FBAUS
18 248 PU C Cable 2 non-committal representation e Cut-out switch for conv. brake; q Switch box
19
20
235
212
ABSICH D E 200 control unit O Relays only for brake valve r Starter inhibitor relay
BS
21 221.1 -UB E Connection: level con- P CAN Bus f Pressure switch for s Starter
off
on

22
verter and diagnostic PC Q Connection cable for gearshift inhibitor st Start button
ABS P P F Cable 1 brake valve and g Pressure switch for t Battery
G Load transmitter kickdown switch ANS activation u Overvoltage protection
d e f g H Speed and temperature R Kickdown switch h Relay for control unit v Generator
sensors S Brake valve i Relay for starter inhibitor w Regulator
L
inactive
J Solenoid valves T Manual switch for j Relay for centr. warn. light x Connections
K Connection cable converter brake k Relay for converter brake y Position Circuit diagram DIWA.3E
+ 24V for vehicle wiring U Switch for converter l Relay for reversing light z Stage no.
brake; stage no. 3 55.6168.10
Voith Turbo GmbH & Co. KG
Produktgruppe Nutzfahrzeuggetriebe
Alexanderstraße 2
D-89522 Heidenheim
Telephone (07321) 37-0
Telefax (07321) 37 7618
3 AUTOMATIC GEARBOXES
DB 250 PF Series ZF-ECOMAT 2 Transmissions

1. REPAIR MANUAL ZF-ECOMAT 2 STAGES 1-2

0145 1-1
AUTOMATIC GEARBOXES 3
ZF-ECOMAT 2 Transmissions 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Instructions for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Arrangement of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cutaway views of Ecomat transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch and brake combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1


1.2 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Checking oil level at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.8 Checking oil level when cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.9 Checking oil level with engine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.10 Checking oil level on versions with heat exchanger higher than center line of transmission . . . . . . . . . . . 1-3
1.11 Changing oil at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Renewing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1


2.2 Renewing retarder solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Renewing accumulator solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Renewing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Renewing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6 Renewing output sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6.1 Renewing retarder resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7 Removing and fitting oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.8 Renewing turbine sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.9 Renewing complete hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.10 Changing complete oil level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.11 Renewing impulse sensor for speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2.12 Renewing output flange and/or radial seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.13 Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Contents HP 502 C / HP 592 C / HP 602 C

Page

3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Terminal tester concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1


3.2 Test instructions for test cable 1 PO1 138 153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Annex
Description/menus for “ZF Testman”

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 mainte-
nance 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 Damage resulting from work performed by non-ZF


C.V./Special Transmissions personnel in an improper and unprofessional manner
Service Plant 2 and any consequential costs are excluded from the con-
Tel.: (0 75 41) 77-0 tractual liability agreement. Exclusion of liability also
Fax: (0 75 41) 77-5726 applies if genuine ZF spares are not used.

5
Important information HP 502 C / HP 592 C / HP 602 C

SAFETY NOTICE GENERAL INFORMATION

Companies repairing ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.

To avoid injury to personnel and damage to pro-


ducts, all safety regulations and legal requirements CAUTION
which apply to repair and maintenance work must Pictures, drawings and components do not always
be adhered to. represent the original object, but are used to illustrate
Before starting work, mechanics must familiarize working procedures.
themselves with these regulations. Pictures, drawings and components are not to scale.
Conclusions about size and weight should not be
Personnel required to carry out repairs on ZF products drawn (even within a complete illustration).
must receive appropriate training in advance. It is the Always follow the working steps as described in the
responsibility of each company to ensure that their text.
repair staff is properly trained.

After completion of repair work and testing, skilled staff


must satisfy themselves that the product is functioning
The following safety instructions appear in this correctly.
manual:

 THREATS TO THE ENVIRONMENT !


NOTE Lubricants and cleaning agents must not be allowed
Refers to special processes, techniques, data, use to enter the soil, ground water or sewage system.
of auxiliary equipment, etc. • Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
CAUTION • Collect used oil in a suitably large container.
This is used when incorrect, unprofessional • Dispose of used oil, dirty filters, lubricants
working practices could damage the product. and cleaning agents in accordance with
environmental protection guidelines.
• When working with lubricants and cleaning
 DANGER agents always refer to the manufacturer’s
This is used when lack of care could lead to instructions.
personal injury or death.

CAUTION
The transmission must NOT be hung by the input
shaft NOR by the output flange.

6
HP 502 C / HP 592 C / HP 602 C Instructions for repairs

In case of doubt always turn to the relevant depart- GASKETS, LOCKING PLATES
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed expertly Parts which cannot be removed without being damaged
and under clean conditions. must always be replaced with new parts (e.g. gaskets
Use specified tools to dismantle and assemble trans- and locking plates).
missions.

After removing the transmission from the vehicle,


clean thoroughly with a suitable cleaning agent before SHAFT SEALS
opening.
Pay particular attention to the projections and recesses Always change shaft seals with rough, ripped or
of housings and covers when cleaning. hardened packing washers. Seal contact surfaces must
Parts joined with Loctite are easier to separate if be totally clean and in perfect condition.
warmed with a fan heater.

RE WO R K I N G
CLEANING PARTS
Rework may be carried out on seal contact surfaces
Remove remains of old gaskets on all seal-faces. using plunge-cut grinding only, never use an emery
Carefully remove burrs or similar patches of roughness cloth. Ensure that there are no traces of grinding or
using an oil-stone. riffling.

Lube bores and grooves must be free of anti-corrosion If rework is needed on distance washers, shims etc.
agents and foreign matter; check for perfect passage. because of clearance settings, ensure that the reworked
areas contain no face runout and have the same surface
Carefully cover opened transmissions to prevent foreign quality.
matter from entering.

TRANSMISSION ASSEMBLY
REUSING PARTS
Find a clean site to assemble the transmission. Gaskets
Parts such as ball or roller bearings, multi-discs, thrust are installed without the use of sealing compound or
washers etc., must be inspected by a competent person, grease. When measuring silicon-coated gaskets, take
who should decide whether or not they can be re-used. care not to include the silicon layer in the measure-
Replace parts which are damaged or have suffered from ment.
excessive wear. During assembly, comply with all adjustment data,
checking data and tightening torques in the Repair
Manual.

7
Instructions for carrying out repairs HP 502 C / HP 592 C / HP 602 C

BEARINGS d) Dual shaft seals have two sealing


lips. The dust-proof sealing lip (X)
If bearings are mounted in heated condition, they are to must face outwards.
be heated evenly (e.g. heating cabinet). ;
Temperature should be at ca. 85 °C and must not exceed e) Fill the gap between the sealing
120 °C. Each mounted bearing must be oiled with lips so it is 60% filled with grease (e.g. produced
operating oil. 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
SEALING mounting or faceplate onto the relevant installation
depth plan.
If a specific sealing agent* is to be used for sealing,
comply with the manufacturer’s 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 R E TAI NI NG AG E NT S
sealing agent on the surfaces to be sealed near apertures
to ensure that no sealing agent enters the oil feeds when Retaining agents* may only be used in places as
the surfaces are sealed. specified in the parts list.
Always comply with manufacturer’s 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 After completing repairs, fill transmissions with trans-
8420 to the outer edge or wet with a lubricant, e.g. a mission oil. For the procedure and approved oils, refer
water-soluble, concentrated washing-up liquid (e.g. to the transmission operating manual and List of Lubri-
Pril, Coin, Palmolive). cants TE-ML (refer to identification plate) which are
available from any ZF After-Sales Service Point. After
c) Shaft seals with steel and rubber surrounds should be filling the transmission with oil, tighten the screw plugs
treated on the outer edge of the rubber surround as at the oil filling point and the oil overflow to the speci-
described above in section b). fied torques.

* refer to expendable material

8
HP 502 C / HP 592 C / HP 602 C Tightening torques

Tightening torques for nuts and bolts, extract from


ZFN 148

This standard applies to bolts acc. to DIN 912, DIN 931, Surface condition of bolts: thermally blackened and
DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934. oiled or galvanized and oiled or galvanized, chrome-pla-
This Standard contains data on tightening torques (MA) ted and oiled.
for bolts and nuts in strength categories 8.8, 10.9 and
12.9 and nuts in strength categories 8, 10 and 12. Tighten screws with a calibrated torque spanner.

NOTE
Irregular tightening torques are listed separately in the
Repair Manual.

Regular screw thread Fine screw thread

Size Tightening torque Size Tightening torque


MA (Nm) for MA (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12

M 4 2.8 4.1 4.8 M 8x1 24 36 43


M 5 5.5 8.1 9.5 M 9x1 36 53 62
M 6 9.5 14 16.5 M 10 x 1 52 76 89

M 7 15 23 28 M 10 x 1.25 49 72 84
M 8 23 34 40 M 12 x 1.25 87 125 150
M 10 46 68 79 M 12 x 1.5 83 122 145

M 12 79 115 135 M 14 x 1.5 135 200 235


M 14 125 185 215 M 16 x 1.5 205 300 360
M 16 195 280 330 M 18 x 1.5 310 440 520

M 18 280 390 460 M 18 x 2 290 420 490


M 20 390 560 650 M 20 x 1.5 430 620 720
M 22 530 750 880 M 22 x 1.5 580 820 960

M 24 670 960 1100 M 24 x 1.5 760 1100 1250


M 27 1000 1400 1650 M 24 x 2 730 1050 1200
M 30 1350 1900 2250 M 27 x 1.5 1100 1600 1850

M 27 x 2 1050 1500 1800


M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500

Edition: August 1991 / checked 1997

9
Tightening torques HP 502 C / HP 592 C / HP 602 C

Screw plugs DIN 908, 910 and 7604 Union screws DIN 7643

The screw plug tightening torques MA were determined The tightening torques MA were determined for
according to DIN 7604 for screwing into steel, grey cast screwing into steel, grey cast and aluminum alloys.
and aluminum alloys. The values are based on experience and are intended
The values are based on experience and are as reference values for the fitter.
intended as reference values for the fitter. General rule: screw/bolt class 5, ZFN 148-1
The values for the tightening torque MA apply analo- Material: 9SMnPb28K acc. to DIN 1651
gously for screw plugs according to DIN 908 and Surface condition: as manufactured
DIN 910, as the thread geometries are almost identical. (without surface protection) and lightly
General rule: Screw/bolt class 5, ZFN 148-1 oiled or galvanized, chromated and
Screw/bolt material: steel acc. to lightly oiled.
DIN 7604. Surface condition: as manufac-
tured (without surface protection) and
lightly oiled or galvanized, chromated and
lightly oiled.

Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)

Dimensions Tightening torque Pipe Thread Tightening


screwed into outer torque MA
steel/gray cast Al alloy diameter in Nm
M 8x1 20 10 4-5 M8x1 20 - 25
M 10 x 1 25 / 30* 15 / 20*
M 12 x 1.5 35 25 6 M 10 x 1 25 - 35
M 14 x 1.5 35 25
M 16 x 1.5 40 30 8 M 12 x 1.5 30 - 40
M 18 x 1.5 50 35
M 20 x 1.5 55 45 10 M 14 x 1.5 35 - 40
M 22 x 1.5 60 / 80* 50 / 65*
M 24 x 1.5 70 60 12 M 16 x 1.5 45
M 26 x 1.5 80 / 105* 70 / 90*
M 27 x 2 80 70 15 M 18 x 1.5 50
M 30 x 1.5 100 / 130* 90 / 130*
M 30 x 2 95 85 18 M 22 x 1.5 60
M 33 x 2 120 110
M 36 x 1.5 130 115 22 M 26 x 1.5 90
M 38 x 1.5 140 120
M 42 x 1.5 150 130 28 M 30 x 1.5 130
M 42 x 2 145 125
M 45 x 1.5 160 140 35 M 38 x 1.5 140
M 45 x 2 150 130
M 48 x 1.5 170 145
M 48 x 2 160 135
M 52 x 1.5 180 150
M 60 x 2 195 165
M 64 x 2 205 175
* DIN 7604 Form C
Status: October 1995

10
HP 502 C / HP 592 C / HP 602 C Expendables

Description Name Approx. Application Remarks


ZF reference no. quantity

Grease for example: General assembly aid


0750 199 001 Spectron FO 20

Sealing compound WEVO-L100 Screwing connection on


0666 790 017 output flange

Grease Industrial grade General assembly aid


0671 190 016 Vaseline 8420

Transmission oil refer to TE-ML14 General assembly aid


List of Lubricants

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 Dimension Measurement device Remarks

01. Internal resistance of R = approx. 67 ohm Ohmmeter and test Resistance rises with tempe-
solenoid valves for at 68 °F cable 1P01 138 153 rature to approx. 74 Ohm
clutches and brakes in (20 °C) or terminal tester when transmission at
transmission 6008 006 002 operating temperature.

02. Internal resistance of R = 1080 Ohmmeter Resistance rises with tempe-


inductive sensors (speed ± 40 ohm at rature to approx. 1350 Ohm
sensors) nT and nOut 68 °F (20 °C) when transmission at
operating temperature.

03. Tightening torque for 26 ft-lbs Torque wrench Renew copper sealing ring.
M14x1.5 temperature 35 Nm
sensor

04. Tightening torque for 37 ft-lbs Torque wrench Renew copper sealing ring.
M22x1.5 oil drain plug in 50 Nm
oil pan

05. Clearance between induc- 0.02 - 0.027" Depth gauge, slider Adjust clearance with shims
tive sensor - output and 0.5 - 0.7 mm gauge 1X56 138 149
face end gears on plane- /1X56 138 150
tary carrier

06. Clearance between induc- 0.024 - 0.03" Depth gauge, slider Adjust clearance with shims
tive sensor - turbine and 0.6 - 0.8 mm gauge 1X56 138 149 /
pulse sensor ring 1X56 138 150

07. Tightening torque for M6 7 ft-lbs Torque wrench Do not overtighten


fixing bolts on inductive 9.5 Nm
sensor

08. Clearance between speedo 0.027 - 0.055" Depth gauge Clearance is supplied,
sensor and toothedring on 0.7 - 1.4 mm check value.
output

09. Tightening torque for 26 ft-lbs Torque wrench Do not overtighten.


speedo sensor 35 Nm

10. Insertion depth of shaft 0.55 - 0.59" Use to 1X56 136 824
seal in output cover 14 - 15 mm This gives correct insertion
depth.

12
HP 502 C / HP 592 C / HP 602 C Adjustment data

Description Dimension Measurement device Remarks

11. Tightening torque for M6 5 ft-lbs Torque wrench Do not overtighten


hex nuts on inductive sen- 6 Nm
sor cover-output

12. Tightening torque for M12 44 ft-lbs Torque wrench Secure with lock plate
hex bolts at output flange 60 Nm Use to 1X56 136 471

13. Tightening torque for 67 - 74 ft-lbs Torque wrench


M42x2 screw plug in 90 - 100 Nm
duct plate

14. Tightening torque for 9 ft-lbs Torque wrench Do not overtighten


M10x1 screw plugs on the 12 Nm
pressure measuring points

13
14
HP 502 C / HP 592 C / HP 602 C Special tools

Fig. Special tools Order no. Application Qty. Remarks


no.

1X56 136 471 1

Tool
1 for lock plate on output flange

1X56 136 824 1

Tool
2 for fitting radial seal in
output flange

1P01 136 670 1

Pressure test gauge


3 0 - 25 bar with
M10x1 connectors

1P01 137 856 1

Pressure test gauge


4 0 - 10 bar with
M10x1 connectors

1X56 137 126 1

Lifting attachment
5 for transmission

15
Special tools HP 502 C / HP 592 C / HP 602 C

Fig. Special tools Order no. Application Qty. Remarks


no.

1X56 138 149 1

Measuring rod
6 to determine distance between
inductive sensor and pulse sensor on
turbine and output (in connection
with test fixture 1X56 138 150)

1X56 138 150 1

Test fixture
7 to determine distance between
inductive sensor and pulse sensor on
turbine and output (in connection
with measuring rod 1X56 138 149)

1X56 103 755 1

Gripper
8 to mount output flange
(in connection with mounting fixture
1X56 136 512)

1X56 136 512 1

Mounting fixture
9 to mount output flange (in connec-
tion with gripper 1X56 103 755)

1X56 136 513 (220V) 1 Options


or available:
1X56 137 575 (110V) for 220 Volts or
10 for 110 Volts
Hot air blower
to heat various parts.

16
HP 502 C / HP 592 C / HP 602 C Special tools

Fig. Special tools Order no. Application Qty. Remarks


no.

1P01 138 153 1

Test cable
11 for testing solenoid valves

6008 006 002 1

68-pin terminal tester


12 for electrical troubleshooting

6008 208 003


Complete
Testman Diagnostic System system
3 4
(for Windows 95, 98 and NT) for Windows
95, 98 and NT
Complete system without PC.
Contains: without PC
2
13 1
6008 308 901 Testman software
on disc (1) Optionally
6008 208 004
6008 308 600 DPA 04 I adapter (2) or 6008 208
5 003 but
6008 308 601 RS 232-cable(3) also with
1
0501 211 104
0501 211 103 ISO cable (4) SAE cable (5).

6008 308 114 1

Diagnostic software
14 Testman
Diagnose - Software
6008 308 014
for Ecomat 2

17
Special tools HP 502 C / HP 592 C / HP 602 C

Fig. Special tools Order no. Application Qty. Remarks


no.

6008 307 001 1

Diagnostic system for


15 MobiDig 2001 ZF-Service
Complete system only
in portable case

0501 301 068 1

EPD1 for
16 Simple programming device ZF-Service
only

6008 298 029 1


Plug-In
memory card for
17 for EPD1 ZF-Service
only

0501 211 103 1

ISO cable for


18 for EPD1 ZF-Service
only

0501 211 648 1

SAE cable for


19 for EPD1 ZF-Service
only

18
Arrangement of
HP 502 C / HP 592 C / HP 602 C peripheral equipment

Arrangement of peripheral equipment

N R

3 D
1 2


 



 

   




013190



Key to drawing

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

19
Cutaway view HP 502 C / HP 592 C / HP 602 C

ZF Ecomat transmission,
4-speed version

1 2 4 5 6 7 9 10 11 12 13



26 25 24 23 22 21 20 19 18 17 16 15 14
013468

Key to drawing

1 Input 15 Inductive sensor “output”


2 Cover plate 16 Brake “F”
4 Control element 17 Brake “E”
5 Oil feed flange 18 Brake “D”
6 Clutch “A” 19 Control unit
7 Clutch “B” 20 Inductive sensor “Turbine”
9 Housing 21 Oil pan
10 Planet gear set I 22 Retarder
11 Planet gear set II 23 Primary pump
12 Planet gear set III 24 Converter
13 Speedo sensor 25 Torque converter “WK”
14 Output 26 Turbine shaft

20
HP 502 C / HP 592 C / HP 602 C Cutaway view

ZF Ecomat transmission,
5 & 6-speed version

1 2 4 5 6 7 8 9 10 11 12 13



26 25 24 23 22 21 20 19 18 17 16 15 14
013467

Key to drawing

1 Input 15 Inductive sensor “Output”


2 Cover plate 16 Brake “F”
4 Control element 17 Brake “E”
5 Oil feed flange 18 Brake “D”
6 Clutch “A” 19 Control unit
7 Clutch “B” 20 Inductive sensor “Turbine”
8 Clutch “C” 21 Oil pan
9 Housing 22 Retarder
10 Planet gear set I 23 Primary pump
11 Planet gear set II 24 Converter
12 Planet gear set III 25 Torque converter “WK”
13 Speedo sensor 26 Turbine shaft
14 Output

21
Clutch combination HP 502 C / HP 592 C / HP 602 C

Clutch and brake combinations

Transmission model and Parts List No.


