Voith Diwa.3 Trouble Shooting

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Voith. 55.6293.31 / 2002-03



Voith. Trouble Shooting I

It is your responsibility to familiarize yourself with the warnings and precautions described in thismanual.

This manual only contains the most important information, however. It is impossible to describeall conceivable mistakes and danger conditions.

Therefore, everybody who performs installation, repair or service work must very carefully en-sure that his personal safety or that of other persons is not at risk.

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 de-scribed in detail in the „Customer service letters“.

Furthermore, all work must be performed in accordance with Voith requirements to prevent dam-age to parts and tools.

Danger! in conjunction with the symbol on the left is used if personal injury or danger tolife may result if work is not carried out carefully.

Note! in conjunction with the symbol on the left denotes information that is particularlyimportant.



II Voith. Trouble Shooting

What is it for?

The manual serves the following purpose:

Special fault tracing in electrical transmission components or parts using the Voith PC-based diagnostic program DIWAGNOSIS.

Assistance in commissioning, maintenance, and repair of DIWA.3 and DIWA.3E trans-missions.

Additional DIWA.3 and DIWA.3E documentation

The following publications are available for transmission description, design, installation,the main tasks of maintenance and repair, etc.:

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?

Service technicians (e.g. testing, acceptance, etc.)

Automobile mechanics and electricians

Brochure Part No.for

transmission

Purpose

Technical Manual 55.6354. ..55.6356. ..

DIWA.3DIWA.3E

Function description of the transmis-sion, transmission data, installationinstructions, design and dimensionaldata for transmission assemblies

Servicing Schedule 55.6373. .. AllDIWA

Maintenance of DIWA transmissions

Lists of Lubricants 55.6335. ..55.6336. ..

AllDIWA

List of the lube oils that are approvedby Voith for DIWA transmissions

Fault Finding 55.6302. .. DIWA.3,DIWA.3E

General fault tracing, analysis, andrepair

Driving Instructions 55.6290. .. DIWA.3,DIWA.3E

Brief description of transmission op-eration for the bus driver

Diagnostic Manual 55.6263. .. DIWA.3,DIWA.3E

Use of the Voith PC-based diagnosticprogram DIWAGNOSIS

Spare Parts Catalogs 55.6600. ..55.6601. ..55.6602. ..55.6603. ..

D 851.3ED 854.3ED 863.3ED 864.3E

Illustration and designation of trans-mission parts for spare parts ordering

Repair Manual 55.6320. ..55.6704. ..

DIWA.3DIWA.3E

Description of transmission disas-sembly and assembly of 3- and 4-

speed transmissions

Technical Description withOil and Control Circuit

Diagrams

55.6308. ..55.6310. ..

DIWA.3DIWA.3E

Representation of the oil circuits forthe various transmission gear shifts



Voith. Trouble Shooting III

If transmission malfunctions occur, fault may be present in

a) the control unit records,b) in the electrical orc) mechanical part of electromechanical ord) purely mechanical components.

In the case of faults in a) and b), use of "Diagnostic Manual" and "Trouble Shooting", if required,alone may be sufficient for repair. However, since malfunctions in c) and d) are not detected bythe control and/or diagnosis, it is recommended to refer to the appropriate Voith documentationand programs for transmission malfunction repairs in the following order, for example:

Read out the fault memory of the transmission control unit by means of the diagnostic programDIWAGNOSIS:

Malfunction analysis and information about possible remedies, if required, information abouttransmission design and function in the "Technical Manuals" and in the "Technical Descriptionswith Oil and Control Circuit Diagrams" for DIWA.3 and DIWA.3E:

Use of the diagnostic program for fault tracing:

Tracing of possible faults in the electrical system of DIWA.3 and DIWA.3E transmissions:

Transmission repair and spare parts ordering:

Diagnostic Manual

Fault Finding

Diagnostic Manual

Trouble Shooting

Repair Manual,Spare Parts Catalogs



IV Voith. Trouble Shooting



Voith. Trouble Shooting V

Page

Differences between DIWA.3 and DIWA.3E in terms of trouble-shooting................................VII

A. Introduction ......................................................................................................................... 1

1. Control and diagnosis......................................................................................................... 3

1.1 Faulty component: Voltage supply to control unit ..................................................... 3

1.2 Faulty component: Diagnosis connection................................................................ 4

2. Sensors...............................................................................................................................5

2.1 Faulty component: Inductive pick-up N1...................................................................5

2.2 Faulty component: Inductive pick-up N2.................................................................. 6

2.3 Faulty component: Inductive pick-up N3.................................................................. 7

2.4 Faulty component: Oil temperature transmitter ....................................................... 8

3. Solenoids ............................................................................................................................9

3.1 Solenoids with measuring coil .................................................................................. 9

3.1.1 Faulty component: EK solenoid................................................................... 93.1.2 Faulty component: TB solenoid ................................................................. 103.1.3 Faulty component: PB solenoid.................................................................113.1.4 Faulty component: DK solenoid ................................................................123.1.5 Faulty component: SK solenoid.................................................................133.1.6 Faulty component: RBK solenoid ..............................................................14

3.2 Solenoids without measuring coil .......................................................................... 15

3.2.1 Faulty component: RBG solenoid..............................................................153.2.2 Faulty component: WP solenoid for DIWA.3 .............................................163.2.3 Faulty component: WP solenoid for DIWA.3E...........................................173.2.4 Faulty component: WR solenoid ............................................................... 18

