050498 group 3_r

3 CONTENTS

0145

DB 250 PF Series

AUTOMATIC GEARBOXES

PROPELLER SHAFTS

TECHNICAL DATA

ANGLE DRIVES

DIAGNOSES

CONTENTS 3

DB 250 PF Series

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Gearboxtypes Reductions

Engine type

PE 160 PE 183

Voith D851.3 5,20 - 1,05:1 X(1) X(1)

Voith D854.3 5,20 - 0,77:1 X(2) 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)

Type of gearboxOil capacity (in litres)

Mass in kg(1) Fitting length in mm1e filling after

extendingwhenchanging 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)

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0) 7$1 $. 8,/5#'$5(9!(:!6 '5!42!;9.%?9 0.5 - 0.8 bar),

forward gear engaged.

1. Inductive pick-up N2, connector or con-necting cable defective.

Check inductive pick-up, connectorand connecting cable, repair or re-place, if required.

!"#

2a. Control unit does not receive L0 signal.For VDO or Voith load transmitter: connection between injection pump and loadtransmitter set improperly.

Check and adjust connection, if re-quired.

$

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2b. Control unit does not receive L0 signal.For E-Gas systems: faulty assignment of accelerator pedal positi-on and load transmitter level.

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

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3a. No signal from pressure switch for ANSactivation (BS): switch, connector or con-necting cable defective.

Check switch, connector or connect-ing cable and repair or replace, if re-quired.

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3b. If provided: stop brake (HSB) relay,switch, connector or connecting cable defec-tive.

Check relay, switch, connector orconnecting cable and repair or repla-ce, if required.

'

*"

3c. No signal from service (foot) brake switch(FB): one of the 3 microswitches, connectoror connecting cable defective.

Check switch at brake, connector orconnecting cable and repair or repla-ce, if required.

+

*"!,!

4. Pushbutton switch (TS), connector or con-necting cable defective.

Check switch, connector or connect-ing cable and repair or replace, if re-quired.

-

*)

Possible cause Check / remedy Note / continue with

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

Input clutch (EK) does not open

For ANS activation without stop brake(HSB): roll-back safety (simultaneousswitching of turbine brake TB and reversegear brake RB) without effect

Field coil or one of the spools of the EK sole-noid valve, connector or connecting cabledefective.

1. Check oil pressure at EK connec-tion (measuring cover):pArequd = 0 bar. 2. Check solenoid valve, connectorand cable and repair or replace, if re-quired.

./

%0,

Field coil or one of the spools of solenoid val-ves TB or RBK, connector or connecting ca-ble defective.

1. Check operating resp. converterpressure at connections TB and RBK(measuring cover). 2. Check solenoid valves, connec-tors and cables and repair or replace,if required.

+1

./ 1(2320,

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


Control unit E 200 is not supplied withvoltage - transmission remains in neutral

Solenoid valves without voltage

Input clutch (EK) does not close

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

-",4*,)5

Fuse 8A for line +UZ, connector or connect-ing cable defective.

Check fuse, connector and cable, re-pair or replace, if required.

,4677*,6

,!,

dS relay "control", connector or connectingcable defective.

Check relay, connector and cable,repair or replace, if required.

,46 ,4)!,6

!,

1. Idle speed N1 too high. 1. Check idle speed - setpoint: n 850 rpm (for gas engine: n 1000). 2. If required, adjust idle speed.

+,$

/

2. Gear safety pressure switch (ABSICH) isnot activated for pressure > 3 bar, connectoror connecting cable defective.

Check switch, connector and cable,repair or replace, if required.

'

(4)

3. Field coil or one of the spools of the EK so-lenoid valve, connector or connecting cabledefective.

1. Check oil pressure at EK connec-tion (measuring cover): pArequd 3.5 bar. 2. Check solenoid valve, connectorand cable and repair or replace, if re-quired.

+,

. %0,

4. Transmission with ANS activation: pressure switch for ANS activation (BS),connector or connecting cable defective. Note! Switch may only be closed whenthe brake device is operated!

Check switch, connector and cable,repair or replace, if required.Note! EK closes when load trans-mitter operated!

'

() !

5. Bus with gas engine: relay dNEUTR, connector or connecting ca-ble defective.Note! Idle seed is reached after the trans-mission was in neutral for some time!


.

$#%83



Disks of input clutch (EK) slip

Pushbutton switch not ready to operate

3.2 After engagement of the R gear and releasing the parkingbrake, the vehicle does not move - but transmission functionis normal when engaging a F gear

No release of reverse gear by the controlunit

1. Operating pressure too low. Check operating pressure:pArequd 3.5 bar. Adjust pressure, if required.

+,

2. EK solenoid valves hard to move or stuck,e.g. by soiling of a spool or the field coil.

1. Check oil pressure at EK connec-tion (measuring cover): pArequd 3.5 bar. 2. Repair or replace solenoid valve.

+

. %0,

3. Oil pressure after EK solenoid valve toolow: oil supply reduced or interrupted.

1. Check pressure as discr. above. 2. Check oil-supplying componentsand repair or replace, if required.

39,

4. EK disks damaged - possibly by used, pol-luted, wrong or too little transmission oil.

Replace disks, replenish or changeoil.

39, ! ,::*

Pushbutton switch, connector or connectingcable defective.


-

*)

1. Inductive pick-up N1 or N2, connector orconnecting cable defective.

Check inductive pick-up, connectorand connecting cable and repair orreplace, if required.

1. Diagnostics: function J, 2. Tr. Shoot., chapter 2.1/2:inductive pick-up N1 or N2

2. Field coil of solenoid valves RBG or RGK,connector or connecting cable defective.Note! if RBG is defective, the R gear is leftafter approx. 1 sec.!

Check solenoid valves, connectorsand cables and repair or replace, ifrequired.

.

1(32.320,



Transmission with inhibiting switch forreverse gear (SPERR): switch not closed

Pushbutton not ready to operate

Reverse gear brake (RB) does not close

Converter pressure too low

1. Inhibiting switch not operated.

2. Switch, connector or connecting cable de-fective.


-

*)

Pushbutton switch, connector or connectingcable defective.


-

*)

RBG or RBK solenoid valve hard to move orstuck, e.g. by soiling of a spool or field coil.

1. Check operating resp. converterpressure at connections RBG andRBK (measuring cover). 2. Check solenoid valves, connec-tors and cables and repair or replace,if required.

+1

. 1(32.320,

1. Field coil or one of the spools of the WRsolenoid valve, connector or connecting ca-ble defective.

1. Check converter pressure pW atmeasuring point (fig. 6/2): pWrequd 2 bar. 2. Check solenoid valve, connectorand cable and repair or replace, if re-quired.

+7

. ;3,

2. One of the control spools of the converteroutlet valve hard to move or stuck.

If required, disassemble and repairconverter outlet valve.

39,

3. Converter leaks. Check converter seal and repair, ifrequired.

- !:$

39,

4. Only for DIWA.3E: The converter inlet val-ve hard to move or stuck, valve does notopen properly.

1. Check oil pressure at WP connec-tion (measuring cover):pArequd 8.3 bar. 2. Check converter filling valve andrepair or replace, if required.

+,

39,

5. Only for DIWA.3E: The breather valvehard to move or stuck, valve does not closeproperly.

1. Check converter pressure pW atmeasuring point (fig. 6/2): pWrequd 2 bar. 2. Check breather valve and repair orreplace, if required.

+7

39,



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

Service (foot) brake switch (FB) for con-verter brake on unintentionally

3.4 Vehicle jerks after engagement of neutral - 1st gear or neutral- R gear

Input clutch (EK) closes too hard - oilpressure fault before EK

1. Operating pressure too low. Check operating pressure: pArequd 3.5 bar. Adjust pressure, if required.

+,

2. RBG or RBK solenoid valve hard to moveor stuck, e.g. by soiling of a spool or field coil.

1. Check operating resp. converterpressure at connections RBG andRBK (measuring cover). 2. Check solenoid valves, connec-tors and cables and repair or replace,if required.