No. of speeds HP 502 HP 592 HP 602 Ratio range
4-speed 4149 002 . . . 4149 052 . . . 4149 062 . . . 2.81 - 1.00
4-speed 4149 006 . . . 4149 056 . . . 4149 066 . . . 3.43 - 1.00
5-speed 4149 001 . . . 4149 051 . . . 4149 061 . . . 2.81 - 0.80
5-speed 4149 003 . . . 4149 053 . . . 4149 063 . . . 3.43 - 0.83
6-speed 4149 004 . . . 4149 054 . . . 4149 064 . . . 3.43 - 0.59

Ecomat 2 without NBS Ecomat 2 with NBS

Clutch / brake A B1 B2 D E F1 F2 Clutch / brake A B1 B2 D E F 1 F2


i = 2.81 to 1.00 4 speed i = 2.81 to 1.00
4 speed
i= 3.43 to 1.00 i = 3.43 to 1.00
Reverse • • • Reverse • • •
Neutral Neutral •*
1st gear • • Neutral NBS • •*
2nd gear • • 1st gear • •
3rd gear • • 2nd gear • •
4th gear • • 3rd gear • •
4th gear • •

Ecomat 2 without NBS Ecomat 2 with NBS


Clutch / brake A B2 C D E F1 F2 Clutch / brake A B2 C D E F1 F 2
5-speed i = 2.81 to 0.80 5-speed i = 2.81 to 0.80
and i = 3.43 to 0.83 and i = 3.43 to 0.83
6-speed i = 3.43 to 0.59 6-speed i = 3.43 to 0.59
Reverse • • • Reverse • • •
Neutral Neutral •*
1st gear • • Neutral NBS • •*
2nd gear • • 1st gear • •
3rd gear • • 2nd gear • •
4th gear • • 3rd gear • •
5th gear • • 4th gear • •
6th 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 Maintenance

1. Maintenance
1.1 Oil change intervals

NOTE : The suction filter must be renewed at every oil change. Before changing the filter, drain off the oil
(while still hot). The complete filter kit (filter and sealing rings) is available with order No. 4139 298 936.

Transmission oil change Mileage Operating hours

Oil change following transmission repair. ≈ 600 miles (1,000 km) 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. ≈ 18,000 miles (30,000 km)

Oil change in tough operating conditions*. ≈ 12,000 miles (20,000 km)

Construction machinery or special vehicles


mobile cranes, garbage trucks, etc. 1,000 h

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. ≈ 37,000 miles (60,000 km)

Oil change in tough operating conditions*. ≈ 28,000 miles (45,000 km)

Construction machinery or special vehicles


mobile cranes, garbage trucks, etc. 2,000 h

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. ≈ 75,000 miles (120,000 km)

Oil change in tough operating conditions*. ≈ 56,000 miles (90,000 km)

Construction machinery or special vehicles


mobile cranes, garbage trucks, etc. 3,000 h

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) ≈ 8 gal. (30 liters)
At oil changes ≈ 31/2 - 41/2 gal. (14-17 liters)
Refilling after installing transmission in vehicle ≈ 51/2 gal. (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 HP 502 C / HP 592 C / HP 602 C

1.4 Checking oil level


– The oil level must be checked at least once every Oil measuring rod
week. (check oil level / oil condition)
– Vehicle must be standing level.
– Engine at idling speed.
– Before checking oil level, shift into Neutral.
Oil pipe (oil filling up)
CAUTION
An electronic oil level display only provides informa-
tion. 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 trans-
mission to overheat.

 DANGER
011576
Insufficent oil can cause partial or regular retarder
failure: i.e. reduced or zero braking action.

1.5 Operating temperature

The correct operating temperature at which to


check the oil level can be seen on the gauge in the 
vehicle.  $F

NOTE
Before the oil level is checked, the transmission 
oil must have reached an operating temperature of 
180 - 195°F (80 - 90 °C). 
9'2

1.6 Adding oil

Pour in transmission oil through the same hole


as is used for measuring with the dipstick.1 quart 001683

(1 liter) changes the oil level by approx. 0.4"


(10 mm).

1.7 Checking oil level at operating temperature

Conditions:
Hot range } 80-90°C
• Vehicle standing level
• Speed range selector at “N” (Neutral)
• Engine idling (approx. 2 minutes)
• Transmission oil 80 - 90°C / 180 - 195°F

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.
011577

1-2
HP 502 C / HP 592 C / HP 602 C Maintenance

1.8 Checking oil level when cold

Conditions:

• Vehicle standing level


• Speed range selector at "N" (Neutral)
• Engine idling
• Transmission oil ca. 30°C / 86°F

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 Cold range } approx. 30°C
oil is below the lower mark, add oil immediately.
Adjust the final oil level after checking again at
operating temperature.

011577

1.9 Checking oil level with engine off

Conditions:

• Vehicle on level ground


• Engine at standstill
Stationary range } (nEng = 0)

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.

011577

1.10 Checking oil level on versions with heat ex-


changer 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 HP 502 C / HP 592 C / HP 602 C

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 filter cover
Section 2.1).

– Screw in drain plug (37 ft-lbs/50 Nm) and fit filter bolts (23 Nm)
cover (17 ft-lbs/23 Nm), see Section 2.1.

CAUTION
When working on a transmission with a converter
drain valve, always use genuine oil drain plug. The
drain plug controls and closes the converter drain oil drain plug 37 ft-lbs (50 Nm)
valve. 009871

– 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.

011576

– Run vehicle until transmission oil reaches


operating temperature (180 - 195°F / 80 - 90°C).
Check oil level at operating temperature (see
Section 1.7) and adjust if necessary.

Hot range } 80-90°C

011577

1-4
HP 502 C / HP 592 C / HP 602 C Overhaul

2. Overhaul

2.1 Renewing filter 2

1 Drain oil at oil drain plug (1) in acc. with descrip-


tion in Section 1.11.

 DANGER
Collect used oil in a large enough container and dis-
pose of this in strict accordance with environmental 1
protection legislation. Refer to general notes on
threats to the environment.

2 Remove filter cover (2).

011578

3 Pull out old filter element (1).

NOTE 1
Check filter for contamination.

 DANGER
Dispose of contaminated filters in strict accordance
with environmental protection legislation. Refer to
general notes on threats to the environment.

011579

4 Insert new filter element (No. 0750 131 003).


1
NOTE
Filter must always be renewed. It must not be clea-
ned and reused.

5 Check that O-ring of filter (1) is still correctly sea-


ted and is undamaged.

6 Smear O-ring with transmission oil.

008513

2-1
Overhaul HP 502 C / HP 592 C / HP 602 C

7 Renew O-ring (1) in filter cover (2).

010483

8 Replace filter cover (1).

9 Tighten four hex. bolts (2).


1
Tightening torque: 17 ft-lbs (23 Nm)

011578

2-2
HP 502 C / HP 592 C / HP 602 C Overhaul

2.2 Renewing retarder solenoid valve

1 Disconnect cable connector (1) from solenoid


valve.

2 Unscrew two M8 hex bolts (2).

011580

3 Remove solenoid valve (1) and insert new


solenoid valve with new O-ring (2).

011581

4 Tighten both M8x22 hex bolts.


Tightening torque: 17 ft-lbs (23 Nm)

5 Reconnect cable connector.

011580

2-3
Overhaul HP 502 C / HP 592 C / HP 602 C

2.3 Renewing accumulator solenoid valve

1 Disconnect 2-core cable connector from solenoid


valve.

2 Disconnect air line.

3 Unscrew both M8 hex bolts.


1

011583

4 Smear new O-ring (1) with industrial grade Vase-


line and insert into groove in solenoid valve.

5 Fit valve.

011584

6 Tighten both M8x55 hex bolts (1) to 17 ft-lbs


(23 Nm).

7 Reconnect air line and cable connector.

011585

2-4
HP 502 C / HP 592 C / HP 602 C Overhaul

2.4 Renewing accumulator

1 Remove solenoid valve from accumulator (1) as


described in Section 2.3.

2 Unscrew two M8 hex bolts with nuts (2) from end


of accumulator nearest transmission output. 2 1

011584

3 Remove two M8 socket-head bolts (1) from end of


accumulator nearest transmission input.

011587

4 Smear new O-ring (1) with industrial grade Vase-


line and insert into groove in accumulator.

5 Insert accumulator. Screw in two M8x25 socket-


head 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)

011588

2-5
Overhaul HP 502 C / HP 592 C / HP 602 C

2.5 Renewing temperature sensor

1 Release 2-core cable connector from temperature


sensor.

2 Unscrew temperature sensor.

011589

3 Slide new copper sealing ring (1) onto tempera-


ture sensor. Screw in temperature sensor.
Tightening torque 26 ft-lbs (35 Nm).

011590

4 Reconnect 2-core cable connector with marking


“TG”(1).
1

011591

2-6
HP 502 C / HP 592 C / HP 602 C Overhaul

2.6 Renewing output sensor

1 Remove cover (1) from inductive sensor.

011592

2 Disconnect cables (1) on inductive sensor.


They have flat-pin plugs and are to be pulled
out with a straight pull. 1

CAUTION
Use suitable pliers and pull on the plugs - not on the
cables! 2

3 Screw out TORX screw (2) and remove inductive


sensor.

011775

4 Remove O-ring (1), spacers (2) and TORX screw


(3) from inductive sensor (4).
4

1 2 3

011776

2-7
Overhaul HP 502 C / HP 592 C / HP 602 C

5 Turn output flange until gearing (1) on planet car-


rier in the center of the bore for the inductive sen-
sor becomes visible.

011598

6 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) 1

7 Introduce measuring sensor (3) until it abuts


against face-end of gearing and secure by tighte-
ning the screw (4). 2

8 Screw out fixing bolt (2) of the measuring rod and


carefully pull out the measuring rod. 4 3

012901

9 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 Overhaul

10 Insert new inductive sensor in test fixture 1X56


138 150 and screw-tighten.
Tightening torque: 7 ft-lbs (9.5 Nm)

011779

11 Measure distance from contact surface of induc-


tive sensor to contact surface of inductive sensor
holder and note down as "dimension c".

Inductive sensor distance "dimension a" must be be-


tween 0.02 and 0.027" (0.5 and 0.7 mm).
c
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) 011780

Calculation example:
52.6 mm - 51.3 mm = 1.3 mm 2 3
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 Gearing of planet carrier


2 Output cover of housing
3 Inductive sensor
4 Spacers 1
5 Fixing bolt of inductive sensor a 4 5

011620

2-9
Overhaul HP 502 C / HP 592 C / HP 602 C

12 Insert TORX screw (1) and washer in bore


on inductive sensor (2). Slide spacers as determi- 2
ned (3) onto the TORX screw and secure with O-
ring (4).

4 3 1

011776

13 Connect cable plug (1) with inductive sensor.

14 Insert inductive sensor and tighten with TORX 1


screw M6x45 (2).
Tightening torque: 7 ft-lbs (9.5 Nm)

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 Overhaul

2.6.1 Renewing retarder resistor

1 Remove cover on output inductive sensor in acc.


with Section 2.6

2 Unfasten cable plug on resistor. This is a flat-pin


plug which should be pulled out in a straight line.