4. Relays and pilot lights ....................................................................................................... 19

4.1 Faulty component: Converter brake relay dW ........................................................19

4.2 Faulty component: Speed switch relay dN ............................................................ 20

4.3 Faulty component: Reversing light relay dR.......................................................... 21

4.4 Faulty component: Starter inhibitor relay............................................................... 22

4.5 Faulty component: Stop brake............................................................................... 23

4.5.1 Faulty component: Stop brake relay dHSB ............................................... 234.5.2 Faulty component: Stop brake actuation...................................................24

4.6 Faulty component: Central warning light (ZW) ...................................................... 25

4.6.1 Faulty component: ZW relay .....................................................................254.6.2 Faulty component: ZW bulb ......................................................................26

4.7 Faulty component: Voltage supply to solenoid valves........................................... 27

4.7.1 Faulty component: Control relay dS .......................................................... 27

4.7.2 Faulty component: Solenoid valve voltage................................................28

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VI Voith. Trouble Shooting

5. Controllers.........................................................................................................................29

5.1 Faulty component: Push-button switch ...................................................................29

5.2 Faulty component: Manual converter brake switch................................................ 31

5.3 Faulty component: Switch for converter braking stage 3 ....................................... 33

5.4 Faulty component: Brake valve (service brake transmitter)................................... 35

5.5 Faulty component: Voith load transmitter orEMR with VDO load transmitter ............................................................................. 37

5.6 Faulty component: Kickdown switch...................................................................... 39

6. Signal conductors to motor control units ...........................................................................41

6.1 Faulty component: BOSCH electronic throttle control EMS 3.3 B/G ......................41

6.2 Faulty component: MB FMR .................................................................................. 42

6.3 Faulty component: CAN-Bus ................................................................................. 43

6.4 Faulty component: dNEUTR output....................................................................... 44

7. Other switches and warning lights ....................................................................................45

7.1 Faulty component: ABS connection........................................................................45

7.2 Faulty component: Transmission oil warning light ..................................................46

7.3 Faulty component: Converter brake release switch............................................... 47

7.4 Faulty component: Gearshift inhibitor switch ......................................................... 48

7.5 Faulty component: ANS activation switch.............................................................. 49

8. Cables and plugs ..............................................................................................................51

8.1 Connection of cable 1 to control unit.......................................................................51

8.2 Connection of cable 1 to transmission housing ..................................................... 52

8.3 Connection of cable 2 to control unit...................................................................... 53

8.4 Measuring cable 56.4461.12.................................................................................. 54

8.5 Level converter 56.4219.10 ................................................................................... 55

9. Appendices .......................................................................................................................57

1 Circuit diagram DIWA.3

1 Circuit diagram DIWA.3E

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Voith. Trouble Shooting VII

As mentioned in the next chapter, only parts or components that can be accessed by the Voithdiagnostic system are concerned here, i. e. mainly electrical parts.

The decisive reference is the circuit diagram. Since there are hardly any fundamental differencesbetween the circuit diagrams of DIWA.3 and DIWA.3E transmissions (see chap. 9. Circuit dia-gram DIWA.3 55.3705.20 and Circuit diagram DIWA.3E 55.6168.10), however, the differencesin fault-tracing procedures are minor, too.

See also:

Chap. 3.2.2 and Chap. 3.2.3,

Chap. 8.1,

Chap. 8.2,

Chap. 8.4



VIII Voith. Trouble Shooting



Voith. Trouble Shooting 1

Purpose

The purpose of this manual is to enable the service engineer to systematically search for defec-tive components or malfunctions in DIWA.3 and DIWA.3E transmissions. However, the manualonly covers parts or components that can be tested using the Voith diagnostic system, i. e. most-ly electrical parts.

Before trouble-shooting

The following preparations described in the "Diagnostic Manual" are necessary before trouble-shooting can begin:

Connect a suitable PC (laptop) to the transmission control via the cable (level converter) pro-vided for this purpose

Start the diagnostic program

Start communication

Read fault memory (function B)

Test faulty components individually once again (functions C, D, E, F, G, H and J). This is tofind out whether the fault still exists.

How to proceed with the "Trouble Shooting"

The trouble-shooting procedure is as follows:

1. Switch off vehicle ignition for all measurements unless you are expressly instructed at somepoint in this manual not to do so.

2. Open plug connection between control unit and cable 1 or cable 2. This is where the test mea-surements should begin.

If measured values differ from set points, narrow down the number of potentially defective partsor components by proceeding with the next step.With regard to relay and plug designs and theircontact designations the circuit diagrams 55.3705.20 for DIWA.3 and 55.6168.10 for DIWA.3Eare used, provided that the respective components were shown in it.

After completion of "Trouble Shooting"

Erase fault memory after repair of the defect by pressing function key B (see "Diagnostic Manu-al").

Danger! Always apply the parking brake before proceeding with diagnosis at vehiclestandstill.

Note! In the case of other circuit diagrams, relay and plug designs and their contact des-ignations may differ.



