SERVICE BULLETIN

SI 192203 ZF Ecosplit Gearbox Valve

SV-09-039 05 JUN 09
Block Test Step List

ATTENTION: ALL SERVICE MANAGERS AND WORKSHOP STAFF

Please find attached SI 192203 regarding Pneumatic and electrical test step list for ZF Ecosplit valve block.

Please make this bulletin available to all relevant staff and file in Transmission section (Group 03).

Page 1
MAN Automotive Imports Pty Ltd
72 Formation St WACOL QLD 4076 Ph: 07 3271 7777 Fx: 07 3271 2047 (admin/sales) 07 3271 2720 (parts/service)
MAN Nutzfahrzeuge Aktiengesellschaft
Service Information
Date Issued by SI number: 192203a
04.02.2009 SASTI Gearbox

Vehicle(s) affected TGA, TGS, TGX with New Ecosplit gearbox

Component(s) affected Valve block of New Ecosplit gearbox

Problem Valve block is replaced too quickly if a gearshift complaint is made and/or in
the event of fault entries in the vehicle management computer (FFR).
Remedy/urgency DURING REPAIR WORK
Before replacement, check valve block with attached test step lists for electrics
and pneumatics.
If the valve block can without doubt be classified as faulty and if the vehicle
is subject to liability for defects, the defective part must be sent in with a
completed copy of the test step list (as from page 30).
Warranty processing is possible only if the completed test step list is
enclosed with valve blocks that have been clearly identified as defective.

Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft

ppa. i.V.

This SI replaces SI 192203 dated 21.02.2006 and

the first supplement, dated 29.06.2006.
Distribution of this SI to the worldwide service organisation
Forwarding within the MAN service workshop organisation:
Workshop management yes Personnel in spare parts store yes
Workshop personnel for performance of the work yes Emergency service mechanics no
Workshop personnel in general yes Customers' workshops authorised for servicing no
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Parts
Quantity Description Part number
1 Double groove ring 81.32527-0022
2 Sealing washer 81.96503-0230
1 Guide ring 81.91710-0357
1 Seal 81.32903-0274

Standard time
Job No. Text WU
0 277A005 418 00 00 00 Connect/disconnect MAN-cats diagnostic system
TGA 3
TGX, TGS 2
0 326E105 880 00 00 00 Check valve block with MAN-cats in accordance with test electrics step 2
H 326E105 161 00 W1 00 Valve block, test step 1, check for leaks 5
H 326E105 161 00 W2 00 Valve block, test step 2, check for leaks 3
H 325E010 161 Y7 00 00 Check shift cylinder(s) of range-change group for leaks 3
H 325E020 161 Y7 00 00 Check shift cylinder(s) of splitter box for leaks 3
H 326E105 711 00 00 00 Complete valve block report/form 3
0 326E105 450 00 00 00 Replace valve block 7
H 325E020 473 Y7 00 15 Repair shift cylinder(s) ofsplitter box (gearbox removed) ****
0 325E010 40I Y7 00 00 Repair shift cylinder(s) ofrange-change group (remove from bottom) 13
0 325E010 47H Y7 00 00 Repair shift cylinder(s) ofrange-change group (remove from top) 9
0 063D070 391 -- -- -- Coolant pipe, intarder ****
0 061B005 621 00 00 00 Drain, fill coolant 6
0 429A070 361 00 00 CM Remove, fit step over manual gearbox 3

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Overview of pneumatic and electric interfaces

13

1
2

12

4
11

5 6 7 8 9 10

1 Valve block 8 Plug connection, electrics. Assignment,

2 Connection (P1), reservoir see table on page 28
3 Connection (P2), output clutch; 9 Connection (A26), high range-change group
connection is omitted for valve block with 10 Connection (A25), low range-change group
MAN part number 81.32550-6010 11 Switch, neutral position
4 Connection (A5), ServoShift cylinder 12 Switch, reverse gear
5 Breather R1; 13 Switch housing
breather R2 is located on the bottom side,
illustration see page 33
TD Truck Direct Drive (direct drive gearbox)
6 Connection (A1) of the low splitter box for TD
TO Truck Overdrive (overdrive gearbox)
gearboxes or of the high splitter box for TO
gearboxes
7 Connection (A2) of the high splitter box for TD
gearboxes or of the low splitter box for TO
gearboxes

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Function chart for valve block

11 10
12
1

9
2
8

7
4

3 5 6

1 Gear lever with switch for splitter box and 7 High/low splitter box
range-change group 8 Shuttle valve
2 Air supply connection 9 Valve block
3 Displacement sensor, clutch 10 Vehicle management computer (FFR)
4 Clutch actuator 11 Shift lock
5 ServoShift cylinder 12 Shuttle valve, enabling for range-change
6 High/low range-change group group

Functional description
Switchover of the range-change group:
The vehicle management computer (FFR) permanently supplies a current to the solenoid valve for the
range-change group in the valve block. A gearshift in the range-change group is mechanically/pneumatically
triggered in neutral gearbox position by means of the solenoid valve for the range-change group which is
activated at the gear lever by the driver. Before enabling of the range-change group, the FFR checks the
switching conditions (gearbox output speed).