+ 1

. 1(32.320,

3. Oil pressure after solenoid valve RBG orRBK too low: oil supply reduced or interrup-ted.

1. Check pressure as disribed above.2. Check oil-supplying componentsand repair or replace, if required.

39,

4. RB disks damaged - possibly by used, pol-luted, wrong or too little transmission oil.


39, ! ,::*

One of the 3 microswitches, connector orconnecting cable defect.

Check switch at brake, connector orconnecting cable and repair or repla-ce, if required.

+

*"!,!

1. One of the coils or spools of the EK sole-noid valve, connector or connecting cabledefective.

Check solenoid valve, connector andcable and repair or replace, if requi-red.

.

%0,

2. EK solenoid valve hard to move, e.g. dueto pollution of a spool or the field coil.

Repair or replace solenoid valve. 39,

3. EK disks damaged - possibly by used, pol-luted, wrong or too little transmission oil.


39, ! ,::*



3.5 When starting uphill: after engaging of a F gear, release ofparking brake and accelerating, the bus rolls backward

Insufficient tractive power

Roll-back safety fails

Converter pressure too low

Accelerator pedal not depressed enough.

Field coil or one of the spools of solenoid val-ves TB or RBK, connector or connecting ca-ble defective.

1. Check operating resp. converterpressure at connections TB and RBK(measuring cover). 2. Check solenoid valves, connec-tors and cables and repair or replace,if required.

+1

. 1(2320,


1. Check converter pressure pW atmeasuring point (fig. 6/2): pWrequd 2 bar. 2. If required, disassemble and repairconverter outlet valve.

+7,

39,


- !:$

39,

3. Only for DIWA.3E: The converter fillingvalve hard to move or stuck, valve does notopen properly.

Check converter filling valve and re-pair or replace, if required.

39,



+7

39,



"

4.1 Poor acceleration in all gears

Wrong load transmitter signals or enginedoes not put out full power

4.2 Poor acceleration in 1st gear, but normal in 2nd and 3rd gear

Converter pressure too low - enginespeed in 1st gear too high with respect tospeed

1a. For VDO or Voith load transmitter: connection between injection pump and loadtransmitter set improperly.

Check and adjust connection, if re-quired.

$

%

1b. For E-Gas systems: engine power restricted due to faulty assign-ment of accelerator pedal position and loadtransmitter level.

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

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$%

2. Engine power. 1. Measure speed at stall point. 2. Compare results to design values.

$


1. Check converter pressure pW atmeasuring point (fig. 6/2): pWrequd 2 bar. 2. If required, disassemble and repairconverter outlet valve.

+7,

39,


- !:$

39,

3. Only for DIWA.3E: The converter fillingvalve hard to move or stuck, valve does notopen properly.

Check converter filling valve and re-pair or replace, if required.

39,



+7

39,



Turbine brake (TB) does not close - engi-ne speed is greatly decreased

Turbine brake (TB) disks slip

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

Field coil or one of the spools of solenoid val-ve TB, connector or connecting cable defec-tive.

1. Check operating resp. converterpressure at connection TB (measur-ing cover). 2. Check solenoid valve, connectorand cable and repair or replace, if re-quired.

+ 1

. 2,


+,

2. TB solenoid valve hard to move or stuck,e.g. by pollution of a spool or the field coil.

1. Check operating resp. converterpressure at connection TB (measur-ing cover). 2. Repair or replace solenoid valve.

+1

. 2,

3. Oil pressure after TB solenoid valve toolow: oil supply reduced or interrupted.


39,

4. TB disks damaged - possibly by used, pol-luted, wrong or too little transmission oil.


39, ! ,::*

1. Hand brake switch (HB) not in 0 position orservice brake switch (FB) operated.2. One of the 3 sliding contacts in the handbrake switch, one of the 3 microswitches inthe service brake switch, connector or con-nect-ing cable defective.

Check hand brake switch, micro-switch in service brake switch, con-nector and cable, repair or replace, ifrequired.

+

1!*")

3. Pushbutton switch (e.g. terminal S1 with-out power), connector or connecting cabledefective.


-

*)



4.4 Braking too strong with accelerator pedal released

Converter brake turned on

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

No signal regarding vehicle speed

Wrong power transmitter signals - enginedoes not reach full power

See chapter 4.3, items 1 and 2.

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

2. Pushbutton switch (e.g. continuous cur-rent terminal S1, although button 1 not pres-sed), connector or connecting cable defecti-ve.


-

*)

Inductive pick-up N2, connector or connect-ing cable defective.

Check inductive pick-up N2, connec-tor and connecting cable and repairor replace, if required.

!"#


Check connection and adjust, if re-quired.

$

%


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

&

$%



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

Pump brake (PB) does not close

Pump brake (PB) disks slip - enginespeed is greatly reduced

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

TB solenoid valve does not open - turbinebrake remains closed.

Field coil or one of the spools of the PB sole-noid valve, connector or connecting cabledefective.

1. Check oil pressure at PB connec-tion (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connectorand cable, repair or replace, if requi-red.

+,

.



4.8 Transmission does not shift to 3rd gear - operation only pos-sible in 1st and 2nd gear

Automatic shifting from 2nd to 3rd gearinhibited

Lock-up clutch (DK) does not close

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

Lock-up clutch (DK) disks slip

1. Pushbutton 2 (4, 5 or 6-pushbutton switch)depressed.

2. Pushbutton switch, connector or connect-ing cable defective.


-

*)

Field coil or one of the spools of the DK sole-noid valve, connector or connecting cabledefective.

1. Check oil pressure at DK connec-tion: pArequd 8.3 bar. 2. Check solenoid valve, connectorand cable, repair or replace.

+

. 0,


+,

2. DK solenod valve hard to move or stuck,e.g. by pollutionof a spool or the field coil.

1. Check oil pressure at DK connec-tion (measuring cover): pArequd 8.3 bar. 2. Repair or replace solenoid valve.

+

. 0,

3. Oil pressure after DK solenoid valve toolow: oil supply reduced or interrupted.

1. Check pressure as discr. above.2. Check oil-supplying componentsand repair or replace, if required.

39,

4. DK disks damaged - possibly by used, pol-luted, wrong or too little transmission oil.


39, ! ,::*



4.10 For 4-gear transmissions: transmission does not shift to 4thgear, operation only possible in 1st, 2nd and 3rd gear

Automatic shifting from 3rd to 4th gear in-hibited

Fast gear clutch (SK) does not close

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

Fast gear clutch (SK) disks slip

1. Pushbutton 3 of 6-pushbutton switch de-pressed.

2. Pushbutton switch (e.g. continuous currentterminal S3, although button 3 not pressed),connector or connecting cable defective.


-

*)

Field coil or one of the spools of solenoid valveDK, connector or connecting cable defective.

1. Check oil pressure at SK connec-tion (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connectorand cable, repair or replace, if re-quired.

+,

. 0,


+,

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

1. Check operating at SK connec-tion (measuring cover): pArequd 8.3 bar. 2. Repair or replace solenoid valve.

+

. 0,

3. Oil pressure after SK solenoid valve too low:oil supply reduced or interrupted.


39,

4. SK disks damaged - possibly by used, pollu-ted, wrong or too little transmission oil.


39, ! ,::*



4.12 Kickdown shifting not possible

No signal for separate kickdown switch(KD)

No load transmitter signal - load transmit-ter stage L7 is not reached

4.13 Engine stalls in reverse gear

Converter pressure is not controlled forseed over 1 km/h (= 30 Hz)

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

No signal regarding vehicle speed

Kickdown switch, connector or connectingcable defective.