2 Voith. Trouble Shooting




1.1 Faulty component: Voltage supply to control unit

Ω

V

Ω

Ω

Relay "control" Electronic control unit

E 200

Vehicle

supply

system

Cable 2

Connection cable

Rtarget = 0 Ω

Utarget = approx. 24 V

Rtarget = ∞ Ω

Rtarget = 0 Ω

Step Activity and location Fuse, pins or contacts

1. Switch on ignition.If control unit E 200 does not operate properly, checkwhether 8 A fuse F1 in connection cable to vehicle sup-

ply system is blown.2. Open connection SV.2.

Measure voltage between contacts 19and 21 (cable 2). Utarget = approx. 24 V.Switch off ignition.

SV.2

3. Measure resistance between contact19 and the conductor to contact 30 (dSrelay). Rtarget = 0 Ω.

4. Measure resistance between contact19 and the conductor in connection ca-ble to fuse F1. Rtarget = 0 Ω.

5. Measure resistance between contact21 and vehicle earth. Rtarget = 0 Ω.If R = Rtarget for all of measurements 3to 5, proceed with step 8.

6. Open SV.19.Measure resistance between contact 19 (cable 2) andcontact X (+UZ) of the connection cable to the vehiclesupply system. The number of X is shown in the circuitdiagram. Rtarget = 0 Ω.

SV.19; variant

7. Measure resistance between contact Y (-UB) of earth-ing cable (M) and vehicle earth. The number of Y is

shown in the circuit diagram. Rtarget = 0 Ω.

8. SV.2: Measure resistance between contact 19 and earth. Rtarget = ∞ Ω.

9. SV.19: Measure resistance between contact X (+UZ) and earth. Rtarget = ∞ Ω.



1. Control and diagnosis


1.2 Faulty component: Diagnosis connection

Ω

Ω

V

Rtarget = ∞ Ω Rtarget = 0 Ω

Utarget = approx. 24 VLevel converter ( see Chap. 8. )

Diagnosis-PC

Electronic control unit

E 200

Step Activity and location Pins or contacts

1. Switch on ignition.Open plug connection SV.31 (cable 2).Measure voltage between contacts 1and 2 (earth).Utarget = approx. 24 V.Switch off ignition.

SV.31

2. Open plug connections SV.2 (cable 2).Measure resistance betweencontacts 16 (SV.2) and 10 (SV.31),contacts 19 (SV.2) and 1 (SV.31),contacts 21 (SV.2) and 2 (SV.31),contacts 52 (SV.2) and 8 (SV.31).Rtarget = 0 Ω.

SV.2

3. SV.2: Measure resistance betweencontacts 16, 19, 21, and 52 (cable 2)

and vehicle earth. Rtarget = ∞ Ω.




2.1 Faulty component: Inductive pick-up N1

Ω

Ω

DIWA.3/.3E

transmission Cable 1

Cable harness

Connection for in-

ductive pick-up N1

Inductive

pick-up N1Electronic control unit

E 200

Rtarget = ∞ Ω

Rtarget = 800-1400 Ω


1. Open plug connection SV.1.Measure resistance between contacts11 and 47 of cable 1.

Rtarget = 800-1400 Ω.If R = Rtarget continue with step 5.(For the plug see Chap. 8.)

SV.1

2. Open SV.3.Measure resistance between pins Cand D of cable harness or the N1-con-tacts of the measuring cable.(For the plug see Chap. 8.)Rtarget = 800-1400 Ω.

SV.3; Cable harness SV.3; Measuring cable56.4461.12

3. Remove control cover.Open SV.4.Measure resistance between contacts 1 and 2 of the connector forinductive pick-up N1. Rtarget = 800-1400 Ω.

SV.4

4. Remove oil sump.Remove gear pump with inductive pick-up N1.Open SV.5.Measure resistance between pins of pick-up N1.Rtarget = 800-1400 Ω.

SV.5

5. Measure resistance between contact 47 and vehicle earth. Rtarget = ∞ Ω.

6. Open SV.3. Measure resistance between contact C and earth. Rtarget = ∞ Ω.

7. Open SV.4. Measure resistance between contact 2 and earth. Rtarget = ∞ Ω.

8. Open SV.5. Measure resistance between a contact and earth. Rtarget = ∞ Ω.



2. Sensors



Ω

Ω

DIWA.3/.3E


Cable harness

with connection

for inductive pick-

up N2

Inductive

pick-up N2 Electronic control unit E 200

Rtarget = ∞ Ω



1. Open plug connection SV.1.Measure resistance between contacts10 and 29 of cable 1.

Rtarget = 800-1400 Ω.If R = Rtarget continue with step 4.

SV.1

2. Open SV.3.Measure resistance between pins Eand F of cable harness or the N2-con-tacts of the measuring cable.Rtarget = 800-1400 Ω.


3. On transmission output side: remove cap from above pick-up N2.

Open SV.7.Measure resistance between pins of pick-up N2.Rtarget = 800-1400 Ω.

SV.7


5. Open SV.3. Measure resistance between contact F and earth. Rtarget = ∞ Ω.




2. Sensors



Ω

Ω

DIWA.3/.3E


Cable harness

with connection

for inductive

pick-up N3

Inductive pick-up N3


E 200

Rtarget = ∞ Ω



1. Open plug connection SV.1.Measure resistance between contacts28 and 46 of cable 1.Rtarget = 800-1400 Ω.If R = Rtarget continue with step 4.

SV.1

2. Open SV.3.Measure resistance between pins Gand H of cable harness or the N3-con-tacts of the measuring cable.Rtarget = 800-1400 Ω.


