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DB 250 PF Series
CONTENTS
0 1 2 3 4
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CONTENTS
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DB 250 PF Series
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DB 250 PF Series
TECHNICAL DATA
Contents
CONTENTS
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Page Date
1. AUTOMATIC GEARBOXES ....................................................................... 1-1 .............. 0145 1.1 Gearbox types .................................................................................. 1-1 .............. 0145 1.2 Capacities, mass, fitting length ....................................................... 1-2 .............. 0145 1.3 Tightening torques ............................................................................ 1-3 .............. 0145 2. DRIVE SHAFTS 2.1 General ............................................................................................. 2-1 .............. 0145 2.2 Tightening torques ............................................................................ 2-2 .............. 0145 2.3 Filling capacities .............................................................................. 2-2 .............. 0145
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TECHNICAL DATA
Contents
DB 250 PF Series
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DB 250 PF Series
TECHNICAL DATA
Automatic gearboxes
1. AUTOMATIC GEARBOXES
1.1 GEARBOX TYPES
0
Engine type
Gearbox types
Voith D851.3
5,20 - 1,05:1
X(1)
X(1) X(2)
Voith D854.3
5,20 - 0,77:1
X(2)
ZF 4 HP 500
3,43 - 1,05:1
X(2)
X(2)
ZF 5 HP 500
3,43 - 0,83:1
X(2)
X(2)
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TECHNICAL DATA
Automatic gearboxes
DB 250 PF Series
1.2
Oil capacity (in litres) Type of gearbox 1e filling Voith D851.3 Voith D854.3 ZF 4HP500 ZF 5HP500 ca. 25-28 ca. 25-28 ca. 30 ca. 30 after extending ca. 20 ca. 20 when changing oil ca. 23-26 ca. 23-26 ca. 15 ca. 15 Mass in kg(1) Fitting length in mm
(1) Weight of transmission + oil cooler dry (2) Depends on type of propeller shaft
1-2
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DB 250 PF Series
TECHNICAL DATA
Automatic gearboxes
1.3
TIGHTENING TORQUES M16 10.9 M16 10.9 M10 10.9 M10 10.9 M10 8.8 M10 10.9 260 20 Nm 260 20 Nm 60 4 Nm 60 4 Nm 46 4 Nm 60 4 Nm
Driveline Silent blocks on flywheel housing Silent blocks on angle drive Vibration damper on flywheel housing Reducing ring on flywheel housing (A) Angle drive on reducing ring (B) Automatic gearbox on angle drive (C)
Plugs Voith DIWA.3E Drain plug oil sump (A) Drain plug torq converter (B) Cover (C) Cover oil filter (D)
50 Nm 50 Nm 25 Nm 25 Nm
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TECHNICAL DATA
Automatic gearboxes
DB 250 PF Series
25 Nm 50 Nm
1-4
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DB 250 PF Series
TECHNICAL DATA
Drive shafts
2. DRIVE SHAFTS
2.1 GENERAL Make: Type: Drive flange Type: Diameter (A) gearbox side: Type: Diameter (B) rear axle side: Angle of flex per universal joint (b): Length (LZ min.): Extension length: Spline diameter (W): Lubricant: Gelenk Wellen Bau 2045 (Compact 2000 series) KV (serrated flange) 155 mm KV (serrated flange) 180 mm max. 25 534 mm 90 mm 68 mm High-temperature grease. -25 to +80 C Specifications according to STANDARD 4006 -005 and Material STD 2953 DIN/ISO-Bez. KP 2N-20 / KP 2P-30 / KP 2P-20
Inspection: There must be no clearly noticeable play on universal joints and sliding joint. Gelenk-Wellen-Bau Balancing speed Radial play universal joints 3000 rpm-1 0.01 - 0.05 mm
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TECHNICAL DATA
Drive shafts
DB 250 PF Series
2.2 TIGHTENING TORQUES Serrated flanges M12 10.9 M14 10.9 Plain flanges M12 10.9 M14 10.9 M16 10.9 105-126 Nm 136-204 Nm 113-127 Nm 178-202 Nm 281-309 Nm The thread must be lightly oiled when fitting the flange bolts. 2.3 FILLING CAPACITIES Grease must be seen to protrude from the spider(s) and sliding sleeve.
2-2
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DB 250 PF Series
DIAGNOSIS
Contents
CONTENTS
Pages
Date
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DIAGNOSIS
Contents
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DB 250 PF Series
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DB 250 PF Series
DIAGNOSIS
Drive shafts
1. DRIVE SHAFTS
1. FAULT-FINDING TABLE
FAULT: DRIVE LINE VIBRATION AT LOW VEHICLE SPEED Possible cause Excessive universal joint angle (for example, caused by excessive caster) Play in universal joints Play in sliding joint Forks not in line Remedy Check the universal joint angle
FAULT: DRIVE LINE VIBRATION AT HIGH VEHICLE SPEED Possible cause Drive shaft imbalance Remedy Balance or replace the drive shafts, if necessary
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DIAGNOSIS
Drive shafts
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DB 250 PF Series
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AUTOMATIC GEARBOXES
Contents
CONTENTS
VOITH DIWA.3 Transmissions 1. 2. 3.
Page
Date
SERVICING ......................................................................................... 1-1................................... 0102 TROUBLE SHOOTING ........................................................................ 2-1................................... 0203 FAULT FINDING .................................................................................. 3-1................................... 0203
ZF-ECOMAT Transmissions 1. REPAIR MANUAL ZF-ECOMAT 2 Stages 1-2 (4149 751 601) ........... 1-1................................... 0103
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AUTOMATIC GEARBOXES
Contents
3
DB 250 PF Series
0145
3
DB 250 PF Series
AUTOMATIC GEARBOXES
Servicing VOITH DIWA.3 Transmissions
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1-1
AUTOMATIC GEARBOXES
Servicing VOITH DIWA.3 Transmissions
3
DB 250 PF Series
1-2
0145
I Press the N key and thus bring the transmission to its neutral position. I Start the engine and let it run at idle speed.
I Withdraw the dipstick from its guide tube and clean it. I Insert the dipstick again briefly to prevent wrong oil level reading by splash
oil.
Note! For silumin heat exchangers: Only use anti-freeze and/or anti-corrosive agents in the cooling water which do not attack light metal (see also "Technical Manuals").
With oil grades according to List of Lubricants 55.6335. ..* (G 607): every 60 000 km, at least every 2 years, however. With oil grades according to List of Lubricants 55.6336. ..* (G 1363): every 120 000 km, at least every 3 years, however.
I Stop the engine. I Remove the drain plug (1) for the oil in the oil pan (allen wrench 12 mm) and
drain the oil.
I Remove the drain plug (2) for the converter oil and drain the oil. The plug is
accessible through the oil pan drain hole.
I Install drain plugs with new copper seals. Tighten drain plug (2) to 50 Nm
and drain plug (1) to 120 Nm. 3
I Remove the drain plug (4) for the filter oil (width across flats 13 resp. 10)
and drain the oil. 4
I Unscrew (width across flats 13) and remove the cover (3).
5
I Replace gasket (7), oil filter element (8) and sealing ring (9). Install gasket
with coated side (white) toward the filter housing. Note! If the used filter element is very dirty, unscrew the oil pan and check the disks!
5 3 4
I Fit cover (3), washers B8.4, spring washers B8 and tighten nuts M8 (6) to
25 Nm.
I Install drain plug (4) with new copper seal and tighten to 15 Nm.
6 7
*Note!
I Measure the oil level, check transmission - especially oil filter - for leaks. I Check the oil hoses (5). Replace if found very porous, cracked or chafed.
With oil grades according to List of Lubricants 55.6335. ..* (G 607): every 60 000 km, at least every 2 years, however. With oil grades according to List of Lubricants 55.6336. ..* (G 1363): every 120 000 km, at least every 3 years, however.
I Stop the engine. I Remove the drain plug (11) for the oil in the oil pan (allen wrench 12 mm)
and drain the oil. 12
I Remove the drain plug (12) for the converter oil and drain the oil. The plug
is accessible through the oil pan drain hole.
11
I Install drain plugs with new copper seals. Tighten drain plug (12) to 50 Nm
and drain plug (11) to 120 Nm.