Active gate lock:

To avoid incorrect gearshifts when shifting down from gear 5 to gear 2 and from gear 6 to gear 1, the gear
lever is pneumatically pressed into position 3-4 (active gate lock). The FFR enables gate 1-2 if greater
deceleration occurs.

Servo air deactivation:

To avoid synchroniser damage, the servo air is controlled at the ServoShift cylinder depending on clutch
operation. With FFR lower than step 12, servo air is enabled as from 70 percent. With FFR Step 12 or
higher, enabling takes place as from 85 percent. Servo air is enabled by means of the splitter box control
unit.

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Instructions for specific fault memory entries for the New Ecosplit gearbox
All tests relating to the control unit connector and the valve block are carried out with break boxes
(terminal tester) and adapter cables. The pin assignments on the control unit connector and at the
plug connection of the valve block are identical to the test connections at the break box.
Break boxes and corresponding adapter cables can be obtained from
Cartool, Strauenlettenstrasse 15, D-85053 Ingolstadt.
Vehicle management computer: item number break box: 97 10 and adapter cable: 97 0 080
Valve block: item number break box: 97 1 070 and adapter cable: 97 1 074
Control unit affected: vehicle management computer (FFR)

Overview of the affected plug connections:

X1553

Engine
D20/D26

Figure 1:
Plug connection X1948, enginegearbox
In engine D28, this plug connection is located
in the MP-box. Figure 2:
Plug connection X1553, cab isolating point, left

X1 X2 X3 X4

Valve block

FFR

Figure 3: Figure 4:
Plug connection for control unit FFR Plug connection for valve block New Ecosplit

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Circuit diagram of New Ecosplit gearbox (TGS/TGX)
Circuit diagram for TGA identical except for installation locations.

A403 Vehicle management computer X1562 Plug connection for gearbox

(TGA: located in the area of the control
unit slot, TGS/TGX: on the cable harness
in the centre section)
Y307 Valve block of New Ecosplit X1553 Plug connection, cab isolating point, left
Y308 Solenoid valve, clutch servo X1948 Plug connection, enginegearbox
X1972 Plug connection, pedals

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Fault code: 770
Fault code description: High splitter box
Priority: 5: Driving capability restricted
Fault indication:
The central warning light (H111) lights up yellow when vehicle is
driving and when it is stationary.
Symptom: Gearshifts are difficult
Splitter box shifting not possible

Potential cause: 7-pin connector at valve block

Cable from FFR to solenoid valves in valve block (Y307) at gearbox
Plug connection X1948, enginegearbox (figure 1)
Plug connection X1553 (figure 2), cab isolation point, left
Plug connection X1562, in cab
Pin X3 and X4 at FFR (figure 3)
Valve block at gearbox (figure 4)
Vehicle management computer (figure 3)

Test steps:
Check cables, plug connectors and solenoid
valves for splitter box and range-change group
in valve block.

Remove 7-pin connector (figure 4)
at valve block of the gearbox.
Visual check:
check plugs for damage, pushed back No Replace plug and/or contacts, repair damage
plug contacts and contact oxidation, etc. on the cable(s).

Check cables for loose contacts,
water/moisture in the cable harness.
Check OK?
Yes

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 Check functionality of vehicle management Check solenoid valve of high splitter box
computer and cables. in the valve block.
Switch off ignition Connect valve block break box to
Yes
valve block using adapter cable.
Connect valve block break box to cable
harness Check the following pins for open
circuits by measuring resistance:
Carry out voltage measurement at the
following pins of the valve block (break box): pin 5 (+) and pin 4 (-)
pin 5 (+) and pin 4 (-)
Carry out actuator test "Split High" with Setpoint: R = 78
MAN-cats II (high splitter box) during Measurement values OK?
FFR diagnosis.
No
Setpoint: solenoid valve
Replace valve block Yes
activated: battery voltage
deactivated: 0V
No cause for the fault could be identified
Was it possible to measure battery voltage in on the basis of the measurement.
activated state?
Please note that cables may also be
damaged although the corrugated tube
seems undamaged from outside.
If you need further assistance, create a
ServiceDesk case.
No
Check cables from FFR to valve block.
Switch off ignition
Remove plugs X1 to X4 (figure 3) from
control unit FFR
Connect break box and adapter cable FFR
on the cable harness side
Check cables of the following pins at Check cables and plug connectors (control
control unit FFR: unit, X1562, X1553, X1948 and valve block)
for
X3/5, X3/10, X3/13, X4/1, X4/6, X4/7, X4/13
No Oxidation
Carry out resistance measurement
Damage to insulation
to check for:
Loose contact
Short circuit to negative
Water/moisture in the cable harness
Short circuit to positive
(e.g. FFR, pin X1/1) Repair, if necessary.
Short circuit between cables