3. On transmission housing: remove cap from above pick-up N3.Open SV.8. Measure resistance between pins of pick-up N3.Rtarget = 800-1400 Ω.

SV.8


5. Open SV.3. Measure resistance between contact H and earth. Rtarget = ∞ Ω.




2. Sensors


2.4 Faulty component: Oil temperature transmitter

Ω

Ω

DIWA.3/.3E

transmission Cable 1Cable harness

Oil temperature

transmitter Electronic control unit

E 200

Rtarget = ∞ Ω

Connection for oil temperature

transmitter

Oil temp. ϑ Rtarget

0 [°C] 810 [Ω]

20 [°C] 950 [Ω]

70 [°C] 1360 [Ω]

90 [°C] 1550 [Ω]

120 [°C] 1860 [Ω]

140 [°C] 2090 [Ω]


1. Open plug connection SV.1.Measure resistance between contacts8 and 44 of cable 1.For Rtarget see chart above.If R = Rtarget continue with step 5.

SV.1

2. Open SV.3.Measure resistance between pins a

and Z of cable harness or the N1-con-tacts of the measuring cable.For Rtarget see chart above.


3. Remove control cover.Open SV.4. Measure resistance between contacts 3 and 4 of theconnector for the oil temperature transmitter.For Rtarget see chart above.

SV.4

4. Remove oil sump.Open SV.9.On TB accumulator: measure resistance between pins of oil temper-ature transmitter.For Rtarget see chart above.

SV.9


6. Open SV.3. Measure resistance between contact Z and earth. Rtarget = ∞ Ω.

7. Open SV.4. Measure resistance between contact 4 and earth. Rtarget = ∞ Ω.





3.1 Solenoids with measuring coil

3.1.1 Faulty component: EK solenoid

Ω

Ω

DIWA.3/.3E

transmission

Cable harness


E 200

Cable 1

EK solenoid

Working

coil

Measur-

ing coil

Rtarget = ∞ Ω

RtargetCoil +

cable 1Coil only

Working coil 11 - 20 [Ω] 11±0,7 [Ω]Measuring

coil5 - 10 [Ω] 5,2±0,3 [Ω]


1. Open plug connection SV.1.a) Working coil: Measure resistancebetween contacts 19 and 52 or 53 ofcable 1.R

target = 11-20 Ω.

b) Measuring coil: Measure resistancebetween contacts 15 and 31 or 49.Rtarget = 5-10 Ω.If R = Rtarget continue with step 4.

SV.1

2. Open SV.3.a) Working coil: Measure resistancebetween contacts L and A or B (cableharness) or EK and – UB (measuringcable). Rtarget = 11-20 Ω.b) Measuring coil: Measure resistancebetween contacts c and h or j (cable

harness) or EKM and SENSE (measur-ing cable).Rtarget = 5-10 Ω.

SV.3; Cable harness SV.3; measuring cable56.4461.12

3. Remove control cover.Open SV.10.a) Working coil: Measure resistance between pins 1 and 2 of the EKsolenoid flat pin connector. Rtarget = 11±0,7 Ω.b) Measuring coil: Measure resistance between pins 3 and 4 of theEK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.

SV.10

4. Measure resistance between contact 15 and vehicle earth. Rtarget = ∞ Ω.Measure resistance between contacts 15 and 19. Rtarget = ∞ Ω.

5. Open SV.3. Measure resistance between contact c (or EKM) and earth. Rtarget = ∞ Ω.Measure resistance between contacts c (or EKM) and L (or EK). Rtarget = ∞ Ω.

6. Open SV.10. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω.Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.



3. Solenoids


3.1.2 Faulty component: TB solenoid

Ω

Ω

DIWA.3/.3E

transmission

Cable harness


E 200

Cable 1

TB solenoid

Working

coil

Measur-

ing coil

Rtarget = ∞ Ω

RtargetCoil +

cable 1Coil only

Working coil 11 - 20 [Ω] 11±0,7 [Ω]

Measuringcoil

5 - 10 [Ω] 5,2±0,3 [Ω]


1. Open plug connection SV.1.a) Working coil: Measure resistancebetween contacts 20 and 52 or 53 ofcable 1.Rtarget = 11-20 Ω.b) Measuring coil: Measure resistancebetween contacts 50 and 31 or 49.Rtarget = 5-10 Ω.If R = Rtarget continue with step 4.

SV.1

2. Open SV.3.a) Working coil: Measure resistancebetween contacts S and A or B (cableharness) or TB and – UB (measuringcable).Rtarget = 11-20 Ω.b) Measuring coil: Measure resistancebetween contacts f and h or j (cableharness) or TBM and SENSE (measur-ing cable).Rtarget = 5-10 Ω.


3. Remove control cover.Open SV.11.a) Working coil: Measure resistance between pins 1 and 2 of the TBsolenoid flat pin connector. Rtarget = 11±0,7 Ω.b) Measuring coil: Measure resistance between pins 3 and 4 of theTB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.

SV.11


5. Open SV.3. Measure resistance between contact f (or TBM) and earth. Rtarget = ∞ Ω.Measure resistance between contacts f (or TBM) and S (or TB). Rtarget = ∞ Ω.

6. Open SV.11. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω.

Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.