I Unscrew and remove the access cover (10) of the oil pan (width across
flats 36).
I Unscrew and remove the cover (15) of the integrated oil filter (14) (width
13 across flats 36).
I Install cover (15) with oil filter element (17) and sealing ring (18) and tighten
to 25 Nm.
I Install access cover (10) with new sealing ring (16) and tighten to 25 Nm. I Fill in transmission oil.
Only use oils tested by Voith and approved in the Lists of Lubricants 55.6335. .. (G 607) and 55.6336. .. (G 1363), respectively! Quantity: Approx. 21 - 23 liters (approx. 25 - 28 liters for first filling). The dipstick reading counts in any case!
*Note!
I Measure the oil level, check transmission - especially the cover (10) of the
oil pan - for leaks. 17
I Check the oil hoses (13). Replace if found very porous, cracked or chafed.
18 15
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DB 250 PF Series
AUTOMATIC GEARBOXES
Trouble shooting VOITH DIWA.3 Transmissions
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2-1
AUTOMATIC GEARBOXES
Trouble shooting VOITH DIWA.3 Transmissions
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DB 250 PF Series
2-2
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DB 250 PF Series
AUTOMATIC GEARBOXES
Fault finding VOITH DIWA.3 Transmissions
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3-1
AUTOMATIC GEARBOXES
Fault finding VOITH DIWA.3 Transmissions
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DB 250 PF Series
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Important information
Note! in conjunction with the symbol on the right denotes information that is particularly important.
Additional notes
When replacing parts, always pay attention to the instructions in the spare parts catalog! Design improvements which should be taken into account during transmission overhauls are described in detail in the "Customer service letters". Furthermore, all work must be performed in accordance with Voith requirements to prevent damage to parts and tools.
'BVMU 'JOEJOH
What is it for? The manual serves the following purposes: n Support for commissioning, maintenance and repair work, n it lists the possible causes of faults in DIWA.3 and DIWA.3E transmissions and tasks for further testing, fault finding and removal. Additionel DIWA.3 and DIWA.3E documentation The following publications are available for transmission description, design, installation, the main tasks of maintenance and repair, etc.: Brochure Part No. for transmission DIWA.3 DIWA.3E All DIWA All DIWA DIWA.3, DIWA.3E DIWA.3, DIWA.3E D 851.3E D 854.3E D 863.3E D 864.3E DIWA.3, DIWA.3E DIWA.3 DIWA.3E DIWA.3 DIWA.3E Purpose Function description of the transmission, transmission data, installation instructions, design and dimensional data for transmission assemblies Maintenance of DIWA transmissions List of the lube oils that are approved by Voith for DIWA transmissions Brief description of transmission operation for the bus driver Use of the Voith PC-based diagnostic program DIWAGNOSIS Illustration and designation of transmission parts for spare parts ordering Detection of defective electrical components or assemblies using the PC diagnostic program Description of transmission disassembly and assembly of 3- and 4speed transmissions Representation of the oil circuits for the various transmission gear shifts
Technical Manual
55.6355. .. 55.6357. ..
55.6374. .. 55.6335. .. 55.6336. .. 55.6291. .. 55.6264. .. 55.6600. .. 55.6601. .. 55.6602. .. 55.6603. .. 55.6293. ..
Trouble Shooting
Repair Manual
55.6320. .. 55.6704. ..
Technical Description 55.6309. .. with Oil and Control Cir55.6311. .. cuit Diagrams
All of the above brochures are available from department "ant" or "anv". This documentation is protected by copyright Subject to change Who is it for? n Service technicians (e.g. testing, acceptance, etc.) n Automobile mechanics and electricians
II Voith. Fault Finding DIWA.3, DIWA.3E
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
Diagnostic Manual
Tracing of possible faults in the electrical system of DIWA.3 and DIWA.3E transmissions: Trouble Shooting
Transmission repair and spare parts ordering: Repair Manual, Spare Parts Catalogs
III
5BCMF PG DPOUFOUT
Page Differences concerning the symptoms of transmission malfunctions in DIWA.3E and DIWA.3 1. General recommendations ...................................................................................................................... 1 First check in case of faults.................................................................................................................. 1 Continued operation possible............................................................................................................... 1 Emergency operation possible............................................................................................................. 1 Towing.................................................................................................................................................. 1 2. Faults with vehicle stopped ..................................................................................................................... 3 ANS activation without effect ............................................................................................................... 3 3. Faults on engagement of gears .............................................................................................................. 5 3.1 After engagement of a forward (V) or reverse gear (R) and releasing the parking brake, the vehicle does not move - engine revs up to max. speed when accelerating......................... 5 3.2 After engagement of the R gear and releasing the parking brake, the vehicle does not move- but transmission function is normal when engaging a F gear........ 6 3.3 After engaging the R gear and releasing the parking brake, the bus e.g. first rolls forward, then backward or vice versa, or no vehicle movement............. 7 3.4 Vehicle jerks after engagement of neutral - 1st gear or neutral - R gear ................................... 8 8.3 When starting uphill: after engaging of a F gear, release of parking brake and accelerating, the bus rolls backward ........................................... 8 4. Faults while driving................................................................................................................................ 11 4.1 Poor acceleration in all gears................................................................................................... 11 4.2 Poor acceleration in 1st gear, but normal in 2nd and 3rd gear ................................................ 11 4.3 Transmission shifts to 2nd gear with button 1 pressed............................................................ 12 4.4 Braking too strong with accelerator pedal released ................................................................. 12 4.5 Transmission does not shift to 2nd gear - operation only possible in 1st gear ........................ 13 4.6 Transmission shifts to 2nd gear, but no power transmission ................................................... 13 4.7 Poor acceleration after shifting to 2nd gear, but normal in 1st gear ........................................ 14 4.8 Transmission does not shift to 3rd gear - operation only possible in 1st and 2nd gear ........... 14 4.9 Poor acceleration after shifting to 3rd gear, but normal in 1st and 2nd gear ........................... 15 4.10 For 4-gear transmissions: transmission does not shift to 4th gear, operation only possible in 1st, 2nd and 3rd gear ..................................................................... 15 4.11 Poor acceleration after shifting to 4th gear, but normal in 1st, 2nd and 3rd gear .................... 16 4.12 Kickdown shifting not possible ................................................................................................. 16 4.13 Engine stalls in reverse gear.................................................................................................... 17 4.14 Transmission does not shift up, but back to 1st gear and stays there ..................................... 17 4.15 Transmission shifts to neutral while driving ............................................................................. 17 4.16 Hard shifting from 1st to 2nd gear............................................................................................ 18 4.17 Hard shifting from 2nd to 3rd gear ........................................................................................... 18 4.18 For 4-gear transmissions: hard shifting from 3rd to 4th gear ................................................... 19
IV
5. Faults while braking with the converter brake ....................................................................................... 21 5.1 The converter brake does not operate in all F gears via service (foot) and hand brake switch ................................................................................. 21 5.2 The converter brake does not operate in 1st gear via service and hand brake switch........................................................................................... 22 5.3 The converter brake does not operate in 1st, 2nd, 3rd and 4th gear via service and hand brake switch........................................................................................... 22 5.4 One of the 3 or all brake stages of the converter brake does not operate via service brake switch (brake pedal)..................................................................................... 23 5.5 One of the 3 or all brake stages of the converter brake does not operate via the 3-stage hand brake switch (manual switch) ................................................................. 23 5.6 For one-stage hand brake switch (manual switch): stage 2 or 3 of the converter brake does not operate.............................................................. 23 5.7 For DIWA.3: In 2nd, 3rd or 4th gear: hard activation of converter brake ................................. 24 5.8 For DIWA.3: In 2nd, 3rd or 4th gear: brake force in stage I too high ....................................... 25 5.9 For DIWA.3: In 2nd, 3rd or 4th gear: brake force in brake stage II or III too low or too high ................................................................................................................... 25 5.10 For DIWA.3E: In 2nd, 3rd or 4th gear: hard activation of converter brake............................... 26 5.11 For DIWA.3E: In 2nd, 3rd or 4th gear: brake force in stage I too high..................................... 27 5.12 For DIWA.3E: In 2nd, 3rd or 4th gear: brake force in brake stage II or III too low or too high ................................................................................................................... 27 5.13 In 1st gear drive range: brake force in brake stage II or III too low or too high........................ 28 6. Faults in warning lamps, relays or switches.......................................................................................... 29 6.1 The central warning lamp (ZW) does not light after turning on the ignition ............................. 29 6.2 The pushbutton lighting (TL) does not light after turning on the ignition.................................. 29 6.3 The warning lamp tranmission oil temprature (TOEL) does not light after turning on the ignition ...................................................................................................... 29 6.4 Consumer via relays - converter brake (dW), reversing lamp (dR) or speed (dN) - cannot be activated........................................................ 29 7. Measuring devices ................................................................................................................................ 31 8. Checking oil pressures.......................................................................................................................... 33 8.1 Operating pressure .................................................................................................................. 33 8.2 Converter pressure .................................................................................................................. 34 9. Testing the motor control / transmission interface ................................................................................ 35 9.1 Engine idle speed .................................................................................................................... 35 9.2 Test: load transmitter signals as function of accelerator pedal position .................................. 35 9.3 Test: rated engine torque as function of load stage or engine speed...................................... 37 10. Appendices .......................................................................................................................................... 39 1 hydraulic control diagram DIWA.3, 1 hydraulic control diagram DIWA.3E, 1 circuit diagram DIWA.3, 1 circuit diagram DIWA.3E
T DIBQU DIBQU DIBQU TFF DIBQUFS TFF BQQFOEJDFT JO DIBQUFS
VI
(FOFSBM SFDPNNFOEBUJPOT
First check in case of faults
I By means of the Voith diagnostic program. Its use is described in the Diagnostic Manual.
