213070228-050498-group-3-r
Short Description
Descripción: v b...
Description
3
CONTENTS
DB 250 PF Series
TECHNICAL DATA
DIAGNOSES
0145
AUTOMATIC GEARBOXES
PROPELLER SHAFTS
ANGLE DRIVES
CONTENTS
3 DB 250 PF Series
Engine type Gearbox types
Reductions PE 160
VoithD851.3
5,20 1,05:1 -
VoithD854.3
5,20-0,77:1
PE 183
X(1)
X(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)
Oil capacity (in litres) Type of gearbox 1e filling
after extending
when changing oil
Mass in kg(1)
Fitting length in mm
VoithD851.3
ca.25-28
-
ca.23-26
ca.305
796
VoithD854.3
ca.25-28
-
ca.23-26
ca.340
874
ZF4HP500
ca. 30
ca. 20
ca. 15
ca. 259
693
(2)
ZF5HP500
ca. 30
ca. 20
ca. 15
ca. 269
693
( 2)
3 D
DIAGNOSIS 2B5PS0Fer ies
Contents
CONTENTS
Pa ge s
Da te
1. DRIVE SHAFTS .......... ......... ......... ......... ......... ......... .......... ......... ......... ..... 1-1 ......... .... 0145
3
DIAGNOSIS
3 D
DIAGNOSIS 2B5P0SFeries
Dr ivsehafts
1. D R I V E S H A F T S 1.
FAULT-F INDING T ABLE
FAULT: DRIVE LINE VIBRATION AT LOW VEHICLE SPEED Possiblceause Excessive universal joint angle (for example, caused by excessive caster) Playinuniversaljoints Playinslidingjoint
R emedy Check the universal joint angle
Replaceuniversaljoint Replacedriveshaft
Forks not in line
Alignforks
FAULT: DRIVE LINE VIBRATION AT HIGH VEHICLE SPEED Possiblceause Driveshaftimbalance
R emedy Balanceorreplacethedriveshafts, if necessary
3
DIAGNOSIS
3 D
AUTOMATIC GEARBOXES 2B5PS0Feries
CONTENTS
C o nt e n ts
Pa ge
Date
VOITH DIWA.3 Transmissions 1.
SERVICING ......................................................................................... 1-1..... .............................. 0102
2.
TROUBLE SHOOTING ........................................................................ 2-1..... .............................. 0203
3.
FAULT FINDING ..................................................................................3-1 ................................... 0203
ZF-ECOMAT Transmissions 1.
0145
REPAIR MANUAL ZF-ECOMAT 2 Stages 1-2 (4149 751 601) ........... 1-1.... ............................... 0103
1
3
AUTOMATIC GEARBOXES
3
AUTOMATIC GEARBOXES
1. SERVIC ING SC HEDULE T RAN SMI SSI ONS D IWA.3
0145
1-1
3
AUTOMATIC GEARBOXES
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 the cooling water temperature indicator can therefore be used for determining 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 leas t every 2 years , however. With oil grad es according to Lis t of Lubric ants 55.6336. ..* (G 1363): every 120 000 km, at lea st every 3 yea rs, 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.
Remove the drain plug (2) for the converter oil and drain the oil. The plug is accessible through the oil pan drain hole.
Install drain plugs with new copper seals. Tighten drain plug (2) to 50 Nm and drain plug (1) to 120 Nm.
Remove the drain plug (4) for the filter oil (width across flats 13 resp. 10) and drain the oil.
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.
Install drain plug (4) with new copper seal and tighten to 15 Nm.
6 7
Fill in transmission oil. *Note! Only use oils tested by Voith and approved in the Lists of Lubricants 55.6335. .. (G 607) and 55.6336. .. (G 1363), respectively! Quantity: Approx. 21 - 23 liters (approx. 25 - 28 liters for first filling). The dipstick reading counts in any case!
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.
2
1
3
4
4
9
With oil gra des according to Lis t of Lubric ants 55.6335. ..* (G 607): every 60 000 km, at lea st every 2 yea rs, however. With oil gra des according to Lis t of Lubric ants 55.6336. ..* (G 1363): every 120 000 km, at lea st every 3 yea rs, however.
Change oil and oil filter f or DIWA.3E 10 11
Note!
Drain oil at operating temperature only!
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.
Remove the drain plug (12) for the converter oil and drain the oil. The plug is accessible through the oil pan drain hole.
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 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 Lubricants 55.6335. .. (G 607) and 55.63 36. .. (G 1363), res pectively! 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.
Check the oil hoses (13). Replace if found very porous, cracked or chafed.
12
11
13
17
18 15
Check load transmitter setting if necessary for DIWA.2, DIWA.3, DIWA.3E See leaflets "Fault finding".
3 DB 250 PF Series
AUTOMATIC GEARBOXES
2. TRO UBL E SHO OTIN G DIWA.3 T RAN SMIS SIO NS
0145
2-1
AUTOMATIC GEARBOXES
3
3 DB 250 PF Series
AUTOMATIC GEARBOXES
3. FAULT FIND ING VOI TH DIW A.3 TRA NSM ISS IONS
0145
3-1
3
AUTOMATIC GEARBOXES
SYMPTOMS CAUSES REMEDIES
Voith. 55.6303.22 / 2002-03
Important safety instructions! It is your responsibility to familiarize yourself with the warnings and precautions described in this manual. Danger! in conjunction with the symbol on the right is used if personal injury or danger to life may result if work is not carried out carefully. This manual only contains the most important information, however. It is impossible to describe all conceivable mistakes and danger conditions. Therefore, everybody who performs installation, repair or service work must very carefully ensure that his person al safety or that of other persons is not at risk.
Important information Note! in conjunction with the symbol on the ri ght denotes information that is particularly important.
Additional notes When replacing parts, always pay attention to the instructions in the spare parts catalog! Design improvements which should be taken into account during transmission overhauls are described in detail in the "Customer service letters". Furthermore, all work must be performed in accordance with Voith requirements to prevent damage to parts and tools.
Consequences of oil loss, treatment of used oil Danger! If oil leaks because to piping, seals or O-rings are not properly installed or have become leaky over time, accidents may occur. In conjunction with the symbol on the right: be aware of environmental pollution due to oil loss! Used oil must be disposed of in accordance with envi ronmental regulations.
Voith. Fault Finding DIWA.3, DIWA.3E
I
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.:
PartNo.
for transmission
Purpose
Technical Manual
55.6355. .. 55.6357. ..
DIWA.3 DIWA.3E
Function description of the transmission, transmission data, installation instructions, design and dimensional data for transmission assemblies
Servicing Schedule
55.6374. ..
All DIWA
Maintenance of DIWA transmissions
Lists of Lubricants
55.6335. .. 55.6336. ..
All DIWA
List of the lube oils that are approved by Voith for DIWA transmissions
Driving Instructions
55.6291. ..
DIWA.3, DIWA.3E
Brief description of transmission operation for the bus driver
Diagnostic Manual
55.6264. ..
DIWA.3, DIWA.3E
Use of the Voith PC-based diagnostic program DIWAGNOSIS
Spare Parts Catalogs
55.6600. 55.6601. 55.6602. 55.6603.
D D D D
851.3E 854.3E 863.3E 864.3E
Illustration and designation of transmission parts for spare parts ordering
Trouble Shooting
55.6293. ..
DIWA.3, DIWA.3E
Detection of defective electrical components or assemblies using the PC diagnostic program
Repair Manual
55.6320. .. 55.6704. ..
DIWA.3 DIWA.3E
Description of transmission disassembly and assembly of 3- and 4speed transmissions
Technical Description 55.6309. .. with Oil and Control Cir55.6311. .. cuit Diagrams
DIWA.3 DIWA.3E
Representation of the oil circuits for the various transmission gear shifts
Brochure
.. .. .. ..
All of the above brochures are available from department "ant" or "anv".
This documentation is protected by copyright Subject to change
Who is it for? n Service technicians (e.g. testing, acceptance, etc.) n Automobile mechanics and electricians II
Voith. Fault Finding DIWA.3, DIWA.3E
Procedure for finding faults in DIWA.3 and DIWA.3E transmissions If transmission malfunctions occur, fault may be present in a) the control unit records, b) in the electrical or c) mechanical part of electromechanical or d) purely mechanical components. In the case of faults in a) and b), use of "Diagnostic Manual" and "Trouble Shooting", if required, alone may be sufficient for repair. However, since malfunctions in c) and d) are not detected by the control or diagnosis, it is recommended to refer to the appropriate Voith documentation and programs for transmission malfunction repairs in the following order, for example: Read out the fault memory of the transmission control unit by means of the diagnostic program DIWAGNOSIS:
Diagnostic Manual
Analysis of malfunctions and list of remedies, including, perhaps, information about transmission design and operation in the "Technical Manuals" and "Technical Descriptions with Oil Control Diagrams" for DIWA.3 and DIWA.3E:
Fault Finding
Use of the diagnostic program for fault tracing:
Diagnostic Manual
Tracing of possible faults in the electrical system of DIWA.3 and DIWA.3E transmissions: Trouble Shooting
Transmission repair and spare parts ordering:
Repair Manual, Spare Parts Catalogs
Voith. Fault Finding DIWA.3, DIWA.3E
III
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 forw ard (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 gea r, 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 no t shift to 2nd gear - oper ation only po ssible in 1s t 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 - op eration only possible in 1st and 2nd g ear...... ..... 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) do es not li ght after turning on the igni tion ............................. 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 drive range), the reverse gear, and braking with the converter.
2. The location of SK and WR solenoid valves in the valve block has been changed.
3. There were some minor changes to the circuit diagram.
VI
Voith. Fault Finding DIWA.3, DIWA.3E
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 electronic 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
Possiblecause
Checkr/ emedy
Notec / ontinuewith
Danger! Apply the parking brake when the bus is stopped for repairing to prevent that the vehicle can move unintentionally!
ANS activation without effect (ANS means Automatic Neutral at Standstill) One of the conditions for ANS activation not met: – driving speed less than 1 km/h, – accelerator pedal in idle position, – service (foot) brake switch (FB) and/or parking brake (HSB) operated (pcompr. air > 0.5 - 0.8 bar), – forward gear engaged.
No release of ANS activation by control unit 1. Inductive pick-up N2, connector or connecting cable defective.
Check inductive pick-up, connector and connecting cable, repair or replace, if required.
2a. Control unit does not receive L0 signal. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly.
Check and adjust connection, if required.
2b. Control unit does not receive L0 signal. For E-Gas systems: faulty assignment of accelerator pedal position and load transmitter level.
1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
3a. No signal from pressure switch for ANS activation (BS): switch, connector or connecting cable defective.
Check switch, connector or connecting cable and repair or replace, if required.
3b. If provided: stop brake (HSB) relay, switch, connector or connecting cable defective.
Check relay, switch, connector or connecting cable and repair or replace, if required.
3c. No signal from service (foot) brake switch (FB): one of the 3 microswitches, connector or connecting cable defective.
Check switch at brake, connector or connecting cable and repair or replace, if required.
4. Pushbutton switch (TS), connector or connecting cable defective.
Check switch, connector or connecting cable and repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
3
Possiblecause
Checkr/ emedy
Notec / ontinuewith
Input clutch (EK) does not open Field coil or one of the spools of the EK solenoid valve, connector or connecting cable defective.
1. Check oil pressure at EK connection (measuring cover): pArequ’d = 0 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required.
1. Check operating resp. converter pressure at connections TB and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required.
For ANS activation without stop brake (HSB): roll-back safety (simultaneous switching of turbine brake TB and reverse gear brake RB) without effect Field coil or one of the spools of solenoid valves TB or RBK, connector or connecting cable defective.
4
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
Checkr/ emedy
Notec / ontinuewith
3.1
After engagement of a for ward (F) o r reverse gear (R) a nd releasing the parking brake, the vehicle does not move - engine 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 connecting cable defective.
Check fuse, connector and cable, repair or replace, if required.
Check relay, connector and cable, repair or replace, if required.
Solenoid valves without voltage dS relay "control", connector or connecting cable defective.
Input clutch (EK) does not close 1.Idle speed N1 toohigh.
1.Check idlespeed setpoint: n ≤ 850 rpm (for gas engine: n ≤ 1000). 2. If required, adjust idle speed.
2. Gear safety pressure switch (ABSICH) is not activated for pressure > 3 bar, connector or connecting cable defective.
Check switch, connector and cable, repair or replace, if required.
3. Field coil or one of the spools of the EK solenoid valve, connector or connecting cable defective.
1. Check oil pressure at EK connection (measuring cover): pArequ’d ≥ 3.5 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required.
4. Transmission with ANS activation: pressure switch for ANS activation (BS), connector or connecting cable defective. Note! Switch may only be closed when the brake device is operated!
Check switch, connector and cable, repair or replace, if required. Note! EK closes when load transmitter operated!
5. Bus with gas engine: relay dNEUTR, connector or connecting cable defective. Note! Idle seed is reached after the transmission was in neutral for some time!
Check relay, connector and cable, repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
5
Possiblecause
Checkr/ emedy
Notec / ontinuewith
Disks of input clutch (EK) slip 1. Operating pressure too low.
Check operating pressure: pArequ’d ≥ 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 connection (measuring cover): pArequ’d ≥ 3.5 bar. 2. Repair or replace solenoid valve.
3. Oil pressure after EK solenoid valve too low: oil supply reduced or interrupted.
1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required.
4. EK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
Check switch, connector and cable, repair or replace, if required.
Pushbutton switch not ready to operate Pushbutton switch, connector or connecting cable defective.
3.2
After engagement of th e R gea r and re leasing the p arking brake, the vehicle does not move - but transmission function is normal when engaging a F gear
No release of reverse gear by the control unit 1. Inductive pick-up N1 or N2, connector or connecting cable defective.
Check inductive pick-up, connector and connecting cable and repair or replace, 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 left after approx. 1 sec.!
Check solenoid valves, connectors and cables and repair or replace, if required.
6
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
Checkr/ emedy
Notec / ontinuewith
Transmission with inhibiting switch for reverse gear (SPERR): switch not closed 1. Inhibiting switch not operated. 2. Switch, connector or connecting cable defective.
Check switch, connector and cable, repair or replace, if required.
Check switch, connector and cable, repair or replace, if required.
1. Check operating resp. converter pressure at connections RBG and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required.
1. Check converter pressure pW at measuring point (fig. 6/2): pWrequ’d ≥ 2 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required.
If required, disassemble and repair converter outlet valve.
Pushbutton not ready to operate Pushbutton switch, connector or connecting cable defective.
Reverse gear brake (RB) does not close RBG or RBK solenoid valve hard to move or stuck, e.g. by soiling of a spool or field coil.
Converter pressure too low 1. Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective.
2. One of the control spools of the converter outlet valve hard to move or stuck. 3.Converterleaks. 4. Only for DIWA.3E: The converter inlet valve hard to move or stuck, valve does not open properly.
5. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
Check converter seal and repair, if required. 1. Check oil pressure at WP connection (measuring cover): pArequ’d ≥ 8.3 bar. 2. Check converter filling valve and repair or replace, if required.
1. Check converter pressure pW at measuring point (fig. 6/2): pWrequ’d ≥ 2 bar. 2. Check breather valve and repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
7
Possiblecause
3.3
Checkr/ emedy
Notec / ontinuewith
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.
2. RBG or RBK solenoid valve hard to move or stuck, e.g. by soiling of a spool or field coil.
Check operating pressure: pArequ’d ≥ 3.5 bar. Adjust pressure, if required. 1. Check operating resp. converter pressure at connections RBG and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required.
3. Oil pressure after solenoid valve RBG or RBK too low: oil supply reduced or interrupted.
1. Check pressure as disribed above. 2. Check oil-supplying components and repair or replace, if required.
4. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
Check switch at brake, connector or connecting cable and repair or replace, if required.
Service (foot) brake switch (FB) for converter brake on unintentionally One of the 3 microswitches, connector or connecting cable defect.
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
noid valve, connector or connecting cable defective.
cable and repair or replace, if required.
2. EK solenoid valve hard to move, e.g. due to pollution of a spool or the field coil.
Repair or replace solenoid valve.
3. EK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
8
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
3.5
Checkr/ emedy
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When starting uphill: after engaging of a F gear, release of parking brake and accelerating, the bus rolls backward
Insufficient tractive power Accelerator pedal not depressed enough.
Roll-back safety fails Field coil or one of the spools of solenoid valves TB or RBK, connector or connecting cable defective.
1. Check operating resp. converter pressure at connections TB and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required.
1. Check converter pressure pW at measuring point (fig. 6/2): pWrequ’d ≥ 2 bar. 2. If required, disassemble and repair converter outlet valve.
Converter pressure too low 1. One of the control spools of the converter outlet valve hard to move or stuck.
2.Converterleaks.
Check converter seal and repair, if required.
3. Only for DIWA.3E: The converter filling valve hard to move or stuck, valve does not open properly.
Check converter filling valve and repair or replace, if required.
4. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
1. Check converter pressure pW at measuring point (fig. 6/2): pWrequ’d ≥ 2 bar. 2. Check breather valve and repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
9
10
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
Checkr/ emedy
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4.1
Poor acceleration in all gears
Wrong load transmitter signals or engine does not put out full power 1a. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly.
Check and adjust connection, if required.
1b. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level.
1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
2.Enginepower.
4.2
1.Measurespeedatstallpoint. 2. Compare results to design values.
Poor acceleration in 1 st gear, bu t norm al in 2 nd and 3rd g ear
Converter pressure too low - engine speed in 1st gear too high with respect to speed 1. One of the control spools of the converter outlet valve hard to move or stuck.
2.Converterleaks.
1. Check converter pressure pW at measuring point (fig. 6/2): pWrequ’d ≥ 2 bar. 2. If required, disassemble and repair converter outlet valve. Check converter seal and repair, if required.
3. Only for DIWA.3E: The converter filling valve hard to move or stuck, valve does not open properly.
Check converter filling valve and repair or replace, if required.
4. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
1. Check converter pW at measuring point (fig. pressure 6/2): pWrequ’d ≥ 2 bar. 2. Check breather valve and repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
11
Possiblecause
Checkr/ emedy
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Turbine brake (TB) does not close - engine speed is greatly decreased Field coil or one of the spools of solenoid valve TB, connector or connecting cable defective.
1. Check operating resp. converter pressure at connection TB (measuring cover). 2. Check solenoid valve, connector and cable and repair or replace, if required.
Turbine brake (TB) disks slip 1. Operating pressure too low.
Check operating pressure: pArequ’d ≥ 8.3 bar. Adjust pressure, if required.
2. TB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
1. Check operating resp. converter pressure at connection TB (measuring cover). 2. Repair or replace solenoid valve.
3. Oil pressure after TB solenoid valve too low: oil supply reduced or interrupted.
1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required.
4. TB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
4.3
Transmission shifts to 2n d gear with p ushbutton 1 pr essed
Inhibition for shifting 1-2 not active - inhibition 1-2 is released when converter brake is activated 1. Hand brake switch (HB) not in 0 position or service brake switch (FB) operated. 2. One of the 3 sliding contacts in the hand brake switch, one of the 3 microswitches in the service brake switch, connector or connect-ing cable defective.
Check hand brake switch, microswitch in service brake switch, connector and cable, repair or replace, if required.
3. Pushbutton switch (e.g. terminal S1 without power), connector or connecting cable defective.
Check switch, connector and cable, repair or replace, if required.
12
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
4.4
Checkr/ emedy
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Braking too s trong with accelerator pedal r eleased
Converter brake turned on See chapter 4.3, items 1 and 2.
4.5
Trans missi does not shift to 2nd gear - operation only possible in 1st on gear
Automatic shift from 1st to 2nd gear inhibited 1. Pushbutton 1 (5 or 6-pushbutton switch) depressed. Check switch, connector and cable, repair or replace, if required.
Check inductive pick-up N2, connector and connecting cable and repair or replace, if required.
1a. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly.
Check connection and adjust, if required.
1b. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level.
1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
2. Pushbutton switch (e.g. continuous current terminal S1, although button 1 not pressed), connector or connecting cable defective.
No signal regarding vehicle speed Inductive pick-up N2, connector or connecting cable defective.
Wrong power transmitter signals - engine does not reach full power
Voith. Fault Finding DIWA.3, DIWA.3E
13
Possiblecause
4.6
Checkr/ emedy
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Transmission shifts to 2nd gear, but without power transmission
Pump brake (PB) does not close Field coil or one of the spools of the PB solenoid valve, connector or connecting cable defective.
1. Check oil pressure at PB connection (measuring cover): pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector and cable, repair or replace, if required.
Pump brake (PB) disks slip - engine speed is greatly reduced 1. Operating pressure too low.
Check operating pressure: pArequ’d ≥ 8.3 bar. Adjust pressure.
2. 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 (measuring cover): pArequ’d ≥ 8.3 bar. 2. Repair or replace solenoid valve.
3. Oil pressure after PB solenoid valve too
1. Check pressure as discr. above.
low: oil supply reduced or interrupted.
2. components andCheck repair oil-supplying or replace, if required.
4. PB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
4.7
Poor acceleration after shifting to 2nd gear, but normal in 1st gear
TB solenoid valve does not open - turbine brake remains closed. Field coil or one of the spools of solenoid valve TB, connector or connecting cable defective.
14
Voith. Fault Finding DIWA.3, DIWA.3E
1. Check oil pressure at TB connection (measuring cover): p = 0 bar. 2.Arequ’d Check solenoid valve, connector and cable and repair or replace, if required.
Possiblecause
4.8
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Transmission does not shift to 3rd gear - operation only possible in 1st and 2nd gear
Automatic shifting from 2nd to 3rd gear inhibited 1. Pushbutton 2 (4, 5 or 6-pushbutton switch) depressed. 2. switch, connector or connectingPushbutton cable defective.
Check switch, connector and cable, repair or replace, if required.
1. Check oil pressure at DK connection: pArequ’d ≥ 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace.
Lock-up clutch (DK) does not close Field coil or one of the spools of the DK solenoid valve, connector or connecting cable defective.
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: pArequ’d ≥ 8.3 bar. Adjust pressure, if required.
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 connection (measuring cover): pArequ’d ≥ 8.3 bar. 2. Repair or replace solenoid valve.
3. Oil pressure after DK solenoid valve too low: oil supply reduced or interrupted.
1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required.
4. DK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
Voith. Fault Finding DIWA.3, DIWA.3E
15
Possiblecause
Checkr/ emedy
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4.10 For 4-gear transmissions: transmission does not shift to 4th gear, operation only possible in 1st, 2nd and 3rd gear Automatic shifting from 3rd to 4th gear inhibited 1. Pushbutton 3 of 6-pushbutton switch depressed. 2. Pushbutton switch (e.g. continuous current terminal S3, although button 3 not pressed), connector or connecting cable defective.
Check switch, connector and cable, repair or replace, if required.
1. Check oil pressure at SK connection (measuring cover): pArequ’d ≥ 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required.
Fast gear clutch (SK) does not close Field coil or one of the spools of solenoid valve DK, connector or connecting cable defective.
4.11 Poor acceleration after shifting to 4t h gear, but normal in 1 st, 2nd, and 3rd gear Fast gear clutch (SK) disks slip 1. Operating pressure too low.
Check operating pressure: pArequ’d ≥ 8.3 bar. Adjust pressure, if required.
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 connection (measuring cover): pArequ’d ≥ 8.3 bar. 2. Repair or replace solenoid valve.
3. Oil pressure after SK solenoid valve too low: oil supply reduced or interrupted.
1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required.
4. SK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
16
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
Checkr/ emedy
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4.12 Kickdown shifting not possible No signal for separate kickdown switch (KD) Check switch, connector and cable, repair or replace, if required.
1a. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly.
Check connection and adjust, if required.
1b. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level.
1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
1. Check oil pressure at WP connection (measuring cover): pArequ’d ≥ 3.5 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required.
Disassemble converter outlet valve and replace, if required.
Kickdown switch, connector or connecting cable defective.
No load transmitter signal - load transmitter stage L7 is not reached
4.13 Engine stalls in r everse gear Converter pressure is not controlled for seed over 1 km/h (= 30 Hz) 1. Coil or one of the spools of the WP solenoid valve, connector or connecting cable defective.
2. One of the control spools in the converter outlet valve hard to move or stuck.
4.14 Transmission does not shift up, but back to 1st gear and stays there No signal regarding vehicle speed Inductive pick-up N2, connector or connecting cable defective.
Check inductive pick-up N2, connector and connecting cable and repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
17
Possiblecause
Checkr/ emedy
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4.15 Transmission shifts to neutral while driving Control unit E 200 is not supplied with voltage Fuse 8A for line +UZ, connector or connecting cable defective.
Check fuse, connector and cable, repair or replace, if required.
Solenoid valves without voltage dS relay "control", connector or connecting cable defective.
Check relay, connector and cable, repair or replace, if required.
4.16 Hard shifting fro m 1st to 2nd gear Pump brake (PB) closes too hard - oil pressure fault before PB
1. One of the field coils or spools of the PB solenoid valve, connector or connecting cable defective.
Check solenoid valve, connector and cable, repair or replace, if required.
2. PB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
Repair or replace solenoid valve.
3. PB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
4. Inductive pick-up N1, connector or connecting cable defective.
Check inductive pick-up, connector and connecting cable and repair or replace, if required.
18
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
Checkr/ emedy
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4.17 Hard shifting fr om 2nd to 3rd gear Lock-up clutch (DK) closes too hard - oil pressure fault before DK
1. One of the field coils or spools of the DK solenoid valve, connector or connecting cable defective.
Check solenoid valve, connector and cable, repair or replace, if required.
2. DK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
Repair or replace solenoid valve.
3. DK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
4. Inductive pick-up N1, connector or connecting cable defective.
Check inductive pick-up, connector and connecting cable and repair or replace, if required.
4.18 For 4-gear transmissions: hard shifting from 3rd to 4th ge ar Fast gear clutch (SK) closes too hard - oil pressure fault in front of SK
1. One of the coils or spools of the SK solenoid valve, connector or connecting cable defective.
Check solenoid valve, connector and cable, repair or replace, if required.
2. SK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
Repair or replace solenoid valve.
3. SK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
4. Inductive pick-up N1, connector or connecting cale defective.
Check inductive pick-up, connector and connecting cable and repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
19
20
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
Checkr/ emedy
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5.1
The converter brake (CB) does not operate in all F gears via service (foot) and hand brake switch
One of the conditions for activation of the converter brake not met: – Accelerator pedal in idle position. – service or hand brake switch operated.
No release of converter brake by control unit 1. ABS active. 2a. Control does not receive L0 signal. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly.
Check connection and adjust, if required.
2b. does not receive L0 signal. For Control E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level.
1. Check transmission control unit item (compare type number to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
3. Field coil of solenoid valves PB, WP or RBK, connector or connecting cable defective.
Check solenoid valves, connectors and cables, repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
21
Possiblecause
5.2
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The converter brak e does not op erate in 1s t gear vi a ser vice and hand brake switch
Converter brake not released by control unit 1. See chapter 5.1. 2. Converter brakeforwas activated in 1st gear (it is possible some versions).
Converter brake must3rdalready have been activated in 2nd, or 4th gear.
Turbine (TB) or reverse gear brake (RB) does not close 1. Coil or one of the spools of the TB solenoid valve, connector or connecting cable defective.
1. Check operating resp. converter pressure at TB connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required.
2. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required.
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:
e.g. by pollution of a spool or the field coil.
pArequ’d ≥ 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required.
2. Coil or one of the spools of the RBG solenoid valve, connector or connecting cable defective.
1. Check operating resp. converter pressure at RBG connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required.
22
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
5.4
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One of the 3 o r all b rake stages of the converter b rake does not operate via service brake switch (brake pedal)
Switch not operated or defective 1. Converter brake deactivated by the OFF switch for activation by the brake pedal (FBAUS).
Indicator lamp (if installed) at the manual switch is not lit when the service brake switch is operated.
2. Switch, connector or connecting cable defective.
Check switch, connector and cable, repair or replace, if required.
3. One of the 3 microswitches in the service brake switch (FB), connector or connective cable defective.
Check switch, connector and cable, repair or replace, if required.
5.5
One of the 3 o r all b rake stages of the converter b rake does not operate via the 3-stage hand brake switch (manual switch)
One of the(HB), 3 sliding contacts the hand brake switch connector orinconnecting cable defective.
5.6
Check brakeorswitch, connector and cable, repair replace, if required.
For one-stage hand brake switch: stage 2 or 3 of the converter brake does not operate
Hand brake switch (HB), connector or connecting cable defective.
Check brake switch, connector and cable, repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
23
Possiblecause
5.7
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For DIWA.3 in 2 nd, 3rd, o r 4th ge ar: hard activation of co nverter brake
Converter pressure uncontrolled or too high 1. Check oil pressure at WP connection (measuring cover):
pArequ’d ≥ 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required.
2. Oil pressure after WP solenoid valve too low: WP oil supply reduced or interrupted.
1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required.
3. One of the control spools in converter outlet valve hard to move or stuck.
Disassemble converter outlet valve and repair, if required.
1. Check operating resp. converter pressure at RBK connection (measu-
ring cover).solenoid valve, connector 2. Check and cable, repair or replace, if required.
2. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
3. Inductive pick-up N2 or N3, connector or connecting cable defective.
Check inductive pick-up, connector and connecting cable and repair or replace, if required.
1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
Reverse brake (RB) closes too hard - oil pressure fault before RBK 1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
4.Wrong control unit.
24
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
5.8
Checkr/ emedy
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For DI WA.3 in 2n d, 3rd , or 4th g ear: brak e force in bra ke stage I too high
Converter pressure too high 1. Check oil pressure at WP connection (measuring cover): pArequ’d ≥ 8.3 bar.