3. Solenoids


3.1.3 Faulty component: PB solenoid

Ω

Ω

DIWA.3/.3E

transmission

Cable harness


E 200

Cable 1

PB solenoid

Working

coil

Measur-

ing coil

Rtarget = ∞ Ω

RtargetCoil +

cable 1Coil only

Working coil 11 - 20 [Ω] 11±0,7 [Ω]

Measuringcoil

5 - 10 [Ω] 5,2±0,3 [Ω]


1. Open plug connection SV.1.a) Working coil: Measure resistancebetween contacts 2 and 52 or 53 of ca-ble 1.Rtarget = 11-20 Ω.b) Measuring coil: Measure resistancebetween contacts 14 and 31 or 49.Rtarget = 5-10 Ω.If R = Rtarget continue with step 4.

SV.1

2. Open SV.3.a) Working coil: Measure resistancebetween contacts M and A or B (cableharness) or PB and – UB (measuringcable).Rtarget = 11-20 Ω.b) Measuring coil: Measure resistancebetween contacts d and h or j (cableharness) or PBM and SENSE (measur-ing cable).Rtarget = 5-10 Ω.


3. Remove control cover.Open SV.12.a) Working coil: Measure resistance between pins 1 and 2 of the PBsolenoid flat pin connector. Rtarget = 11±0,7 Ω.b) Measuring coil: Measure resistance between pins 3 and 4 of thePB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.

SV.12


5. Open SV.3. Measure resistance between contact d (or PBM) and earth. Rtarget = ∞ Ω.Measure resistance between contacts d (or PBM) and M (or PB). Rtarget = ∞ Ω.





3. Solenoids


3.1.4 Faulty component: DK solenoid

Ω

Ω

DIWA.3/.3E

transmission

Cable harness


E 200

Cable 1

DK solenoid

Working

coil

Measur-

ing coil

Rtarget = ∞ Ω

RtargetCoil +

cable 1Coil only

Working coil 11 - 20 [Ω] 11±0,7 [Ω]

Measuringcoil

5 - 10 [Ω] 5,2±0,3 [Ω]



SV.1

2. Open SV.3.a) Working coil: Measure resistancebetween contacts K and A or B (cableharness) or DK and – UB (measuringcable).Rtarget = 11-20 Ω.b) Measuring coil: Measure resistancebetween contacts b and h or j (cableharness) or DKM and SENSE (mea-suring cable).Rtarget = 5-10 Ω.


3. Remove control cover.Open SV.13.a) Working coil: Measure resistance between pins 1 and 2 of the DKsolenoid flat pin connector. Rtarget = 11±0,7 Ω.b) Measuring coil: Measure resistance between pins 3 and 4 of theDK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.

SV.13


5. Open SV.3. Measure resistance between contact b (or DKM) and earth. Rtarget = ∞ Ω.Measure resistance between contacts b (or DKM) and K (or DK). Rtarget = ∞ Ω.





3. Solenoids


3.1.5 Faulty component: SK solenoid

Ω

Ω

DIWA.3/.3E

transmission

Cable harness


E 200

Cable 1

SK solenoid

Working

coil

Measur-

ing coil

Rtarget = ∞ Ω

RtargetCoil +

cable 1Coil only

Working coil 11 - 20 [Ω] 11±0,7 [Ω]

Measuringcoil

5 - 10 [Ω] 5,2±0,3 [Ω]



SV.1

2. Open SV.3.a) Working coil: Measure resistancebetween contacts U and A or B (cableharness) or SK and – UB (measuringcable).Rtarget = 11-20 Ω.b) Measuring coil: Measure resistancebetween contacts g and h or j (cableharness) or SKM and SENSE (measur-ing cable).Rtarget = 5-10 Ω.


3. Remove control cover.Open SV.14.a) Working coil: Measure resistance between pins 1 and 2 of the SKsolenoid flat pin connector. Rtarget = 11±0,7 Ω.b) Measuring coil: Measure resistance between pins 3 and 4 of theSK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.

SV.14


5. Open SV.3. Measure resistance between contact g (or SKM) and earth. Rtarget = ∞ Ω.Measure resistance between contacts g (or SKM) and U (or SK). Rtarget = ∞ Ω.





3. Solenoids


3.1.6 Faulty component: RBK solenoid

Ω

Ω

DIWA.3/.3E

transmission

Cable harness


E 200

Cable 1

RBK solenoid

Working

coil

Measur-

ing coil

Rtarget = ∞ Ω

RtargetCoil +

cable 1Coil only

Working coil 11 - 20 [Ω] 11±0,7 [Ω]

Measuringcoil

5 - 10 [Ω] 5,2±0,3 [Ω]



SV.1

2. Open SV.3.a) Working coil: Measure resistancebetween contacts P and A or B (cableharness) or RBK and – UB (measuringcable).Rtarget = 11-20 Ω.b) Measuring coil: Measure resistancebetween contacts e and h or j (cableharness) or RBKM and SENSE (mea-suring cable).Rtarget = 5-10 Ω.


3. Remove control cover.Open SV.15.a) Working coil: Measure resistance between pins 1 and 2 of theRBK solenoid flat pin connector. Rtarget = 11±0,7 Ω.b) Measuring coil: Measure resistance between pins 3 and 4 of theRBK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω

SV.15


5. Open SV.3. Measure resistance between contact e (or RBKM) and earth. Rtarget = ∞ Ω.Measure resistance between contacts e (or RBKM) and P (or RBK). Rtarget = ∞ Ω.