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1. Coil or one of the spools of the WP soleno-id valve, connector or connecting cable de-fective.

1. Check oil pressure at WP connec-tion (measuring cover): pArequd 3.5 bar. 2. Check solenoid valve, connectorand cable, repair or replace, if requi-red.

+,

. ;



4.15 Transmission shifts to neutral while driving

Control unit E 200 is not supplied withvoltage

Solenoid valves without voltage

4.16 Hard shifting from 1st to 2nd gear

Pump brake (PB) closes too hard - oilpressure fault before PB

Fuse 8A for line +UZ, connector or connect-ing cable defective.

Check fuse, connector and cable, re-pair or replace, if required.

,4677*,6

,!,

dS relay "control", connector or connectingcable defective.


,46 ,4)!,6

,!,!!,

1. One of the field coils or spools of the PBsolenoid valve, connector or connecting ca-ble defective.

Check solenoid valve, connector andcable, repair or replace, if required.

.



4.17 Hard shifting from 2nd to 3rd gear

Lock-up clutch (DK) closes too hard - oilpressure fault before DK

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

Fast gear clutch (SK) closes too hard - oilpressure fault in front of SK

1. One of the field coils or spools of the DKsolenoid valve, connector or connecting ca-ble defective.


.

0,

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


3. DK disks damaged - possibly by used, pol-luted, wrong or too little transmission oil.


39, ! ,::*

4. Inductive pick-up N1, connector or con-necting cable defective.


!"#

1. One of the coils or spools of the SK sole-noid valve, connector or connecting cabledefective.


.

0,

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


3. SK disks damaged - possibly by used, pol-luted, wrong or too little transmission oil.


39, ! ,::*

4. Inductive pick-up N1, connector or con-necting cale defective.


!"#



# $% $

5.1 The converter brake (CB) does not operate in all F gears viaservice (foot) and hand brake switch

One of the conditions for activation of theconverter brake not met:

No release of converter brake by controlunit

Accelerator pedal in idle position. service or hand brake switch operated.

1. ABS active.

2a. Control does not receive L0 signal. For VDO or Voith load transmitter: connection between injection pump and loadtransmitter set improperly.


$

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2b. Control does not receive L0 signal. For E-Gas systems: engine power restricted due to faulty assign-ment of accelerator pedal position and loadtransmitter level.


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$%

3. Field coil of solenoid valves PB, WP orRBK, connector or connecting cable defecti-ve.

Check solenoid valves, connectorsand cables, repair or replace, if requi-red.

.

,



5.2 The converter brake does not operate in 1st gear via serviceand hand brake switch

Converter brake not released by controlunit

Turbine (TB) or reverse gear brake (RB)does not close

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

Converter brake not released by controlunit

Pump (PB) or reverse gear brake (RB)does not close

1. See chapter 5.1.

2. Converter brake was activated in 1stgear (it is possible for some versions).

Converter brake must already havebeen activated in 2nd, 3rd or 4th gear.

1. Coil or one of the spools of the TB sole-noid valve, connector or connecting cabledefective.

1. Check operating resp. converterpressure at TB connection (measuringcover). 2. Check solenoid valve, connector andcable, repair or replace, if required.

+,1

. 2,

2. RBK solenoid valve hard to move orstuck, e.g. by pollution of a spool or thefield coil.

1. Check operating resp. converterpressure at RBK connection (measur-ing cover). 2. Check solenoid valve, connector andcable, repair or replace, if required.

+,1

. (320,

See chapter 5.1.

1. PB solenoid valve hard to move or stuck,e.g. by pollution of a spool or the field coil.

1. Check oil pressure at PB connection:pArequd 8.3 bar. 2. Check solenoid valve, connector andcable, repair or replace, if required.

+,

.



5.4 One of the 3 or all brake stages of the converter brake doesnot operate via service brake switch (brake pedal)

Switch not operated or defective

5.5 One of the 3 or all brake stages of the converter brake doesnot operate via the 3-stage hand brake switch (manualswitch)

5.6 For one-stage hand brake switch: stage 2 or 3 of the conver-ter brake does not operate

1. Converter brake deactivated by the OFFswitch for activation by the brake pedal(FBAUS).

Indicator lamp (if installed) at the ma-nual switch is not lit when the servicebrake switch is operated.

2. Switch, connector or connecting cable de-fective.


'

(!*"=++)

3. One of the 3 microswitches in the servicebrake switch (FB), connector or connectivecable defective.


+

!*")

One of the 3 sliding contacts in the hand bra-ke switch (HB), connector or connecting ca-ble defective.

Check brake switch, connector andcable, repair or replace, if required.

*")

Hand brake switch (HB), connector or con-necting cable defective.

Check brake switch, connector andcable, repair or replace, if required.

'2)



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

Converter pressure uncontrolled or toohigh

Reverse brake (RB) closes too hard - oilpressure fault before RBK

1. WP solenoid valve hard to move or stuck,e.g. by pollution of a spool or the field coil.


+,

. ;



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

Converter pressure too high

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

1. WP solenoid valve hard to move or stuck,e.g. by pollution of a spool or the field coil.


+,

. ;



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

In 2nd, 3rd, and perhaps 4th gear and atall speeds: Converter pressure too high

In 2nd, 3rd, and perhaps 4th gear and atall speeds: Reverse brake (RB) closes toohard - oil pressure fault before RBK

In 3rd and perhaps 4th gear and at highspeeds: Converter filling control (CFC)malfunction - converter pressure toohigh

(High speed means: transmissionoutput speed is higher than the limitset for activation of converter fillingcontrol, e. g. about 2000 to 2200 rev/min in 4th gear).

=,-,-7/;&%*-+-

1. WP solenoid valve hard to move or stuck,e.g. by pollution of a spool or the field coiland doesn't close correcly.

1. Check oil pressure at WP connec-tion (measuring cover): pArequd = 0 bar. 2. Check solenoid valve, connectorand cable, repair or replace, if requi-red.

+7,

. ;



5.11 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brakestage I too high

Converter pressure too high

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

Converter pressure too high or too low

One of the control spools in converter outletvalve hard to move or stuck.

Disassemble converter outlet valveand repair, if required.

39,

1a. Brake force too low: Field coil or one ofthe spools of the WR solenoid valve, connec-tor or connecting cable defective.

1. Check converter pressure pW atmeasuring point (fig. 6/2). 2. Check solenoid valve, connectorand cable, repair or replace, if requi-red.

+7,

. ;3,

1b. Brake force too low: Oil pressure afterWR solenoid valve too low because oil supp-ly is reduced or interrupted.

Check oil-supplying componets andrepair or replace, if required.

39,

1c. Brake force too low: Converter filling val-ve hard to move or stuck and doesnt opencorrecly.

1. Check oil pressure at WP connec-tion (measuring cover): pArequd 8.3 bar.2. Check converter filling valve andrepair or replace, if required.

+,

39,

1d. Brake force too low: Breather valve hardto move or stuck and doesnt close correcly.

1. Check converter pressure pW atmeasuring point (fig. 6/2).2. Check breather valve and repair orreplace, if required.

+7,

39,

2. One of the control spools in converter out-let valve hard to move or stuck.

Disassemble converter outlet valveand repair, if required.

39,

3. Wrong control unit. 1. Check item number of control unit(compare transmission type to con-trol unit nameplate). 2. Check assignment. 3. Replace control unit, if required.

&/



5.13 In 1st gear range: brake force in brake stage II or II too lowor too high

RBK oil pressure too low or too high

1. RBK solenoid valve hard to move orstuck, e.g. by pollution of a spool or the fieldcoil.

1. Check operating resp. converterpressure at RBK connection (measu-ring cover). 2. Check solenoid valve, connectorand cable, repair or replace, if requi-red.