2. Check solenoid valve, connector and cable, repair or replace, if required.
2. Oil pressure after WP solenoid valve too low: WP oil supply reduced or interrupted.
1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required.
3. One of the control spools in converter outlet valve hard to move or stuck.
Disassemble converter outlet valve and repair, if required.
1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
5.9
For DI WA.3 in 2n d, 3rd , or 4th g ear: brak e force in bra ke stage II or III too low or too high
Converter pressure too high or too low 1a. Brake force too low: Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective.
1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check solenoid valve, connector and cable, repair or replace, if required.
1b. Brake force too low: Oil pressure after WR solenoid valve too low because oil supply is reduced or interrupted.
Check oil-supplying componets and repair or replace, if required.
2a. Brake force too high: WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
1. Check oil pressure at WP connection (measuring cover): pArequ’d ≥ 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required.
2b. Brake force too high: Oil pressure after
Check oil-supplying componets and
WP too low because oil supply is solenoid reduced valve or interrupted.
repair or replace, if required.
3. One of the control spools in converter outlet valve hard to move or stuck.
Disassemble converter outlet valve and repair, if required.
4. Wrong control unit.
1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
25
Possiblecause
Checkr/ emedy
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5.10 For DIWA.3E in 2nd, 3rd, or 4th gear: hard activation of converter brake In 3rd and perhaps 4th gear and at high speeds: Converter filling control (CFC) malfunction - converter pressure too high
(”High speed” means: transmission output speed is higher than the limit set for activation of converter filling control, e. g. about 2000 to 2200 rev/ min in 4th gear).
1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil and doesn't close correcly.
1. Check oil pressure at WP connection (measuring cover): pArequ’d = 0 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required.
2. Converter filling valve hard to move or stuck and doesn't close correcly.
1. Check pressure as discr. above. 2. Check converter filling valve and repair or replace, if required.
3. Breather valve hard to move or stuck and doesn't open correcly.
1. Check converter pressure at measur. point (6/2): pWrequ’d = 0 bar. 2. Check breather valve and repair or replace, if required.
Disassemble converter outlet valve and repair, if required.
1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace.
2. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Replace disks, replenish or change oil.
3. Inductive pick-up N2 or N3, connector or connecting cable defective.
Check inductive pick-up, connector and connecting cable and repair or replace, if required.
1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
In 3rd,Converter and perhaps 4th gear all 2nd, speeds: pressure tooand highat One of the control spools in converter outlet valve hard to move or stuck.
In 2nd, 3rd, and perhaps 4th gear and at all speeds: Reverse brake (RB) closes too hard - oil pressure fault before RBK
4. Wrong control unit.
26
Voith. Fault Finding DIWA.3, DIWA.3E
Possiblecause
Checkr/ emedy
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5.11 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake stage I too high Converter pressure too high One of the control spools in converter outlet valve hard to move or stuck.
Disassemble converter outlet valve and repair, if required.
5.12 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake stage II or III too low or too high Converter pressure too high or too low 1a. Brake force too low: Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective.
1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check solenoid valve, connector and cable, repair or replace, if required.
1b. Brake force too low: Oil pressure after WR solenoid valve too low because oil supply is reduced or interrupted.
Check oil-supplying componets and repair or replace, if required.
1c. Brake force too low: Converter filling valve hard to move or stuck and doesn’t open correcly.
1. Check oil pressure at WP connection (measuring cover): pArequ’d ≥ 8.3 bar. 2. Check converter filling valve and repair or replace, if required.
1d. Brake force too low: Breather valve hard to move or stuck and doesn’t close correcly.
1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check breather valve and repair or replace, if required.
2. One of the control spools in converter outlet valve hard to move or stuck.
Disassemble converter outlet valve and repair, if required.
3. Wrong control unit.
1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment.
3. Replace control unit, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
27
Possiblecause
Checkr/ emedy
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5.13 In 1st gear range: brake force in brake stage II or II to o low or too high RBK oil pressure too low or too high 1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
2. Oil pressure after RBK solenoid valve too low: RBK oil supply reduced or interrupted. 3. Wrong control unit.
28
Voith. Fault Finding DIWA.3, DIWA.3E
1. Check operating resp. converter pressure at RBK connection (measuring cover).
2. Check solenoid valve, connector and cable, repair or replace, if required.
1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required.
1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required.
Possiblecause
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6.1
The central warning lamp (ZW) do es not ligh t afte r turn ing on the ignition (ZW is energized a few seconds for test purposes)
1. Lamp defective. 2. If controlled through relays: relay, connector or connecting cable defect.
6.2
Check relay, connector and cable, repair or replace, if required.
The p ushbutton switch ligh ting ( TL) do es no t ligh t afte r turning on the ignition
1. For single pushbutton: lamp defective. 2. Pushbutton switch (e.g. terminal TL without voltage), connector or connecting cable defect.
6.3
The warning lamp transmission oil temperature (TOEL) does not light after turning on the ignition (TOEL is energized a few seconds for test purposes)
Lamp, connector or connecting cable defect.
6.4
Check switch, connector and cable, repair or replace, if required.
Check lamp, connector and cable, repair or replace, if required.
Consumer via r elays - con verter b rake (dW), rev ersing lamp (dR) or speed (dN) - cannot be activated
1. Consumer not activated in record.
Load correct record.
2. Consumer defective.
Repair or replace consumer.
3. Relay dW, dR or dN, connector or connecting cable defect.
Check relay, connector and cable, repair or replace, if required.
Voith. Fault Finding DIWA.3, DIWA.3E
29
30
Voith. Fault Finding DIWA.3, DIWA.3E
The following equipment is required for troubleshooting if faults in DIWA.3 and DIWA.3E transmissions occur: PC or laptop with PC program Diwagnosis 59.2500. .. (latest version), level converter and connecting cable If the diagnostic program is used. Cable: Voith order no. 56.4219.10
Measuring cover (high design) To measure the oil pressures of clutches, brakes and valves of the transmission. Voith order no. 56.4218.10
Measuring cover (flat design) For restricted spaces in the transmission space. Voith order no. 56.4217.10
Pressure gauge To measure the operating and converter pressure. Voith order no. 58.2748.11
Multimeter To measure voltages and resistances.
Voith. Fault Finding DIWA.3, DIWA.3E
31
32
Voith. Fault Finding DIWA.3, DIWA.3E
8.1
Operating pr essure
The uniform nominal value for the operating pressure is: pA = 8.5 bar (tolerance ± 0.2 bar). Measure the pressure only at an oil temperature of 80 - 90 °C (= 176 - 194 °F), immediately after shifting to 2nd gear (engine speed approx. 1500 rpm). Nominal value at idle speed (n
≥
approx. 500 - 600 rpm) pA
≥
3.5 bar.
Measuring points The operating is point usually measured at thepressure measuring (figure 1/1).
1
If a measuring cover (figs. 2 and 3) is used, pressures which must correspond to the operating pressure are measured at the measuring points for the clutches resp. brakes DK, EK, PB, WP and SK. Fig. 2: Meas. points for DIWA.3 Fig. 3: Meas. points for DIWA.3E 2
Note! The WR oil pressure is cycled and therefore variable over time, its amount in addition depending on the relevant operating state (during braking or reversing). Therefore, simple pressure measurements by means of pressure gauges are not adequate for more thorough troubleshooting. 3
The measuring points TB, RBG and RBK are each pressurized with the higher operating or converter pressure. Exceptions: The RBK pressure is set to 1. approx. 2.5 bar for converter pressure reduction WDA, 2. max. approx. 2 bar for braking in 1st gear range (chapters 5.4 and 5.6).
Danger! Connect pressure gauge, or change measuring cover, only with the engine stopped, otherwise hot oil may result in scalding!
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 intermediate flange (if installed) of the oil filter: If the pressure is measured before (4/1) or after (4/2) the filter, approx. 0.5 bar must be added as flow resistance to obtain the value for the operating pressure. Note! Only measure before the fil-
4
ter if the filter element is clean! The working pressure can be set at the threaded pin of the operating pressure valve (5/1) - only possible with special screwdriver and socket wrench through the oil filler! If the required operating pressure is not reached, check piping for leakage and sealing gaps of the gear pump.
5
8.2
Converter pressure
The converter pressure must be: pW ≥ 2 bar at an oil temperature t oil of approx. 80 - 90 °C (= 176 - 194 °F), with forward gear engaged, engine at idle speed (500 ± 50 rpm) and parking brake applied. If this value is not reached, converter sealing must be improved.
Measuring point Usually, the converter pressure is measured at measuring point (6/2).
6
34
Voith. Fault Finding DIWA.3, DIWA.3E
Converter pressure with WDA deactivation At toil of = 80 - 90 °C (= 176 - 194 °F), the converter pressure must be 0,7 < pW < 2 bar
Converter pressure when converter filling control (CFC) is active pW = 0 bar
Converter pressure during braking At toil of = 80 - 90 °C (= 176 - 194 °F), with 2nd gear engaged (3rd gear inhibited) and approx. 50 % of maximum speed for 2nd gear, the converter pressure pW must be: brake stage I: pW = 0.2 - 0.7 bar brake stage II: pW = 1.8 - 2.5 bar brake stage III: pW = 3.6 - 4.9 bar
9.1
Engine idle speed
In particular in conjunction with electronic engine control units, it is frequently not possible to set the idle speed n in a simple manner. In addition, the settings are systemdependent (guideline: n ≥ approx. 500 - 600 rpm with warm engine). On the other hand, the idle speed must not be too high, because the input clutch, for example, will not close: n ≤ 850 rpm (for gas engine: n ≤ 1000 rpm ).
During a function check, the speed can be measured by means of the diagnostic program, for example. Note! If the idle speed must be changed, contact th e bus manufacturer, if required.
9.2
Test: load transmitter signals as function of accelerator pedal position
The life of DIWA transmissions to a considerable extent depends on proper pressures in front of the disk clutches and brakes during shifting. Along with the input and output speeds, the motor torque is important, which to a great extent is in turn affected by the accelerator pedal position resp. the appropriate load levels L0 - L6 (or L0 - L7). The associated electronic signals are provided to the transmission in a different manner dependent on the engine control system.
The following settings can be checked in a relatively simple manner with the bus stopped by means of the diagnostic program:
1. Load level L0 = "idle", acc elerator pedal completely released. 2. Load level L6 = "full load", accele rator depressed to the stop (firs t, if any). Depen dent 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 = "kickd own", accelerator pedal depressed bey ond the first and to the end stop against greater resistance. 4. Gradually depress the accelerator pedal from idl e to full load and check tha t the "partial load" signals L2 to L5 are also displayed by the diagnostic system. Note! For an accurate check of the load transmitter partial load signals as function of the accelerator pedal travel, documents from the bus manufacturer are required.
Danger! When settings are made with the bus stopped, apply the parking brake to prevent unintended rolling of the vehicle! If the diagnostic system indicates load levels that do not correspond to the accelerator pedal position, the following causes for faults may exist, apart from cable and connector defects: 1. Setting of accelerator pedal stops (idl e, full load, kick down, if installed). 2. With a VDO or Voith lo ad transmitter: connection between load transmitter and injection pump, see figures 7 and 8 on next page. 3. With electronic engine control units: conn ection between accelerator pedal and load transmitter (setpoint switch), see figure 9 on next page. 4. Wrong control unit with data of the wron g load transmitter type (indicated by diagnostic system).
Voith. Fault Finding DIWA.3, DIWA.3E
35
Adjusting the connection between load transmitter and injection pump
Injection pump
Connection
transmitter
Mark for 0 load position
Mark for full load position 7
If the injection pump lever isin0loadposition
the load transmitter lever must beonthe0loadmarktoo!
8
If the injection pump lever isinfullloadposition
the load transmitter lever must beonthefullloadmarktoo!
Otherwise, move the fastening with the link accordingly. Then recheck the setting in 0 load position! Note! the adjustment angles of the levers of injection pump and load transmitter must be in proportion to each other! For example, if the injection pump lever is moved by 1/3 of the angle between 0 and full load, the load transmitter lever must also be move by 1/3 of its angle between 0 and full load!
Example for load transmitter adjustment with electronic engine control unit
9
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 operation. Indirectly, they can be determined in a relatively simple manner by speed measurements in the so-called stall point - e.g. by means of the diagnostic program.
First of all pay attention: Danger! Apply parking brake to prevent unintentional bus movement! After that as example for full load operation (= load level L6): 1. engage forward gear, 2. depress accelerator pedal to the full load stop, 3. enter the measured engine speed N1 (= st all speed) in the diagram bel ow (figure 10). The intersection with the appropriate pump characteristic of the transmission - for pump design, check the transmission nameplate, for example shows the maximum possible engine torque with the bus stopped. Note! The latter torque may deviate significantly from the maximum possible engine torque while driving with electronic engine control units. These tests are performed during acceptance protocol measurements.
4H
1500 1400 1300 1200 1100 )
4X
4V 4G 3H 4F 3X 3V
m (N 1000 1 900 M e 800 u q r 700 to e 600 n i g n 500 E
400 300 200 100 0 400
3G 3F
600
800
1000
1200
1400
Engine speed N1 (rpm)
1600
1800
2000
2200 10
Voith. Fault Finding DIWA.3, DIWA.3E
37
38
Voith. Fault Finding DIWA.3, DIWA.3E
1 1 1 1
hydraulic control diagram DIWA.3 hydraulic ccontrol diagram DIWA.3E circuit diagram DIWA.3 circuit diagram DIWA.3E
Voith. Fault Finding DIWA.3, DIWA.3E
39
C WR
SK
9 8
B
DK
7
pa
EK
TB
PB
RBG
WP
A B C D E F G H J
RBK
1-6 CDV 7, 9 10 11 12 13 14 15
pw
15
14 13
12
11
10
Shiftingf u n c t i o n
EK DK
ANS activation
6
ANS activ. via parking brake
G
1st gear (DIWA drive range)
x
Upshift 1st-2nd gear*
5
D
A
E
x
2nd gear
x
3rd gear
x
4th gear
x
Braking 1st gear range
x
1st braking stage - 2nd gear
x
2nd and 3rd brak. stage - 2nd gear x 2nd and 3rd brak. stage - 3rd gear
J 4
3
2
1
H
F
x
2nd and 3rd brak. stage - 4th gear Reverse gear < 1 km/h
x
Reverse gear > 1 km/h
x
* = Transition
1) 2)
= Valve = Valve
Drawn: Neutral position
Hydraulic control DIWA . 3
C
D
9
SK
WR
8
10
DK
pA
7
EK
B
PB
WP
TB A B C
RBG
D E F G H
RBK
1-6 CDV 7 8, 10 11 12 13 14 15 16 17
pW
17
16 15
14
13
12
11
E Shiftingf u n c t i o n
F
6
E K DK
1st gear (DIWA drive range)
x
Upshift 1st-2nd gear*
x
2nd gear
x
x
x
3rd gear
x
x
4th gear
5
x
3rd gear with converter filling control (CFC) 4th gear with CFC
A
x xx
1st, 2nd and 3rd brak. stage - 4th gear with CFC*
x
1st braking stage - 4th gear
x
2nd and 3rd brak. stage - 4th gear
x
2nd and 3rd brak. stage - 3rd gear
H 4
3
2
1
G
x
2nd and 3rd brak. stage - 2nd gear
x
Braking 1st gear range
x
ANS activation ANS activation via parking brake Reverse gear < 1 km/h
x
Reverse gear > 1 km/h
x
* = Transition
1) 2)
= Valve regulated = Valve oscilated
Drawn: Rest position
Hydraulic control DIW A. 3 E
Voith Turbo GmbH & Co. KG Produktgruppe Nutzfahrzeuggetriebe Alexanderstraße 2 D-89522 Heidenheim Telephone (07321) 37-0 Telefax (07321) 37 7618
3 DB 250 PF Series
AUTOMATIC GEARBOXES
1. REPAIR MA NUA L ZF- ECO MAT 2 ST AGE S 1-2
0145
1-1
3
AUTOMATIC GEARBOXES
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
HP502C H / P592C H / P602C
Contents Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutaway views of Ecomat transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch and brake combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 6 7 9 11 12 15 19 20 22
1.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1.1 1.2 1.3 1.4 1.5 1.6 1.7
Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Checking oil level level with whenengine cold .off . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1.9 Checking oil 1.10 Checking oil level on versions with heat exchanger higher than center line of transmission . . . . . . . . . . . 1.11 Changing oil at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-4
2.