Setpoint: R = or O.L.
Measurement values OK?

Yes

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Check cables from FFR to valve block for
open circuits.
Check the following cables for open
circuits by measuring resistance Check cables 60354 and 31023 and

between the following pins: No plug connectors (control unit, X1562,

X1553, X1948 and valve block) for
FFR, plug X3 pin 13 and valve block pin 5
damage, loose contacts, pushed back plug
FFR, plug X4 pin 6 and valve block pin 4
contacts and contact oxidation, etc. Repair
Setpoint: R = 0 0,5 if necessary.
Measurement values OK?

Yes
Replace FFR

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Fault code: 771
Fault code description: Low splitter box
Priority: 5: Driving capability restricted
Fault indication:
The central warning light (H111) lights up yellow when vehicle is
driving and when it is stationary.
Symptom: Gearshifts are difficult
Splitter box shifting not possible

Potential cause: 7-pin connector at valve block of the gearbox

Cable from FFR to solenoid valves in valve block (Y307) at gearbox
Plug connection X1948 (figure 1)
Plug connection X1553 (figure 2), cab isolation point, left
Plug connection X1562, in cab
Pin X3 and X4 at FFR (figure 3)
Valve block at gearbox (figure 4)
Vehicle management computer (figure 3)

Test steps:
Check cables, plug connectors and solenoid
valves for splitter box and range-change group
in valve block.

Remove 7-pin connector (figure 4)
at valve block of the gearbox.
Visual check:
check plugs for damage, pushed back No Replace plug and/or contacts,
plug contacts and contact oxidation, etc. repair damage on the cable(s).

Check cables for loose contacts,
water/moisture in the cable harness.
Check OK?
Yes

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Check functionality of vehicle management Check solenoid valve of low splitter box in
computer and cables. the valve block.
Switch off ignition Connect valve block break box to
Yes
Connect valve block break box to cable valve block using adapter cable.
harness
Check the following pins for open
Carry out voltage measurement at the circuits by measuring resistance:
following pins of the valve block (break box): pin 6 (+) and pin 4 (-)
pin 6 (+) and pin 4 (-)
Carry out actuator test "Split Low" with
Setpoint: R = 78
MAN-cats II during FFR diagnosis
(low splitter box). Measurement values OK?
Setpoint: solenoid valve No
activated: battery voltage Replace valve block Yes
deactivated: 0V

Was it possible to measure battery No cause for the fault could be identified
voltage in activated state? on the basis of the measurement.
Please note that cables may also be
damaged although the corrugated tube
seems undamaged from outside.
If you need further assistance,
create a ServiceDesk case.
No
Check cables from FFR to valve block.
Switch off ignition
Remove plugs X1 to X4 (figure 3)
from control unit FFR
Connect break box and adapter cable FFR
on the cable harness side
Check cables of the following pins at Check cables and plug connectors (control
control unit FFR: unit, X1562, X1553, X1948 and valve block)
for
X3/5, X3/10, X3/13, X4/1, X4/6, X4/7, X4/13
No Oxidation
Carry out resistance measurement to check
Damage to insulation
for:
Loose contact
Short circuit to negative
Water/moisture in the cable harness
Short circuit to positive
(e.g. FFR, pin X1/1) Repair, if necessary.
Short circuit between cables

Setpoint: R = or O.L.
Measurement values OK?

Yes

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 Check cables from FFR to
valve block for open circuits.
Check the following cables for open
circuits by measuring resistance Check cables 60353 and 31023 and

between the following pins: No plug connectors (control unit, X1562,

X1553, X1948 and valve block) for
FFR, plug X4 pin 7 and valve block pin 6
damage, loose contacts, pushed back plug
FFR, plug X4 pin 6 and valve block pin 4
contacts and contact oxidation, etc. Repair if
Setpoint: R = 0 0,5 necessary.
Measurement values OK?