3. Solenoids


3.2 Solenoids without measuring coil

3.2.1 Faulty component: RBG solenoid

Ω

Ω

DIWA.3/.3E

transmission

Cable harness


E 200

Cable 1

RBG solenoid

RtargetCoil +

cable 1Coil only

11 - 20 [Ω] 11±0,7 [Ω]

Rtarget = ∞ Ω


1. Open plug connection SV.1.Measure resistance between contacts17 and 52 or 53 of cable 1.Rtarget = 11-20 Ω.If R = Rtarget continue with step 4.

SV.1

2. Open SV.3.Measure resistance between contactsR and A or B (cable harness) or RBGand – UB (measuring cable).Rtarget = 11-20 Ω.


3. Remove control cover.Open SV.16.Measure resistance between pins 1 and 2 of the RBG solenoid flat

pin connector.Rtarget = 11±0,7 [Ω].

SV.16




3. Solenoids


3.2.2 Faulty component: WP solenoid for DIWA.3

Ω

Ω

DIWA.3

transmission

Cable harness


E 200

Cable 1

WP solenoid

RtargetCoil +

cable 1Coil only

11 - 20 [Ω] 11±0,7 [Ω]

Rtarget = ∞ Ω



SV.1

2. Open SV.3.Measure resistance between contacts

N and A or B (cable harness) or WPand – UB (measuring cable).Rtarget = 11-20 Ω.


3. Remove control cover.Open SV.17.Measure resistance between pins 1 and 2 of the WP solenoid flat pinconnector.Rtarget = 11±0,7 [Ω].

SV.17




3. Solenoids


3.2.3 Faulty component: WP solenoid for DIWA.3E

Ω

Ω

DIWA.3E

transmission

Cable harness


E 200

Cable 1

WP solenoid

RtargetCoil +

cable 1Coil only

11 - 20 [Ω] 11±0,7 [Ω]

Rtarget = ∞ Ω



SV.1

2. Open SV.3.Measure resistance between contactsT and A or B (cable harness) or WPand – UB (measuring cable).Rtarget = 11-20 Ω.


3. Remove control cover.Open SV.17.Measure resistance between pins 1 and 2 of the WP solenoid flat pinconnector.

Rtarget = 11±0,7 [Ω].

SV.17




3. Solenoids


3.2.4 Faulty component: WR solenoid

Ω

Ω

DIWA.3/.3E

transmission

Cable harness


E 200

Cable 1

WR solenoid

RtargetCoil +

cable 1Coil only

11 - 20 [Ω] 11±0,7 [Ω]

Rtarget = ∞ Ω



SV.1

2. Open SV.3.Measure resistance between contactsJ and A or B (cable harness) or WR

and – UB (measuring cable).Rtarget = 11-20 Ω.


3. Remove control cover.Open SV.18.Measure resistance between pins 1 and 2 of the WR solenoid flat pinconnector.Rtarget = 11±0,7 [Ω].

SV.18






4. Relays and pilot lights


4.2 Faulty component: Speed switch relay dN

Ω

Ω


E 200

Cable 2

Speed switch

relay

Connection cable

Rtarget = 0 Ω Rtarget = 285-310 Ω


1. Replace dN relay by a new one or re-move relay and measure resistance di-rectly between coil contacts 85 and 86.Rtarget = 285-310 Ω.

2. Open plug connector SV.2.For the following steps, connect one

feeler of the ohmmeter to vehicle earth.Measure resistance at contact 50 ofcable 2.Rtarget = 285-310 Ω.If R = Rtarget continue with step 5.

SV.2

3. Open SV.19.Measure resistance at pin X (dN) of theconnection cable to the dN relay. Thenumber of contact X can be found inthe circuit diagram.Rtarget = 285-310 Ω.

SV.19; variant

4. Mounting plug SV.20: Measure resis-tance at the cable to the start of thewinding of the dN relay (pin 86).Rtarget = 285-310 Ω.

SV.20

5. SV.20: Measure resistance at the ca-ble to the end of the winding of the dNrelay (pin 85) and earthing point M.Rtarget = 0 Ω.

dN





4.3 Faulty component: Reversing light relay dR

Ω

Ω

Electronic control unit E 200

Cable 2

Reversing light

relay

Connection cable



1. Replace dR relay by a new one or re-move relay and measure resistance di-rectly between coil contacts 85 and 86.Rtarget = 285-310 Ω.

2. Open plug connector SV.2.For the following steps, connect one

feeler of the ohmmeter to vehicle earth.Measure resistance at contact 14 ofcable 2.Rtarget = 285-310 Ω.If R = Rtarget continue with step 5.

SV.2

3. Open SV.19.Measure resistance at pin X (dR) of theconnection cable to the dR relay. Thenumber of contact X can be found inthe circuit diagram.Rtarget = 285-310 Ω.

SV.19; variant

4. Mounting plug SV.20: Measure resis-tance at the cable to the start of thewinding of the dR relay (pin 86).Rtarget = 285-310 Ω.