3 Take out resistor.

CAUTION
Each resistor is assigned to the relevant transmission
by checking the type of retarder fitted. Each is identi-
fied by an item number. This item number should be
read since you may only install a new resistor which
has an item number which is identical to the old one.
012902

NOTE
The resistor has a ten digit item number. Eight of
these digits (6029 201 6) can be found on the face
surfaces of the resistor (1). The two other item
number digits (2) are located, as is shown, on its 2
circumference.

Example: 6029 201 6(48) = resistance of 46.40 k1

OTK resistance = 1.96 - 150 kW


1
Item number Designation Check on retarder
fitted
6029 201 652 Resistance 150.00 k1
6029 201 651 Resistance 100.00 k1
6029 201 650 Resistance 75.00 k1
6029 201 649 Resistance 57.60 k1 012903

6029 201 648 Resistance 46.40 k1


6029 201 647 Resistance 37.40 k1
6029 201 646 Resistance 31.60 k1
6029 201 645 Resistance 26.10 k1
6029 201 644 Resistance 22.10 k1
6029 201 643 Resistance 18.70 k1
6029 201 642 Resistance 15.80 k1
6029 201 641 Resistance 13.30 k1
6029 201 640 Resistance 11.30 k1
6029 201 639 Resistance 9.31 k1
6029 201 638 Resistance 7.68 k1
6029 201 637 Resistance 6.34 k1
6029 201 636 Resistance 5.11 k1
6029 201 635 Resistance 3.92 k1
6029 201 634 Resistance 2.94 k1
6029 201 633 Resistance 1.96 k1

2-11
Overhaul HP 502 C / HP 592 C / HP 602 C

4 Connect new resistor (item number must be


identical to the old resistor) and install as is
shown.

011775

2-12
HP 502 C / HP 592 C / HP 602 C Overhaul

2.7 Removing and fitting oil pan

1 Drain out oil and remove oil filter as described in


Section 2.1.

011578

2 Remove hex bolts (1) from oil pan.

3 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 1
cannot fall over.

4 Remove oil pan.

CAUTION 011579

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.

016072

2-13
Overhaul HP 502 C / HP 592 C / HP 602 C

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.
1

016073

6 Check actuation bolt (1) for converter drain valve


for ease of movement.

016072

7 Place new gasket onto oil pan.

8 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 Overhaul

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.

011603

10 Tighten all M8x60 hex bolts on the oil pan.


Tightening torque: 17 ft-lbs (23 Nm)

11 Insert and tighten oil drain plug as described in


Section 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.

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 Overhaul

2.8 Renewing turbine sensor

1 Remove oil pan as described in Section 2.7.

011579

2 Remove M42x2 screw plug (1).

011607

3 Disconnect cable connectors (1) from sensor.


These are blade connectors which should be
pulled off straight.
1
4 Unscrew socket-head bolt (2) and remove
inductive sensor

011608

2-17
Overhaul HP 502 C / HP 592 C / HP 602 C

5 Remove O-ring (1), spacers (2) and socket-head


bolt (3) from inductive sensor. 4

1 2 3

011776

6 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). 1

011783

7 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 Overhaul

8 Introduce measuring rod 1X56 138 149 into the


bore of the inductive sensor and screw-
tighten (1).
Tightening torque: 7 ft-lbs (9.5 Nm)
1

011784

9 Introduce measuring sensor (1) until it is firmly


wedged against the raised section of the pulse sen- 1
sor ring and secure by tightening the screw (2).

10 Screw out fixing bolt (3) of the measuring rod and 2


carefully pull out the measuring rod.

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 HP 502 C / HP 592 C / HP 602 C

12 Insert new inductive sensor in test fixture


1X56 138150 and screw-tighten.
Tightening torque: 7 ft-lbs (9.5 Nm)

011779

13 Measure distance from contact surface of induc-


tive 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).
c

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 011780

Dimension “a” = 0.7 mm (0.6 - 0.8 mm)

Calculation example:
1 2 4
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 5

Spacers OTK 0769 143 377 are available from


0.8 to 6 mm, in steps of 0.1 mm.
3
1 Sensor induction ring
2 Mounting plate
3 Inductive sensor
4 Shim washers a
5 Socket-head bolt
011622

2-20
HP 502 C / HP 592 C / HP 602 C Overhaul

14 Insert TORX screw (1) and washer in bore


on inductive sensor (2). Slide spacers as determi- 2
ned (3) onto the TORX screw and secure with O-
ring (4).

4 3 1

011776

15 Insert inductive sensor and tighten with M6x45


socket-head screw (1).
Tightening torque: 7 ft-lbs (9.5 Nm)
2
16 Connect cable plug (1) to inductive sensor.

011610

17 Screw M42x2 screw plug into duct plate and


tighten.
Tightening torque: 67 - 74 ft-lbs (90 - 100 Nm)

011607

2-21
Overhaul HP 502 C / HP 592 C / HP 602 C

18 Fit oil pan as described in Section 2.7.

19 Screw in oil drain plugs as described in


Section 1.9.

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 Overhaul

2.9 Renewing complete hydraulic control module

CAUTION
Before unscrewing cable harness from transmission,
remove any dirt and dust from the area around the
cable harness connector.

1 Release cable harness connector by turning


locking ring anti-clockwise.

013480

2 Unscrew the two M8 hex bolts (1) with washers


from the KOSTAL socket.

011624

3 Remove oil pan as described in Section 2.7.

011579

2-23
Overhaul HP 502 C / HP 592 C / HP 602 C

4 Use a screwdriver to snap flat connector for induc-


tive sensor output (1) and flat connector for retar-
der resistance (2) off valve body and disconnect
from connector bush.
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 4 3


of protective sleeve (5). 1 2

015825

6 If the transmission is fitted with an oil level dis-


play, remove protective cap (1) from connector
and disconnect connector (2) from oil level elec-
tronic unit.

2
1

015826

7 Loosen, but do not remove, the 39 M8 torx bolts


which hold the shift control module in the trans-
mission 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 Overhaul

8 Fully unscrew the M8 torx screws and remove


shift control module.

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

9 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 HP 502 C / HP 592 C / HP 602 C

11 The 39 M8 torx screws which hold the shift con-


trol module are of two different lengths:
30 M8x43 screws (1) 2
9 M8x35 screws (2)

The 9 shorter torx screws are for the recessed


areas. 1

Tighten all M8 torx screws to 17 ft-lbs (23 Nm).

015827

12 If the transmission is fitted with an oil level dis-


play, insert connector (1) into bush of oil level
electronic unit.
1
CAUTION 3
The oil level electronic unit (2) is very sensitive and
must not be bent as the connector is inserted. Hold 2
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 5
3 Sump temperature sensor
4
NOTE
The sump temperature sensor is integrated in the
connector (3).
1 2
15 Insert temperature sensor cable (4) in protective
sleeve (5). 3

015825

2-26
HP 502 C / HP 592 C / HP 602 C Overhaul

16 Insert connector socket into recess in housing and


screw in both M8x20 hex bolts with washers.
Tightening torque 17 ft-lbs (23 Nm).

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 HP 502 C / HP 592 C / HP 602 C

2.10 Changing complete oil level display

Remove oil pan and transmission control unit in accor-


dance with sections 2.7 and 2.9.

Installation position of complete oil level display (1).

015829

1 Unscrew two M6 Torx bolts (1) on oil level elec-


tronic unit.

CAUTION
Handle oil level electronic unit with care. It is very
sensitive to impact.
1

015830

2 Unscrew two M6 Torx bolts (1) and take out oil


level indicator complete with retaining plate, sen- 1
sor 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 Overhaul

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).

2
3

015832

4 Insert new oil level sensor (i.e. not yet set and not
secured) complete with retaining plate and use 1
two M6x30 Torx bolts (1) to screw into place.
Tightening torque: 7 ft-lbs (9.5 Nm)

015833

CAUTION
The Torx bolts on the retaining plate screw connec- 1
tion are each fitted with two O-rings for damping.
Check that O-rings are seated properly. 3 2
4

1 Torx bolt
2 Washer 5
3 9x2.5 O-ring 6
4 Retaining plate
5 14x2.5 O-ring
6 Bush
7 O-ring for fastening 7 Length X =
5.0 +3 mm

015834

2-29
Overhaul HP 502 C / HP 592 C / HP 602 C

5 Unfasten M6x16 Torx bolt (1).

6 Correct setting length of oil level sensor between 015833

face end on sensor and housing sealing face.

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 Length X


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 installati-
on position.
Tightening torque: 7.5 ft-lbs (10 Nm)
015835

8 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°.

015832

2-30
HP 502 C / HP 592 C / HP 602 C Overhaul

9 Reinsert secured oil level sensor and use two


M6x30 Torx bolts (1) to screw into place. gt hX
Tightening torque: 7 ft-lbs (9.5 Nm)
1 Len

10 Check sensor installation length “X” again.

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. 1

015830

2-31
Overhaul HP 502 C / HP 592 C / HP 602 C

2.11 Renewing pulse sensor

1 Unscrew pulse sensor (1).

011635

2 Smear threads of new pulse sensor with trans-


mission oil.

011636

3 Screw in new pulse sensor.


Tightening torque: 26 ft-lbs (35 Nm)

011637

2-32
HP 502 C / HP 592 C / HP 602 C Overhaul

2.12 Renewing output flange and/or shaft seal

1 Remove lock plate from output flange (1).

DANGER
Wear eye protection, metal chips may fly out.

011638

2 Unscrew both M12 hex bolts from output shaft.

NOTE
When unscrewing bolts, use a suitable lever to
1
prevent output flange from turning.

3 Remove clamping plate (1). If necessary, release


by tapping with plastic mallet

011639

4 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 HP 502 C / HP 592 C / HP 602 C

5 Pull shaft seal off input shaft using a suitable tool.

CAUTION
Take care not to damage seal bore while pulling
out seal.

012273

6 Place shaft seal (1) onto tool 1X56 136 824 with
sealing lip facing towards output cover.

CAUTION
Do not fit seal the wrong way round. The spring load
on the sealing lip must be visible when the seal is on
the tool.