Yes
Replace FFR

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Fault code: 1045
Fault code description: Output stage gate lock
Priority: 5: Driving capability restricted
Fault indication:
The central warning light (H111) lights up yellow
when vehicle is driving and when it is stationary.
Symptom: Handling apparently unchanged
Caution: Destruction of engine and clutch probable due
to overspeeding as a result of shifting errors!

Potential cause: 7-pin connector at valve block of the gearbox

Cable from FFR to solenoid valves in valve block (Y307) at gearbox
Plug connection X1948 (figure 1)
Plug connection X1553 (figure 2), cab isolation point, left
Plug connection X1562, in cab
Pin X3 and X4 at FFR (figure 3)
Valve block at gearbox (figure 4)
Vehicle management computer (figure 3)

Test steps:
Check cables, plug connectors and solenoid
valves for splitter box and range-change group
in valve block.

Remove 7-pin connector (figure 4) at
valve block of the gearbox.
Visual check:
check plugs for damage, pushed back No Replace plug and/or contacts,
plug contacts and contact oxidation, etc. repair damage on the cable(s).

Check cables for loose contacts,
water/moisture in the cable harness.
Check OK?
Yes

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 Check functionality of vehicle management Check gate lock solenoid valve in
computer and cables. valve block.
Switch off ignition Connect valve block break box to
Yes
Connect valve block break box to valve block using adapter cable.
cable harness
Check the following pins for open
Carry out voltage measurement at the circuits by measuring resistance:
following pins of the valve block (break box): pin 7 (+) and pin 1 (-)
pin 7 (+) and pin 1 (-)
Carry out actuator test "Gate detent" with
Setpoint: R = 131
MAN-cats II during FFR diagnosis.
Setpoint: solenoid valve Measurement values OK?

activated: battery voltage No

deactivated: 0V Replace valve block Yes
Was it possible to measure battery voltage in
activated state? No cause for the fault could be identified
on the basis of the measurement.
Please note that cables may also be
damaged although the corrugated tube
seems undamaged from outside.
If you need further assistance,
create a ServiceDesk case.
No
Check cables from FFR to valve block.
Switch off ignition
Remove plugs X1 to X4 (figure 3)
from control unit FFR
Connect break box and adapter cable FFR
on the cable harness side
Check cables of the following pins at Check cables and plug connectors (control
control unit FFR: unit, X1562, X1553, X1948 and valve block)
for
X3/5, X3/10, X3/13, X4/1, X4/6, X4/7, X4/13
No Oxidation
Carry out resistance measurement to check
Damage to insulation
for:
Loose contact
Short circuit to negative
Water/moisture in the cable harness
Short circuit to positive
(e.g. FFR, pin X1/1) Repair, if necessary.
Short circuit between cables

Setpoint: R = or O.L.
Measurement values OK?

Yes

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Check cables from FFR to valve block for open
circuits.
Check the following cables for open circuits
by measuring resistance Check cables 60372 and 31025 and

between the following pins: No plug connectors (control unit, X1562,

X1553, X1948 and valve block) for
FFR, plug X4 pin 13 and valve block pin 7
damage, loose contacts, pushed back plug
FFR, plug X3 pin 5 and valve block pin 1
contacts and contact oxidation, etc. Repair if
Setpoint: R = 0 0,5 necessary.
Measurement values OK?

Yes
Replace FFR

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Fault code: 3305
Fault code description: Output stage, high range-change group
Priority: 5: Driving capability restricted
Fault indication:
The central warning light (H111) lights up yellow
when vehicle is driving and when it is stationary.
Symptom: Driving possible only in low range-change group
Shifting into high range-change group not possible

Potential cause: 7-pin connector at valve block of the gearbox

Cable from FFR to solenoid valves in valve block (Y307) at gearbox
Plug connection X1948 (figure 1)
Plug connection X1553 (figure 2), cab isolation point, left
Plug connection X1562, in cab
Pin X3 and X4 at FFR (figure 3)
Valve block at gearbox (figure 4)
Vehicle management computer (figure 3)

Test steps:
Check cables, plug connectors and solenoid
valves for splitter box and range-change group
in valve block.

Remove 7-pin connector (figure 4)
at valve block of the gearbox.
Visual check:
check plugs for damage, pushed back No Replace plug and/or contacts,
plug contacts and contact oxidation, etc. repair damage on the cable(s).