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.7
Renewing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Renewing retarder solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Renewing accumulator solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Renewing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Renewing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Renewing output sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Renewing retarder resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Removing and fitting oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.8 2.9 2.10 2.11 2.12 2.13
Renewing turbine sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Renewing complete hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Changing complete oil level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Renewing impulse sensor for speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Renewing output flange and/or radial seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2-1
Contents
HP502C H / P592C H / P602 C Page
3.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 3.2 3.3
Terminal tester concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test instructions for test cable 1 PO1 138 153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annex Description/menus for “ZF Testman”
4.
Circuit d iagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1 3-2
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 H /P 592 C H /P 602 C
Preface This repair manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF product in accordance with the state of development on the date of issue.
However, due to continuing development of the product, repair work might require work practices and test or adjustment data not contained in this manual. We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training centers. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually trained personnel 2. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out conscientiously and with utmost care. Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case. ZF FRIEDRICHSHAFEN AG C.V./Special Transmissions Service Plant 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726
Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.
5
Importantinformation
HP502C/HP592C/HP602C
SAFETY NOTICE
GENERAL
Companies repairing ZF units are responsible for their own work safety.
Read this manual carefully before starting any tests or repair work.
To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations.
Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.
The following safety instructions appear in this manual:
CAUTION Pictures, drawings and components do not always represent the srcinal object, but are used to illustrate working procedures. Pictures, drawings and components are not to scale. Conclusions about size and weight should not be drawn (even within a complete illustration). Always follow the working steps as described in the text.
After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly.
NOTE Refers to special processes, techniques, data, use of auxiliary equipment, etc.
CAUTION This is used when incorrect, unprofessional working practices could damage the product.
DANGER This is used when lack of care could lead to personal injury or death.
INFORMA TION
THREATS TO THE ENVIRONMENT !
Lubricants agents not system. be allowed to enter the and soil,cleaning ground w ater ormust sewage • 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 fil ters, lubricants and cleaning agents in accordance with environmental protection guidelines. • When working with lubricants and cleaning agents always refer to the manufacturer’s instructions.
CAUTION The transmission must NOT be hung by the input shaft NOR by the output flange.
6
HP502C/HP592C/HP602C In case of doubt always turn to the relevant department within ZF After-Sales Services for advice. All work on transmissions is to be performed expertly and under clean conditions. Use specified tools to dismantle and assemble transmissions.
After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening. Pay particular attention to the projections and recesses of housings and covers when cleaning. Parts joined with Loctite are easier to separate if warmed with a fan heater.
Instructionsforrepairs GASKET S, LOCKING P LA TES
Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).
SHAFT SEALS
Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition.
REWORKING CLEAN ING P ARTS
Remove remains of old gaskets on all seal-faces. Carefully remove burrs or similar patches of roughness using an oil-stone.
Lube bores and grooves must be free of anti-corrosion agents and foreign matter; check for perfect passage. Carefully cover opened transmissions to prevent foreign matter from entering.
Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or riffling.
If reworkofisclearance needed onsettings, distanceensure washers, etc. because thatshims the reworked areas contain no face runout and have the same surface quality.
TRANSMISSION ASSEMBLY REUSIN G P ARTS
Parts such as ball or roller bearings, multi-discs, thrust washers etc., must be inspected by a competent person, who should decide whether or not they can be re-used. Replace parts which are damaged or have suffered from excessive wear.
Find a clean site to assemble the transmission. Gaskets are installed without the use of sealing compound or grease. When measuring silicon-coated gaskets, take care not to include the silicon layer in the measurement. During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual.
7
Instructions for carrying out repairs BEARINGS
If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet). Temperature should be at ca. 85 °C and must not exceed 120 °C. Each mounted bearing must be oiled with operating oil.
SEALING
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 sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the surfaces are sealed.
H P 5 0 2 C / H P 5 9 2 C / HP 6 0 2 C d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.
e) Fill the gap between the sealing lips so it is 60% filled with grease (e.g. produced by Aral such as Aralub HL2 or by DEA such as Spectron FO 20). f) If possible, heat shaft seal bores to between 40 and 50 °C (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.
RETAINING AGENTS
Retaining agents* may only be used in places as specified in the parts list. Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite). During assembly, withtorques. all adjustment data, checking data andcomply tightening
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 agentto shaft seals with “rubber surround”, but apply a thin coat of Vaseline 8420 to the outer edge or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g. Pril, Coin, Palmolive). c) Shaft seals with steel and rubber surrounds should be treated on the outer edge of the rubber surround as described above in section b).
After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques.
* refer to expendable material
8
HP502C/HP592C/HP602C
Tighteningtorques
Tightening torques for nuts and bolts, extract from ZFN 148
This standard applies to bolts acc. to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934. This Standard contains data on tightening torques (MA) for bolts and nuts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12.
Surface condition of bolts: thermally blackened and oiled or galvanized and oiled or galvanized, chrome-plated and oiled. Tighten screws with a calibrated torque spanner. NOTE Irregular tightening torques are listed separately in the Repair Manual.
Regularscrewthread
Size Bolt Nut 4M 5M 6 M
Finescrewthread
Tighteningtorque MA (Nm) for 8.8 10.9 8 10 2.8 5.5 9.5
Size M 12.9 12
4.1 8.1 14
4.8 9.5 16.5
Bolt Nut 1 x 8M 1 x 9M 1 x10 M
24 36 52
1.25 x10 M 1.25 12 x M 1.5 12 xM
Tighteningtorque A (Nm) for 8.8 10.9 8 10 36 53 76
49 87 83
43 62 89
7 M M 8 10 M
15 23 46
23 34 68
28 40 79
M 12 M 14 M 16
79 125 195
115 185 280
135 215 330
M 1.5 14 x M 16 1.5 x M 18 1.5 x
135 205 310
200 300 440
235 360 520
M 18 M20 M 22
280 390 530
390 560 750
460 650 880
M 18 2x M20x1.5 M 22 1.5 x
290 430 580
420 620 820
490 720 960
M 24 M 27 M30
670 1000 1350
960 1400 1900
1100 1650 2250
M 24 1.5 x M 24 2x M27 x1.5 M27x2 M30x1.5 M30x2
72 125 122
760 730 1100 1050 1550 1500
12.9 12
84 150 145
1100 1050 1600 1500 2200 2100
1250 1200 1850 1800 2550 2500
Edition: August 1991 / checked 1997 9
Tighteningtorques
HP502C/HP592C/HP602C
Screw plugs DIN 908, 910 and 7604
Union screws DIN 7643
The screw plug tightening torques M A were determined according to DIN 7604 for screwing into steel, grey cast and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. The values for the tightening torque M A apply analogously for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical. General rule: Screw/bolt class 5, ZFN 148-1 Screw/bolt material: steel acc. to DIN 7604. Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled.
The tightening torques M A were determined for screwing into steel, grey cast and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. General rule: screw/bolt class 5, ZFN 148-1 Material: 9SMnPb28K acc. to DIN 1651 Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled.
Screw plugs (DIN 908, 910, 7604)
Dimensions
Tightening torque screwed into steel/gray cast Al alloy
1 x 8M 20 25/30* 10 15/20* M10x1 M12x1.5 35 25 M 1.5 14 x 35 25 M 1.5 16 x 40 30 M 1.5 18 x 50 35 M20x1.5 55 45 M22x1.5 60/80* 50/65* M 1.5 24 x 70 60 M26x1.5 80/105* 70/90* 2 x27 M 80 70 M30x1.5 100/130* 90/130* 2 x30 M 95 85 2M 33 x 120 110 M 36 1.5 x 130 115 M 38 1.5 x 140 120 M 42 1.5 x 2M 42 x M 45 1.5 x 2M 45 x M 48 1.5 x 2M 48 x M 52 1.5 x 2M 60 x 2M 64 x * DIN 7604 Form C
10
150 145 160 150 170 160 180 195 205
130 125 140 130 145 135 150 165 175
Union screws (DIN7643)
Pipe outer diameter 5-4
Thread
M 1 x 8
Tightening torque M A in Nm 20 25 -
6
M 10 1x
25 35 -
8
M12x1.5
30 40 -
10
M14x1.5
3540 -
12
M 16 1.5 x
45
15
M 18 1.5 x
50
18
M 22 1.5 x
60
22
M 26 1.5 x
90
28
M 30 1.5 x
130
35
M 38 1.5 x
140
Status: October 1995
HP502CH / P592CH / P602C
Description ZFreferenceno.
Grease 0750 199 001
Name
for example: Spectron FO 20
Sealingcompound WEVO-L100 0666 790 017 Grease 0671 1 90 016
Industrial grade Vaseline 8420
Transmissionoil
refertoTE-ML14 List of Lubricants
Expendables
Approx. quantity
Application
Remarks
General assembly aid
Screwingconnectionon output flange General assembly aid
Generalassemblyaid
NOTE: Inquire about the size of bundles that can be delivered before placing any orders!
11
Adjustment data
Description
HP 502 C / HP 592 C / HP 602 C
Dimension
Measurementdevice
Remarks
01. Internal resistance of solenoid valves for clutches and brakes in transmission
R = approx. 67 ohm at 68 °F (20 °C)
Ohmmeter and test cable 1P01 138 153 or terminal tester 6008 006 002
Resistance rises with temperature to approx. 74 Ohm when transmission at operating temperature.
02. Internal resistance of inductive sensors (speed sensors) nT and nOut
R = 1080 ± 40 ohm at 68 °F (20 °C)
Ohmmeter
Resistance rises with temperature to approx. 1350 Ohm when transmission at operating temperature.
03. Tightening torque for M14x1.5 temperature sensor
26 ft-lbs 35 Nm
Torque wrench
Renew copper sealing ring.
04. Tightening torque for M22x1.5 oil drain plug in oil pan
37 ft-lbs 50 Nm
Torque wrench
Renew copper sealing ring.
05. Clearance between inductive sensor - output and face end gears on planetary carrier
0.02 - 0.027" 0.5 - 0.7 mm
Depth gauge, slider gauge 1X56 138 149 /1X56 138 150
Adjust clearance with shims
06. Clearance between inductive sensor - turbine and pulse sensor ring
0.024 - 0.03" 0.6 - 0.8 mm
Depth gauge, slider gauge 1X56 138 149 / 1X56 138 150
Adjust clearance with shims
07. Tightening torque for M6 fixing bolts on inductive sensor
7 ft-lbs 9.5 Nm
Torque wrench
Do not overtighten
08. Clearance between speedo sensor and toothedring on output
0.027 - 0.055" 0.7 - 1.4 mm
Depth gauge
Clearance is supplied, check value.
09. Tightening torque for speedo sensor
26 ft-lbs 35 Nm
Torque wrench
Do not overtighten.
10. Insertion depth of shaft seal in output cover
0.55 - 0.59" 14 - 15 mm
12
Use to 1X56 136 824 This gives correct insertion depth.
HP 502 C / HP 592 C / HP 602 C
Description
Adjustment data
Dimension
Measurementdevice
Remarks
11. Tightening torque for M6 hex nuts on inductive sensor cover-output
5 ft-lbs 6 Nm
Torque wrench
Do not overtighten
12. Tightening torque for M12 hex bolts at output flange
44 ft-lbs 60 Nm
Torque wrench
Secure with lock plate Use to 1X56 136 471
13. Tightening torque for M42x2 screw plug in duct plate
67 - 74 ft-lbs 90 - 100 Nm
Torque wrench
14. Tightening torque for M10x1 screw plugs on the pressure measuring points
9 ft-lbs 12 Nm
Torque wrench
Do not overtighten
13
14
HP 502 C / HP 592 C / HP 602 C
Fig. no.
Specialtools
Special tools
Orderno.
Application
1X56 136 471
Qty.
Remarks
1
Tool 1
for lock plate on output flange
1X56 136 824
2
Tool for fitting radial seal in output flange
1P01 136 670
3
1
Pressure test gauge 0 - 10 bar with M10x1 connectors
1X56 137 126
5
1
Pressure test gauge 0 - 25 bar with M10x1 connectors
1P01 137 856
4
1
1
Lifting attachment for transmission
15
Special tools
Fig. no.
Specialtools
HP 502 C / HP 592 C / HP 602 C
Orderno.
Application
1X56 138 149
Qty.
Remarks
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
7
Test fixture to determine distance between inductive sensor and pulse sensor on turbine and output (in connection with measuring rod 1X56 138 149)
1X56 103 755
8
1
Mounting fixture to mount output flange (in connection with gripper 1X56 103 755)
1X56 136 513 (220V) or 1X56 137 575 (110V) 10 Hot air blower to heat various parts.
16
1
Gripper to mount output flange (in connection with mounting fixture 1X56 136 512)
1X56 136 512
9
1
1
Options available: for 220 Volts or for 110 Volts
HP 502 C / HP 592 C / HP 602 C
Fig. no.
Specialtools
Special tools
Orderno.
Application
1P01 138 153
Qty.
Remarks
1
Test cable
for testing solenoid valves
11
6008 006 002
1
68-pin terminal tester for electrical troubleshooting
12
6008 208 003 3
4
2 13
Testman Diagnostic System (for Windows 95, 98 and NT)
Complete system for Windows 95, 98 and NT
Complete system without PC. Contains:
without PC
6008 308 901 Testman software on disc (1)
1
Optionally 6008 208 004 or 6008 208 003 but also with 0501 211 104 SAE cable (5).