+,1

. (320,

2. Oil pressure after RBK solenoid valve toolow: RBK oil supply reduced or interrupted.


39,

3. Wrong control unit. 1. Check item number of control unit(compare transmission type to controlunit nameplate). 2. Check assignment.3. Replace control unit, if required.

&/



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

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

6.3 The warning lamp transmission oil temperature (TOEL) doesnot light after turning on the ignition (TOEL is energized afew seconds for test purposes)

6.4 Consumer via relays - converter brake (dW), reversing lamp(dR) or speed (dN) - cannot be activated

1. Lamp defective.

2. If controlled through relays: relay, con-nector or connecting cable defect.

Check relay, connector and cable, re-pair or replace, if required.

.

(,),7

1. For single pushbutton: lamp defective.

2. Pushbutton switch (e.g. terminal TL wit-hout voltage), connector or connecting ca-ble defect.


-

*)

Lamp, connector or connecting cable de-fect.

Check lamp, connector and cable, re-pair or replace, if required.

.

(7,),7

1. Consumer not activated in record. Load correct record. .

2. Consumer defective. Repair or replace consumer.

3. Relay dW, dR or dN, connector or con-necting cable defect.

Check relay, connector and cable, re-pair or replace, if required.

.

,4;3#


) *

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 cableIf the diagnostic program is used.Cable: Voith order no. 56.4219.10

Measuring cover (high design)To measure the oil pressures of clut-ches, brakes and valves of thetransmission. 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 gaugeTo measure the operating and con-verter pressure. Voith order no. 58.2748.11

Multimeter To measure voltages and resi-stances.

*,


+ ,$!

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 usuallymeasured 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 pressureare measured at the measuringpoints for the clutches resp. brakesDK, EK, PB, WP and SK.Fig. 2: Meas. points for DIWA.3Fig. 3: Meas. points for DIWA.3E

Note! The WR oil pressure is cy-cled and therefore variable overtime, its amount in addition de-pending on the relevant operatingstate (during braking or rever-sing). Therefore, simple pressuremeasurements by means of pres-sure gauges are not adequate formore thorough troubleshooting.

The measuring points TB, RBG and RBK are each pressurized with the higher ope-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!

1

2

3


If the measuring points mentionedare not accessible, the operatingpressure can also be measured forDIWA.3 transmissions at the inter-mediate flange (if installed) of the oilfilter: 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 theoperating pressure.Note! Only measure before the fil-ter if the filter element is clean!

The working pressure can be set atthe threaded pin of the operatingpressure valve (5/1) - only possiblewith special screwdriver and socketwrench through the oil filler!If the required operating pressure isnot reached, check piping for leaka-ge and sealing gaps of the gearpump.

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 forwardgear engaged, engine at idle speed (500 50 rpm) and parking brake applied.If this value is not reached, converter sealing must be improved.

Measuring pointUsually, the converter pressure ismeasured at measuring point (6/2).

Converter pressure with WDA de-activationAt toil of = 80 - 90 C (= 176 - 194 F),the converter pressure must be0,7 < pW < 2 bar

Converter pressure when conver-ter filling control (CFC) is activepW = 0 bar

Converter pressure during bra-kingAt toil of = 80 - 90 C (= 176 - 194 F),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 barbrake stage II: pW = 1.8 - 2.5 barbrake stage III: pW = 3.6 - 4.9 bar

,4/;&5

39,

- !:$

39,

,4/;&5

,4/;&%5

/;&%,4)-+-!5

4

5

6


- . %

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 otherhand, the idle speed must not be too high, because the input clutch, for example, willnot close: n 850 rpm (for gas engine: n 1000 rpm). 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 pressuresin front of the disk clutches and brakes during shifting. Along with the input and outputspeeds, the motor torque is important, which to a great extent is in turn affected bythe 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-ner dependent on the engine control system.

The following settings can be checked in a relatively simple manner with the bus stop-ped by means of the diagnostic program:1. Load level L0 = "idle", accelerator pedal completely released. 2. Load level L6 = "full load", accelerator depressed to the stop (first, if any). 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 thefirst and to the end stop against greater resistance.

4. Gradually depress the accelerator pedal from idle to full load and check that the"partial load" signals L2 to L5 are also displayed by the diagnostic system.

Note! For an accurate check of the load transmitter partial load signals as func-tion of the accelerator pedal travel, documents from the bus manufacturer arerequired.

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

If the diagnostic system indicates load levels that do not correspond to the acceleratorpedal 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-

gnostic system).

/

,9,

%

/

&


Adjusting the connection between load transmitter and injection pump

If the injection pump lever the load transmitter lever mustis in 0 load position be on the 0 load mark too!

If the injection pump lever the load transmitter lever mustis 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 leveris moved by 1/3 of the angle between 0 and full load, the load transmitter levermust also be move by 1/3 of its angle between 0 and full load!

Example for load transmitter adjustmentwith electronic engine control unit

9,

Mark for full load position

Mark for 0 load position

ConnectionInjectionpump

transmitter

7

8

9


9.3 Test: rated engine torque as function of load stage or enginespeed

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 speedmeasurements in the so-called stall point - e.g. by means of the diagnostic program.

First of all pay attention:Danger! Apply parking brake to prevent unintentional bus movement!After that as example for full load operation (= load level L6):1. engage forward gear, 2. depress accelerator pedal to the full load stop, 3. enter the measured engine speed N1 (= stall speed) in the diagram below

(figure 10). The intersection with the appropriate pump characteristic of the 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 possibleengine torque while driving with electronic engine control units. These testsare performed during acceptance protocol measurements.

/

&,/,&

0100200300400500600700800900

100011001200130014001500

400 600 800 1000 1200 1400 1600 1800 2000 22000

100200300400500600700800900

100011001200130014001500

0100200300400500600700800900

100011001200130014001500

400 600 800 1000 1200 1400 1600 1800 2000 22000

100200300400500600700800900

100011001200130014001500

400 600 800 1000 1200 1400 1600 1800 2000 2200

3X

4X

3V

4V

3F3G

3H4F

4G4H

Engi

ne

torq

ue

M1

(Nm

)

Engine speed N1 (rpm)10


/!!

1 hydraulic control diagram DIWA.31 hydraulic ccontrol diagram DIWA.3E1 circuit diagram DIWA.31 circuit diagram DIWA.3E

pw

pa

A

B

C

DE

F

G

HJ12

4

5

6

7

89

101112131415

WR

DK

EK

PB

WP

SK

TB

RBG

RBK

3

Drawn: Neutral position

Hydraulic control diagramDIWA.3 55.2059.12

A Converterdrainvalve(CDV)B Operatingpressure

valve(OPV)C SolenoidvalvesD ReliefvalveE PressureaccumulatorTBF DIWA.3transmissionG GearpumpH HeatexchangerJ Oilfilter

1-6 CDVspools7,8 OPVspools9 Shuttlevalve10 ReversegearbrakeRB11 TurbinebrakeTB12 PumpbrakePB13 Step-upgearclutchSK14 Lock-upclutchDK15 InputclutchEK

Shiftingfunction EK DK SK PB TB WP WR RBK RBGANSactivation x x1)

ANSactiv.viaparkingbrake x1stgear(DIWAdriverange) x x xUpshift1st-2ndgear* x x2ndgear x x x3rdgear x x x4thgear x x xBraking1stgearrange x x x x x1)

1stbrakingstage-2ndgear x x x x x2ndand3rdbrak.stage-2ndgear x x x x2) x x2ndand3rdbrak.stage-3rdgear x x x x2) x x2ndand3rdbrak.stage-4thgear x x x x2) x xReversegear1km/h x x x1,2) x x*=Transition 1)=Valveregulated