SV.20

5. SV. 20: Measure resistance at the ca-ble to the end of the winding of the dRrelay (pin 85) and earthing point M.Rtarget = 0 Ω.

dR





4.4 Faulty component: Starter inhibitor relay

Ω

Ω

Cable 2

Starter inhibitor

relay

Connection cable

Rtarget = 0 ΩRtarget = 285-310 Ω

Vehicle

electrical

system

Step Activity and location Pins or contacts, relay

1. Replace starter inhibitor relay by a newone or measure resistance directly be-tween winding contacts 85 and 86 afterremoval of the relay.Rtarget = 285-310 Ω.

2. Open connection SV.24(see Chap. 5.1).For the following steps, connect onefeeler of the ohmmeter to vehicle earth.Measure resistance at contact 16 ofcable 2.Rtarget = 285-310 Ω.If R = Rtarget, continue with step 5.

SV.24

3. Open SV.19.Measure resistance at pin contact X(SSP) of the connection cable to thestarter inhibitor relay. The number ofcontact X is shown in the circuit dia-

gram.Rtarget = 285-310 Ω.

SV.19; variant

4. Mounting plug SV.20: Measure resis-tance at the cable to the beginning ofthe winding of the starter inhibitor relay(pin contact 86).Rtarget = 285-310 Ω.

SV.20

5. SV.20: Measure resistance at the ca-ble to the end of the winding of thestarter inhibitor relay (pin contact 85)and earthing point M.Rtarget = 0 Ω.

Starterinhibitor





4.5 Faulty component: Stop brake

4.5.1 Faulty component: Stop brake relay dHSB

Ω

Ω

Cable 2

Stop brake

relay

Connection cable

Rtarget = 0 Ω


Stop brake

switch (HSB)


E 200


First, check whether the diagnosis shows a defect of the dHSB relay (a) or not (b).Case a: take steps 1 to 5.Case b: take steps 1 and 6 to 13 (see opposite page).

1. Replace dHSB relay by a new one ormeasure resistance directly betweenwinding contacts 85 and 86 after re-moval of the relay.Rtarget = 285-310 Ω.

2. Open connection SV.2.For steps 1 to 5, connect one feeler ofthe ohmmeter to vehicle earth. Mea-sure resistance at contact 32 of cable2.Rtarget = 285-310 Ω.If R = Rtarget, continue with step 5.

SV.2

3. Open SV.19.Measure resistance at pin contact X(dHSB) of the connection cable to thedHSB relay. The number of contact Xis shown in the circuit diagram.Rtarget = 285-310 Ω.

SV.19; variant

4. Mounting plug SV.20: Measure resis-tance at the cable to the beginning ofthe winding of the dHSB relay (pin con-tact 86).Rtarget = 285-310 Ω.

SV.20

5. SV.20: Measure resistance at the ca-ble to the end of the winding of thedHSB relay (pin contact 85) and earth-

ing point M1.Rtarget = 0 Ω.

dHSB







4.6 Faulty component: Central warning light (ZW)

4.6.1 Faulty component: ZW relay

Ω

Ω

Cable 2

Central warning

light relay

Connection cable


Central warning light


E 200


First, check whether the diagnosis shows a defect of the ZW relay (a) or not (b).Case a: take steps 1 to 5.Case b: take steps 1 and 6 to 9 (see opposite page).

1. Replace ZW relay by a new one ormeasure resistance directly betweenwinding contacts 85 and 86 after re-moval of the relay.Rtarget = 285-310 Ω.

2. Open connection SV.2.For steps 1 to 5, connect one feeler ofthe ohmmeter to vehicle earth. Mea-sure resistance at contact 51 of cable2.Rtarget = 285-310 Ω.If R = Rtarget, continue with step 5.

SV.2

3. Open SV.19Measure resistance at pin contact X

(ZW) of the connection cable to the ZWrelay. The number of contact X isshown in the circuit diagram.Rtarget = 285-310 Ω.

SV.19; variant

4. Mounting plug SV.20: Measure resis-tance at the cable to the beginning ofthe winding of the ZW relay (pin con-tact 86).Rtarget = 285-310 Ω.

SV.20

5. SV.20: Measure resistance at the ca-ble to the end of the winding of the ZW

relay (pin contact 85) and earthingpoint M1.Rtarget = 0 Ω.

ZW







4.7 Faulty component: Voltage supply to solenoid valves

4.7.1 Faulty component: Control relay dS

Ω

Ω

Cable 2

Control

relay

Connection cable

Rtarget = 0 Ω


Vehicle

electrical

system

Electronic control unit E 200


1. Replace dS relay by a new one or mea-sure resistance directly between wind-ing contacts 85 and 86 after removal ofthe relay.Rtarget = 285-310 Ω.

2. Open connection SV.2.For the following steps, connect onefeeler of the ohmmeter to vehicle earth.Measure resistance at contact 13 ofcable 2.Rtarget = 285-310 Ω.If R = Rtarget, continue with step 5.

SV.2

3. Open SV.19.Measure resistance at pin contact X(dS) of the connection cable to the dSrelay. The number of contact X isshown in the circuit diagram.Rtarget = 285-310 Ω.

SV.19; variant

4. Mounting plug SV.20: Measure resis-tance at the cable to the beginning ofthe winding of the dS relay (pin contact86).Rtarget = 285-310 Ω.

SV.20

5. SV.20: Measure resistance at the ca-ble to the end of the winding of the dSrelay (pin contact 85) and earthingpoint M.Rtarget = 0 Ω.