Towing
Note! In order to prevent damage to the DIWA transmission when the vehicle is towed, the following must be observed: I Set the transmission to neutral and screw off plug from the transmission or electronic control unit. I In case of transmission damage: remove cardan shaft or stub shaft of rear axle. I If there is no transmission damage the vehicle can be towed with the cardan shaft installed, yet only up to a distance of 10 km. The maximum towing speed is 30 km/h.
Possible cause
Check / remedy
No release of ANS activation by control unit 1. Inductive pick-up N2, connector or connecting cable defective. 2a. Control unit does not receive L0 signal. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 2b. Control unit does not receive L0 signal. For E-Gas systems: faulty assignment of accelerator pedal position and load transmitter level. 3a. No signal from pressure switch for ANS activation (BS): switch, connector or connecting cable defective. 3b. If provided: stop brake (HSB) relay, switch, connector or connecting cable defective. 3c. No signal from service (foot) brake switch (FB): one of the 3 microswitches, connector or connecting cable defective. 4. Pushbutton switch (TS), connector or connecting cable defective. Check inductive pick-up, connector and connecting cable, repair or replace, if required. Check and adjust connection, if required. %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ / 4FF DIBQUFS %JBHOPTUJDT GVODUJPO &
1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. Check switch, connector or connecting cable and repair or replace, if required. Check relay, switch, connector or connecting cable and repair or replace, if required. Check switch at brake, connector or connecting cable and repair or replace, if required. Check switch, connector or connecting cable and repair or replace, if required.
%JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO ) 5S 4IPPU DIBQUFS QSFTT TX "/4 BDUJWBUJPO %JBHOPTUJDT GVODUJPO ) 5S 4IPPU DIBQUFS TUPQ CSBLF %JBHOPTUJDT GVODUJPO ' 5S 4IPPU DIBQUFS CSBLF WBMWF %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
Possible cause
Check / remedy
Input clutch (EK) does not open Field coil or one of the spools of the EK solenoid valve, connector or connecting cable defective. 1. Check oil pressure at EK connection (measuring cover): pArequd = 0 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required. %JBHOPTUJDT GVODUJPOT ( * 5S 4IPPU DIBQUFS &, TPMFOPJE
For ANS activation without stop brake (HSB): roll-back safety (simultaneous switching of turbine brake TB and reverse gear brake RB) without effect Field coil or one of the spools of solenoid valves TB or RBK, connector or connecting cable defective. 1. Check operating resp. converter pressure at connections TB and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required. 'PS TFUQPJOUT TFF DIBQUFS %JBHOPTUJDT GVODUJPOT ( * 5S 4IPPU DIBQUFS 5# PS 3#, TPMFOPJE
Possible cause
Check / remedy
Control unit E 200 is not supplied with voltage - transmission remains in neutral Fuse 8A for line +UZ, connector or connecting cable defective. Check fuse, connector and cable, repair or replace, if required. %JBHO EJTQMBZ DPNNVOJ DBUJPOT OPU FTUBCMJTIFE 5S 4IPPU DIBQUFS DPOUSPM VOJU WPMUBHF
Solenoid valves without voltage dS relay "control", connector or connecting cable defective. Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT EJTQMBZ E4 SFMBZ XJUIPVU WPMUBHF 5S 4IPPU DIBQU WPMUBHF
Input clutch (EK) does not close 1. Idle speed N1 too high. 1. Check idle speed setpoint: n 850 rpm (for gas engine: n 1000). 2. If required, adjust idle speed. Check switch, connector and cable, repair or replace, if required. 1. Check oil pressure at EK connection (measuring cover): pArequd 3.5 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required. Check switch, connector and cable, repair or replace, if required. Note! EK closes when load transmitter operated! Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS PVUQVU E/&653 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO * %JBHOPTUJDT GVODUJPO ) 5S 4IPPU DIBQUFS HFBS TBGFUZ QSFTTVSF TXJUDI 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS &, TPMFOPJE %JBHOPTUJDT GVOUJPO ) 5S 4IPPU DIBQUFS QSFTT TX "/4 BDUJWBUJPO
2. Gear safety pressure switch (ABSICH) is not activated for pressure > 3 bar, connector or connecting cable defective. 3. Field coil or one of the spools of the EK solenoid valve, connector or connecting cable defective.
4. Transmission with ANS activation: pressure switch for ANS activation (BS), connector or connecting cable defective. Note! Switch may only be closed when the brake device is operated! 5. Bus with gas engine: relay dNEUTR, connector or connecting cable defective. Note! Idle seed is reached after the transmission was in neutral for some time!
Possible cause
Check / remedy
Disks of input clutch (EK) slip 1. Operating pressure too low. Check operating pressure: pArequd 3.5 bar. Adjust pressure, if required. 1. Check oil pressure at EK connection (measuring cover): pArequd 3.5 bar. 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT T DIBQU %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS &, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. EK solenoid valves hard to move or stuck, e.g. by soiling of a spool or the field coil.
3. Oil pressure after EK solenoid valve too low: oil supply reduced or interrupted. 4. EK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Pushbutton switch not ready to operate Pushbutton switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
3.2 After engagement of the R gear and releasing the parking brake, the vehicle does not move - but transmission function is normal when engaging a F gear
No release of reverse gear by the control unit 1. Inductive pick-up N1 or N2, connector or connecting cable defective. 2. Field coil of solenoid valves RBG or RGK, connector or connecting cable defective. Note! if RBG is defective, the R gear is left after approx. 1 sec.! Check inductive pick-up, connector and connecting cable and repair or replace, if required. Check solenoid valves, connectors and cables and repair or replace, if required. 1. Diagnostics: function J, 2. Tr. Shoot., chapter 2.1/2: inductive pick-up N1 or N2 %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQ 3#( PS 3#, TPMFOPJE
Possible cause
Check / remedy
Transmission with inhibiting switch for reverse gear (SPERR): switch not closed 1. Inhibiting switch not operated. 2. Switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
Pushbutton not ready to operate Pushbutton switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $ 5S 4IPPU DIBQUFS QVTICVUUPO TXJUDI
Reverse gear brake (RB) does not close RBG or RBK solenoid valve hard to move or stuck, e.g. by soiling of a spool or field coil. 1. Check operating resp. converter pressure at connections RBG and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required. 'PS TFUQPJOUT T DI %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQU 3#( PS 3#, TPMFOPJE
Converter pressure too low 1. Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required. If required, disassemble and repair converter outlet valve. Check converter seal and repair, if required. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check converter filling valve and repair or replace, if required. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. Check breather valve and repair or replace, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T DIBQUFS %BHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 83 TPMFOPJE 3FQBJS .BOVBM $VTU 4FSW -FUUFS OP 3FQBJS .BOVBM 'PS TFUQPJOUT TFF BMTP DIBQUFS 3FQBJS .BOVBM 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T DIBQUFS 3FQBJS .BOVBM
2. One of the control spools of the converter outlet valve hard to move or stuck. 3. Converter leaks. 4. Only for DIWA.3E: The converter inlet valve hard to move or stuck, valve does not open properly.
5. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
Possible cause
Check / remedy
3.3 After engaging the R gear and releasing the parking brake, the bus e.g. first rolls forward, then backward or vice versa, or no vehicle movement
Disks of reverse gear brake (RB) slip 1. Operating pressure too low. Check operating pressure: pArequd 3.5 bar. Adjust pressure, if required. 1. Check operating resp. converter pressure at connections RBG and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required. 1. Check pressure as disribed above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT
TFF BMTP DIBQUFS 'PS TFUQPJOUT
TFF DIBQUFS %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQU 3#( PS 3#, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
4FSWJDJOH 4DIFEVMF
-JTUT PG -VCSJDBOUT
2. RBG or RBK solenoid valve hard to move or stuck, e.g. by soiling of a spool or field coil.
3. Oil pressure after solenoid valve RBG or RBK too low: oil supply reduced or interrupted. 4. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
Service (foot) brake switch (FB) for converter brake on unintentionally One of the 3 microswitches, connector or connecting cable defect. Check switch at brake, connector or connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO ' 5S 4IPPU DIBQUFS CSBLF WBMWF
3.4 Vehicle jerks after engagement of neutral - 1st gear or neutral - R gear
Input clutch (EK) closes too hard - oil pressure fault before EK 1. One of the coils or spools of the EK solenoid valve, connector or connecting cable defective. 2. EK solenoid valve hard to move, e.g. due to pollution of a spool or the field coil. 3. EK disks damaged - possibly by used, polluted, wrong or too little transmission oil. Check solenoid valve, connector and cable and repair or replace, if required. Repair or replace solenoid valve. Replace disks, replenish or change oil. %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS &, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
4FSWJDJOH 4DIFEVMF
-JTUT PG -VCSJDBOUT
Possible cause
Check / remedy
3.5 When starting uphill: after engaging of a F gear, release of parking brake and accelerating, the bus rolls backward
Insufficient tractive power Accelerator pedal not depressed enough.
Roll-back safety fails Field coil or one of the spools of solenoid valves TB or RBK, connector or connecting cable defective. 1. Check operating resp. converter pressure at connections TB and RBK (measuring cover). 2. Check solenoid valves, connectors and cables and repair or replace, if required. 'PS TFUQPJOUT T DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQU 5# PS 3#, TPMFOPJE
Converter pressure too low 1. One of the control spools of the converter outlet valve hard to move or stuck. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. If required, disassemble and repair converter outlet valve. Check converter seal and repair, if required. Check converter filling valve and repair or replace, if required. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. Check breather valve and repair or replace, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU TFF BMTP DIBQU 3FQBJS .BOVBM $VTU 4FSW -FUUFS OP 3FQBJS .BOVBM 3FQBJS .BOVBM
2. Converter leaks. 3. Only for DIWA.3E: The converter filling valve hard to move or stuck, valve does not open properly. 4. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T DIBQUFS 3FQBJS .BOVBM
10
Possible cause
Check / remedy
4.2 Poor acceleration in 1st gear, but normal in 2nd and 3rd gear
Converter pressure too low - engine speed in 1st gear too high with respect to speed 1. One of the control spools of the converter outlet valve hard to move or stuck. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. If required, disassemble and repair converter outlet valve. Check converter seal and repair, if required. Check converter filling valve and repair or replace, if required. 1. Check converter pressure pW at measuring point (fig. 6/2): pWrequd 2 bar. 2. Check breather valve and repair or replace, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU
TFF BMTP DIBQU 3FQBJS .BOVBM $VTU 4FSW -FUUFS OP
3FQBJS .BOVBM 3FQBJS .BOVBM
2. Converter leaks. 3. Only for DIWA.3E: The converter filling valve hard to move or stuck, valve does not open properly. 4. Only for DIWA.3E: The breather valve hard to move or stuck, valve does not close properly.
'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T DIBQUFS 3FQBJS .BOVBM
11
Possible cause
Check / remedy
Turbine brake (TB) does not close - engine speed is greatly decreased Field coil or one of the spools of solenoid valve TB, connector or connecting cable defective. 1. Check operating resp. converter pressure at connection TB (measuring cover). 2. Check solenoid valve, connector and cable and repair or replace, if required. 'PS TFUQPJOUT TFF DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 5# TPMFOPJE
Turbine brake (TB) disks slip 1. Operating pressure too low. Check operating pressure: pArequd 8.3 bar. Adjust pressure, if required. 1. Check operating resp. converter pressure at connection TB (measuring cover). 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT T DIBQ %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 5# TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. TB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
3. Oil pressure after TB solenoid valve too low: oil supply reduced or interrupted. 4. TB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
12
Possible cause
Check / remedy
4.5 Transmission does not shift to 2nd gear - operation only possible in 1st gear
Automatic shift from 1st to 2nd gear inhibited 1. Pushbutton 1 (5 or 6-pushbutton switch) depressed. 2. Pushbutton switch (e.g. continuous current terminal S1, although button 1 not pressed), connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $
5S 4IPPU
DIBQUFS QVTICVUUPO TXJUDI
No signal regarding vehicle speed Inductive pick-up N2, connector or connecting cable defective. Check inductive pick-up N2, connector and connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ /
Wrong power transmitter signals - engine does not reach full power 1a. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 1b. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level. Check connection and adjust, if required. 1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 4FF DIBQUFS %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO &
13
Possible cause
Check / remedy
Pump brake (PB) disks slip - engine speed is greatly reduced 1. Operating pressure too low. Check operating pressure: pArequd 8.3 bar. Adjust pressure. 1. Check oil pressure at PB connection (measuring cover): pArequd 8.3 bar. 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT TFF BMTP DIBQUFS 'PS TFUQPJOUT T DIBQU %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 1# TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT
2. PB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
3. Oil pressure after PB solenoid valve too low: oil supply reduced or interrupted. 4. PB disks damaged - possibly by used, polluted, wrong or too little transmission oil.
4.7 Poor acceleration after shifting to 2nd gear, but normal in 1st gear
TB solenoid valve does not open - turbine brake remains closed. Field coil or one of the spools of solenoid valve TB, connector or connecting cable defective. 1. Check oil pressure at TB connection (measuring cover): pArequd = 0 bar. 2. Check solenoid valve, connector and cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO ( 5S 4IPPU
DIBQUFS 5# TPMFOPJE
14
Possible cause
Check / remedy
4.8 Transmission does not shift to 3rd gear - operation only possible in 1st and 2nd gear
Automatic shifting from 2nd to 3rd gear inhibited 1. Pushbutton 2 (4, 5 or 6-pushbutton switch) depressed. 2. Pushbutton switch, connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $
5S 4IPPU
DIBQUFS QVTICVUUPO TXJDI
Lock-up clutch (DK) does not close Field coil or one of the spools of the DK solenoid valve, connector or connecting cable defective. 1. Check oil pressure at DK connection: pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace. 'PS TFUQPJOUT T DIBQ %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS %, TPMFOPJE
4.9 Poor acceleration after shifting to 3rd gear, but normal in 1st and 2nd gear
Lock-up clutch (DK) disks slip 1. Operating pressure too low. Check operating pressure: pArequd 8.3 bar. Adjust pressure, if required. 1. Check oil pressure at DK connection (measuring cover): pArequd 8.3 bar. 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT
TFF BMTP DIBQUFS 'PS TFUQPJOUT
T DIBQU %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS %, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