6008 308 600 DPA 04 I adapter (2) 5 6008 308 601 RS 232-cable(3)
1
0501 211 103 ISO cable (4)
6008 308 114
14 Diagnose - Software 6008 308 014
1
Diagnostic software Testman for Ecomat 2
17
Special tools
Fig. no.
Specialtools
HP 502 C / HP 592 C / HP 602 C
Orderno.
Application
6008 307 001
Qty.
1
for
Diagnostic system 15
16
18
1
for ZF-Service only
1
for ZF-Service only
ISO cable for EPD1
0501 211 648
19
for ZF-Service only
Plug-In memory card for EPD1
0501 211 103
18
1
EPD1 Simple programming device
6008 298 029
17
ZF-Service only
MobiDig 2001 Complete system in portable case
0501 301 068
SAE cable for EPD1
Remarks
1
for ZF-Service only
Arrangement of peripheralequipment
HP502C/HP592C/HP602C
Arrangement of peripheral equipment
N R 3 D 1 2
013190
Key to drawing
1 2 3
Transmission electrical power plug EST 46C / EST 47C plug Retarder plug
10 11
Pedal brake valve for actuation of service brake and continuous retarder actuation via CAN Accelerator pedal
4 5 6 7 8 9
Accumulator plug Temperature sensor plug Kickdown switch MOBiDIG connection plug Speed range selector (Push-button switch) Dipstick (Oil level check, oil condition)
12 13 14 15 16 17
Retarder switch OFF - ON Vehicle power supply Pressure switch for NBS EST 46 C / EST 47 C electronic control unit Electric retarder hand lever Speedometer pulse sensor
19
Cutawayview
HP502CH / P592CH / P602C 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 2 4 5 6 7 9 10 11 12 13 14
20
Input Cover plate Control element
15 16 17
Inductive sensor “output” Brake “F” Brake “E”
Oil feed flange Clutch “A” Clutch “B” Housing Planet gear set I Planet gear set II Planet gear set III Speedo sensor Output
18 19 20 21 22 23 24 25 26
Brake “D” Control unit Inductive sensor “Turbine” Oil pan Retarder Primary pump Converter Torque converter “WK” Turbine shaft
HP502CH / P592CH / P602C
Cutawayview 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 2 4 5 6 7 8 9 10 11 12 13 14
Input Cover plate Control element
15 16 17
Inductive sensor “Output” Brake “F” Brake “E”
Oil feed flange Clutch “A” Clutch “B” Clutch “C” Housing Planet gear set I Planet gear set II Planet gear set III Speedo sensor Output
18 19 20 21 22 23 24 25 26
Brake “D” Control unit Inductive sensor “Turbine” Oil pan Retarder Primary pump Converter Torque converter “WK” Turbine shaft
21
Clutchcombination
HP502C/HP592C/HP602C
Clutch and brake combinations
No. of speeds 4-speed 4-speed
Transmission model and Parts List No. HP 592 HP 602 4149 052 . . . 4149 062 . . . 4149 056 . . . 4149 066 . . .
HP 502 4149 002 . . . 4149 006 . . .
5-speed 5-speed
4149 001 . . . 4149 003 . . .
4149 051 . . . 4149 053 . . .
4149 061 . . . 4149 063 . . .
2.81 - 0.80 3.43 - 0.83
6-speed
4149 004 . . .
4149 054 . . .
4149 064 . . .
3.43 - 0.59
Ecomat 2 with NBS
Ecomat 2 without NBS Clutch/brake
A
B
Reverse Neutral 1st gear 2nd gear 3rd gear 4th gear
1
B2
D
E
F 1 F2
i = 2.81 to 1.00 i= 3.43 to 1.00
4 speed
• • • • • •
•
Clutch/brake 5-speed and 6-speed
A
B
2
•
Reverse Neutral Neutral NBS 1st gear 2nd gear 3rd gear 4th gear
CDEF
1
F2
4th gear 5th gear 6th gear
• • •
• • • •
•
•
•
B1 = inner piston face, clutch B B2 = outer piston face, clutch B F1 = outer piston face, brake F F2 = inner piston face, brake F *
Clutch/brake 5-speed and 6-speed
• • • •
B
1
B2
D
E
F1 F 2
i = 2.81 to 1.00 i = 3.43 to 1.00
• • • • •• •
•
• • •* •* •
•
Ecomat 2 with NBS
i = 2.81 to 0.80 i=3.43to0.83 i=3.43to0.59
Reverse Neutral 1st gear 2nd gear 3rd gear
A
4 speed
• • •
Clutch/brake
Ecomat 2 without NBS
22
Ratio range 2.81 - 1.00 3.43 - 1.00
= reduced pressure (only for transissions with NBS)
A
B
2
CDEF
1
F2
i = 2.81 to 0.80 i=3.43to0.83 i=3.43to0.59
•
Reverse Neutral Neutral NBS 1st gear 2nd gear
• • •
3rd gear 4th gear 5th gear 6th gear
• • • •
• • •
•
• • •* •* •
HP502CH / P592CH / P602C 1. 1.1
Maintenance
Maintenance 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 (f ilter and sealing rings) is available with order No. 4139 298 936. Transmissionoicl hange
Oil change following transmission repair.
≈
Mileage
Operatinghours
600miles(1,000km)
50h
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) At oil changes Refilling after installing transmission in vehicle
≈
≈ 8gal. 31/2 - 41/2 gal. ≈ 51/2 gal.
(30liters) (14-17liters) (20liters)
The above quantities are reference quantities; the exact amount must always be found by measuring with the dipstick. 1.3
Oil grade See ZF List of Lubricants TE-ML 14. This list can be requested from any ZF After-Sales Service point.
1-1
Maintenance 1 .4
Checking oil level – The oil level must be checked at least once every week. – Vehicle must be standing level. – Engine at idling speed. – Before checking oil level, shift into Neutral.
HP502CH / P592CH / P602C
Oil measuring rod (check oil level / oil condition)
Oil pipe (oil filling up) CAUTION An electronic oil level display only provides information. Regular checks must be conducted on the oil dipstick at operating temperature. Always ensure that the correct oil level is maintained. Too little oil may cause malfunction or failure of the transmission. Too much oil may cause the transmission to overheat. DANGER Insufficent oil can cause partial or regular retarder failure: i.e. reduced or zero braking action.
1.5
011576
Operating te mperature
The correct operating temperature at which to check the oil level can be seen on the gauge in the vehicle. NOTE Before the oil level is checked, the transmission oil must have reached an operating temperature of 180 - 195°F (80 - 90 °C). 1 .6
Adding oil
Pour in transmission oil through the same hole as is used for measuring with the dipstick.1 quart (1 liter) changes the oil level by approx. 0.4" (10 mm). 1.7
001683
Checking oil level at operating temperature
Conditions:
Hot range • • • •
Vehicle standing level Speed range selector at “N” (Neutral) Engine idling (approx. 2 minutes) Transmission oil 80 - 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.
1-2
}
80-90°C
011577
HP502CH / P592CH / P602C 1.8
Maintenance
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 oil is below the lower mark, add oil immediately. Adjust the final oil level after checking again at operating temperature.
Cold range
}
approx. 30°C
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 exchanger higher than center line of transmission
Conditions: • Vehicle standing level • Speed range selector in Neutral setting • Run engine at 1200 to 1500 rpm for 15 to 20 seconds Then within 3 minutes, with engine idling, check oil level as described in "Checking oil level when cold" and recheck as described in "Checking oil level at operating temperature".
1-3
Maintenance
HP502CH / P592CH / P602C
1.11 Changing oil at op erating temp erature
– Switch off engine. – Drain oil through drain hole in oil pan. – Unscrew filter cover and renew suction filter (see Section 2.1).
filter cover
bolts (23 Nm)
– Screw in drain plug (37 ft-lbs/50 Nm) and fit filter cover (17 ft-lbs/23 Nm), see Section 2.1. CAUTION When working on a transmission with a converter drain valve, always use genuine oil drain plug. The drain plug controls and closes the converter drain valve.
oil drain plug 37 ft-lbs (50 Nm) 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
HP502C H / P592C H / P602C 2.
Overhaul
2.1
Renewing f ilter
1
Drain oil at oil drain plug (1) in acc. with description in Section 1.11.
Overhaul
2
DANGER Collect used oil in a large enough container and dispose of this in strict accordance with environmental protection legislation. Refer to general notes on threats to the environment.
2
Remove filter cover (2).
3
Pull out old filter element (1).
1
011578
NOTE Check filter for contamination.
1
DANGER
Dispose ofonmental contaminated filterslegislation. in strict accordance with envir protection Refer to general notes on threats to the environment.
011579
4
Insert new fi lter element (No. 0750 131 003).
1
NOTE Filter must always be renewed. It must not be cleaned and reused.
5
Check that O-ring of filter (1) is still correctly seated and is undamaged.
6
Smear O-ring with transmission oil.
008513
2-1
Overhaul 7
HP502C H / P592C H / P602C
Renew O-ring (1) in filter cover (2).
2
1
010483
8
Replace filter cover (1).
9
Tighten four hex. bolts (2). Tightening torque: 17 ft-lbs (23 Nm)
1
2
011578
2-2
HP502C H / P592C H / P602C 2.2
Renewing retarder solenoid valve
1
Disconnect cable connector (1) from solenoid valve.
2
Unscrew two M8 hex bolts (2).
Overhaul
2
1
011580
3
Remove solenoid valve (1) and insert new solenoid valve with new O-ring (2).
1 2 011581
4
Tighten both M8x22 hex bolts. Tightening torque: 17 ft-lbs (23 Nm)
5
Reconnect cable connector.
011580
2-3
Overhaul 2.3
Renewing accumulator s olenoid valve
1
Disconnect 2-core cable connector from solenoid valve.
2
Disconnect air line.
3
Unscrew both M8 hex bolts.
HP502C H / P592C H / P602C
1
011583
4
Smear new O-ring (1) with industrial grade Vaseline and insert into groove in solenoid valve.
5
Fitvalve.
1
011584
6
Tighten both M8x55 hex bolts (1) to 17 ft-lbs (23 Nm).
7
Reconnect air line and cable connector.
1
011585
2-4
HP502C H / P592C H / P602C 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.
Overhaul
1
2
011584
3
Remove two M8 socket-head bolts (1) from end of accumulator nearest transmission input.
1
011587
4
Smear new O-ring (1) with industrial grade Vaseline and insert into groove in accumulator.
5
Insert accumulator. Screw in two M8x25 sockethead bolts with washers on input side and screw in two M8 hex bolts with washers on output side and tighten. Tightening torque: 17 ft-lbs (23 Nm) 1
011588
2-5
Overhaul 2.5
Renewing t emperature se nsor
1
Release 2-core cable connector from temperature sensor.
2
Unscrew temperature sensor.
HP502C H / P592C H / P602C
011589
3
Slide new copper sealing ring (1) onto temperature sensor. Screw in temperature sensor. Tightening torque 26 ft-lbs (35 Nm).
1
011590
4
Reconnect 2-core cable connector with marking “TG”(1). 1
011591
2-6
HP502C H / P592C H / P602C 2.6
Renewing output sensor
1
Remove cover (1) from inductive sensor.
Overhaul
1
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
2
cables!
3
Screw out TORX screw (2) and remove inductive sensor.
4
Remove O-ring (1), spacers (2) and TORX screw (3) from inductive sensor (4).
011775
4
1
2
3
011776
2-7
Overhaul 5
HP502C H / P592C H / P602C
Turn output flange until gearing (1) on planet carrier in the center of the bore for the inductive sensor becomes visible.
1
011598
6
7
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
Introduce measuring sensor (3) until it abuts against ning theface-end screw (4)of. gearing and secure by tighte-
8
Screw out fixing bolt (2) of the measuring rod and carefully pull out the measuring rod.
2
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
HP502C H / P592C H / P602C 10
Insert new inductive sensor in test fixture 1X56 138 150 and screw-tighten. Tightening torque: 7 ft-lbs (9.5 Nm)
11
Measure distance from contact surface of inductive sensor to contact surface of inductive sensor holder and note down as " dimension c".
Overhaul
011779
Inductive sensor distance "dimension a" must be between 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 1.3 mm + 0.6 mm = 1.9 mm
2
3
Determined thickness "S" of spacer = 1.9 mm
Spacers WTB 0769 143 377 are available from 0.80 to 6.00 mm, in steps of 0.1 mm.
1 2 3 4 5
Gearing of planet carrier Output cover of housing Inductive sensor Spacers Fixing bolt of inductive sensor
1
a
4
5 011620
2-9
Overhaul 12
HP502C H / P592C H / P602C
Insert TORX screw (1) and washer in bore on inductive sensor (2). Slide spacers as determined (3) onto the TORX screw and secure with Oring (4).
2
4
1
3
011776
13
Connect cable plug (1) with inductive sensor.
14
Insert inductive sensor and tighten with TORX screw M6x45 (2). Tightening torque: 7 ft-lbs (9.5 Nm)
1
2
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
HP502C H / P592C H / P602C
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 identified by an item number. This item number should be read since you may only install a new resistor which has an item number which is identical to the old one. 012902
NOTE The resistor has a ten digit item number. Eight of these digits (6029 201 6) can be found on the face surfaces of the resistor (1). The two other item number digits (2) are located, as is shown, on its circumference.
2
Example: 6029 201 6 (48) = resistance of 46.40 k OTK resistance = 1.96 - 150 kW Item number
Designation
6029 201 652 6029 201 651 6029 201 650 6029201649 6029201648 6029201647 6029201646 6029201645 6029201644
Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance
6029201643 6029201642 6029201641 6029201640 6029201639 6029201638 6029201637 6029201636 6029201635 6029201634 6029201633
Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance
Check on retarder fitted 150.00 k 100.00 k 75.00 k 57.60k 46.40k 37.40k 31.60k 26.10k 22.10k
1
012903
18.70k 15.80k 13.30k 11.30k 9.31k 7.68k 6.34k 5.11k 3.92k 2.94k 1.96k
2-11
Overhaul 4
HP502C H / P592C H / P602C
Connect new resistor (item number must be identical to the old resistor) and install as is shown.
011775
2-12
HP502C H / P592C H / P602C 2.7
Removing and fi tting oil pan
1
Drain out oil and remove oil filter as described in Section 2.1.
2
Remove hex bolts (1) from oil pan.
3
Release oil pan from sealing face by tapping lightly with plastic mallet.
Overhaul
011578
DANGER
Beware of any the oil pan. Ensure that theoil oilremaining pan is wellin supported so that it cannot fall over.
4
1
Remove oil pan.
CAUTION If the transmission is f itted with a converter drain valve, do not damage the actuation bolt (1) for the converter drain valve when taking off the oil pan.
011579
1
016072
2-13
Overhaul 5
HP502C H / P592C H / P602C
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.
1
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
HP502C H / P592C H / P602C 9
Overhaul
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.
1
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
2-16
HP502C H / P592C H / P602C
HP502C H / P592C H / P602C 2.8
Renewing turbine sensor
1
Remove oil pan as described in Section 2.7.