Check cables for loose contacts,
water/moisture in the cable harness.
Check OK?
Yes

192203aen
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Check functionality of vehicle management Check solenoid valve of high range-change
computer and cables. group in the valve block.
Switch off ignition Connect valve block break box to
Yes
Connect valve block break box to valve block using adapter cable.
cable harness
Check the following pins for open
Carry out voltage measurement at the circuits by measuring resistance:
following pins of the valve block (break box): pin 2 (+) and pin 1 (-)
pin 2 (+) and pin 1 (-)
Carry out actuator test "High Range" with
Setpoint: R = 131
MAN-cats II (high range-change group)
during FFR diagnosis. Measurement values OK?
Setpoint: solenoid valve No
activated: battery voltage Replace valve block Yes
deactivated: 0V

Was it possible to measure battery voltage in No cause for the fault could be identified on
activated state? the basis of the measurement.
Please note that cables may also be
damaged although the corrugated tube
seems undamaged from outside.
If you need further assistance,
create a ServiceDesk case.
No
Check cables from FFR to valve block.
Switch off ignition
Remove plugs X1 to X4 (figure 3)
from control unit FFR
Connect break box and adapter cable FFR
on the cable harness side
Check cables of the following pins at Check cables and plug connectors (control
control unit FFR: unit, X1562, X1553, X1948 and valve block)
for
X3/5, X3/10, X3/13, X4/1, X4/6, X4/7, X4/13
No Oxidation
Carry out resistance measurement to check
Damage to insulation
for:
Loose contact
Short circuit to negative
Water/moisture in the cable harness
Short circuit to positive
(e.g. FFR, pin X1/1) Repair, if necessary.
Short circuit between cables

Setpoint: R = or O.L.
Measurement values OK?

Yes

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 Check cables from FFR to valve block
for open circuits.
Check the following cables for open
circuits by measuring resistance Check cables 60371 and 31025 and

between the following pins: No plug connectors (control unit, X1562,

X1553, X1948 and valve block) for
FFR, plug X4 pin 1 and valve block pin 2
damage, loose contacts, pushed back plug
FFR, plug X3 pin 5 and valve block pin 1
contacts and contact oxidation, etc. Repair if
Setpoint: R = 0 0,5 necessary.
Measurement values OK?

Yes
Replace FFR

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Fault code: 3306
Fault code description: Output stage, low range-change group
Priority: 5: Driving capability restricted
Fault indication:
The central warning light (H111) lights up yellow
when vehicle is driving and when it is stationary.
Symptom: Warning in instrument display "clutch overloaded SHIFT DOWN"
Driving possible only in high range-change group
Shifting into low range-change group not possible
Driving off possible in fast gears, vehicle accelerates although
Low-Range-Go function is active (limiting the engine to idling
speed when driving off in the high range)
Caution: Clutch damage probable due to overloading!

Potential cause: 7-pin connector at valve block of the gearbox.

Cable from FFR to solenoid valves in valve block (Y307) at gearbox
Plug connection X1948 (figure 1)
Plug connection X1553 (figure 2), cab isolation point, left
Plug connection X1562, in cab
Pin X3 and X4 at FFR (figure 3)
Valve block at gearbox (figure 4)
Vehicle management computer (figure 3)

Test steps:
Check cables, plug connectors and solenoid
valves for splitter box and range-change group
in valve block.

Remove 7-pin connector (figure 4) at valve block
of the gearbox.
Visual check:
check plugs for damage, pushed back plug No Replace plug and/or contacts,
contacts and contact oxidation, etc. repair damage on the cable(s).

Check cables for loose contacts,
water/moisture in the cable harness.
Check OK?
Yes

192203aen
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 Check functionality of vehicle management Check solenoid valve of low range-change
computer and cables. group in the valve block.
Switch off ignition Connect valve block break box to
Yes
Connect valve block break box to valve block using adapter cable.
cable harness
Check the following pins for open
Carry out voltage measurement at the circuits by measuring resistance:
following pins of the valve block (break box): pin 3 (+) and pin 1 (-)
pin 3 (+) and pin 1 (-)
Carry out actuator test "Low Range" with
Setpoint: R = 131
MAN-cats II (high range-change group)
during FFR diagnosis. Measurement values OK?
Setpoint: solenoid valve No
activated: battery voltage Replace valve block Yes
deactivated: 0V

Was it possible to measure battery voltage in No cause for the fault could be identified
activated state? on the basis of the measurement.
Please note that cables may also be
damaged although the corrugated tube
seems undamaged from outside.
If you need further assistance,
create a ServiceDesk case.
No
Check cables from FFR to valve block.
Switch off ignition
Remove plugs X1 to X4 (figure 3) from
control unit FFR
Connect break box and adapter cable FFR
on the cable harness side
Check cables of the following pins at Check cables and plug connectors (control
control unit FFR: unit, X1562, X1553, X1948 and valve block)
for
X3/5, X3/10, X3/13, X4/1, X4/6, X4/7, X4/13
No Oxidation
Carry out resistance measurement to check
Damage to insulation
for:
Loose contact
Short circuit to negative
Water/moisture in the cable harness
Short circuit to positive
(e.g. FFR, pin X1/1) Repair, if necessary.
Short circuit between cables

Setpoint: R = or O.L.
Measurement values OK?