4FSWJDJOH 4DIFEVMF
-JTUT PG -VCSJDBOUT
2. DK solenod valve hard to move or stuck, e.g. by pollutionof a spool or the field coil.
3. Oil pressure after DK solenoid valve too low: oil supply reduced or interrupted. 4. DK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
15
Possible cause
Check / remedy
4.10 For 4-gear transmissions: transmission does not shift to 4th gear, operation only possible in 1st, 2nd and 3rd gear
Automatic shifting from 3rd to 4th gear inhibited 1. Pushbutton 3 of 6-pushbutton switch depressed. 2. Pushbutton switch (e.g. continuous current terminal S3, although button 3 not pressed), connector or connecting cable defective. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $
5S 4IPPU
DIBQUFS QVTICVUUPO TXJUDI
Fast gear clutch (SK) does not close Field coil or one of the spools of solenoid valve DK, connector or connecting cable defective. 1. Check oil pressure at SK connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 4, TPMFOPJE
4.11 Poor acceleration after shifting to 4th gear, but normal in 1st, 2nd, and 3rd gear
Fast gear clutch (SK) disks slip 1. Operating pressure too low. Check operating pressure: pArequd 8.3 bar. Adjust pressure, if required. 1. Check operating at SK connection (measuring cover): pArequd 8.3 bar. 2. Repair or replace solenoid valve. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Replace disks, replenish or change oil. 'PS TFUQPJOUT
TFF BMTP DIBQUFS 'PS TFUQPJOUT
T DIBQU %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS 4, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
4FSWJDJOH 4DIFEVMF
-JTUT PG -VCSJDBOUT
2. SK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
3. Oil pressure after SK solenoid valve too low: oil supply reduced or interrupted. 4. SK disks damaged - possibly by used, polluted, wrong or too little transmission oil.
16
Possible cause
Check / remedy
No load transmitter signal - load transmitter stage L7 is not reached 1a. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 1b. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level. Check connection and adjust, if required. 1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 4FF DIBQUFS %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO &
2. One of the control spools in the converter outlet valve hard to move or stuck.
4.14 Transmission does not shift up, but back to 1st gear and stays there
No signal regarding vehicle speed Inductive pick-up N2, connector or connecting cable defective. Check inductive pick-up N2, connector and connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO +
5S 4IPPU
DIBQUFS JOEVDUJWF QJDLVQ /
17
Possible cause
Check / remedy
Solenoid valves without voltage dS relay "control", connector or connecting cable defective. Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT EJTQMBZ E4 SFMBZ XJUIPVU WPMUBHF 5S 4IPPU DIBQUFS TPMFOPJE WBMWF WPMUBHF
18
Possible cause
Check / remedy
4.18 For 4-gear transmissions: hard shifting from 3rd to 4th gear
Fast gear clutch (SK) closes too hard - oil pressure fault in front of SK 1. One of the coils or spools of the SK solenoid valve, connector or connecting cable defective. 2. SK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 3. SK disks damaged - possibly by used, polluted, wrong or too little transmission oil. 4. Inductive pick-up N1, connector or connecting cale defective. Check solenoid valve, connector and cable, repair or replace, if required. Repair or replace solenoid valve. Replace disks, replenish or change oil. Check inductive pick-up, connector and connecting cable and repair or replace, if required. %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS 4, TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
4FSWJDJOH 4DIFEVMF
-JTUT PG -VCSJDBOUT %JBHOPTUJDT GVODUJPO +
5S 4IPPU
DIBQUFS JOEVDUJWF QJDLVQ /
19
20
Possible cause
Check / remedy
No release of converter brake by control unit 1. ABS active. 2a. Control does not receive L0 signal. For VDO or Voith load transmitter: connection between injection pump and load transmitter set improperly. 2b. Control does not receive L0 signal. For E-Gas systems: engine power restricted due to faulty assignment of accelerator pedal position and load transmitter level. 3. Field coil of solenoid valves PB, WP or RBK, connector or connecting cable defective. Check connection and adjust, if required. 4FF DIBQUFS %JBHOPTUJDT GVODUJPO &
1. Check control unit item number (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. Check solenoid valves, connectors and cables, repair or replace, if required.
%JBHOPTUJDT GVODUJPO " TFF DIBQUFS BOE %JBHOPTUJDT GVODUJPO & %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS TPMFOPJET
21
Possible cause
Check / remedy
5.2 The converter brake does not operate in 1st gear via service and hand brake switch
Converter brake not released by control unit 1. See chapter 5.1. 2. Converter brake was activated in 1st gear (it is possible for some versions). Converter brake must already have been activated in 2nd, 3rd or 4th gear.
Turbine (TB) or reverse gear brake (RB) does not close 1. Coil or one of the spools of the TB solenoid valve, connector or connecting cable defective. 1. Check operating resp. converter pressure at TB connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 5# TPMFOPJE 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 3#, TPMFOPJE
2. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
5.3 The converter brake does not operate in 1st, 2nd, 3rd and 4th gear via service and hand brake switch
Converter brake not released by control unit See chapter 5.1.
Pump (PB) or reverse gear brake (RB) does not close 1. PB solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check oil pressure at PB connection: pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check operating resp. converter pressure at RBG connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 1# TPMFOPJE 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( * 5S 4IPPU DIBQUFS 3#( TPMFOPJE
2. Coil or one of the spools of the RBG solenoid valve, connector or connecting cable defective.
22
Possible cause
Check / remedy
5.4 One of the 3 or all brake stages of the converter brake does not operate via service brake switch (brake pedal)
Switch not operated or defective 1. Converter brake deactivated by the OFF switch for activation by the brake pedal (FBAUS). 2. Switch, connector or connecting cable defective. 3. One of the 3 microswitches in the service brake switch (FB), connector or connective cable defective. Indicator lamp (if installed) at the manual switch is not lit when the service brake switch is operated. Check switch, connector and cable, repair or replace, if required. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO )
5S 4IPPU
DIBQUFS DPOWFSUFS CBLF 0'' TXJUDI %JBHOPTUJDT GVODUJPOT '
5S 4IPPU
DIBQUFS TFSWJDF CSBLF TXJUDI
5.5 One of the 3 or all brake stages of the converter brake does not operate via the 3-stage hand brake switch (manual switch)
One of the 3 sliding contacts in the hand brake switch (HB), connector or connecting cable defective.
5.6 For one-stage hand brake switch: stage 2 or 3 of the converter brake does not operate
23
Possible cause
Check / remedy
5.7 For DIWA.3 in 2nd, 3rd, or 4th gear: hard activation of converter brake
Converter pressure uncontrolled or too high 1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Disassemble converter outlet valve and repair, if required. 'PS TFUQPJOUT
TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
2. Oil pressure after WP solenoid valve too low: WP oil supply reduced or interrupted. 3. One of the control spools in converter outlet valve hard to move or stuck.
Reverse brake (RB) closes too hard - oil pressure fault before RBK 1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. Replace disks, replenish or change oil. Check inductive pick-up, connector and connecting cable and repair or replace, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 3#, TPMFOPJE 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ / PS / %JBHOPTUJDT GVODUJPOT " *
2. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil. 3. Inductive pick-up N2 or N3, connector or connecting cable defective. 4. Wrong control unit.
24
Possible cause
Check / remedy
5.8 For DIWA.3 in 2nd, 3rd, or 4th gear: brake force in brake stage I too high
Converter pressure too high 1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. Disassemble converter outlet valve and repair, if required. 'PS TFUQPJOUT
TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM 3FQBJS .BOVBM
2. Oil pressure after WP solenoid valve too low: WP oil supply reduced or interrupted. 3. One of the control spools in converter outlet valve hard to move or stuck.
5.9 For DIWA.3 in 2nd, 3rd, or 4th gear: brake force in brake stage II or III too low or too high
Converter pressure too high or too low 1a. Brake force too low: Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective. 1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check solenoid valve, connector and cable, repair or replace, if required. Check oil-supplying componets and repair or replace, if required. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. Check oil-supplying componets and repair or replace, if required. Disassemble converter outlet valve and repair, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU
TFF BMTP DIBQ %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS 83 TPMFOPJE 3FQBJS .BOVBM
1b. Brake force too low: Oil pressure after WR solenoid valve too low because oil supply is reduced or interrupted. 2a. Brake force too high: WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil.