011642

7 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 Overhaul

NOTE
Correct seal insertion depth of 0.59–0.04 in. 
(15-1 mm), measured from the face of the bearing
inner ring to the face of the seal, is given by using
tool 1X56 136 824.

9 Pack the space between the sealing lip and the


dust lip with grease.



001654

10 Heat output flange to 210° to 230°F


(100 – 110°C).

CAUTION
Do not heat output flange over 230°F (110°C) or seal
will be damaged.

 DANGER
Always wear protective gloves when handling hot out-
put flange.

NOTE
Insert hex bolts before fitting flange if necessary.

11 Screw gripper 1X56 103 755 onto output shaft,


attach output flange and use tightening tool 011645

1X56 136 512 to tighten until firmly home.

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 HP 502 C / HP 592 C / HP 602 C

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.

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 manufacturer’s
instructions. 1

011649

2-36
HP 502 C / HP 592 C / HP 602 C Overhaul

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
4
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 5 3
2 = Throttle pressure PD1
3 = Pressure before converter PD2
4 = Pressure after heat exchanger PD6 5 PD7*
1
5 = Retarder pressure PR3 6 2
6 = Retarder control pressure PRR3
011650

* (4) for Retarder "ON" = PD6


* (4) for Retarder "OFF" = PD6 5 PD7 = Lubricating oil
pressure

2 Conduct pressure test in acc. with following table.

3 After finishing pressure tests, remove test pressure


gauges.

4 Fit in screw plugs with new copper seal rings.


Tightening torque: 9 ft-lbs (12 Nm)

011651

2-37
Overhaul HP 502 C / HP 592 C / HP 602 C

Pressure table: 3 = Pressure before converter PD2


A = Normal main pressure 4 = Pressure after heat exchanger PD6 5 PD7*
B = Higher main pressure for engines more powerful * for Retarder "ON" = PD6
than 1036 ft-lbs (1400 Nm) * for Retarder "OFF" = PD6 5 PD7 = Lubricating oil
pressure
Pressure measurement: 5 = Retarder pressure PR3
6 = Retarder control pressure PRR3
1 = Main pressure PH 7 = Oil temperature toil
2 = Throttle pressure PD1 neng = Engine speed
(PD1 = no current = 10 bar) WK = Lock-up clutch

Pressure table A 7 1 2 3 4 5*/6*

NORMAL MAIN PRESSURE


M 10x1 M 10x1 M 10x1 M 10x1 M 10x1
neng toil PH PD1 PD2 PD6/D7 PR3/PRR3
Load Gear WK (min-1) (°C) (bar) (bar) (bar) (bar) (bar)
Idling N open 700 20 - 40 7 - 15 4±0,3 4.0 - 5.5 0.8 - 1.8

0.2 - 1.0

cold
Idling N D open 550 20 - 40 7 - 15 4.0 - 5.5 0.8 - 1.8
for 2 sec.
Full load N open 2000-2500 20 - 40 18 - 21 4±0,3 6.0 - 8.5 1.8 - 2.5
Full load Engaged closed 2000-2500 20 - 40 10 - 12 4±0,3 6.0 - 8.5 1.8 - 2.8
Idling N open 700 80 - 90 7 - 15 4±0,3 3.0 - 4.5 0.1 - 0.8
0.2 - 1.0

warm
Idling N D open 550 80 - 90 7 - 15
for 2 sec.
3.0 - 4.5 0.1 - 0.8

Full load N open 2000-2500 80 - 90 ◆16 - 20 4±0,3 6.0 - 8.5 1.8 - 2.5

Full load Engaged closed 2000-2500 80 - 90 10 - 12 4±0,3 6.0 - 8.5 1.8 - 2.5
* Values are shown in the relevant parts list or may be obtained from ZF.
◆ If the pressure falls below this value: Please contact the relevant ZF service agency before removing the transmission.

Pressure table B 7 1 2 3 4 5*/6*

HIGHER MAIN PRESSURE


M 10x1 M 10x1 M 10x1 M 10x1 M 10x1
neng toil PH PD1 PD2 PD6/D7 PR3/PRR3
Load Gear WK (min-1) (°C) (bar) (bar) (bar) (bar) (bar)
Idling N open 700 20 - 40 13 -22 4±0,3 4.0 - 5.5 0.8 - 1.8
cold

Idling N D open 550 20 - 40 13 - 22 0.2 - 1.5 0.8 - 1.8


4.0 - 5.5
for 2 sec.
Full load N open 2000-2500 20 - 40 21 - 25 4±0,3 6.0 - 8.5 1.8 - 2.5
Full load Engaged closed 2000-2500 20 - 40 12 - 16 4±0,3 6.0 - 8.5 1.8 - 2.8
Idling N open 700 80 - 90 10 - 17 4±0,3 3.0 - 4.5 0.1 - 0.8
warm

0.2 - 1.5
Idling N D open 550 80 - 90 10 - 17 3.0 - 4.5 0.1 - 0.8
for 2 sec.
Full load N open 2000-2500 80 - 90 21 - 24 4±0,3 6.0 - 8.5 1.8 - 2.5

Full load Engaged closed 2000-2500 80 - 90 12 - 15 4±0,3 6.0 - 8.5 1.8 - 2.5
*Values are shown in the relevant parts list or may be obtained from ZF.

2-38
HP 502 C / HP 592 C / HP 602 C Troubleshooting

3 Troubleshooting
3.1 Terminal tester concept
25-, 55-, 68-pin EST electronic control unit

68-pin 55-pin
terminal tester terminal tester

6008 006 002 1P01 137 834


(1)

*6008 199 001 can no longer be supplied


contains
(1) (2) (3)

68-pin - 55-pin
reduction adapter cable

*6008 004 024 (2)


from vehicle power supply to 55-pin - 25-pin
Buka reduction adapter cable

*6008 004 025 (3)


from Buka to EST plug 6008 004 026
bush

6008 004 027


plug

68-pin 55-pin 25-pin


electronic control unit electronic control unit electronic control unit

EST 31 AS Tronic EST 14 AVS EST 32 Intarder


EST 37 WG EST 15 Retarder
EST 45 T 7000 EST 18 Ecomat
EST 46 Ecomat 2
EST 47 Ecomat 2

3-1
Troubleshooting HP 502 C / HP 592 C / HP 602 C

3.2 1PO1 138 153 test cable

a) Insert Kostal plug of test cable into Kostal socket CAUTION


on transmission. Do not apply voltage to emergency cut-off switch (yel-
low sockets) or to inductive sensor (green sockets), or
! DANGER the switch or sensor will be short-circuited and irre-
Only use test cable with vehicle stationary and parably damaged. If the switch is damaged, the trans-
engine off. mission must be removed from the vehicle

Table for checking model of retarder fitted

Item number Designation Retarder check CAUTION


Each resistor is assigned to the relevant transmission
6029 201 652 Resistance 150.00 k W by checking the type of retarder fitted. Each is
6029 201 651 Resistance 100.00 k W identified by an item number. This item number
6029 201 650 Resistance 75.00 k W should be read since you may only install a new
6029 201 649 Resistance 57.60 k W resistor which has an item number which is
6029 201 648 Resistance 46.40 k W identical to the old one.
6029 201 647 Resistance 37.40 k W
6029 201 646 Resistance 31.60 k W
6029 201 645 Resistance 26.10 k W
6029 201 644 Resistance 22.10 k W
6029 201 643 Resistance 18.70 k W
6029 201 642 Resistance 15.80 k W
6029 201 641 Resistance 13.30 k W
6029 201 640 Resistance 11.30 k W
6029 201 639 Resistance 9.31 k W
6029 201 638 Resistance 7.68 k W
6029 201 637 Resistance 6.34 k W
6029 201 636 Resistance 5.11 k W
6029 201 635 Resistance 3.92 k W
6029 201 634 Resistance 2.94 k W
6029 201 633 Resistance 1.96 k W

3-2
HP 502 C / HP 592 C / HP 602 C Troubleshooting

b) Resistance measurements:
Measure resistance of solenoid valve coils and On solenoid valves the resistance value rises with rising
inductive sensors, see list below. temperature.

NOTE: Resistance values may change with rising or On the temperature sensor B14 the resistance value
dropping temperatures. drops with rising temperature.

Brakes, A4 Ohmmeter
Clutches,
Test specimen Nominal readings
Inductive sensors,
Resistance Marking Pin

Solenoid valve Y17 Clutch A A 13 approx. 67 ± 4 W at 20°C

Solenoid valve Y16 Clutch B1 B 12 approx. 67 ± 4 W at 20°C

Solenoid valve Y15 Clutch B2 C 11 approx. 67 ± 4 W at 20°C

Solenoid valve Y14 Brake D D 22 approx. 67 ± 4 W at 20°C

Solenoid valve Y13 Brake E E 24 approx. 67 ± 4 W at 20°C

Solenoid valve Y12 Brake F F 19 approx. 67 ± 4 W at 20°C

Solenoid valve Y11 Brake G / F2 G 6 approx. 67 ± 4 W at 20°C

Solenoid valve Y18 Clutch WK WK 9 approx. 67 ± 4 W at 20°C

Solenoid valve Y19 Retarder RET 8 approx. 67 ± 4 W at 20°C

D1-
Prop.-solenoid Y20
D1 valve D1 10 approx. 8,6 ± 0,5 W at 20°C

Inductive sensor B11 n Output nAB 2 approx. 850 ± 100 W at 20°C

Retarder- Retarder RET.K 18 * 1.96 to 150 kW


resistor B16 recognition

Oil level sensor B15 Oil level display Oil 23 ** PWM %, VPE 5 Volt

¨ Temp. sensor B14 Sump temperature TG 4 approx. 125 ± 5 kW at 20°C

Inductive sensor B12 n Turbine nT 1 approx. 850 ± 100 W at 20°C

¨ Tolerance and
characteristics
Ground/earth GM1 15
temperature sensor
see next page Ground/earth GM2 17

VM1 21
Ground/earth
VM2 20
* see table for checking model of retarder fitted
** no resistance measurements must be carried out
3-3
Troubleshooting HP 502 C / HP 592 C / HP 602 C