2)=Valveoscilated

pA

pW

DK

SK

EK

PB

RBK

TB

RBG

WP

WR

A

B

C D

E

F

GH

124

5

6

7

8

9

10

11121314151617

3

Drawn: Rest position

Hydraulic control diagramDIWA.3E 55.5661.15

A Converterdrainvalve(CDV)B Converterfillingvalve(CFV)C Operatingpressure

valve(OPV)D SolenoidvalvesE DIWA.3EtransmissionF GearpumpG HeatexchangerH Oilfilter

1-6 CDVspools7 CFVspool8,9 OPVspools10 Shuttlevalve11 ReversegearbrakeRB12 TurbinebrakeTB13 Breathervalve14 PumpbrakePB15 Step-upgearclutchSK16 Lock-upclutchDK17 InputclutchEK

Shiftingfunction EK DK SK PB TB WP WR RBK RBG1stgear(DIWAdriverange) x x xUpshift1st-2ndgear* x x2ndgear x x x3rdgear x x x4thgear x x x3rdgearwithconverterfillingcontrol(CFC) x x4thgearwithCFC x x1st,2ndand3rdbrak.stage-4thgearwithCFC* x x x1stbrakingstage-4thgear x x x x x2ndand3rdbrak.stage-4thgear x x x x2) x x2ndand3rdbrak.stage-3rdgear x x x x2) x x2ndand3rdbrak.stage-2ndgear x x x x2) x xBraking1stgearrange x x x x x1)

ANSactivation x x1)

ANSactivationviaparkingbrake xReversegear1km/h x x x2) x x*=Transition 1)=Valveregulated

2)=Valveoscilated

M50f

D+61 D-

+HB 1

HBC

1

0 3

0 1HBA 0 1

1

HBAHBBHBC

1 10

001

11

0 2 3

+HB 1 1

00

01

0 1 2 3

1

1

S1

RD N1 RND2

321

R

R

N

N

D

D

2

S2 S3 S3/3S3/2S2/2S2/1

GD+50e

1

2 3

gn/gebl

swbr

1234

FB1

FB2

FB3+FB

10

123456789

KD 204219240249

211202

204

240249202211

204

240249

211202

HBC

+HB

219+UZ

219

76543

1

8

2

HBA

120382

21393

22

423415

24426

25437

26448

27459

2846102947113048123149133250143351153452

16

3553173654183755

19

10821

DIAGN-LDIAGN-K

+UZ-UB

227

228

229

230

245209

210

233

246

207226244208

202

211

249

238

221.1

212

213

214

215

216

231

232

235

248

250

251

252

253

FB3

FB2

+UB

S1S2S3

dS

+V

dR

+R

+TS/N

BS

RS

+TL

+FB

-UB

FBAUS

ABS

dWdN

ZW

PU

ABSICH

HBAHBBHBC+HB

TOEL

221

221.3252.1216.1

219.1

240 FB140KD

204.1204

KD

252.1DIAGN-L

221.3

DIAGN-K

255 dNEUTR219

219.2

219.2

+UZ

150

+HB207226244

208HBAHBBHBC

226

208

-UB

221.2

A B C D E F G H J K L M N P R S T U V W X Y Z a b c d e f g h j

12345678910

1955371854361753351652341551331450321349311248301147291046289

4527844267

4325

44022339212

38201

EK

DKSK

RBG

WR

EKMDKMSKMPBMTBM

RBKMSENSESENSE

N1AN1BN2AN2BN3AN3B

TS+TS-

WP

RBKPB

TB

-UB

-UB

-UB

-UB-UB-UB

-UB-UB-UB

-UB

-UB

-UB

-UB

-UB

IO9

REA0

PA

119

137118

117153135

152

148

111147129110146128

103

121102

120101

101

120

102

121

103

118

117

119

137

135

146

128

129

110

111

147

153

152

12

3

4

5

6

78

910

148

12

34sw

sw sw

ws

wsws

blbl

blbl

+-12

642245

4123

LGM-LG+LGIO3

124

141105

1234

124141

105

200200

227245209228246230229233210221

123456789

101112131415161718

S1S2S3+V+R

/N

+TSRS

+TL

-UB

207226244

208

227245209228246230229233210221

207226244

208

221.2

+HB207226244

208HBAHBBHBC

226

208

-UB3

7654

21

0 1 2 3

+

12

456

+8

3

221.2

227245209228246230229233210221

87

123456

9101112

N RD1 2 3

S1S2S3+V+R

/N

+TSRS

+TL

-UB

1314

S3/3

S3/2

S2/2

S2/1

+RRSRFSSP 200

200 200256

256

DKRDKE

DKV/PWM

224.1205.1241.1

DKEDKR

DKV/PWM

SSPRF

DIAGN-K252DIAGN-L

ABSICH

DKV/PWM

+ 24V

231

P

1819202122

P

235248

212221.1

1011

1314151617

216200

215204.1

12 205.1224.1241.1

FBAUS

-UBBS

PU

TOELKD

SSPDKRDKE

dNEUTR

23456789

214232251253250

219.1213

255

1238

8586 85 87 87a30 86 85 87 87a30 86 85 87 87a30 86 85 87 87a30 8630

dS dW dR

87 87a 86 85 8730 87a

dN

gege

dR

dS+UZ

ABSdN

dWZW

+UB

br

bl1

sw

rt

2

gnbl

brgegnbl

134

2

134

rtbl

rt

swgebl

blrt

brgegnbl

br13

24

2sw

rtblge

1

sw

brsw 2

ge ge

brgegnbl

1

4

sw

rt

gebl

2

3

blgn

bl

br134

rtbl

1

2

rt

sw

bl rt

br

1

2sw

brgegn

2

34

sw

blge

swws

216.1

n1 n3

+LGLGM-LG

WP

PB

EK

DK

WR

RBK

TB

RBG

SK

n2

A

b

a

B C

A c

D

E F

G

H

JK

d e f g

h

L

on off

j k l m

n

M

NO

Q

RS

pq sts

t

u

vw

ABS

i

x yz

x yz

o

U T

inactive

r

217236

CAN-H

237 CAN-L

CBA

217237236

sw CAN-Hge CAN-M

CAN-L

CAN-HCAN-MCAN-L

CAN-M

PM

A Push-button switchB Connection cable for

push-button switch andconverter brake

C Cable 2D E 200 control unitE Connection: level con-

verter and diagnostic PCF Cable 1G Load transmitterH Speed and temperature

sensorsJ Solenoid valvesK Connection cable

for vehicle wiring

L Switches and warning light transmission oil

M Engine controlN Vehicle electrical system -

non-committal representationO RelaysP CAN BusQ Connection cable for

brake valve and kickdown switch

R Kickdown switchS Brake valveT Manual switch for

converter brakeU Switch for converter

brake; stage no. 3

a Inhibitor switch for reverse gearb Connectionsc Bridgesd Warning light transm. oile Cut-out switch for conv. brake;

only for brake valvef Pressure switch for

gearshift inhibitorg Pressure switch for

ANS activationh Relay for control uniti Relay for starter inhibitorj Relay for centr. warn. lightk Relay for converter brakel Relay for reversing light

m Relay for speedn Central warning lighto Fuse 8Ap Relay for batteryq Switch boxr Starter inhibitor relays Starterst Start buttont Batteryu Overvoltage protectionv Generatorw Regulatorx Connectionsy Positionz Stage no.