Yes

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Check cables from FFR to valve block
for open circuits.
Check the following cables for open
circuits by measuring resistance Check cables 60370 and 31025

between the following pins: No plug connectors (control unit, X1562,

X1553, X1948 and valve block) for
FFR, plug X3 pin 10 and valve block pin 3
damage, loose contacts, pushed back plug
FFR, plug X3 pin 5 and valve block pin 1
contacts and contact oxidation, etc. Repair if
Setpoint: R = 0 0,5 necessary.
Measurement values OK?

Yes
Replace FFR

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Fault code: 3308
Fault code description: Output stage ground, range-change group/gate lock
Priority: 5: Driving capability restricted
Fault indication:
The central warning light (H111) lights up yellow
when vehicle is driving and when it is stationary.
Symptom: Range-change group shifting not possible
Driving off possible in fast gears although Low-Range-Go function is
active (limiting the engine to idling speed when driving off in the high
range), if the fault occurred while driving in high range-change group
Caution: Destruction of clutch and engine probable due to
overspeeding as a result of shifting errors.

Potential cause: 7-pin connector at valve block of the gearbox

Cable from FFR to solenoid valves in valve block (Y307) at gearbox
Plug connection X1948 (figure 1)
Plug connection X1553 (figure 2), cab isolation point, left
Plug connection X1562, in cab
Pin X3 and X4 at FFR (figure 3)
Valve block at gearbox (figure 4)
Vehicle management computer (figure 3)

Test steps:
Check cables, plug connectors and solenoid
valves for splitter box and range-change group
in valve block.

Remove 7-pin connector (figure 4) at valve block
of the gearbox.
Visual check:
check plugs for damage, pushed back plug No Replace plug and/or contacts,
contacts and contact oxidation, etc. repair damage on the cable(s).

Check cables for loose contacts,
water/moisture in the cable harness.
Check OK?
Yes

192203aen
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Check functionality of vehicle Check solenoid valve of low range-change
management computer and group in the
cables. valve block.
Yes
Switch off ignition Connect valve block break box to
Connect valve block break valve block using
box to cable harness adapter cable.
Carry out voltage Check the following pins for open
measurement at the circuits by measuring resistance:
following pins of the pin 3 (+) and pin 1 (-)
valve block (break box):
pin 3 (+) and pin 1 (-)
Setpoint: R = 131
Carry out actuator test "Low Range" with
MAN-cats II (low range-change group) Measurement values OK?
during FFR diagnosis.
No
Setpoint: solenoid valve
Replace valve block Yes
activated: battery voltage
deactivated: 0V
No cause for the fault could be identified
Was it possible to measure battery voltage in on the basis of the measurement.
activated state? Please note that cables may also be
damaged although the corrugated tube
seems undamaged from outside.
If you need further assistance,
create a ServiceDesk case.
No
Check cables from FFR to valve block.
Switch off ignition
Remove plugs X1 to X4 (figure 3) from
control unit FFR
Connect break box and adapter cable FFR on
the cable harness side
Check cables of the following pins at control Check cables and plug connectors (control
unit FFR: unit, X1562, X1553, X1948 and valve block)
for
X3/5, X3/10, X3/13, X4/1, X4/6, X4/7, X4/13
No Oxidation
Carry out resistance measurement to check
Damage to insulation
for:
Loose contact
Short circuit to negative
Water/moisture in the cable harness
Short circuit to positive (e.g. FFR, pin
X1/1) Repair, if necessary.
Short circuit between cables

Setpoint: R = or O.L.
Measurement values OK?

Yes

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Page 23 of 33
 Check cables from FFR to valve block
for open circuits.
Check the following cables for open
circuits by measuring resistance Check cables 60370 and 31025 and

between the following pins: No plug connectors (control unit, X1562,

X1553, X1948 and valve block) for
FFR, plug X3 pin 10 and valve block pin 3
damage, loose contacts, pushed back plug
FFR, plug X3 pin 5 and valve block pin 1
contacts and contact oxidation, etc. Repair if
Setpoint: R = 0 0,5 necessary.
Measurement values OK?