2
Remove M42x2 screw plug (1).
Overhaul
011579
1
011607
3
Disconnect cable connectors (1) from sensor. These are blade connectors which should be pulled off straight.
4
Unscrew socket-head bolt (2) and remove
1
inductive sensor 2
011608
2-17
Overhaul 5
HP502C H / P592C H / P602C
Remove O-ring (1), spacers (2) and socket-head bolt (3) from inductive sensor.
4
1
3
2
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
HP502C H / P592C H / P602C 8
Overhaul
Introduce measuring rod 1X56 138 149 into the bore of the inductive sensor and screwtighten (1). Tightening torque: 7 ft-lbs (9.5 Nm) 1
011784
9
10
Introduce measuring sensor (1) until it is firmly wedged against the raised section of the pulse sensor ring and secure by tightening the screw (2).
1
2
Screw out fixing bolt (3) of the measuring rod and carefully pull out the measuring rod.
3
011785
11
Measure distance from front end of measuring sensor to contact surface of measuring rod holder and note down as dimension “b”. b
011778
2-19
Overhaul 12
Insert new inductive sensor in test fixture 1X56 138150 and screw-tighten. Tightening torque: 7 ft-lbs (9.5 Nm)
13
Measure distance from contact surface of inductive sensor to contact surface of inductive sensor holder and note down as dimension “c”.
HP502C H / P592C H / P602C
011779
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 Dimension “a” = 0.7 mm (0.6 - 0.8 mm)
011780
Calculation example: 52.6 mm – 50.9 mm = 1.7 mm 1.7 mm + 0.7 mm = 2.4 mm
1
Determined thickness “S” of spacer = 2.4 mm
2
4
5
Spacers OTK 0769 143 377 are available from 0.8 to 6 mm, in steps of 0.1 mm. 3
1 2 3 4 5
Sensor induction ring Mounting plate Inductive sensor Shim washers Socket-head bolt
a 011622
2-20
HP502C H / P592C H / P602C 14
Overhaul
Insert TORX screw (1) and washer in bore on inductive sensor (2). Slide spacers as determined (3) onto the TORX screw and secure with Oring (4).
2
4
3
1
011776
15
16
Insert inductive sensor and tighten with M6x45 socket-head screw (1). Tightening torque: 7 ft-lbs (9.5 Nm)
2
Connect cable plug (1) to inductive sensor.
1
011610
17
Screw M42x2 screw plug into duct plate and tighten. Tightening torque: 67 - 74 ft-lbs (90 - 100 Nm)
011607
2-21
Overhaul 18
Fit oil pan as described in Section 2.7.
19
Screw in oil drain plugs as described in Section 1.9.
HP502C H / P592C H / P602C
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
HP502C H / P592C H / P602C 2.9
Overhaul
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.
2
Unscrew the two M8 hex bolts (1) with washers from the KOSTAL socket.
013480
1
011624
3
Remove oil pan as described in Section 2.7.
011579
2-23
Overhaul 4
HP502C H / P592C H / P602C
Use a screwdriver to snap flat connector for inductive sensor output (1) and flat connector for retarder resistance (2) off valve body and disconnect from connector bush. 5 NOTE The sump temperature sensor is integrated in the connector (3). Only remove if necessary..
5
Guide cable for sump temperature sensor (4) out of protective sleeve (5).
1
4 2
3
015825
6
If the transmission is fitted with an oil level display, remove protective cap (1) from connector and disconnect connector (2) from oil level electronic unit. 2 1
015826
7
Loosen, but do not remove, the 39 M8 torx bolts which hold the shift control module in the transmission housing.
DANGER
When the control module is released, oil will spurt out. Protect yourself and especially your eyes from the oil. Let the oil continue to drip out and be sure to catch all of it.
DANGER The shift control module weighs approx. 40 lbs. (18 kg). Ensure it is well supported so that it cannot fall and injure you or other persons under the vehicle.
015827
2-24
HP502C H / P592C H / P602C 8
Overhaul
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 srcinals 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 11
HP502C H / P592C H / P602C
The 39 M8 torx screws which hold the shift control module are of two different lengths: 30 M8x43 screws (1) 9 M8x35 screws (2)
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 display, insert connector (1) into bush of oil level electronic unit. 1 3
CAUTION The oil level electronic unit (2) is very sensitive and must not be as theunit connector is inserted. Hold . back rear of bent electronic when inserting connector
13
2
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
15
Insert temperature sensor cable (4) in protective sleeve (5).
2 3
015825
2-26
HP502C H / P592C H / P602C 16
Insert connector socket into recess in housing and screw in both M8x20 hex bolts with washers. Tightening torque 17 ft-lbs (23 Nm).
17
Measure sensor clearance as described in Section 2.8, screw in sensor with new shim washers and reconnect cables.
18
Fit oil pan and new filter as described in Section 2.7.
Overhaul
011624
011607
011578
2-27
Overhaul
HP502C H / P592C H / P602C
2.10 Changing co mplete oi l level dis play
Remove oil pan and transmission control unit in accordance with sections 2.7 and 2.9. Installation position of complete oil level display (1).
1
015829
1
Unscrew two M6 Torx bolts (1) on oil level electronic unit.
CAUTION Handle oil level electronic unit with care. It is very sensitive to impact. 1
015830
2
Unscrew two M6 Torx bolts (1) and take out oil level indicator complete with retaining plate, sensor and oil level electronic unit.
1
NOTE
Do not unfasten M6 Torx bolt (2).
1
2
015831
2-28
HP502C H / P592C H / P602C 3
Overhaul
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).
1
2 3
015832
4
Insert new oil level sensor (i.e. not yet set and not secured) complete with retaining plate and use two M6x30 Torx bolts(1) to screw into place. Tightening torque: 7 ft-lbs (9.5 Nm)
1
1
015833
CAUTION The Torx bolts on the retaining plate screw connection are each f itted with two O-rings for damping. Check that O-rings are seated properly.
1 3
2 4
1 2 3 4 5 6 7
Torx bolt Washer 9x2.5 O-ring Retaining plate 14x2.5 O-ring Bush O-ring for fastening
5 6
7
Length X = 5.0 +3 mm
015834
2-29
Overhaul
5
HP502C H / P592C H / P602C
Unfasten M6x16 Torx bolt (1).
1
6
Correct setting length of oil level sensor between face end on sensor and housing sealing face.
015833
CAUTION Setting lengths are different depending on the parts list. Take the correct setting length from the parts list.
Example:
Length X
Oil level indicator parts list 4149 043 005 Setting length X = 0.62 ± 0.02" (15.7 ± 0.5 mm) 7
Once the sensor is set, tighten the M6x16 Torx bolt (1) on the holder and secure correct installation position. Tightening torque: 7.5 ft-lbs (10 Nm)
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°.
015835
2
1
015832
2-30
HP502C H / P592C H / P602C 9
10
Reinsert secured oil level sensor and use two M6x30 Torx bolts (1) to screw into place. Tightening torque: 7 ft-lbs (9.5 Nm)
Overhaul
1
gt h Len
X
Check sensor installation length “X” again.
2
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
HP502C H / P592C H / P602C
2.11 Renewing pulse sensor
1
Unscrew pulse sensor (1).
1
011635
2
Smear threads of new pulse sensor with transmission oil.
3
Screw in new pulse sensor. Tightening torque: 26 ft-lbs (35 Nm)
011636
011637
2-32
HP502C H / P592C H / P602C
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.
1
011638
2
Unscrew both M12 hex bolts from output shaft. NOTE When unscrewing bolts, use a suitable lever to prevent output flange from turning.
3
(1). If necessary, release Remove clamping plate mallet by tapping with plastic
4
Pull off output flange using a standard 2-arm puller.
1
011639
NOTE Protect end of output shaft with a washer or
similar.
011640
2-33
Overhaul 5
HP502C H / P592C H / P602C
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.
1
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
HP502C H / P592C H / P602C 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
Overhaul
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 f lange over 230°F (110°C) or seal will be damaged.
DANGER Always wear protective gloves when handling hot output flange.
NOTE Insert hex bolts before fitting flange if necessary.
11
Screw gripper 1X56 103 755 onto output shaft, attach output flange and use tightening tool 1X56 136 512 to tighten until firmly home.
011645
CAUTION Never knock output flange into place.
12
Coat sealing face (flat face without bevels) of pressure washer (1) with sealing compound (WEVO L100 produced by WEVOCHEMIE) and attach on flange.
1
011646
2-35
Overhaul 13
HP502C H / P592C H / P602C
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
HP502C H / P592C H / P602C
Overhaul
2.13 Pressure te sts
Pressure tests with transmission installed in vehicle: 1
Set up the pressure measurement connections intended for the test. Unfasten screw plug and screw in test pressure gauge. Test pressure gauge1PO1 136 670 (up to 25 bar) Test pressure gauge1PO1 137 856 (up to 10 bar)
1 = Main pressure PH 2=Throttlepressure P D1 3 = Pressure before converter P D2 4 = Pressure after heat exchanger PD6 PD7* 5=Retarderpressure P R3 6 = Retarder control pressure P RR3
4
5
1 6
3
2 011650
* (4) for Retarder "ON" = P D6 * (4) for Retarder "OFF" = P D6 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
HP502C H / P592C H / P602C
Pressure table: A = Normal main pressure B = Higher main pressure for engines more powerful than 1036 ft-lbs (1400 Nm) Pressure measurement:
H P 1 pressure 2= = Main Throttle pressure PD1 (PD1 = no current = 10 bar)
A
3 = Pressure before converter PD2 4 = Pressure after heat exchanger PD6 PD7* * for Retarder "ON" = P D6 * for Retarder "OFF" = P D6 PD7 = Lubricating oil pressure 5 = Retarder pressure PR3 6 = Retarder control pressure PRR3 7 = Oil temperature toil neng = Engine speed WK = Lock-up clutch
7
Pressure table NORMAL MAIN PRESSURE neng
1
2
3
4
M 10x1
M 10x1
M 10x1
M 10x1
PH (bar)
PD1 (bar)
PD2 (bar)
PD6/D7 (bar)
Load
Gear
WK
(min-1)
toil (°C)
Idling
N
open
700
20 - 40
7 - 15
4±0,3
4.0 - 5.5
0.8 - 1.8
open
550
20 - 40
7 - 15
0.2 - 1.0 for 2 sec.
4.0 - 5.5
0.8 - 1.8
Idling
N
D
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
N
open
700
80 - 90
7 - 15
4±0,3
3.0 - 4.5
0.1 - 0.8
7 - 15
0.2 - 1.0 for 2 sec.
3.0 - 4.5
0.1 - 0.8
◆16 - 20
4±0,3
6.0 - 8.5
1.8 - 2.5
10-12
4±0,3
6.0 - 8.5
1.8 - 2.5
Idling
N
Idling
open
N
open
Engaged
closed
Full load Full load
D
550
80 - 90
2000-2500 80 - 90 2000-2500 80-90
5*/6*
M 10x1 PR3/PRR3 (bar)
d l o c
m r a w
* 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.
B
7
Pressure table HIGHER MAIN PRESSURE neng
1
2
3
4
M 10x1
M 10x1
M 10x1
M 10x1
M 10x1
PH (bar)
PD1 (bar)
PD2 (bar)
PD6/D7 (bar)
PR3/PRR3 (bar)
Load
Gear
WK
(min )
toil (°C)
Idling
N
open
700
20 - 40
13 -22
4±0,3
4.0 - 5.5
0.8 - 1.8
open open
550
20 - 40
13 - 22
0.2 - 1.5 for 2 sec.
4.0 - 5.5
0.8 - 1.8
2000-2500
20 - 40
21 - 25
4±0,3
6.0 - 8.5
1.8 - 2.5
Idling
N
Full load Full load
N Engaged
closed
2000-2500
20 - 40
12 - 16
4±0,3
6.0 - 8.5
1.8 - 2.8
N
open
700
80 - 90
10 - 17
4±0,3
3.0 - 4.5
0.1 - 0.8
80 - 90
10 - 17
0.2 - 1.5 for 2 sec.
3.0 - 4.5
0.1 - 0.8
2000-2500 80 - 90
21 - 24
4±0,3
6.0 - 8.5
1.8 - 2.5
Idling Idling Full load Full load
D
-1
N
D
open
N
open
Engaged
closed
550
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
5*/6*
d l o c
m r a w
HP502C/HP592C/HP602C
3 3.1
Troubleshooting
Troubleshooting Terminal tester concept 25-, 55-, 68-pin EST electro nic control unit
68-pin terminal tester
55-pin terminal tester
6008 006 002 (1)
1P01 137 834
*6008 199 001 contains (1) (2) (3)
can no longer be supplied
68-pin - 55-pin reduction adapter cable *6008 004 024 (2)
from vehicle power supply to Buka
55-pin - 25-pin reduction adapter cable
*6008 004 025 (3) from Buka to EST plug
6008 004 026 bush 6008 004 027 plug
68-pin electronic control unit EST 31 AS Tronic EST 37 WG EST 45 T 7000 EST 46 Ecomat 2 EST 47 Ecomat 2
55-pin electronic control unit EST 14 AVS EST 15 Retarder EST 18 Ecomat
25-pin electronic control unit EST 32 Intarder
3-1
Troubleshooting
HP502C/HP592C/HP602C
3.2
1PO1 138 153 test cable
a)
Insert Kostal plug of test cable into Kostal socket on transmission.
! DANGER Only use test cable with vehicle stationary and engine off.
CAUTION Do not apply voltage to emergency cut-off switch (yellow sockets) or to inductivesensor (green sockets),or the switch or sensor will be short-circuited and irreparably damaged. If the switch is damaged, the transmission must be removed from the vehicle
Table for checking model of retarder fitted Item number
6029201652 6029201651 6029201650 6029201649 6029201648 6029201647 6029201646 6029201645 6029201644 6029201643 6029201642 6029201641 6029201640 6029201639 6029201638 6029201637 6029201636 6029201635 6029201634 6029201633
3-2
Designation
Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance
Retarder check
150.00k 100.00k 75.00k 57.60k 46.40k 37.40k 31.60k 26.10k 22.10k 18.70k 15.80k 13.30k 11.30k 9.31k 7.68k 6.34k 5.11k 3.92k 2.94k 1.96k
CAUTION Each resistor is assigned to the relevant transmission by checking the type of retarder fitted. Each is identified by an item number. This item number should be read since you may only install a new resistor which has an item number which is identical to the old one.
HP502C/HP592C/HP602C
b)
Troubleshooting
Resistance measurements: Measure resistance of solenoid valve coils and inductive sensors, see list below.
On solenoid valves the resistance value rises with rising temperature.
NOTE: Resistance values may change with rising or dropping temperatures.