Circuit diagram DIWA.355.3705.20

M50f

D+61 D-

+HB 1

HBC

1

0 3

0 1HBA 0 1

1

HBAHBBHBC

1 10

001

11

0 2 3

+HB 1 1

00

01

0 1 2 3

1

1

S1

RD N1 RND2

321

R

R

N

N

D

D

2

S2 S3 S3/3S3/2S2/2S2/1

GD+50e

1

2 3

gn/gebl

swbr

1234

FB1

FB2

FB3+FB

10

123456789

KD 204219240249

211202

204

240249202211

204

240249

211202

HBC

+HB

219+UZ

219

76543

1

8

2

HBA

120382

21393

22

423415

24426

25437

26448

27459

2846102947113048123149133250143351153452

16

3553173654183755

19

10821

DIAGN-LDIAGN-K

+UZ-UB

227

228

229

230

245209

210

233

246

207226244208

202

211

249

238

221.1

212

213

214

215

216

231

232

235

248

250

251

252

253

FB3

FB2

+UB

S1S2S3

dS

+V

dR

+R

+TS/N

BS

RS

+TL

+FB

-UB

FBAUS

ABS

dWdN

ZW

PU

ABSICH

HBAHBBHBC+HB

TOEL

221

221.3252.1216.1

219.1

240 FB140KD

204.1204

KD

252.1DIAGN-L

221.3

DIAGN-K

255 dNEUTR219

219.2

219.2

+UZ

150

+HB207226244

208HBAHBBHBC

226

208

-UB

221.2

A B C D E F G H J K L M N P R S T U V W X Y Z a b c d e f g h j

12345678910

1955371854361753351652341551331450321349311248301147291046289

4527844267

4325

44022339212

38201

EK

DKSK

RBG

WR

EKMDKMSKMPBMTBM

RBKMSENSESENSE

N1AN1BN2AN2BN3AN3B

TS+TS-

WP

RBKPB

TB

-UB

-UB

-UB

-UB-UB-UB

-UB-UB-UB

-UB

-UB

-UB

-UB

-UB

IO9

REA0

119

137118

117153135

152

148

111147129110146128

103

121102

120101

101

120

102

121

103

118

117

119

137

135

146

128

129

110

111

147

153

152

12

3

4

5

6

78

910

148

12

34sw

sw sw

ws

wsws

blbl

blbl

+-1

2

642245

4123

LGM-LG+LGIO3

124

141105

1234

124141

105

200

227245209228246230229233210221

123456789

101112131415161718

S1S2S3+V+R

/N

+TSRS

+TL

-UB

207226244

208

227245209228246230229233210221

207226244

208

221.2

+HB207226244

208HBAHBBHBC

226

208

-UB3

7654

21

0 1 2 3

+

12

456

+

8

3

221.2

227245209228246230229233210221

87

123456

9101112

N RD1 2 3

S1S2S3+V+R

/N

+TSRS

+TL

-UB

1314

S3/3

S3/2

S2/2

S2/1

+RRSRFSSP 200

200 200256

256

DKRDKE

DKV/PWM

224.1205.1241.1

DKEDKR

DKV/PWM

SSPRF

DIAGN-K252DIAGN-L

ABSICH

DKV/PWM

+ 24V

231

P

1819202122

P

235248

212221.1

1011

1314151617

216200

215204.1

12 205.1224.1241.1

FBAUS

-UBBS

PU

TOELKD

SSPDKRDKE

dNEUTR

23456789

214232251253250

219.1213

255

1238

8586 85 87 87a30 86 85 87 87a30 86 85 87 87a30 86 85 87 87a30 8630

dS dW dR

87 87a 86 85 8730 87a

dN

gege

dR

dS+UZ

ABSdN

dWZW

+UBbr

bl1

sw

rt

2

gnbl

brgegnbl

134

2

134

rtbl

rt

swgebl

brgegnbl

br13

24

2sw

rtblgesw

br

ge ge

brgegnbl

1

4

sw

rt

gebl

2

3

blgn

bl

br134

rtbl

1

2

rt

sw

br2

sw

swws

216.1

n1 n3

+LGLGM-LG

WP

PB

EK

DK

WR

RBK

TB

RBG

SK

n2

A

b

a

B C

A c

D

E F

G

H

JK

d e f g

h

L

on off

j k l m

n

M

NO

Q

RS

pq sts

t

u

vw

ABS

i

x yz

x yz

o

U T

inactive

r

bl

br

1

2

rt

swgegegnbl

134

rtbl

2sw

217236

CAN-HCAN-M

237 CAN-L

CBA

217237236

sw CAN-Hge CAN-M

CAN-L

CAN-HCAN-MCAN-L

PM

A Push-button switchB Connection cable for

push-button switch andconverter brake

C Cable 2D E 200 control unitE Connection: level con-

verter and diagnostic PCF Cable 1G Load transmitterH Speed and temperature

sensorsJ Solenoid valvesK Connection cable

for vehicle wiring

L Switches and warning light transmission oil

M Engine controlN Vehicle electrical system -

non-committal representationO RelaysP CAN BusQ Connection cable for

brake valve and kickdown switch

R Kickdown switchS Brake valveT Manual switch for

converter brakeU Switch for converter

brake; stage no. 3

a Inhibitor switch for reverse gearb Connectionsc Bridgesd Warning light transm. oile Cut-out switch for conv. brake;

only for brake valvef Pressure switch for

gearshift inhibitorg Pressure switch for

ANS activationh Relay for control uniti Relay for starter inhibitorj Relay for centr. warn. lightk Relay for converter brakel Relay for reversing light

m Relay for speedn Central warning lighto Fuse 8Ap Relay for batteryq Switch boxr Starter inhibitor relays Starterst Start buttont Batteryu Overvoltage protectionv Generatorw Regulatorx Connectionsy Positionz Stage no.

Circuit diagram DIWA.3E55.6168.10

Voith Turbo GmbH & Co. KGProduktgruppe NutzfahrzeuggetriebeAlexanderstrae 2D-89522 HeidenheimTelephone (07321) 37-0Telefax (07321) 37 7618

3 AUTOMATIC GEARBOXES DB 250 PF Series

0145 1-1

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

AUTOMATIC GEARBOXES 3

HP 502 C / HP 592 C / HP 602 CEST 46 C / EST 47 CStages 1-2

4149 751 601e

REPAIR MANUAL

011356

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Instructions for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Arrangement of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Cutaway views of Ecomat transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Clutch and brake combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

1.1 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.3 Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.4 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.5 Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.6 Adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.7 Checking oil level at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.8 Checking oil level when cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.9 Checking oil level with engine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.10 Checking oil level on versions with heat exchanger higher than center line of transmission . . . . . . . . . . . 1-31.11 Changing oil at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

2.1 Renewing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2 Renewing retarder solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32.3 Renewing accumulator solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42.4 Renewing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52.5 Renewing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62.6 Renewing output sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.6.1 Renewing retarder resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112.7 Removing and fitting oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132.8 Renewing turbine sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-172.9 Renewing complete hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-232.10 Changing complete oil level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-282.11 Renewing impulse sensor for speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-322.12 Renewing output flange and/or radial seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-332.13 Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Contents HP 502 C / HP 592 C / HP 602 C

Page

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

3.1 Terminal tester concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 Test instructions for test cable 1 PO1 138 153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.3 Annex

Description/menus for ZF Testman

4. Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Hydraulic circuit diagram without NBS 4149 700 026 / 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Hydraulic circuit diagram with NBS 4149 700 026 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Connection diagram 6029 729 041 / 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Electrical circuit diagram n 6029 729 040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Pin pattern 6029 729 072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

ZF FRIEDRICHSHAFEN AGC.V./Special TransmissionsService Plant 2Tel.: (0 75 41) 77-0Fax: (0 75 41) 77-5726

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 inaccordance with the state of development on the dateof issue.

However, due to continuing development of the product,repair work might require work practices and test oradjustment data not contained in this manual.

We recommend that work done on your ZF product iscarried out only by skilled mechanics who have hadtheir practical and theoretical knowledge updated on aregular basis at our After-Sales Service training centers.

Service points equipped by ZF Friedrichshafen AG allover 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 outconscientiously and with utmost care.

Repair work carried out at ZF service points is subject to the contractual conditions prevailing inthe individual case.