'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM
2b. Brake force too high: Oil pressure after WP solenoid valve too low because oil supply is reduced or interrupted. 3. One of the control spools in converter outlet valve hard to move or stuck. 4. Wrong control unit.
25
Possible cause
Check / remedy
5.10 For DIWA.3E in 2nd, 3rd, or 4th gear: hard activation of converter brake
In 3rd and perhaps 4th gear and at high speeds: Converter filling control (CFC) malfunction - converter pressure too high 1. WP solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil and doesn't close correcly. (High speed means: transmission output speed is higher than the limit set for activation of converter filling control, e. g. about 2000 to 2200 rev/ min in 4th gear). 1. Check oil pressure at WP connection (measuring cover): pArequd = 0 bar. 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check pressure as discr. above. 2. Check converter filling valve and repair or replace, if required. 1. Check converter pressure at measur. point (6/2): pWrequd = 0 bar. 2. Check breather valve and repair or replace, if required. 4FF 0JM BOE $POUSPM $JSDVJU %JBHSBNT GPS %*8"& BCPVU UIF $'$
'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 81 TPMFOPJE 3FQBJS .BOVBM 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T BMTP DIBQUFS 3FQBJS .BOVBM
2. Converter filling valve hard to move or stuck and doesn't close correcly. 3. Breather valve hard to move or stuck and doesn't open correcly.
In 2nd, 3rd, and perhaps 4th gear and at all speeds: Converter pressure too high One of the control spools in converter outlet valve hard to move or stuck. Disassemble converter outlet valve and repair, if required. 3FQBJS .BOVBM
In 2nd, 3rd, and perhaps 4th gear and at all speeds: Reverse brake (RB) closes too hard - oil pressure fault before RBK 1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace. Replace disks, replenish or change oil. Check inductive pick-up, connector and connecting cable and repair or replace, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO ( 5S 4IPPU DIBQUFS 3#, TPMFOPJE 3FQBJS .BOVBM 4FSWJDJOH 4DIFEVMF -JTUT PG -VCSJDBOUT %JBHOPTUJDT GVODUJPO + 5S 4IPPU DIBQUFS JOEVDUJWF QJDLVQ / PS / %JBHOPTUJDT GVODUJPOT " *
2. RB disks damaged - possibly by used, polluted, wrong or too little transmission oil. 3. Inductive pick-up N2 or N3, connector or connecting cable defective. 4. Wrong control unit.
26
Possible cause
Check / remedy
5.11 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake stage I too high
Converter pressure too high One of the control spools in converter outlet valve hard to move or stuck. Disassemble converter outlet valve and repair, if required. 3FQBJS .BOVBM
5.12 For DIWA.3E in 2nd, 3rd, or 4th gear: brake force in brake stage II or III too low or too high
Converter pressure too high or too low 1a. Brake force too low: Field coil or one of the spools of the WR solenoid valve, connector or connecting cable defective. 1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check solenoid valve, connector and cable, repair or replace, if required. Check oil-supplying componets and repair or replace, if required. 1. Check oil pressure at WP connection (measuring cover): pArequd 8.3 bar. 2. Check converter filling valve and repair or replace, if required. 1. Check converter pressure pW at measuring point (fig. 6/2). 2. Check breather valve and repair or replace, if required. Disassemble converter outlet valve and repair, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU
TFF BMTP DIBQ %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS 83 TPMFOPJE 3FQBJS .BOVBM
1b. Brake force too low: Oil pressure after WR solenoid valve too low because oil supply is reduced or interrupted. 1c. Brake force too low: Converter filling valve hard to move or stuck and doesnt open correcly.
'PS TFUQPJOUT TFF BMTP DIBQUFS 3FQBJS .BOVBM 'PS TFUQPJOUT BOE NFBTVS JOH QPJOU T BMTP DIBQUFS 3FQBJS .BOVBM 3FQBJS .BOVBM %JBHOPTUJDT GVODUJPOT " *
1d. Brake force too low: Breather valve hard to move or stuck and doesnt close correcly.
2. One of the control spools in converter outlet valve hard to move or stuck. 3. Wrong control unit.
27
Possible cause
Check / remedy
5.13 In 1st gear range: brake force in brake stage II or II too low or too high
RBK oil pressure too low or too high 1. RBK solenoid valve hard to move or stuck, e.g. by pollution of a spool or the field coil. 1. Check operating resp. converter pressure at RBK connection (measuring cover). 2. Check solenoid valve, connector and cable, repair or replace, if required. 1. Check pressure as discr. above. 2. Check oil-supplying components and repair or replace, if required. 1. Check item number of control unit (compare transmission type to control unit nameplate). 2. Check assignment. 3. Replace control unit, if required. 'PS TFUQPJOUT
TFF BMTP DIBQUFS %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS 3#, TPMFOPJE 3FQBJS .BOVBM %JBHOPTUJDT GVODUJPOT "
*
2. Oil pressure after RBK solenoid valve too low: RBK oil supply reduced or interrupted. 3. Wrong control unit.
28
Possible cause
Check / remedy
6.2 The pushbutton switch lighting (TL) does not light after turning on the ignition
1. For single pushbutton: lamp defective. 2. Pushbutton switch (e.g. terminal TL without voltage), connector or connecting cable defect. Check switch, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO $
5S 4IPPU
DIBQUFS QVTICVUUPO TXJUDI
6.3 The warning lamp transmission oil temperature (TOEL) does not light after turning on the ignition (TOEL is energized a few seconds for test purposes)
Lamp, connector or connecting cable defect. Check lamp, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQU USBOTNJTTJPO PJM XBSO MBNQ
6.4 Consumer via relays - converter brake (dW), reversing lamp (dR) or speed (dN) - cannot be activated
1. Consumer not activated in record. 2. Consumer defective. 3. Relay dW, dR or dN, connector or connecting cable defect. Load correct record. Repair or replace consumer. Check relay, connector and cable, repair or replace, if required. %JBHOPTUJDT GVODUJPO (
5S 4IPPU
DIBQUFS SFMBZ E8
E3 PS E/ %JBHOPTUJDT GVODUJPO (
%JBHOPTUJDT DIBQU
29
30
.FBTVSJOH EFWJDFT
The following equipment is required for troubleshooting if faults in DIWA.3 and DIWA.3E transmissions occur: PC or laptop with PC program Diwagnosis 59.2500. .. (latest version), level converter and connecting cable If the diagnostic program is used. Cable: Voith order no. 56.4219.10
%JBHOPTUJDT
Measuring cover (high design) To measure the oil pressures of clutches, brakes and valves of the transmission. Voith order no. 56.4218.10
Measuring cover (flat design) For restricted spaces in the transmission space. Voith order no. 56.4217.10
Pressure gauge To measure the operating and converter pressure. Voith order no. 58.2748.11
31
32
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!
33
If the measuring points mentioned are not accessible, the operating pressure can also be measured for DIWA.3 transmissions at the intermediate flange (if installed) of the oil filter: If the pressure is measured before (4/1) or after (4/2) the filter, approx. 0.5 bar must be added as flow resistance to obtain the value for the operating pressure. Note! Only measure before the filter if the filter element is clean! The working pressure can be set at the threaded pin of the operating pressure valve (5/1) - only possible with special screwdriver and socket wrench through the oil filler! If the required operating pressure is not reached, check piping for leakage and sealing gaps of the gear pump.
34
%JBHOPTUJDT GVODUJPO *
%JBHOPTUJDT GVODUJPO *
35
Injection pump
Connection
transmitter
the load transmitter lever must be on the full load mark too!
Otherwise, move the fastening with the link accordingly. Then recheck the setting in 0 load position! Note! the adjustment angles of the levers of injection pump and load transmitter must be in proportion to each other! For example, if the injection pump lever is moved by 1/3 of the angle between 0 and full load, the load transmitter lever must also be move by 1/3 of its angle between 0 and full load!