Test specimen
Brakes, Clutches, A4 Inductive sensors, Marking Pin Resistance
Ohmmeter Nominal readings
13
approx. 67 ± 4
at 20°C
B
12
approx. 67 ± 4
at 20°C
Clutch B2
C
11
approx. 67 ± 4
at 20°C
Solenoid valve Y14
Brake D
D
22
approx. 67 ± 4
at 20°C
Solenoid valve Y13
Brake E
E
24
approx. 67 ± 4
at 20°C
Solenoid valve Y12
Brake F
F
19
approx. 67 ± 4
at 20°C
Solenoid valve Y11
Brake G / F2
G
6
approx. 67 ± 4
at 20°C
Solenoid valve Y18
Clutch WK
WK
9
approx. 67 ± 4
at 20°C
Solenoid valve Y19
Retarder
RET
8
approx. 67 ± 4
at 20°C
D1Prop.-solenoid Y20
D1 valve
D1
10
approx. 8,6 ± 0,5
at 20°C
Inductive sensor B11
n Output
nAB
2
approx. 850 ± 100 at 20°C
Retarderresistor B16
Retarder recognition
RET.K
18
* 1.96 to 150 k
Oil level sensor B15
Oil level display
Oil
23
** PWM %, VPE 5 Volt
Sump temperature
TG
4
approx. 125 ± 5 k
n Turbine
nT
1
approx. 850 ± 100 at 20°C
Ground/earth
GM1
15
Ground/earth
GM2
17
Ground/earth
VM1 VM2
21 20
Solenoid valve Y17
Clutch A
Solenoid valve Y16
Clutch B1
Solenoid valve Y15
Temp. sensor B14
Inductive sensor B12
On the temperature sensor B14 the resistance value drops with rising temperature.
Tolerance and characteristics
A
at 20°C
temperature sensor see next page
* see table for checking model of retarder f itted ** no resistance measurements must be carried out
3-3
Troubleshooting
HP502C/HP592C/HP602C Temp. 2*Rt [˚C] [Ohm]
Temperature sensor NTC - Sensor B14 Thermometrics DKS 4261 2 elements in series
Table of tolerance - 20°C bis 150°C
Characteristics Resistance/Temperature
2*Rt (min) 2*Rt (max) [Ohm] [Ohm]
-20 -15 -10 -5 0
957796 720948 547652 419668 324282
896080,6 1023353,4 676412 768108 515240,8 581880,2 395880 444708 306690,8 342746
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
252580,6 198235,8 156760,6 124765,8 99991 80649,2 65448,2 53425,2 43857 36197,6 30031,2 25040 20978,6 17657 14927,6 12674 10804,8 9248
239476,2 188407 149700,6 119130 95685,8 77343 62896,4 51446,4 42316 34992,8 29086 24296 20391,2 17192,4 14559,2 12381,4 10572,4 9063
266295,4 208494 164443,6 130615,8 104448 84063,2 68076,4 55457,8 45435,8 37428,8 30994,8 25796,4 21574 18127 15299,2 12968,2 11038,2 9433
95 100 105 110 115 120 125 130 135 140 145 150
7945,8 6852 5929,8 5149,4 4486,4 3921,6 3438 3023,2 2666,2 2357,8 2090,8 1858,8
7775 6694,8 5785,4 5017 4365 3810 3336 2929,8 2580,6 2279,4 2018,8 1792,8
8117 7010 6075,4 5283,2 4609,4 4034,2 3541,6 3118,4 2753,6 2438,2 2164,6 1926,8
2 elements DKS 4261 (2*in Reihe)in series
100000 90000 ]
80000
2*Rt [Ohm]
h 70000 m O [ 60000 e d c n 50000 n ta a ts r 40000 e is d s i 30000 e W20000 R
10000 0 20
30
40
50
60
70
Temperatur [˚C] Temperature
3-4
80
90
100
110
120
HP 50H C 2/ P 59H C 2/ P 60C 2
Annex
DIAGNOSTIC TOOL
Installation and menus
015955
ZF FRIEDRICH SHAFEN A G 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-Diagnostictoo“l Testman”
Contents Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 5
Contents of the “Testman” diagnosis software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Testman software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Additional settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of the diagnosis software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen display of the repair aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 15
Contents of the repair aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Preface
ZF-Diagnostictoo“l 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 C.V./Special Transmissions Service Plant 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726
4
Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.
ZF-Diagnostictool“Testman”
Safetynotice SAFETY NOTICE
Companies repairing ZF units are responsible for their own work safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations.
Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.
The following safety instructions appear in this manual:
NOTE Refers to special processes, techniques, data, use of auxiliary equipment, etc.
CAUTION This is used when incorrect, unprofessional working practices could damage the product.
! DANGER This is used when lack of care could lead to personal injury or death.
5
Contents of Testman / System c omponents
ZF-Diagnostic tool “Testman”
ZF Testman electronic diagnosis
Aids to
Diagnosis
repair work
Tightening torques Adjustment data Special tools/test equipment Maintenance Repairs Pressures
Test inputs and
Vehicle
Telephone
outputs
configuration
directory
Reading error memory
System check at standstill
Viewing the vehicle data
Deleting error memory
System check in motion
Copying vehicle data
Identification block
Test equipment
Modifying /extending vehicle data
Analogue displays, speeds, currents etc.
Telephone directory of all people in the Technical Service, arranged by product
Circuit diagrams Electrical measuring values
ZF Testman diagnostic tool Order numbers: Order number
6008 208 004
6008 308 900
6
Designation
Item number
Testman software on diskette
6008 308 901
DPA 04 I diagnostic adapter
6008 308 600
RS 232 cable
6008 308 601
Installation instructions
6008 758 703
ISO cable SAE cable
0501 211 103 0501 211 104
Order number
6008 208 003
Batch number for diagnosis software on diskette. You can obtain further information about the desired diagnosis software from your ZF Service Center.
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
2.
disk drive (e.g. “A”). 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.
7.
Select the Testman Setup program and follow the instructions in the software.
1 015917
1 Testman software on diskettes Order No.: 6008 308 901
The Testman installation process is now complete. NOTE The Testman is available in English and German.
These languages only have an effect on system reactions (not on the diagnosis software).
7
Additionalsettings Start the Testman. The first time you open the program, “ZF ISO Man Properties” appears on screen. Here you should select the correct COM port on your PC and confirm this choice. If you need this function again at a later point, double-click the “Z” symbol to the bottom right of the task bar.
ZF-Diagnostictool“Testman” NOTE Communication is not possible unless you have selected the correct COM port.
015911
1. 2.
Click on the Testman icon with your right mouse button. Select “Properties”.
3. 4.
Select the program and select “Close on completion”. Accept and confirm with “OK”.
015948
8
Installation of the diagnosis software Connecting up a programming tool
ZF-Diagnostic tool “Testman” 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.
7.
Depending on the drive, select “Install” or “d”.
8.
1 015916
1. Diagnosis software on diskette Order No. 6008 308 900
Use your mouse to click on “OK”. This installs 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.
Connect an ISO or SAE cable (4) to the appropriate port (ISO 9141 / SAE S1708) on the DPA 04 I adapter and connect to the electronic control unit in the vehicle.
2
1 3
4 015955
Key to drawing 1. Your PC – with appropriate system requirements 2. RS232cable OrderNo.6008308601 3. DPA 04 I diagnosis adapter Order No. 6008 308 600 4. ISOcable OrderNo.0501211103 or SAEcable OrderNo.0501211104
9
DPA04Idescription Description of the DPA 04 I diagnosis and programming adapter
ZF-Diagnostictool“Testman” Front panel
1.
LEDL line • Lights up whenever data have to be transferred on the L line.
2.
LEDdata • Lights up whenever data have to be transferred on the K line.
3.
LEDUbatt • Lights up when the vehicle circuit voltage lies between 12 – 24 V.
The DPA 04 I features three interfaces, V-24, RS 232, ISO 9141 and SAE J1708. • The RS 232 communicates between the DPA 04 I and a laptop computer. • The ISO 9141 and SAE J1708 communicate between the DPA 04 I and the control unit. Appropriate adapter cables are required for the ISO and the SAE interfaces. The same adapter cables as the DPA 02/03 can be used (pins compatible with the ISO interface).
NOTE: In SAE mode, dependent upon switch setting “KL15ECU”
Here are the three basic operating modes of the DPA 04 I: 4. 1.
Data transmission via ISO interface and control unit.
2.
Data transmission via SAE interface and control unit.
3.
NOTE Always ensure the Testman is in the ”OFF” position when working on it.No communication is possible if the switch is in the wrong position.
Interface converter between MobiDig 2001/200 and SAE control unit. 5.
10
UPRG switch • “OFF” setting: programming voltage not present • “ON” setting: programming voltage present.
KL15ECU switch This switch is not relevant in ISO mode.
DPA 04 I programming SelectingCOMport
ZF-Diagnostictool“Testman” The DPA 04 I has a Flash Prom which is supplied with Testman functions.
In the event of the DPA 04 I drive losing data, proceed in accordance with the following instructions in order to restore Testman functionality.
015908
1. 2. 3.
Quit the Testman. Connect DPA 04 I to the laptop. Connect the DPA 04 I to the power supply using
4. 5.
an ISO or SAE cable. NOTE The download software is usually set to COM 1 (i.e. default setting). If your laptop has a different COM port, adapt the setting as follows:
Select directory/folder GDS 3000 / dpaload using the drive (C or D). Start dpa4.bat batch processing. This loads the Testman functions for the DPA 04 I. This process lasts approximately 1 minute.
1. 2. 3. 4.
Open the text editor from the Start bar. Open \GDS3000\dpaload\bload166.cfg. You can enter the correct COM port here (see arrow). Save and close.
015947
11
StartingtheTestman
ZF-Diagnostictool“Testman”
Symbols and switch surfaces
End Testman
Selection of application
Help
Print Return System
Continue Start
012290/013809/013810/013811
Starting the Testman
1. 2.
3. 4.
Double-click the “Testman” icon on your desktop to start the program. If the Testman has been started successfully, you will see a menu with 3 items: File - for exiting the Testman Pal2Application - for selecting the application Help To load an application, use the mouse to click on the "Pal2Application". A selection bar opens containing the menu item "Run".
5.
Click on "Run".
6.
The "Run Pal2Application" window is opened.
7.
Click on "Select".
12
8.
The "Open" window is opened.
9.
Select the transmission application.
10.
Click on "Open".
11.
The "Open" window is closed and the "Run PAL2Application" window is opened.
12.
Click on "Run".
13.
Now the Testman start-up logo "ZF Service" appears.
14.
Click on "Continue".
15.
The product menu appears.
16.
Use the mouse to select the menu item you want (line is highlighted).
17.
Press the "Enter" key on the PC or use the mouse to click on "Continue".
ZF-Diagnostictool“Testman”
Start-uplogo
Continue
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
Productmenu/Contents
ZF-Diagnostictool“Testman”
Continue
Mark menu point using the mouse
☞
Menu point is marked ☞
☞
Menu point appears
Press the "Enter" key on the PC or use the mouse to click on the symbol "Continue"
Maintenance, tightening torques, special tools / test equipment, repairs, circuit and wiring diagrams, pressures and electr. measuring values.
System check: vehicle in motion. Check of all system components which can be tested when vehicle is in motion. Errors are described on the screen when exiting the function test.
Test equipment. Product-specific.
Analogue display: Such as speeds, currents etc.
Product-specific. Reading/deleting error memory. Identification block.
System check: Vehicle at standstill. Check of all system components which can be tested when vehicle is at standstill. Errors are described on the screen when exiting the function test.
14
Vehicle-specific data. Such as customer sheets, vehicle data etc.
ZF contacts. Telephone directory of all people in the Technical Service, arranged by product.
ZF-Diagnostictool“Testman”
Repairaid/Contents
Continue
Mark menu point using the mouse
☞
Menu point is marked ☞
☞
Menu point appears
Press the "Enter" key on the PC or use the mouse to click on the symbol "Continue"
Oil change intervals, types of oil (ZF list of lubricants), oil quantities, oil changes, oil fills (figure) and product-specific maintenance information.
ZF standard 148 and product-specific tightening torques.
Product-specific. All tools required for work on the vehicle are shown as pictures with their ZF nos.
Product-specific.
Product-specific.
Product-specific. Example: Voltages and resistance.
Previous menu is displayed.
Product-specific. Example: Description of how to change the inductive sensor.