Temperature sensor NTC - Sensor B14 Temp. 2*Rt 2*Rt (min) 2*Rt (max)
Thermometrics DKS 4261 [˚C] [Ohm] [Ohm] [Ohm]
2 elements in series
-20 957796 896080,6 1023353,4
-15 720948 676412 768108
Table of tolerance - 20°C bis 150°C -10 547652 515240,8 581880,2
-5 419668 395880 444708
0 324282 306690,8 342746
5 252580,6 239476,2 266295,4
10 198235,8 188407 208494
15 156760,6 149700,6 164443,6
20 124765,8 119130 130615,8
25 99991 95685,8 104448
30 80649,2 77343 84063,2
35 65448,2 62896,4 68076,4
40 53425,2 51446,4 55457,8
45 43857 42316 45435,8
50 36197,6 34992,8 37428,8
55 30031,2 29086 30994,8
60 25040 24296 25796,4
65 20978,6 20391,2 21574
70 17657 17192,4 18127
75 14927,6 14559,2 15299,2
80 12674 12381,4 12968,2
85 10804,8 10572,4 11038,2
90 9248 9063 9433
95 7945,8 7775 8117
100 6852 6694,8 7010
105 5929,8 5785,4 6075,4
110 5149,4 5017 5283,2
115 4486,4 4365 4609,4
120 3921,6 3810 4034,2
125 3438 3336 3541,6
130 3023,2 2929,8 3118,4
135 2666,2 2580,6 2753,6
140 2357,8 2279,4 2438,2
Characteristics
145 2090,8 2018,8 2164,6
Resistance/Temperature
150 1858,8 1792,8 1926,8

2 elements
DKS 4261 (2*in Reihe)in series
100000
90000
80000 2*Rt [Ohm]
Widerstand [Ohm]

70000
60000
Resistance

50000
40000
30000
20000
10000
0
20 30 40 50 60 70 80 90 100 110 120
Tem peratur [˚C]
Temperature

3-4
HP 502 C / HP 592 C / HP 602 C Annex

DIAGNOSTIC TOOL

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contents of the “Testman” diagnosis software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testman software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation of the diagnosis software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting up a programming tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DPA 04 I description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DPA 04 I programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Selecting a COM port ..................................................................... 11
Starting the Testman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Testman screen display – Start-up logo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Screen display of the product menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Contents of the product menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Screen display of the repair aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contents of the repair aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preface ZF-Diagnostic tool “Testman”

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 Damage resulting from work performed by non-ZF


C.V./Special Transmissions personnel in an improper and unprofessional manner
Service Plant 2 and any consequential costs are excluded from the con-
Tel.: (0 75 41) 77-0 tractual liability agreement. Exclusion of liability also
Fax: (0 75 41) 77-5726 applies if genuine ZF spares are not used.

4
ZF-Diagnostic tool “Testman” Safety notice

SAFETY NOTICE

Companies repairing ZF units are responsible for their


own work safety.

To avoid injury to personnel and damage to pro-


ducts, 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.

5
Contents of Testman / System components ZF-Diagnostic tool “Testman”

ZF Testman
electronic diagnosis

Test
Aids to Vehicle Telephone
Diagnosis inputs and
repair work configuration directory
outputs

Tightening torques Reading error System check at Viewing the Telephone direc-
memory standstill vehicle data tory of all people
Adjustment data in the Technical
Deleting error System check in Copying vehicle Service, arranged
Special tools/test memory motion data by product
equipment
Identification Test equipment Modifying /exten-
Maintenance block ding vehicle data
Analogue displays,
Repairs speeds, currents
etc.
Pressures

Circuit diagrams

Electrical measur-
ing values

ZF Testman diagnostic tool

Order numbers:

Order number Designation Item number Order number

Testman software on diskette 6008 308 901


DPA 04 I diagnostic adapter 6008 308 600
6008 208 004 RS 232 cable 6008 308 601 6008 208 003
Installation instructions 6008 758 703
ISO cable 0501 211 103
SAE cable 0501 211 104

Batch number for diagnosis software on diskette. You can obtain further information
6008 308 900
about the desired diagnosis software from your ZF Service Center.

6
ZF-Diagnostic tool “Testman” Testman software installation

Testman software installation

NOTE
This software will run using Windows 95,
Windows 98 and Windows NT. (Installation under
Windows NT only with administrator rights)
1. Insert the “Testman 1” diagnosis software in the
disk drive (e.g. “A”).
2. Use the “Start” symbol (Windows interface) and
pull up the ”Run” command.
3. The “Run” window is opened.
4. Use your mouse to click on “Search”.
5. Select the drive (e.g. “A”). 1
015917
6. The contents of the diskette are now displayed.
1 Testman software on diskettes
7. Select the Testman Setup program and follow the Order No.: 6008 308 901
instructions in the software.
The Testman installation process is now complete.
NOTE
The Testman is available in English and German.
These languages only have an effect on system reac-
tions (not on the diagnosis software).

7
Additional settings ZF-Diagnostic tool “Testman”

Start the Testman. The first time you open the program, NOTE
“ZF ISO Man Properties” appears on screen. Here you Communication is not possible unless you have selected
should select the correct COM port on your PC and con- the correct COM port.
firm this choice. If you need this function again at a later
point, double-click the “Z” symbol to the bottom right of
the task bar.

015911

1. Click on the Testman icon with your right mouse 3. Select the program and select “Close on
button. completion”.
2. Select “Properties”. 4. Accept and confirm with “OK”.

015948

8
Installation of the diagnosis software
ZF-Diagnostic tool “Testman” Connecting up a programming tool

Installation of the diagnosis software


1. Insert the diagnosis software in the disk drive (e.g.
“A”).
2. Use the “Start” symbol (Windows interface) and
pull up the ”Run” command.
3. The “Run” window is opened.
4. Use your mouse to click on “Search”.
5. Select the drive (e.g. “A”).
6. The contents of the diskette are now displayed. 1
7. Depending on the drive, select “Install” or “d”. 015916

1. Diagnosis software on diskette


8. Use your mouse to click on “OK”. This installs
Order No. 6008 308 900
the diagnosis software.
The installation process is now complete. NOTE
You can obtain more detailed information about your
choice of diagnosis software from your nearest ZF
Service Center.

Connecting up a programming tool

1. Connect COM port (1) and DPA 04 I adapter (3)


using an RS 232 cable (2).
2
2. Connect an ISO or SAE cable (4) to the appropria-
te port (ISO 9141 / SAE S1708) on the DPA 04 I
adapter and connect to the electronic control unit
in the vehicle.
1
3

4
015955

Key to drawing
1. Your PC – with appropriate system requirements
2. RS 232 cable Order No. 6008 308 601
3. DPA 04 I diagnosis adapter Order No. 6008 308 600
4. ISO cable Order No. 0501 211 103
or
SAE cable Order No. 0501 211 104

9
DPA 04 I description ZF-Diagnostic tool “Testman”

Description of the DPA 04 I diagnosis and program- Front panel


ming adapter
1. LED L line
The DPA 04 I features three interfaces, V-24, RS 232, • Lights up whenever data have to be transferred
ISO 9141 and SAE J1708. on the L line.

• The RS 232 communicates between the DPA 04 I and 2. LED data


a laptop computer. • Lights up whenever data have to be transferred
on the K line.
• The ISO 9141 and SAE J1708 communicate between
the DPA 04 I and the control unit. 3. LED Ubatt
• Lights up when the vehicle circuit voltage lies
Appropriate adapter cables are required for the ISO and between 12 – 24 V.
the SAE interfaces. The same adapter cables as the DPA
02/03 can be used (pins compatible with the ISO inter- NOTE:
face). In SAE mode, dependent upon switch setting
“KL15ECU”
Here are the three basic operating modes of the DPA 04 I:
4. UPRG switch
1. Data transmission via ISO interface and control • “OFF” setting: programming voltage not
unit. present
• “ON” setting: programming voltage present.
2. Data transmission via SAE interface and control
unit. NOTE
Always ensure the Testman is in the ”OFF”
3. Interface converter between MobiDig 2001/200 position when working on it.No communication is
and SAE control unit. possible if the switch is in the wrong position.

5. KL15ECU switch
This switch is not relevant in ISO mode.

10
DPA 04 I programming
ZF-Diagnostic tool “Testman” Selecting COM port

The DPA 04 I has a Flash Prom which is supplied with In the event of the DPA 04 I drive losing data, proceed in
Testman functions. accordance with the following instructions in order to
restore Testman functionality.

015908

1. Quit the Testman. 4. Select directory/folder GDS 3000 / dpaload


2. Connect DPA 04 I to the laptop. using the drive (C or D).
3. Connect the DPA 04 I to the power supply using 5. Start dpa4.bat batch processing. This loads the
an ISO or SAE cable. Testman functions for the DPA 04 I. This process
lasts approximately 1 minute.

NOTE 1. Open the text editor from the Start bar.


The download software is usually set to COM 1 2. Open \GDS3000\dpaload\bload166.cfg.
(i.e. default setting). 3. You can enter the correct COM port here
If your laptop has a different COM port, adapt the (see arrow).
setting as follows: 4. Save and close.

015947

11
Starting the Testman ZF-Diagnostic tool “Testman”

Symbols and switch surfaces

End Testman Selection of application Help

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Print

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Continue

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012290/013809/013810/013811


Starting the Testman 8. The "Open" window is opened.


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

12
ZF-Diagnostic tool “Testman” Start-up logo

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

13
Product menu / Contents ZF-Diagnostic tool “Testman”

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)LOH3$/$SSOLFDWLRQ+HOS

3URGXFWPHQX

‡ $LGVWRUHSDLUZRUN
‡ 7LSV
‡ 'LDJQRVLV
‡ 7HVWLQSXWVRXWSXWV
‡ 9HKLFOHFRQILJXUDWLRQ
‡ =)6HUYLFHWHOHSKRQHGLUHFWRU\

Continue

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Mark menu point using the mouse ☞ Menu point is marked ☞


Press the "Enter" key on the PC or use
the mouse to click on the symbol "Continue" ☞ Menu point appears

‡ $LGVWRUHSDLUZRUN System check: vehicle in motion.


Check of all system components which can be
Maintenance, tightening torques, special tools /
tested when vehicle is in motion.
test equipment, repairs, circuit and wiring dia-
Errors are described on the screen when exit-
grams, pressures and electr. measuring values.
ing the function test.