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional mannerand any consequential costs are excluded from the con-tractual liability agreement. Exclusion of liability alsoapplies if genuine ZF spares are not used.

HP 502 C / HP 592 C / HP 602 C Preface

5

SAFETY NOTICE

Companies repairing ZF units are responsible for theirown work safety.

To avoid injury to personnel and damage to pro-ducts, all safety regulations and legal requirementswhich apply to repair and maintenance work mustbe adhered to.Before starting work, mechanics must familiarizethemselves with these regulations.

Personnel required to carry out repairs on ZF productsmust receive appropriate training in advance. It is theresponsibility of each company to ensure that theirrepair staff is properly trained.

The following safety instructions appear in thismanual:

NOTERefers to special processes, techniques, data, useof auxiliary equipment, etc.

CAUTIONThis is used when incorrect, unprofessionalworking practices could damage the product.

DANGERThis is used when lack of care could lead to personal injury or death.

GENERAL INFORMATION

Read this manual carefully before starting any tests orrepair work.

CAUTIONPictures, drawings and components do not alwaysrepresent the original object, but are used to illustrateworking procedures.Pictures, drawings and components are not to scale.Conclusions about size and weight should not bedrawn (even within a complete illustration).Always follow the working steps as described in thetext.

After completion of repair work and testing, skilled staffmust satisfy themselves that the product is functioningcorrectly.

THREATS TO THE ENVIRONMENT !Lubricants and cleaning agents must not be allowedto enter the soil, ground water or sewage system. Ask your local environment agency for

safety information on the relevant products and adhere to their requirements.

Collect used oil in a suitably large container. Dispose of used oil, dirty filters, lubricants

and cleaning agents in accordance withenvironmental protection guidelines.

When working with lubricants and cleaningagents always refer to the manufacturers instructions.

CAUTIONThe transmission must NOT be hung by the inputshaft NOR by the output flange.

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

6

7In case of doubt always turn to the relevant depart-ment within ZF After-Sales Services for advice.All work on transmissions is to be performed expertlyand under clean conditions.Use specified tools to dismantle and assemble trans-missions.

After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent beforeopening.Pay particular attention to the projections and recessesof housings and covers when cleaning.Parts joined with Loctite are easier to separate if warmed with a fan heater.

CLEANING PARTS

Remove remains of old gaskets on all seal-faces.Carefully remove burrs or similar patches of roughnessusing an oil-stone.

Lube bores and grooves must be free of anti-corrosionagents and foreign matter; check for perfect passage.

Carefully cover opened transmissions to prevent foreignmatter from entering.

REUSING PARTS

Parts such as ball or roller bearings, multi-discs, thrustwashers etc., must be inspected by a competent person,who should decide whether or not they can be re-used.Replace parts which are damaged or have suffered fromexcessive wear.

GASKETS, LOCKING PLATES

Parts which cannot be removed without being damagedmust always be replaced with new parts (e.g. gasketsand locking plates).

SHAFT SEALS

Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces mustbe totally clean and in perfect condition.

REWORKING

Rework may be carried out on seal contact surfacesusing plunge-cut grinding only, never use an emerycloth. Ensure that there are no traces of grinding or riffling.

If rework is needed on distance washers, shims etc.because of clearance settings, ensure that the reworkedareas contain no face runout and have the same surfacequality.

TRANSMISSION ASSEMBLY

Find a clean site to assemble the transmission. Gasketsare installed without the use of sealing compound orgrease. When measuring silicon-coated gaskets, takecare not to include the silicon layer in the measure-ment.During assembly, comply with all adjustment data,checking data and tightening torques in the RepairManual.

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

8BEARINGS

If bearings are mounted in heated condition, they are tobe heated evenly (e.g. heating cabinet).Temperature should be at ca. 85 C and must not exceed120 C. Each mounted bearing must be oiled with operating oil.

SEALING

If a specific sealing agent* is to be used for sealing,comply with the manufacturers directions for use.Apply a thin layer of sealing agent to the surfaces andspread evenly. Do not allow sealing to enter oil ductsand bores. On oil-carrying ducts and bores, wipe off thesealing agent on the surfaces to be sealed near aperturesto ensure that no sealing agent enters the oil feeds whenthe surfaces are sealed.

SHAFT SEALS

a) Apply a light coat of sealing agent* on outer edge ofshaft seals with steel surround.

b) Never apply sealing agent to shaft seals with rubber surround, but apply a thin coat of Vaseline8420 to the outer edge or wet with a lubricant, e.g. awater-soluble, concentrated washing-up liquid (e.g.Pril, Coin, Palmolive).

c) Shaft seals with steel and rubber surrounds should betreated on the outer edge of the rubber surround asdescribed above in section b).

d) Dual shaft seals have two sealinglips. The dust-proof sealing lip (X)must face outwards.

e) Fill the gap between the sealinglips so it is 60% filled with grease (e.g. produced by Aral such as Aralub HL2 or by DEA such asSpectron FO 20).

f) If possible, heat shaft seal bores to between 40 and50 C (makes fitting easier). Press the seal shaft withmounting or faceplate onto the relevant installationdepth plan.

RETAINING AGENTS

Retaining agents* may only be used in places as specified in the parts list.Always comply with manufacturers directions for usewhen using retaining agents (e.g. Loctite).During assembly, comply with all adjustment data,checking data and tightening torques.

TRANSMISSION OIL

After completing repairs, fill transmissions with trans-mission oil. For the procedure and approved oils, referto the transmission operating manual and List of Lubri-cants TE-ML (refer to identification plate) which areavailable from any ZF After-Sales Service Point. Afterfilling the transmission with oil, tighten the screw plugsat the oil filling point and the oil overflow to the speci-fied torques.

* refer to expendable material

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

;

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

9

Tightening torques for nuts and bolts, extract fromZFN 148

This standard applies to bolts acc. to DIN 912, DIN 931,DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934.This Standard contains data on tightening torques (MA)for bolts and nuts in strength categories 8.8, 10.9 and12.9 and nuts in strength categories 8, 10 and 12.

Surface condition of bolts: thermally blackened andoiled or galvanized and oiled or galvanized, chrome-pla-ted and oiled.

Tighten screws with a calibrated torque spanner.

NOTEIrregular tightening torques are listed separately in theRepair Manual.

Edition: August 1991 / checked 1997

Regular screw thread Fine screw thread

Size Tightening torque Size Tightening torqueMA (Nm) for MA (Nm) for

Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9Nut 8 10 12 Nut 8 10 12

M 4 2.8 4.1 4.8 M 8 x 1 24 36 43M 5 5.5 8.1 9.5 M 9 x 1 36 53 62M 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 84M 8 23 34 40 M 12 x 1.25 87 125 150M 10 46 68 79 M 12 x 1.5 83 122 145

M 12 79 115 135 M 14 x 1.5 135 200 235M 14 125 185 215 M 16 x 1.5 205 300 360M 16 195 280 330 M 18 x 1.5 310 440 520

M 18 280 390 460 M 18 x 2 290 420 490M 20 390 560 650 M 20 x 1.5 430 620 720M 22 530 750 880 M 22 x 1.5 580 820 960

M 24 670 960 1100 M 24 x 1.5 760 1100 1250M 27 1000 1400 1650 M 24 x 2 730 1050 1200M 30 1350 1900 2250 M 27 x 1.5 1100 1600 1850

M 27 x 2 1050 1500 1800M 30 x 1.5 1550 2200 2550M 30 x 2 1500 2100 2500

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

10

Screw plugs DIN 908, 910 and 7604

The screw plug tightening torques MA were determinedaccording to DIN 7604 for screwing into steel, grey castand aluminum alloys.The values are based on experience and are intended as reference values for the fitter.The values for the tightening torque MA apply analo-gously for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical.General rule: Screw/bolt class 5, ZFN 148-1

Screw/bolt material: steel acc. to DIN 7604. Surface condition: as manufac-tured (without surface protection) andlightly oiled or galvanized, chromated andlightly oiled.