15
Technicaldata
ZF-Diagnostictool“Testman”
System prerequisites for your PC
Technical data for the DPA 04 I
Windows 95 / 98 or Windows NT 4.0
Operating voltage
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%
Diskdrive
31/2”
Serialport
COM1orCOM2
Electromagnetic compatibility Electrostatic compatibility
16
12 – 24 volts
80–1000 MHz AM 1kHz 80%
4kVoncontact,and 8kVwithnocontact
HP502C H / P592C H / P602C
Hydraulic ircuid t iagramwithoutNBS4149700026/1
A
B1
NA
4 GANG 4 GEAR
DETAIL X AUSFUEHRUNG HAUPTDRUCKVENTIL MIT DRUCKABSENKUNG
P
NEUTRAL
VERSION MAIN PRESSURE VALVE WITH PRESSURE REDUCER
2 NEBENATRIEBE MOEGLICH PTO'S CAN BEFITTED
i = 2.81 BIS 1.0 3.43 BIS 1.0
RUECKWAERTS REVERSE
1. GANG 1st GEAR 2. GANG 2nd GEAR 3. GANG 3rd GEAR
WK D2
4. GANG 4th GEAR
WK
B1 = INNERE KOLBENFLAECHE KUP 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
B1
B
F 2 = INNERE KOLBENFLAECHE BREMSE F INNER PISTON FACE BRAKE F
P
A
C
5 - &. 6 GANG 5 - & 6 GEAR
B2
RUECKWAERTS REVERSE
C WANDLERENTLEERVENTIL
NEUTRAL
CONVERTERPURGE VALVE
1. GANG 1st GEAR 2. GANG 2nd GEAR
SPEICHER ACCUMULATOR
3. GANG 3rd GEAR
A8
D
4. GANG 4th GEAR 5. GANG 5th GEAR 6. GANG 6th GEAR
WANDLERGEGENDRUCKVENTIL CONVERTER COUNTERPRESSURE VALVE
WANDLERSICHERHEITSVENTIL CONVERTER SAFETY VALVE E
WAERMETAUSCHER OIL COOLER
TEMP.MESSSTELLE TEMPERATUR SWITCH SENSOR
D2
SCHMIERDRUCKVENTIL LUBRICATING PRESSURE VALVE
F1 F1-VENTIL
R3 F1
D4
RR3
D6
D5
D7
R3
X
F
D2 RETARDERREGELVENTIL RETARDER CONTROL VALVE
F2-VENTIL HAUPTDRUCKVENTIL
F2
KUEHLERUMSCHALTVENTIL
MAIN PRESSURE VALVE
COOLER CHANGEOVER VALVE
D8
D8 D1
P
P
D9
R2
RETARDER
PRIMAERPUMPE PRIMARY PUMP
D1 A2
SAUGFILTER
P DROSSELDRUCKVENTIL THROTTLE PRESSURE VALVE
SUCTION FILTER A1
R1
B2 i = 2.81 BIS 0.8 3.43
HP502 C H / P592 C H /P 602 C
Hydraulicircuidt iagram withNBS4149700 26/2
A
B
NA
DETAIL X AUSFUEHRUNG HAUPTDRUCKVENTIL MIT DRUCKABSENKUNG
RUECKWAERTS REVERSE
P
NEUTRAL
VERSION MAIN PRESSURE VALVE WITH PRESSURE REDUCER
2 NEBENABTRIEBE MOEGLICH PTO'S CANBE FITTET
i = 2.81 BIS 1.0 3.43
4 GANG 4 GEAR
NEUTRAL NBS
WK
1. GANG 1st GEAR 2. GANG 2nd GEAR 3. GANG 3rd GEAR 4. GANG 4th GEAR
D2
WK
A
B 1 = INNERE KOLBENFLAECHE KUPPLUNG B INNER PISTON FACE CLUTCH B B 2 = AEUSSERE KOLBENFLA OUTER PISTON FACE CLUTCH B
F 1 = AEUSSERE KOLBENFLAECHE F OUTER PISTON FACE BRAKEBREMSE F
B2 B1
P
B
F 2 = INNERE KOLBENFLAECHE BREMSE F INNER PISTON FACE BRAKE F * = REDUZIERTER DRUCK
A
C
5 - &. 6 GANG 5 - & 6 GEAR
B2
C
RUECKWAERTS REVERSE
WANDLERENTLEERVENTIL
NEUTRAL
CONVERTERPURGE VALVE
NEUTRAL NBS
SPEICHER ACCUMULATOR
1. GANG 1st GEAR 2. GANG 2nd GEAR 3. GANG 3rd GEAR 4. GANG 4th GEAR 5. GANG 5th GEAR 6. GANG 6th GEAR
A8
D
WANDLERGEGENDRUCKVENTIL
WANDLERSICHERHEITSVENTIL CONVERTER SAFETY VALVE E
WAERMETAUSCHER
CONVERTER COUNTERPRESSURE VALVE
TEMP.MESSSTELLE
OIL COOLER
TEMPERATUR SWITCH SENSOR
D2
SCHMIERDRUCKVENTIL F1 VENTIL
LUBRICATING PRESSURE VALVE
R3 D4
F1
D6
D5
D7
RR3 R3
X
F D2
RETARDERREGELVENTIL F2 VENTIL
RETARDER CONTROL VALVE
HAUPTDRUCKVENTIL F2
KUEHLERUMSCHALTVENTIL
MAIN PRESSURE VALVE D8
D8 D1
P G P
P
D9
R2 RETARDER
PRIMAERPUMPE D1
PRIMARY PUMP A2
SAUGFILTER
P
SUCTION FILTER DROSSELDRUCKVENTIL THROTTLE PRESSURE VALVE
A1
COOLER CHANGEOVER VALVE
R1
B
i = 2.81 BIS 0.8
6 C H0P 2/ 5 C H9P 2/ 5 C H0P 2
C E4,S6T
Connection diagram
6 C H0P 2/ 5 C H9P 2/ 5 C H0P 2
C E4S ,6T
Connection diagram
6 C H0P 2/ 5 C H9P 2/ 5 C H0P 2
C E4S ,7T
Connection diagram
6 C H0P 2/ 5 C H9P 2/ 5 C H0P 2
C E4,S7T
Connection diagram
H 6C 0P H /52C 9P H /52C 0P2
C 4E 7 , /S 46 T
Electrical circuit diagram
H5PH 0/C 52PH 9/C 6 2P0C 2
ES44T C /76, Pipnatter6n027920972
1
Wandler • Torque converter • Momentomvandlare • Koppelomvormer
2
Retarder • Retarder • Retarder • Retarde
3
Wandler-Sicherheitsventil • Torque con safety valve • Momentom-vandlarens Säkerhetsventil • Koppel-omvormerVeiligheidsventiel
4
Druckspeicher • Accumulator • Ackumu Drukreservoir
5
Kühler-Umschaltventil • Cooler change valve • Omkopplingsventil kylare • Koeleromschakelventiel
6
Wärmetauscher • Heat Värmeväxlare • Koeler
7
Schaltgetriebe • Planet gear train • Automatväxellåda • Transmissie
8
WK-Ventileinheit • WK valve unit • Ventilenhet WK • WK-ventielunit
8.1 Magnetventil • Solenoid valve • Magnet Magneetventiel
8.2 Drucksteuerventil • Pressure control val Tryckregleringsventil • Drukregelventie 8.3 Ausschaltventil • Shutoff valve • Urkopplingsventil • Afschakelventiel 9
Ventileinheit Kupplung/Bremse • valve Clutches/Brakes • Ventilenhet Lamellko ventielunit Koppeling\Rem
9.1 Magnetventil • Solenoid valve • Magnet Magneetventiel
9.2 Drucksteuerventil • Pressure control val Tryckregleringsventil • Drukregelventie 9.3 Ausschaltventil • Shutoff valve • Urkopplingsventil • Afschakelventiel 10 Kupplung/Bremse A, B, C, D, E, F, G • Clutches/Brakes • Lamellkoppling • Koppeling\Rem
11 Retarderregelventil • Retarder control va Retarderstyrventil • Retarderregelventie
12 Hauptdruckventil • Main pressure valve Huvudtryckventil • Hoofddrukventiel 13 Filter • Filter • Filter • Filter 14 Pumpe • Pump • Pump • Pomp 15 Schmierdruck • Lubrication pressure • Smörjoljetryck • Smeerdruk 8 2 7 7 1 0
16 Wandlergegendruck • Converter counter
Momentomvandlarens mottrycksventil • Koppelomvormertegendruk
17 Drosseldruckventil • Throttle pressure v Tryckmoduleringsventil • Modulatiedru 18 Luft • Air • Luft • Lucht
Technische Änderungen vorbehalten • Subject to Rätt till tekniska ändrigar förbehålles • Technische veranderingen vo
HYDRAULIC 2
Einschaltstellung Position locked Läge till Inschakelstand
ZF FRIEDRICHSHAFEN 4149 753 702
1
Wandler • Torque converter • Momentomvandlare • Koppelomvormer
2
Retarder • Retarder • Retarder • Retarde
3
Wandler-Sicherheitsventil • Torque con safety valve • Momentom-vandlarens Säkerhetsventil • Koppel-omvormerVeiligheidsventiel
4
Druckspeicher • Accumulator • Ackumu Drukreservoir
5
Kühler-Umschaltventil • Cooler change valve • Omkopplingsventil kylare • Koeleromschakelventiel
6
Wärmetauscher • Heat Värmeväxlare • Koeler
7
Schaltgetriebe • Planet gear train • Automatväxellåda • Transmissie
8
WK-Ventileinheit • WK valve unit • Ventilenhet WK • WK-ventielunit
8.1 Magnetventil • Solenoid valve • Magnet Magneetventiel
8.2 Drucksteuerventil • Pressure control val Tryckregleringsventil • Drukregelventie 8.3 Ausschaltventil • Shutoff valve • Urkopplingsventil • Afschakelventiel 9
Ventileinheit Kupplung/Bremse • valve Clutches/Brakes • Ventilenhet Lamellko ventielunit Koppeling\Rem
9.1 Magnetventil • Solenoid valve • Magnet Magneetventiel
9.2 Drucksteuerventil • Pressure control val Tryckregleringsventil • Drukregelventie 9.3 Ausschaltventil • Shutoff valve • Urkopplingsventil • Afschakelventiel 10 Kupplung/Bremse A, B, C, D, E, F, G • Clutches/Brakes • Lamellkoppling • Koppeling\Rem
11 Retarderregelventil • Retarder control va Retarderstyrventil • Retarderregelventie
12 Hauptdruckventil • Main pressure valve Huvudtryckventil • Hoofddrukventiel 13 Filter • Filter • Filter • Filter 14 Pumpe • Pump • Pump • Pomp 15 Schmierdruck • Lubrication pressure • Smörjoljetryck • Smeerdruk 7 2 7 7 1 0
16 Wandlergegendruck • Converter counter
Momentomvandlarens mottrycksventil • Koppelomvormertegendruk
17 Drosseldruckventil • Throttle pressure v Tryckmoduleringsventil • Modulatiedru 18 Luft • Air • Luft • Lucht
Technische Änderungen vorbehalten • Subject to Rätt till tekniska ändrigar förbehålles • Technische veranderingen vo
HYDRAULIC 1
Ausschaltstellung Position opened Läge från Uitschakelstand
ZF FRIEDRICHSHAFEN 4149 753 701
3 D
DRIVE SHAFTS 2B5 PS0Feries
C o nt e n ts
CONTENTS
Page
D a te
1. GENERAL .................................................................................................. 1-1 .............. 0145 1.1 General information .......................................................................... 1-1 .............. 0145 1.2 Inspection ......................................................................................... 1-2 .............. 0145
2. REMOVAL AND INSTALLATION ............................................................... 2-1 .............. 0145 2.1 Drive shaft assembly ........................................................................2-1 .............. 0145 2.2 Drive flange ....................................................................................... 2-2 .............. 0145 2.3 Spider ............................................................................................... 2-3 .............. 0145
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DRIVE SHAFTS
3 D
DRIVE SHAFTS 2B P 5S0Fer ies
General
1. GENERAL 1.1 GENERAL INFORMATION -
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Do not use high pressure when lubricating the lubrication The grease gun must be used evenlypoints. 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 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. treatment, the slip joint During anti-corrosion must be completely covered.
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DRIVE SHAFTS
1.2 SERVICE The drive shaft should be inspected according to the intervals below. Service intervals: There should be a small service every 50,000 km or every six months. There should be a large service every 200,000 km or every two years.
1.2.1 Small service 1. Inspect all the joints. Where necessary, retighten the nuts and bolts using a torqu e spanner. 2.
Check whether all the circlips are still in place and are fitted correctly.
3.
Check whether the bearing/coupling components show signs of heating (discolouring of the material or burnt sealing rings).
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.
1. 2. 3. 4. 5. 6.
Drive shaft Yoke Balance plate Welded-up clamps (G.W.B.) Slip joint Drive shaft
If any faults are found when carrying out the points above, the drive shaft should be replaced.
3 D
DRIVE SHAFTS 2B P 5S0Fer ies
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 t he drive shaft axle and, with the other hand, rotate the drive flange. No play must be felt. Do this for bo th 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 t he 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 doe s 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”).
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DRIVE SHAFTS
6.
Check the slip joint’s radial and tangential play.
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Check for tangential play (play between the teeth). Secure the slip joint’s fixed pipe in a workbench with the yoke in a vertical direction. Place a suitable gauge indicator on a flat part and allow the measuring pin to rest against the side of the yoke. Zero the gauge. Turn the yoke tangentially and measure the play on the splines. This must not be greater than 0.2 mm.
a. b.
c.
m m 7 ,1 0
0,2 mm
02381B
7. a. b. c.
d. e.
f.
Check the slip joint’s radial play. Pull the slip joint out about 45 mm. Lay the drive shaft on a flat table with the fixed yokes touching the table. Place a su itable gauge indicator with a magnetic foot just behind the weld on the drive shaft’s pipe. Put the measuring pin just behind the weld on the yoke and zero the gauge. Lift the drive shaft up a little bit in the middle whilst making sure that the yokes remain touching the table. Check the play. It must not be greater than 0.17 mm.
The drive shaft must be replaced completely if the radial or tangential play is too large.
3 D
DRIVE SHAFTS 2B P 5S0Fer ies
8. -
-
General
Check the slip joint’s splines. Remove the grease nipple. Mark the position of both parts of the slip joint in relation to each oth er. Carefully pull the slip joint apart. Check the innermost and outermost splines for damage, signs of heating and wear. Check the O-ring for damage. If there are any faults, replace the O-ring or the complete drive shaft. If there is no damage, lubricate the O-ring and slip joint and push them together (beware of the alignment!). Fit the grease nipple and lubricate the slip joint.
Use a suitable lubricant (see “Technical information”). MoS2 grease must not be used.
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DRIVE SHAFTS
3 D
DRIVE SHAFTS B250PFSer ies
Removalandinstallation
2. REMOVAL AND INS TALL ATION 2.1 REMO VING AND INST ALLING THE DRIV E SHAFT ASSEMBLY When removing thedo drive make sure that you notshaft, put yourself or others in danger. The drive shaft has components that could trap body parts. Always move and store the drive shaft in a horizontal position. This will prevent damage which would make the drive shaft become unbalanced.
Only use srcinal bolts that are of the correct type. Removal 1. Support the shaft in at l east two places. 2.
Remove thepush fixing bolts from the flanges. necessary, the drive shaft’s slip jointIf 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”).
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DRIVE SHAFTS
2.2 DRIVE FLANGE If a flange must be removed that is directly attached to a spider, see the instructions in 2.3. If a flange must be removed that is directly attached to the gear box or rear axle, see the instructions for the removal and installation of the drive flange for the relevant gear box or rear axle.
It must be possible to move the flanges on the spiders by hand after assembly. They must not fall down by themselves.
3 D
DRIVE SHAFTS B250PFSer ies
Removalandinstallation
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.
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.
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DRIVE SHAFTS
8.
Turn the shaft through 180°. Put the shaft back onto the bush.
9.
Push the spider downwards again in t he direction of the shaft’s yoke until the spider touches the yoke.
10. The spid er and the flang e can be tilted out of shaft’s yoke.
11. Clamp th e partly pushed o ut beari ng bush i n a bench vice. 12. Work the yoke upw ards usi ng a tyre l ever. This will make the bearing bush come completely loose so that it can be removed.
13. Repeat p oints 5 to 12 to remove the flan ge from the spider. 14. Check the components that will be reused for cracks and damage. Always replace the spider together with the bearings.
3 D
DRIVE SHAFTS B250PFSer ies
Removalandinstallation
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 b earing pa rtly 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 (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.
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DRIVE SHAFTS
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. See “Drive shaft removal and installation”.
3 D
ANGLE DRIVES 2B5 PS0Feries
C o nt e n ts
CONTENTS
Page
D a te
1. MAINT ENANC E, REP AIR, SP ARE PARTS ANGLE DRIVES W10, W13 FOR DIWA TRANSMISSIONS .......... .........1-1 ......... .... 9901
2. REPAIR MAN UAL SPRIN G COUP LING DIRECT-SEPERATE INSTALLATION ................. ................. ................. ... 2-1 ............. 0201
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ANGLE DRIVES
3 DB 250 PF Series
ANGLE DRIVES
1. MAINTE NANCE, R EPAIR, SPARE PARTS ANGLE DR IVES W10 , W13 FOR DIWA TRANSMISSIONS (G 1230e99)
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ANGLE DRIVES
3 DB 250 PF Series
ANGLE DRIVES
2. REPAIR MANUAL SP RING COUPL ING DIRECT -SEPER ATE INST ALLATION (G 1051gb/2002)
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ANGLE DRIVES
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