Example for load transmitter adjustment with electronic engine control unit
36
9.3 Test: rated engine torque as function of load stage or engine speed
It may be necessary to determine the maximum possible engine torques in bus operation. Indirectly, they can be determined in a relatively simple manner by speed measurements in the so-called stall point - e.g. by means of the diagnostic program. First of all pay attention: Danger! Apply parking brake to prevent unintentional bus movement! After that as example for full load operation (= load level L6): 1. engage forward gear, 2. depress accelerator pedal to the full load stop, 3. enter the measured engine speed N1 (= stall speed) in the diagram below (figure 10). The intersection with the appropriate pump characteristic of the transmission - for pump design, check the transmission nameplate, for example shows the maximum possible engine torque with the bus stopped. Note! The latter torque may deviate significantly from the maximum possible engine torque while driving with electronic engine control units. These tests are performed during acceptance protocol measurements.
%JBHOPTUJDT GVODUJPO *
1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 400
4H
4X
4V 4G 3H 4F 3X 3V 3G 3F
600
800
1000
1200
1400
1600
1800
2000
2200
10
37
38
"QQFOEJDFT
1 hydraulic control diagram DIWA.3 1 hydraulic ccontrol diagram DIWA.3E 1 circuit diagram DIWA.3 1 circuit diagram DIWA.3E
39
C
WR SK
B
7
DK
EK
TB
pa
PB
RBG
A B C D E F G H J 1-6 7,8 9 10 11 12 13 14 15
WP
RBK
Converter drain valve (CDV) Operating pressure valve (OPV) Solenoid valves Relief valve Pressure accumulator TB DIWA.3 transmission Gear pump Heat exchanger Oil filter CDV spools OPV spools Shuttle valve Reverse gear brake RB Turbine brake TB Pump brake PB Step-up gear clutch SK Lock-up clutch DK Input clutch EK
pw
15
14 13
12
11
10
Shifting function
ANS activation
EK DK SK PB TB WP WR RBK RBG
x x x x x x x x x x x x x x
1)
x1) x x x x
6 5
G E J H F D
ANS activ. via parking brake 1st gear (DIWA drive range) Upshift 1st-2nd gear* 2nd gear 3rd gear 4th gear Braking 1st gear range 1st braking stage - 2nd gear 2nd and 3rd brak. stage - 2nd gear 2nd and 3rd brak. stage - 3rd gear 2nd and 3rd brak. stage - 4th gear Reverse gear < 1 km/h Reverse gear > 1 km/h * = Transition x x x x
x x x x x
x x x x x x
x1) x x x x x x x x x x x x
C
8
D
SK WR
10
pA
DK
EK
TB
A B C D E F G H 1-6 7 8,9 10 11 12 13 14 15 16 17 Converter drain valve (CDV) Converter filling valve (CFV) Operating pressure valve (OPV) Solenoid valves DIWA.3E transmission Gear pump Heat exchanger Oil filter CDV spools CFV spool OPV spools Shuttle valve Reverse gear brake RB Turbine brake TB Breather valve Pump brake PB Step-up gear clutch SK Lock-up clutch DK Input clutch EK
PB
RBG
WP
RBK
pW
17
16 15
14
13
12
11
E
Shifting function
1st gear (DIWA drive range)
EK DK SK PB TB WP WR RBK RBG
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
1)
x x x x
6 5
Upshift 1st-2nd gear* 2nd gear 3rd gear 4th gear 3rd gear with converter filling control (CFC) 4th gear with CFC 1st, 2nd and 3rd brak. stage - 4th gear with CFC* 1st braking stage - 4th gear 2nd and 3rd brak. stage - 4th gear 2nd and 3rd brak. stage - 3rd gear
A H
4 3 2 1
Braking 1st gear range ANS activation ANS activation via parking brake Reverse gear < 1 km/h Reverse gear > 1 km/h * = Transition
A
a
1 20 38 2 21 39 3 22 40
EK -UB DK SK -UB -UB WR -UB -UB -UB EKM DKM SKM PBM TBM RBKM SENSE SENSE -UB -UB -UB N1A N1B N2A N2B N3A N3B -UB TS+ TS-UB REA0 RBG
240 204 204.1 241.1 205.1 224.1 200 207 226 244 208 227 245 209 228 246 210 229 230 211 248 212 231 249
A
D 2 D 1 2 D 1 2 3 D N N N N R R R R
S1
S2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
227 245 209 228 246 230 229 233 210 221 200 256
B
221.2
C
S1 S2 S3 +V +R RS +TS +TL /N -UB 227 245 209 228 246 230 229 233 210 221 221.2 244 226 207 208 200 256
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
z x
HBC HBA +HB 244 226 207 208 -UB HBC HBB HBA +HB
0 3
U
HBC HBA +HB
y
0 0 1 1 1 1
z
221.2
1 2
1
0 0 1 1
3
3
1 1 1 1
x
6 5 4 1 2 3 4 5 6 7 8
y
HBC HBB HBA +HB
0
0 0 0 1
2
0 1 1 1
1 2 3 4 5 6 7 8
227 245 209 228 246 230 229 233 210 221 244 226 207 208 200
4 23 41 5 24 42 6 25 43 HBA 7 HBB 26 HBC 44 +HB 8 S1 27 S2 45 S3 9 +V 28 +R 46 /N 10 +TS 29 47 FB2 11 RS 30 PU 48 BS 12 FBAUS 31 FB3 49 dS 13 dW 32 dN 50 dR 14 +TL 33 ZW 51 TOEL 15 34 DIAGN-K 52 252.1 DIAGN-L 16 216.1 ABSICH 35 ABS 53 CAN-H 17 CAN-M 36 54 CAN-L 18 37 dNEUTR 55
FB1 KD KD
D
-UB -UB
WP RBK PB -UB TB PA
19 55 37 18 54 36 17 53 35 16 52 34 15 51 33 14 50 32 13 49 31 12 48 30 11 47 29 10 46 28 9 45 27 8 44 26 7 43 25 6 42 24 5 41 23 4 40 22 3 39 21 2 38 20 1
119 137 118 117 153 135 152 7 8 3 6 4 5 1 2 148 111 147 129 110 146 128
S2/1
S2/2
S3/2
S3/3
9 10
3 2 1
+UZ 219.2
19
1 2 8 10
E G
2
1 3 4
F
141 124 105 +LG LGM -LG
S
1 2 3
gn/ge bl sw br
1 2 3 4
R
204 219
152 153
147 111
110 129
128 146
135 137 119 102 103 121 117 120 101 118
M
h i
j
dW
P
CAN-H CAN-M CAN-L
1 2 3 4 5 6 7 8 9 10 C B A
A B
C D
E F
G H
J K L MN P R S T U V WX Y Z a b c d e f g h j
n1
+ 1 2
ws sw ws sw
4 3 2 1
bl bl bl bl ws sw ws sw
148 10 9 8 7 6 5 4 3 2 1
n3 n2
sw ge bl rt
k
dR
l
dN
m WR
85 87 87a
sw rt sw ge bl rt sw ge bl rt sw ge bl rt sw
br bl br ge gn bl br ge gn bl br ge gn bl br bl
N
s
M
O
n
dS
1 2 4 3 1 2 4 3 1 2 4 3 1 2
br ge gn bl
2 4 3 1
SK
30 86
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
DK
J K
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
EK PB
br ge gn bl br bl br ge gn bl
2 4 3 1 2
sw ge bl rt sw rt sw ge bl rt
TB RBG RBK
q p t
st
61 50e 50f D+
u
DD+
v w
150
M
ABS d
inactive
on off
238 213 219.1 214 232 251 253 250 255 252 216 200 205.1 224.1 241.1 204.1 215 231 248 235 212 221.1
+UB dS +UZ dR dW ZW ABS dN dNEUTR DIAGN-K DIAGN-L SSP DKR DKE DKV/PWM KD TOEL FBAUS PU ABSICH BS -UB
1 2 4 3 1
WP
rt
+ 24V
A Push-button switch B Connection cable for push-button switch and converter brake C Cable 2 D E 200 control unit E Connection: level converter and diagnostic PC F Cable 1 G Load transmitter H Speed and temperature sensors J Solenoid valves K Connection cable for vehicle wiring
L M N O P Q R S T U
Switches and warning light transmission oil Engine control Vehicle electrical system non-committal representation Relays CAN Bus Connection cable for brake valve and kickdown switch Kickdown switch Brake valve Manual switch for converter brake Switch for converter brake; stage no. 3
a b c d e f g h i j k l
Inhibitor switch for reverse gear Connections Bridges Warning light transm. oil Cut-out switch for conv. brake; only for brake valve Pressure switch for gearshift inhibitor Pressure switch for ANS activation Relay for control unit Relay for starter inhibitor Relay for centr. warn. light Relay for converter brake Relay for reversing light
m n o p q r s st t u v w x y z
Relay for speed Central warning light Fuse 8A Relay for battery Switch box Starter inhibitor relay Starter Start button Battery Overvoltage protection Generator Regulator Connections Position Stage no.