Yes
Replace FFR

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Fault code: 3309
Fault code description: Output stage ground, splitter box
Priority: 2: Driving capability restricted
Fault indication:
The central warning light (H111) lights up yellow
when vehicle is driving and when it is stationary.
Symptom: Gearshifts are difficult
Splitter box shifting not possible

Potential cause: 7-pin connector at valve block of the gearbox

Cable from FFR to solenoid valves in valve block (Y307) at gearbox
Plug connection X1948 (figure 1)
Plug connection X1553 (figure 2), cab isolation point, left
Plug connection X1562, in cab
Pin X3 and X4 at FFR (figure 3)
Valve block at gearbox (figure 4)
Vehicle management computer (figure 3)

Test steps:
Check cables, plug connectors and solenoid
valves for splitter box and range-change group
in valve block.

Remove 7-pin connector (figure 4) at valve block
of the gearbox.
Visual check:
check plugs for damage, pushed back plug No Replace plug and/or contacts,
contacts and contact oxidation, etc. repair damage on the cable(s).

Check cables for loose contacts,
water/moisture in the cable harness.
Check OK?
Yes

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 Check functionality of vehicle management Check solenoid valve of low splitter box
computer and cables. in the valve block.
Switch off ignition Connect valve block break box to
Yes
Connect valve block break box to valve block using adapter cable.
cable harness
Check the following pins for open
Carry out voltage measurement at the circuits by measuring resistance:
following pins of the valve block (break box): pin 6 (+) and pin 4 (-)
pin 6 (+) and pin 4 (-)
Carry out actuator test "Split Low"
Setpoint: R = 78
with MAN-cats II during FFR diagnosis
(low splitter box). Measurement values OK?
Setpoint: solenoid valve No
activated: battery voltage Replace valve block Yes
deactivated: 0V

Was it possible to measure battery voltage in No cause for the fault could be identified
activated state? on the basis of the measurement.
Please note that cables may also be
damaged although the corrugated tube
seems undamaged from outside.
If you need further assistance,
create a ServiceDesk case.
No
Check cables from FFR to valve block.
Switch off ignition
Remove plugs X1 to X4 (figure 3)
from control unit FFR
Connect break box and adapter cable FFR
on the cable harness side
Check cables of the following pins at Check cables and plug connectors (control
control unit FFR: unit, X1562, X1553, X1948 and valve block)
for
X3/5, X3/10, X3/13, X4/1, X4/6, X4/7, X4/13
No Oxidation
Carry out resistance measurement to check
Damage to insulation
for:
Loose contact
Short circuit to negative
Water/moisture in the cable harness
Short circuit to positive
(e.g. FFR, pin X1/1) Repair, if necessary.
Short circuit between cables

Setpoint: R = or O.L.
Measurement values OK?

Yes

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Check cables from FFR to valve block
for open circuits.
Check the following cables for open
circuits by measuring resistance Check cables 60353 and 31023 and

between the following pins: No plug connectors (control unit, X1562,

X1553, X1948 and valve block) for
FFR, plug X4 pin 7 and valve block pin 6
damage, loose contacts, pushed back plug
FFR, plug X4 pin 6 and valve block pin 4
contacts and contact oxidation, etc. Repair if
Setpoint: R = 0 0,5 necessary.
Measurement values OK?

Yes
Replace FFR

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Resistance measurement at the solenoid valves in valve block New Ecosplit
Connect break box for measurement. Item number(s) of the break boxe(s), see page 5.
Measurement values in the following table are based on a temperature of approx. 20C.
Plug connections, Plug connection, Actual
FFR valve block Setpoint
Description value
()
PIN PIN PIN PIN ()

Solenoid valves, splitter box X3/13 X4/6 5 4 78

X4/7 X4/6 6 4 78
Solenoid valves, range-change group X4/1 X3/5 2 1 131
X3/10 X3/5 3 1 131
Solenoid valve, gate lock X4/13 X3/5 7 1 131
Resistance values are 20 to 30 Ohm higher at operating temperature (approx. 80C).
Alternatively to resistance measurement, voltage measurement can be carried out on the basis of the table
shown above. If the wiring is correct, the voltage drop must be a maximum of 0.5 V after a measurement at
the FFR and then at the valve block.

Table: Pin assignment for plug connection of valve block electrics

Pin Description
1 Ground, range-change group and gate lock
2 High range-change group
3 Low range-change group
4 Ground, splitter box
5 Low splitter box in TD gearboxes or high splitter box in TO
gearboxes
6 High splitter box in TD gearboxes or low splitter box in TO
gearboxes
7 Shift lock

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Checking for leaks at the splitter box shift cylinder
Undo any air line of the splitter box shift cylinder.
Fully depress clutch while ignition is switched on. Air lines at the splitter box shift cylinder
If air flows out of the air line, switch over splitter box.
If air flows out of the splitter box shift cylinder,
seal shift cylinder.
(Note: sealing the shift cylinder is only possible
after the gearbox has been removed or disassembled)
Repeat test on the second air line.