‡ 7LSV
Test equipment.
Product-specific.
Analogue display:
Such as speeds, currents etc.
‡ 'LDJQRVLV
Product-specific. ‡ 9HKLFOHFRQILJXUDWLRQ
Reading/deleting error memory.
Vehicle-specific data.
Identification block.
Such as customer sheets, vehicle data etc.

‡ 7HVWLQSXWVDQGRXWSXWV
‡ =)6HUYLFHWHOHSKRQHGLUHFWRU\
System check: Vehicle at standstill.
ZF contacts.
Check of all system components which can be
Telephone directory of all people in the Tech-
tested when vehicle is at standstill.
nical Service, arranged by product.
Errors are described on the screen when exit-
ing the function test.

14
ZF-Diagnostic tool “Testman” Repair aid / Contents

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‡ 7LJKWHQLQJWRUTXHV
‡ 6SHFLDOWRROVWHVWHTXLSPHQW
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‡ &LUFXLWDQGZLULQJGLDJUDPV
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‡ 5HWXUQWRPHQX
Continue

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Mark menu point using the mouse ☞ Menu point is marked ☞


Press the "Enter" key on the PC or use
the mouse to click on the symbol "Continue" ☞ Menu point appears

‡ 0DLQWHQDQFH ‡ &LUFXLWDQGZLULQJGLDJUDPV
Oil change intervals, types of oil (ZF list of lubri- Product-specific.
cants), oil quantities, oil changes, oil fills (figure)
and product-specific maintenance information.
‡ 3UHVVXUHV
Product-specific.
‡ 7LJKWHQLQJWRUTXHV
ZF standard 148 and product-specific tightening
‡ (OHFWUPHDVXULQJYDOXHV
torques.
Product-specific.
Example: Voltages and resistance.
‡ 6SHFLDOWRROVWHVWHTXLSPHQW
Product-specific.
‡ 5HWXUQWRPHQX
All tools required for work on the vehicle are
shown as pictures with their ZF nos. Previous menu is displayed.

‡ 5HSDLUV
Product-specific.
Example: Description of how to change the
inductive sensor.

15
Technical data ZF-Diagnostic tool “Testman”

System prerequisites for your PC Technical data for the DPA 04 I

Windows 95 / 98 or Windows NT 4.0 Operating voltage 12 – 24 volts

Pentium ≥ 90 MHz Operating temperature range 0 to 50° C

RAM ≥ 16 MB / NT 4.0 ≥ 32 MB Storage temperature range -20 to +60° C

Free disk space ≥ 20 MB Humidity 10 – 90%

Disk drive 3 1/2” Electromagnetic 80–1000 MHz AM 1kHz 80%


compatibility
Serial port COM 1 or COM 2
Electrostatic 4 kV on contact, and
compatibility 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
4 GANG i = 2.81 BIS 1.0
DETAIL X 3.43 BIS 1.0
4 GEAR TO
AUSFUEHRUNG RUECKWAERTS
HAUPTDRUCKVENTIL REVERSE
MIT DRUCKABSENKUNG
P NEUTRAL
2 NEBENATRIEBE MOEGLICH VERSION
PTO'S CAN BE FITTED MAIN PRESSURE VALVE
WITH PRESSURE REDUCER 1. GANG
1st GEAR
WK
2. GANG
2nd GEAR
D2 3. GANG
3rd GEAR
4. GANG
WK 4th GEAR

B 1 = INNERE KOLBENFLAECHE KUPPLUNG B


INNER PISTON FACE CLUTCH B
A
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


B1 INNER PISTON FACE BRAKE F
P
B

A B2 C D E F1 F2

5 - &. 6 GANG i = 2.81 BIS 0.8 / 3.43 BIS 0.83


3.43 BIS 0.59 TO
5 - & 6 GEAR TO
C B2
RUECKWAERTS
C REVERSE
WANDLER- NEUTRAL
ENTLEERVENTIL
1. GANG
CONVERTER- 1st GEAR
PURGE VALVE 2. GANG
SPEICHER 2nd GEAR
ACCUMULATOR
3. GANG
3rd GEAR
A8 4. GANG
D 4th GEAR
5. GANG
5th GEAR
WANDLER- WANDLER- 6. GANG
SICHERHEITS- GEGENDRUCK- 6th GEAR
VENTIL VENTIL
WAERMETAUSCHER
CONVERTER CONVERTER OIL COOLER
SAFETY VALVE COUNTER- TEMP.-
PRESSURE MESS-
VALVE STELLE
E
TEMPERATUR SCHMIERDRUCK-
D2 SWITCH VENTIL
SENSOR
LUBRICATING
F1 PRESSURE VALVE

F1-VENTIL R3

D4 D6 D5 D7
F1 RR3
X R3
F
D2
RETARDER-
F2-VENTIL REGELVENTIL
RETARDER KUEHLER-
HAUPTDRUCK- CONTROL VALVE UMSCHALT-
F2 VENTIL VENTIL
MAIN PRESSURE COOLER
VALVE CHANGEOVER
D8 D8 VALVE R1
D1
P

P D9 R2
RETARDER

PRIMAER-
PUMPE
D1 PRIMARY PUMP
A2

SAUGFILTER
P
SUCTION FILTER
011867
A1
DROSSELDRUCKVENTIL
THROTTLE PRESSURE
VALVE
4-1
HP 502 C / HP 592 C / HP 602 C Hydraulic circuit diagram with NBS 4149 700 026/2

A B1 B2 D E F1 F2
NA
4 GANG i = 2.81 BIS 1.0
DETAIL X 3.43 BIS 1.0
4 GEAR TO
AUSFUEHRUNG
RUECKWAERTS
HAUPTDRUCKVENTIL
MIT DRUCKABSENKUNG REVERSE
P NEUTRAL *
2 NEBENABTRIEBE MOEGLICH VERSION
PTO'S CAN BE FITTET MAIN PRESSURE VALVE
WITH PRESSURE REDUCER NEUTRAL NBS *
WK 1. GANG
1st GEAR
D2 2. GANG
2nd GEAR
3. GANG
WK 3rd GEAR
4. GANG
4th GEAR

A
B1 = INNERE KOLBENFLAECHE KUPPLUNG B
INNER PISTON FACE CLUTCH B

B2 = AEUSSERE KOLBENFLAECHE KUPPLUNG B


OUTER PISTON FACE CLUTCH B

F 1 = AEUSSERE KOLBENFLAECHE BREMSE F


B2 OUTER PISTON FACE BRAKE F
B1
P
B F 2 = INNERE KOLBENFLAECHE BREMSE F
INNER PISTON FACE BRAKE F
* = REDUZIERTER DRUCK

A B2 C D E F1 F2

C B2 5 - &. 6 GANG i = 2.81 BIS 0.8 / 3.43 BIS 0.83


3.43 BIS 0.59 TO
C 5 - & 6 GEAR TO
WANDLER- RUECKWAERTS
ENTLEERVENTIL REVERSE
NEUTRAL *
CONVERTER-
PURGE VALVE *
SPEICHER NEUTRAL NBS
ACCUMULATOR
1. GANG
1st GEAR
A8 2. GANG
D 2nd GEAR
3. GANG
3rd GEAR
4. GANG
WANDLER-
WANDLER- GEGENDRUCK- 4th GEAR
SICHERHEITS- VENTIL 5. GANG
VENTIL WAERMETAUSCHER 5th GEAR
CONVERTER TEMP.-
CONVERTER OIL COOLER 6. GANG
COUNTER- MESS-
SAFETY VALVE 6th GEAR
PRESSURE STELLE
E VALVE
TEMPERATUR
D2 SWITCH
SENSOR

SCHMIERDRUCK-
VENTIL
F1 VENTIL R3 LUBRICATING
PRESSURE VALVE
D4 D6 D5 D7
F1 RR3
X R3
F
D2
RETARDER-
REGELVENTIL
RETARDER
F2 VENTIL CONTROL VALVE KUEHLER-
HAUPTDRUCK-
VENTIL UMSCHALT-
VENTIL
F2
MAIN PRESSURE COOLER
VALVE CHANGEOVER
D8 D8 VALVE R1
D1
P

P P D9
R2
RETARDER

PRIMAER-
PUMPE
D1 PRIMARY PUMP
A2

SAUGFILTER
P
SUCTION FILTER 011938
A1
DROSSELDRUCKVENTIL
THROTTLE PRESSURE
VALVE
4-3
HP 502 C / HP 592 C / HP 602 C EST 46 C, Connection diagram 6029 729 041/1

015812

4-5
HP 502 C / HP 592 C / HP 602 C EST 46 C, Connection diagram 6029 729 041/2

015811

4-7
HP 502 C / HP 592 C / HP 602 C EST 47 C, Connection diagram 6029 729 041/3

015810

4-9
HP 502 C / HP 592 C / HP 602 C EST 47 C, Connection diagram 6029 729 041/4

015809

4-11
HP 502 C / HP 592 C / HP 602 C EST 46 / 47 C, Electrical circuit diagram 6029 729 040

015813

4-13
HP 502 C / HP 592 C / HP 602 C EST 46 / 47 C, Pin pattern 6029 729 072

015808

4-15
1 Wandler • Torque converter • Moment-
omvandlare • Koppelomvormer
2 Retarder • Retarder • Retarder • Retarder
3 Wandler-Sicherheitsventil • Torque converter
safety valve • Momentom-vandlarens
Säkerhetsventil • Koppel-omvormer-
 Veiligheidsventiel

2 4 Druckspeicher • Accumulator • Ackumulator •


Drukreservoir
5 Kühler-Umschaltventil • Cooler changeover
valve • Omkopplingsventil kylare •
Koeleromschakelventiel
 6 Wärmetauscher • Heat exchanger •
Värmeväxlare • Koeler

5 7 Schaltgetriebe • Planet gear train •
Automatväxellåda • Transmissie
 8 WK-Ventileinheit • WK valve unit •

1 12 15 8.1
Ventilenhet WK • WK-ventielunit
Magnetventil • Solenoid valve • Magnetventil •

 Magneetventiel
8.2 Drucksteuerventil • Pressure control valve •
Tryckregleringsventil • Drukregelventiel

 
8.3 Ausschaltventil • Shutoff valve •
Urkopplingsventil • Afschakelventiel

 3 16 9 Ventileinheit Kupplung/Bremse • valve unit


Clutches/Brakes • Ventilenhet Lamellkoppling •
ventielunit Koppeling\Rem
9.1 Magnetventil • Solenoid valve • Magnetventil •
 Magneetventiel