A
a
R
221
1 20 38 2 21 39 3 22 40
EK -UB DK SK -UB -UB WR -UB -UB -UB EKM DKM SKM PBM TBM RBKM SENSE SENSE -UB -UB -UB N1A N1B N2A N2B N3A N3B -UB TS+ TS-UB REA0 RBG
A
D 2 D 1 2 D 1 2 3 D
S2/1 S2/2 S3/2 S3/3
S1 N N N N R R R R
S2
S3 S2/1 S2/2 S3/2 S3/3 200 207 226 244 208 227 245 209 228 246 210 229 230 211
1 2 3 4 5 6 7 8 9 10 11 12 13 14
227 245 209 228 246 230 229 233 210 221 200 256
249
B
221.2
C
S1 S2 S3 +V +R RS +TS +TL /N -UB 227 245 209 228 246 230 229 233 210 221 221.2 244 226 207 208 200 256
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
z x y
HBC HBA +HB -UB HBC HBB HBA +HB
U
HBC HBA +HB
1 2 3 4 5 6 7 8
0 0 1
1 1 1
221.2
z x y
HBC HBB HBA +HB -UB HBC HBB HBA +HB
0
0
0 0 0 1
1 2 3
1
0 0 1 1
2
0 1 1 1
3
1 1 1 1
6 5 4
3 2 1
1 2 3 4 5 6 7 8
227 245 209 228 246 230 229 233 210 221 244 226 207 208 200
217 236
235 253
4 23 41 5 24 42 6 25 43 HBA 7 HBB 26 HBC 44 +HB 8 S1 27 S2 45 S3 9 +V 28 +R 46 /N 10 +TS 29 47 FB2 11 RS 30 PU 48 BS 12 FBAUS 31 FB3 49 dS 13 dW 32 dN 50 dR 14 +TL 33 ZW 51 TOEL 15 DIAGN-K 34 52 252.1 DIAGN-L 16 216.1 ABSICH 35 ABS 53 CAN-H 17 CAN-M 36 54 18 CAN-L 37 dNEUTR 55
FB1 KD KD
19 55 37 18 54 36 17 53 35 16 52 34 15 51 33 14 50 32 13 49 31 12 48 30 11 47 29 10 46 28 9 45 27 8 44 26 7 43 25 6 42 24 5 41 23 4 40 22 3 39 21 2 38 20 1
119 137 118 117 153 135 152 7 8 3 6 4 5 1 2 148 111 147 129 110 146 128
9 10
D
-UB -UB
RBK PB -UB TB WP
+UZ 219.2
19
SSP RF
1 2 8 10
E G
2
3 4 1
F
141 124 105 +LG LGM -LG
S
1 2 3
gn/ge bl sw br
1 2 3 4
R
204 219
128 146
152 153
147 111
110 129
135 137 119 102 103 121 117 120 101 118
M
h i
j
dW
P
CAN-H CAN-M CAN-L
1 2 3 4 5 6 7 8 9 10 C B A
A B
C D
E F
G H
J K L MN P R S T U V WX Y Z a b c d e f g h j
n1
1 2
+ -
ws sw ws sw
4 3 2 1
bl bl bl bl ws sw ws sw
148 10 9 8 7 6 5 4 3 2 1
n3 n2
sw
k
dR
l
dN
m SK
85 87 87a
N
s
M
O
n
dS
sw ge bl rt sw ge bl rt sw ge bl rt sw ge bl rt sw
2 4 3 1 2 4 3 1 2 4 3 1 2 4 3 1 2
br ge gn bl br ge gn bl br ge gn bl br ge gn bl br bl
br
bl
rt
WR
30 86
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
DK
J K
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
EK PB WP
br ge gn bl br bl br ge gn bl
2 4 3 1 2
sw ge bl rt sw rt sw ge bl rt
TB RBG RBK
q p t
st
61 50e 50f D+
u
DD+
v w
150
M
ABS d
inactive
on off
238 213 219.1 214 232 251 253 250 255 252 216 200 205.1 224.1 241.1 204.1 215 231 248 235 212 221.1
+UB dS +UZ dR dW ZW ABS dN dNEUTR DIAGN-K DIAGN-L SSP DKR DKE DKV/PWM KD TOEL FBAUS PU ABSICH BS -UB
1 2 4 3 1
rt
+ 24V
A Push-button switch B Connection cable for push-button switch and converter brake C Cable 2 D E 200 control unit E Connection: level converter and diagnostic PC F Cable 1 G Load transmitter H Speed and temperature sensors J Solenoid valves K Connection cable for vehicle wiring
L M N O P Q R S T U
Switches and warning light transmission oil Engine control Vehicle electrical system non-committal representation Relays CAN Bus Connection cable for brake valve and kickdown switch Kickdown switch Brake valve Manual switch for converter brake Switch for converter brake; stage no. 3
a b c d e f g h i j k l
Inhibitor switch for reverse gear Connections Bridges Warning light transm. oil Cut-out switch for conv. brake; only for brake valve Pressure switch for gearshift inhibitor Pressure switch for ANS activation Relay for control unit Relay for starter inhibitor Relay for centr. warn. light Relay for converter brake Relay for reversing light
m n o p q r s st t u v w x y z
Relay for speed Central warning light Fuse 8A Relay for battery Switch box Starter inhibitor relay Starter Start button Battery Overvoltage protection Generator Regulator Connections Position Stage no.
Voith Turbo GmbH & Co. KG Produktgruppe Nutzfahrzeuggetriebe Alexanderstrae 2 D-89522 Heidenheim Telephone (07321) 37-0 Telefax (07321) 37 7618
3
DB 250 PF Series
AUTOMATIC GEARBOXES
ZF-ECOMAT 2 Transmissions
0145
1-1
AUTOMATIC GEARBOXES
ZF-ECOMAT 2 Transmissions
3
DB 250 PF Series
1-2
0145
REPAIR MANUAL
011356
Copyright by ZF These repair instructions are protected by copyright. Any reproduction and dissemination in whatever form also in adapted, paraphrased or extracted form in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law. Printed in Germany
Edition:
2001 - 03
Contents
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutaway views of Ecomat transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch and brake combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 6 7 9 11 12 15 19 20 22
1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level when cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level with engine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level on versions with heat exchanger higher than center line of transmission . . . . . . . . . . . Changing oil at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-4
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.7 2.8 2.9 2.10 2.11 2.12 2.13
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing retarder solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing accumulator solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing output sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing retarder resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and fitting oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing turbine sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing complete hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing complete oil level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing impulse sensor for speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing output flange and/or radial seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 2-1 2-3 2-4 2-5 2-6 2-7 2-11 2-13 2-17 2-23 2-28 2-32 2-33 2-37
Contents
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal tester concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test instructions for test cable 1 PO1 138 153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annex Description/menus for ZF Testman
4.
Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Hydraulic circuit diagram without NBS 4149 700 026 / 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Hydraulic circuit diagram with NBS 4149 700 026 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Connection diagram 6029 729 041 / 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Electrical circuit diagram n 6029 729 040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Pin pattern 6029 729 072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Preface
This repair manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF product in accordance with the state of development on the date of issue. However, due to continuing development of the product, repair work might require work practices and test or adjustment data not contained in this manual. We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training centers. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually trained personnel 2. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out conscientiously and with utmost care. Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case. ZF FRIEDRICHSHAFEN AG C.V ./Special Transmissions Service Plant 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726 Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.
Important information
SAFETY NOTICE Companies repairing ZF units are responsible for their own work safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations. Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.
CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings and components are not to scale. Conclusions about size and weight should not be drawn (even within a complete illustration). Always follow the working steps as described in the text.
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.