No air must flow out after sealing/repairing the splitter box shift cylinder. Repeat test steps 4 and 5 in the test
step list for breather R1 (page 32).

Checking for leaks at the range-change group shift cylinder

Undo any air line of the range-change Air lines at the range-change
group shift cylinder. group shift cylinder
If air flows out of the air line, switch over
range-change group.
If air flows out of the range-change group
shift cylinder, seal shift cylinder.
Repeat test on the second air line.

No air must flow out after sealing/repairing the range-change group shift cylinder.
Repeat test steps 2 and 3 in the test step list for breather R2 (page 33).

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 Test step list for valve block New Ecosplit
(send in completed, enclose damaged component)

General vehicle data

Vehicle Identification No.

Gearbox number

Mileage

Complaint

Fault memory entry*

Initial registration
Previous repairs
Date Km Description

* Enclose MAN-cats II fault memory print-out with the damaged component.

Test sequence:
1. Read out fault memory with MAN-cats II
For fault memory entries 770, 771, 1045, 3305, 3306, 3308, 3309 in the vehicle management
computer (FFR), also see instructions as from page 5
2. Carry out work in accordance with test step list for electrics
3. Carry out work in accordance with test step list for pneumatics

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Test steps for electrics

The function of the valves can be tested with MAN-cats II.

For this purpose, select the following menu items in the main menu of MAN-cats II:
Diagnosis Central computer/instrumentation FFR/PTM/MFR Actuator test
To carry out the test, it is necessary to ensure that the shut-off pressure in the compressed-air system
has been reached.
MAN-cats II
Test Test result Possible remedy
menu item
Does the valve for the Yes ---
High range
highrange-change group
switch? Check cables, plug connections
(High
and valve block (resistance
range-change No
(Compressed air discharges measurement), repair if necessary
group)
during switching) or replace valve block.
Yes ---
Low range Does the valve for the
lowrange-change group switch? Check cables, plug connections
(Low
and valve block (resistance
range-change (Compressed air discharges No
measurement), repair if necessary
group) during switching)
or replace valve block.
Solenoid valve gate lock is Yes ---
operated in cyclical mode.
Hold gear lever and move from
shift gate 3-4 to shift gate 1-2.
Depending on whether the Check cables, plug connections
Gate detent solenoid valve of the gate lock is and valve block (resistance
No
energised, the gear lever can be measurement), repair if necessary
moved to shift gate 1-2 or is or replace valve block.
pressed back.
Was the gear lever pressed
back by the actuator test?
Does the valve of the Yes ---
low splitter box (TD) or the
Split high Check cables, plug connections
high splitter box (TO) switch?
and valve block (resistance
(Splitter box) No
(Compressed air discharges measurement), repair if necessary
during switching) or replace valve block.
Does the valve of the Yes ---
high splitter box (TD) or the
Split low Check cables, plug connections
low splitter box (TO) switch?
and valve block (resistance
(Splitter box) No
(Compressed air discharges measurement), repair if necessary
during switching) or replace valve block.
Solenoid valve testing can also be carried out by measuring resistance (voltage measurement),
measurement values see page 28.

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Test steps for pneumatics
The following tests are designed to establish under which conditions air is discharged from breather
R1 or R2. In addition, tests are listed that make it possible to ensure that no other component is the
cause of an air discharge at breather R1 or R2
Test breather R1

Breather R1

Test step list for breather R1

Breather R1
Test step Description
Not leaking Leaking
1 Ignition switched off
Gearbox position neutral
2 Ignition switched off
Engage gear
3 Switch on the ignition
Gearbox position neutral
Select high range-change group
3 Ignition switched on
Gearbox position neutral
Select low range-change group
4 Ignition switched on
Gearbox position neutral
Select low splitter box
Depress clutch.
5 Ignition switched on
Gearbox position neutral
Select high splitter box
Depress clutch.
If air discharge at breather R1 is determined during these test steps, a leak test must be performed on
the splitter box shift cylinder before replacing the valve block. See page 29.

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Test breather R2

Breather R2

Test step list for breather R2

Breather R2
Test step Description
Not leaking Leaking
1 Ignition switched off
Gearbox position neutral
2 Switch on the ignition
Gearbox position neutral
Select high range-change group
3 Ignition switched on
Gearbox position neutral
Select low range-change group
If air discharge at breather R2 is determined during these test steps, a leak test must be performed on
the range-change group shift cylinder before replacing the valve block. See page 29.

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