14  9.2 Drucksteuerventil • Pressure control valve •


18 Tryckregleringsventil • Drukregelventiel
9.3 Ausschaltventil • Shutoff valve •
Urkopplingsventil • Afschakelventiel
13 7 10 Kupplung/Bremse A, B, C, D, E, F, G •
4 Clutches/Brakes • Lamellkoppling •
Koppeling\Rem
11 11 Retarderregelventil • Retarder control valve •
10 Retarderstyrventil • Retarderregelventiel

12 Hauptdruckventil • Main pressure valve •


Huvudtryckventil • Hoofddrukventiel
8.1 8 9.1 9 13 Filter • Filter • Filter • Filter
14 Pumpe • Pump • Pump • Pomp
8.2 9.2 6 15 Schmierdruck • Lubrication pressure •
Smörjoljetryck • Smeerdruk
16
17
Wandlergegendruck • Converter counterpressure •

017 728
Momentomvandlarens mottrycksventil •
8.3 9.3 Koppelomvormertegendruk


 17 Drosseldruckventil • Throttle pressure valve •
Tryckmoduleringsventil • Modulatiedrukventiel

18 Luft • Air • Luft • Lucht



Technische Änderungen vorbehalten • Subject to technical change without notice


Rätt till tekniska ändrigar förbehålles • Technische veranderingen voorbehouden

Einschaltstellung
ZF FRIEDRICHSHAFEN AG
HYDRAULIC 2 Position locked
Läge till
Inschakelstand 4149 753 702 • MC-C • 08.2002
1 Wandler • Torque converter • Moment-
omvandlare • Koppelomvormer
2 Retarder • Retarder • Retarder • Retarder
3 Wandler-Sicherheitsventil • Torque converter
safety valve • Momentom-vandlarens
Säkerhetsventil • Koppel-omvormer-
 Veiligheidsventiel
2 4 Druckspeicher • Accumulator • Ackumulator •
Drukreservoir
5 Kühler-Umschaltventil • Cooler changeover
valve • Omkopplingsventil kylare •
Koeleromschakelventiel
 6 Wärmetauscher • Heat exchanger •
Värmeväxlare • Koeler

5 7 Schaltgetriebe • Planet gear train •
Automatväxellåda • Transmissie
 8 WK-Ventileinheit • WK valve unit •
1 12 15
Ventilenhet WK • WK-ventielunit
8.1 Magnetventil • Solenoid valve • Magnetventil •

 Magneetventiel
8.2 Drucksteuerventil • Pressure control valve •
Tryckregleringsventil • Drukregelventiel

8.3 Ausschaltventil • Shutoff valve •
Urkopplingsventil • Afschakelventiel

  3 16 9 Ventileinheit Kupplung/Bremse • valve unit


Clutches/Brakes • Ventilenhet Lamellkoppling •
ventielunit Koppeling\Rem
9.1 Magnetventil • Solenoid valve • Magnetventil •
 Magneetventiel
14  9.2 Drucksteuerventil • Pressure control valve •
18 Tryckregleringsventil • Drukregelventiel
9.3 Ausschaltventil • Shutoff valve •
Urkopplingsventil • Afschakelventiel
13 7 10 Kupplung/Bremse A, B, C, D, E, F, G •
4 Clutches/Brakes • Lamellkoppling •

11
Koppeling\Rem
11
10
Retarderregelventil • Retarder control valve •
Retarderstyrventil • Retarderregelventiel

12 Hauptdruckventil • Main pressure valve •

8.1
Huvudtryckventil • Hoofddrukventiel
9.1 13 Filter • Filter • Filter • Filter
14 Pumpe • Pump • Pump • Pomp
8.2 9.2 6 15 Schmierdruck • Lubrication pressure •
Smörjoljetryck • Smeerdruk
16
17 Wandlergegendruck • Converter counterpressure •

017 727
Momentomvandlarens mottrycksventil •
8.3 9.3 Koppelomvormertegendruk


 17 Drosseldruckventil • Throttle pressure valve •
Tryckmoduleringsventil • Modulatiedrukventiel
18 Luft • Air • Luft • Lucht


Technische Änderungen vorbehalten • Subject to technical change without notice


Rätt till tekniska ändrigar förbehålles • Technische veranderingen voorbehouden

Ausschaltstellung
ZF FRIEDRICHSHAFEN AG
HYDRAULIC 1 Position opened
Läge från
Uitschakelstand 4149 753 701 • MC-C • 08.2002
3 DRIVE SHAFTS
DB 250 PF Series Contents

CONTENTS

Page Date

1. GENERAL .................................................................................................. 1-1 .............. 0145


1.1 General information .......................................................................... 1-1 .............. 0145

3
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 1
DRIVE SHAFTS 3
Contents DB 250 PF Series

2 0145
3 DRIVE SHAFTS
DB 250 PF Series 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 shaft’s 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 3
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 3
General 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

3
1. Inspect all the joints. Where necessary,
retighten the nuts and bolts using a torque
spanner.

2. Check whether all the circlips are still in place 1. Drive shaft
and are fitted correctly. 2. Yoke
3. Balance plate
3. Check whether the bearing/coupling 4. Welded-up clamps (G.W.B.)
components show signs of heating (discolou- 5. Slip joint
ring of the material or burnt sealing rings). 6. Drive shaft

4. Check the O-rings on the bearing bushes and


the slip joint visually and by seeing how much
lubricant has been used.

5. Check whether the grease nipples are still


present. Check their condition.

6. Check the visible plastic guide coating on the


slip joint for damage.

7. Check the drive shaft for rust, distortion and


other damage.

8. If there is excessive noise or vibrations when


driving at a certain speed, check the balance
plates on the drive shaft (unbalance).

9. Check whether any play can be felt or seen by


pulling the drive shaft and slip joint upwards.

If any faults are found when carrying out the points


above, the drive shaft should be replaced.

1-2 0145
3 DRIVE SHAFTS
DB 250 PF Series 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”).

3. 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

3
sides. Bear in mind that the slip joint can
extend out a bit. If play can be felt, the spider
and the bearings must be replaced (see
“Spider removal and installation”).

4. 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”).

5. Clean all the grease nipples and lubricate all


the points.

Use a suitable lubricant (see


“Technical information”).
MoS2 grease must not be used.

Check whether lubricant escapes from all the


universal joint’s 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 3
General DB 250 PF Series

6. Check the slip joint’s radial and tangential


play.

0,17 mm
0,2 mm
- Check for tangential play (play between the
teeth).
a. Secure the slip joint’s fixed pipe in a
workbench with the yoke in a vertical direction.
b. Place a suitable gauge indicator on a flat part
and allow the measuring pin to rest against the
side of the yoke. Zero the gauge.
c. Turn the yoke tangentially and measure the
play on the splines. This must not be greater

3
than 0.2 mm.

02381B

7. Check the slip joint’s radial play.


a. Pull the slip joint out about 45 mm.
b. Lay the drive shaft on a flat table with the fixed
yokes touching the table.
c. Place a suitable gauge indicator with a
magnetic foot just behind the weld on the drive
shaft’s pipe.
d. Put the measuring pin just behind the weld on
the yoke and zero the gauge.
e. Lift the drive shaft up a little bit in the middle
whilst making sure that the yokes remain
touching the table.
f. 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 DRIVE SHAFTS
DB 250 PF Series General

8. Check the slip joint’s 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

3
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 3
General DB 250 PF Series

1-6 0145
3 DRIVE SHAFTS
DB 250 PF Series 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 3
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 shaft’s slip joint
inwards a bit, so that the drive shaft can easily
be reached between the rear axle and the gear
box.

3. 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.

Installation
1. Fit the drive shaft in the reverse order to its
removal.
Tighten all the bolts to the required torque (see
“Technical information”).

0145 2-1
DRIVE SHAFTS 3
Removal and installation DB 250 PF Series

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

3
down by themselves.

2-2 0145
3 DRIVE SHAFTS
DB 250 PF Series Removal and installation

2.3 SPIDER

Removal
1. Remove the complete drive shaft.
See “Drive shaft removal and installation”.

2. Place the drive shaft on a strong, flat table


using a bench vice.

3. Remove all the circlips and grease nipples and


throw them away.

3
4. Mark both parts of the slip joint so that they
can be put back in the correct way during
assembly.

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 axle’s 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.

7. Work the yoke upwards using a tyre lever. This


will make the bearing bush come completely
loose so that it can be removed.

0145 2-3
DRIVE SHAFTS 3
Removal and installation DB 250 PF Series

8. Turn the shaft through 180°. Put the shaft back


onto the bush.

9. Push the spider downwards again in the


direction of the shaft’s yoke until the spider
touches the yoke.

10. The spider and the flange can be tilted out of


shaft’s yoke.

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 DRIVE SHAFTS
DB 250 PF Series Removal and installation

Installation
1. Remove the spider, bearing bush and oil
retainer rings from the repair kit.
Apply a thin layer of grease to the bearings so
that the needles remain in place.

2. Press one bearing partly into the yoke.

3. Fit the retaining rings to the spider with a bit of


grease.

4. Tilt the spider into the yoke so that the hole A

3
(for the grease nipple) points towards the shaft.

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
Removal and installation 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 shaft’s yoke.

8. Fit the grease nipple(s).


Lubricate all the lubrication points using the
correct grease (see “Technical information”)
until grease escapes from all the bearings.

9. Fit the drive shaft.

3
See “Drive shaft removal and installation”.

2-6 0145
3 ANGLE DRIVES
DB 250 PF Series 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 1
ANGLE DRIVES 3
Contents DB 250 PF Series

2 0145
3 ANGLE DRIVES
DB 250 PF Series Angle drives W10, W13

1. MAINTENANCE, REPAIR, SPARE PARTS ANGLE DRIVES W10, W13


FOR DIWA TRANSMISSIONS (G 1230e99)

0145 1-1
ANGLE DRIVES 3
Angle drives W10, W13 DB 250 PF Series

1-2 0145
3 ANGLE DRIVES
DB 250 PF Series Spring coupling

2. REPAIR MANUAL SPRING COUPLING DIRECT-SEPERATE INSTALLATION


(G 1051gb/2002)

0145 2-1
ANGLE DRIVES 3
Spring coupling DB 250 PF Series

2-2 0145