Union screws DIN 7643

The tightening torques MA were determined for screwing into steel, grey cast and aluminum alloys.The values are based on experience and are intendedas reference values for the fitter.General rule: screw/bolt class 5, ZFN 148-1

Material: 9SMnPb28K acc. to DIN 1651Surface condition: as manufactured(without surface protection) and lightlyoiled or galvanized, chromated and lightly oiled.

Status: October 1995

Screw plugs (DIN 908, 910, 7604)

Dimensions Tightening torquescrewed into

steel/gray cast Al alloy

M 8 x 1 20 10M 10 x 1 25 / 30* 15 / 20*M 12 x 1.5 35 25M 14 x 1.5 35 25M 16 x 1.5 40 30M 18 x 1.5 50 35M 20 x 1.5 55 45M 22 x 1.5 60 / 80* 50 / 65*M 24 x 1.5 70 60M 26 x 1.5 80 / 105* 70 / 90*M 27 x 2 80 70M 30 x 1.5 100 / 130* 90 / 130*M 30 x 2 95 85M 33 x 2 120 110M 36 x 1.5 130 115M 38 x 1.5 140 120M 42 x 1.5 150 130M 42 x 2 145 125M 45 x 1.5 160 140M 45 x 2 150 130M 48 x 1.5 170 145M 48 x 2 160 135M 52 x 1.5 180 150M 60 x 2 195 165M 64 x 2 205 175

* DIN 7604 Form C

Union screws (DIN7643)

Pipe Thread Tighteningouter torque MA

diameter in Nm

4 - 5 M 8 x 1 20 - 25

6 M 10 x 1 25 - 35

8 M 12 x 1.5 30 - 40

10 M 14 x 1.5 35 - 40

12 M 16 x 1.5 45

15 M 18 x 1.5 50

18 M 22 x 1.5 60

22 M 26 x 1.5 90

28 M 30 x 1.5 130

35 M 38 x 1.5 140

11

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

Description Name Approx. Application RemarksZF reference no. quantity

Grease for example: General assembly aid0750 199 001 Spectron FO 20

Sealing compound WEVO-L100 Screwing connection on 0666 790 017 output flange

Grease Industrial grade General assembly aid0671 190 016 Vaseline 8420

Transmission oil refer to TE-ML14 General assembly aidList of Lubricants

NOTE: Inquire about the size of bundles that can be delivered before placing any orders!

Description Dimension Measurement device Remarks

01. Internal resistance of solenoid valves for clutches and brakes intransmission

02. Internal resistance ofinductive sensors (speedsensors) nT and nOut

03. Tightening torque forM14x1.5 temperature sensor

04. Tightening torque forM22x1.5 oil drain plug inoil pan

05. Clearance between induc-tive sensor - output andface end gears on plane-tary carrier

06. Clearance between induc-tive sensor - turbine andpulse sensor ring

07. Tightening torque for M6fixing bolts on inductivesensor

08. Clearance between speedosensor and toothedring onoutput

09. Tightening torque forspeedo sensor

10. Insertion depth of shaftseal in output cover

R = approx. 67 ohm at 68 F (20 C)

R = 1080 40 ohm at 68 F (20 C)

26 ft-lbs35 Nm

37 ft-lbs50 Nm

0.02 - 0.027"0.5 - 0.7 mm

0.024 - 0.03"0.6 - 0.8 mm

7 ft-lbs9.5 Nm

0.027 - 0.055"0.7 - 1.4 mm

26 ft-lbs35 Nm

0.55 - 0.59"14 - 15 mm

Ohmmeter and testcable 1P01 138 153 or terminal tester 6008 006 002

Ohmmeter

Torque wrench

Torque wrench

Depth gauge, slidergauge 1X56 138 149/1X56 138 150

Depth gauge, slidergauge 1X56 138 149 /1X56 138 150

Torque wrench

Depth gauge

Torque wrench

Resistance rises with tempe-rature to approx. 74 Ohmwhen transmission at operating temperature.

Resistance rises with tempe-rature to approx. 1350 Ohmwhen transmission at operating temperature.

Renew copper sealing ring.

Renew copper sealing ring.

Adjust clearance with shims

Adjust clearance with shims

Do not overtighten

Clearance is supplied, check value.

Do not overtighten.

Use to 1X56 136 824This gives correct insertiondepth.

12

HP 502 C / HP 592 C / HP 602 CAdjustment data

Description Dimension Measurement device Remarks

11. Tightening torque for M6hex nuts on inductive sen-sor cover-output

12. Tightening torque for M12hex bolts at output flange

13. Tightening torque forM42x2 screw plug in duct plate

14. Tightening torque forM10x1 screw plugs on thepressure measuring points

5 ft-lbs6 Nm

44 ft-lbs60 Nm

67 - 74 ft-lbs90 - 100 Nm

9 ft-lbs12 Nm

Torque wrench

Torque wrench

Torque wrench

Torque wrench

Do not overtighten

Secure with lock plateUse to 1X56 136 471

Do not overtighten

13

Adjustment dataHP 502 C / HP 592 C / HP 602 C

Special toolsHP 502 C / HP 592 C / HP 602 C

Fig. Special tools Order no. Application Qty. Remarksno.

1X56 136 471

Toolfor lock plate on output flange

1

1

1X56 136 824

Toolfor fitting radial seal inoutput flange

1

2

1P01 136 670

Pressure test gauge0 - 25 bar with M10x1 connectors

1

3

1P01 137 856

Pressure test gauge0 - 10 bar withM10x1 connectors

1

4

1X56 137 126

Lifting attachmentfor transmission

1

5

15

HP 502 C / HP 592 C / HP 602 CSpecial tools


1X56 138 149

Measuring rodto determine distance between inductive sensor and pulse sensor on turbine and output (in connectionwith test fixture 1X56 138 150)

1

6

1X56 138 150

Test fixtureto determine distance betweeninductive sensor and pulse sensor onturbine and output (in connectionwith measuring rod 1X56 138 149)

1

7

1X56 103 755

Gripperto mount output flange (in connection with mounting fixture1X56 136 512)

1

8

1X56 136 512

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

1

9

1X56 136 513 (220V)or1X56 137 575 (110V)

Hot air blowerto heat various parts.

1 Optionsavailable: for 220 Volts orfor 110 Volts10

16


Special toolsHP 502 C / HP 592 C / HP 602 C

1P01 138 153

Test cablefor testing solenoid valves

1

11

6008 006 002

68-pin terminal testerfor electrical troubleshooting

1

12

6008 208 003

Testman Diagnostic System(for Windows 95, 98 and NT)

Complete system without PC.Contains:

6008 308 901 Testman software on disc (1)

6008 308 600 DPA 04 I adapter (2)

6008 308 601 RS 232-cable(3)

0501 211 103 ISO cable (4)

1

Completesystem

for Windows95, 98 and NT

without PC

Optionally6008 208 004or 6008 208

003 but also with

0501 211 104SAE cable (5).

13

Diagnose - Software6008 308 014

6008 308 114

Diagnostic softwareTestmanfor Ecomat 2

1

14

17

3

2

4

5

1

HP 502 C / HP 592 C / HP 602 CSpecial tools


6008 307 001

Diagnostic systemMobiDig 2001Complete system in portable case

1

forZF-Service

only15

0501 301 068

EPD1Simple programming device

1

forZF-Service

only16

6008 298 029

Plug-Inmemory cardfor EPD1

1

forZF-Service

only17

0501 211 103

ISO cablefor EPD1

1

forZF-Service

only18

0501 211 648

SAE cablefor EPD1

1

forZF-Service

only19

18

Documents

050498 group 3_r