If R = Rtarget continue with step 6 on theopposite page.

dS






5.1 Faulty component: Push-button switch

Check 3, 4, and 5-button switches accordingly

* = Resistance when R-button is depressed too

+TS

Ω

Ω


E 200

6-button switch

Rtarget = ∞ Ω

Rtarget see tables 1, 2, 3

Connections at 3, 4-,5-

and 6-button switches

Reversing inhibitor

switch (Sp.Rg.)

Connection cable Push-button switch

to SV.19, contact X

( see Chap. 4.4 )

Cable 2


1. If switch illumination is defective, re-place bulb.

2. Open connections SV.2 and SV.19.SV.19 see Chap. 4.4 and contact Xsee Chap. 9.Operate button (switch) as per table 1below according to the diagnostic faultindication and measure resistancesbetween contacts.If R = Rtarget for all measurements,continue with step 5.

SV.2

SV.19, variant

Table 1

Button,

Switch

SV.2:

Measurement

btw. contact 33

(TL) and:

Rtarget [Ω]:

Button depr./

not depressed

Measurement

btw. SV.2, con-

tact 29 (TS)

and SV.19:

Rtarget [Ω]:

Button depr.

(N depressed)

[not N depr.]

SV.2: Mea-

surement btw.

contact 29 (TS)

and:

Rtarget [Ω]:

Button depr.

(N depressed)

[not N depr.]

SV.2: Mea-

surement btw.

contact 29 (TS)

and:

Rtarget [Ω]:

Button depr.

(not depressed)

1 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 27 (S1) 0 (∞)

2 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 45 (S2) 0 (∞)

3 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 9 (S3) 0 (∞)

D 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 28 (+V) 0 (∞)

N 21 (-UB) appr. 580 X (SSP) 0 [∞] 10 (/N) ∞ [0]R 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 46 (+R) 0 (∞)

Sp.Rg. appr. 580 30 (RS) 0*(∞)*



5. Controllers





3. Open SV.24.Operate button (switch) as per table 2below according to the diagnostic faultindication and measure resistances

between contacts.

SV.24

Table 2

Button,

Switch

Measurement

btw. contact

8 (TL) and:

Rtarget [Ω]:

Button depr./

not depressed

Measurement

btw. contact

7 (TS) and:

Rtarget [Ω]:

Button depr.

(N depressed)

[not N depr.]

Measurement

btw. contact

7 (TS) and:

Rtarget [Ω]:

Button depr.

(N depressed)

[not N depr.]

Measurement

btw. contact

7 (TS) and:

Rtarget [Ω]:

Button depr.

(not depressed)

1 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 (∞) 1 (S1) 0 (∞)

2 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 (∞) 2 (S2) 0 (∞)

3 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 (∞) 3 (S3) 0 (∞)

D 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 (∞) 4 (+V) 0 (∞)

N 10 (-UB) appr. 580 16 (SSP) 0 [∞] 9 (/N) ∞ [0]R 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 (∞) 5 (+R) 0 (∞)

Sp.Rg. 6 (RS) 0* (∞)*


4. Open SV.25.Operate button (switch) as per table 3below according to the diagnostic faultindication and measure resistances

between contacts.

SV.25

Table 3

Button,

Switch

Measurement

btw. contact

8 (TL) and:

Rtarget [Ω]:

Button depr./

not depressed

Measurement

btw. contact

7 (TS) and:

Rtarget [Ω]:

Button depr.

(N depressed)

[not N depr.]

Measurement

btw. contact

7 (TS) and:

Rtarget [Ω]:

Button depr.

(N depressed)

[not N depr.]

Measurement

btw. contact

7 (TS) and:

Rtarget [Ω]:

Button depr.

(not depressed)

1 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 (∞) 1 (S1) 0 (∞)

2 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 (∞) 2 (S2) 0 (∞)

3 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 (∞) 3 (S3) 0 (∞)

D 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 (∞) 4 (+V) 0 (∞)

N 10 (-UB) appr. 580 11 (SSP) 0 [∞] 9 (/N) ∞ [0]

R 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 (∞) 5 (+R) 0 (∞)

Sp.Rg. 6 (RS) 0* (∞*)

Step Activity

5. Measure resistance to earth of SV.2, contacts 9, 10, 21, 27, 28, 29, 30, 33, 45, 46and SV.19, contact X.Rtarget = ∞ Ω.

6. Open SV.24. Measure resistance of contacts 1-10 and 16 to earth. Rtarget = ∞ Ω.



5. Controllers


5.2 Faulty component: Manual converter brake switch


1. If indicator light is defective, replacebulb.

2. Open connection SV.2.Select braking stage as per table 1 be-low according to the diagnostic fault in-dication and measure resistances be-tween contacts.If R = Rtarget for all measurements,continue with step 5.

SV.2

Table 1

Braking

stage

Measurement

between con-

tact

8 (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

8 (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

8 (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

8 (+HB) and:

Rtarget [Ω]

0 7 (HBA) ∞ 26 (HBB) ∞ 44 (HBC) ∞ 21 (-UB) ∞

1 7 (HBA) 0 26 (HBB) ∞ 44 (HBC) ∞ 21 (-UB) appr. 290

2 7 (HBA) 0 26 (HBB) 0 44 (HBC) ∞ 21 (-UB) appr. 290

3 7 (HBA) 0 26 (HBB) 0 44 (HBC) 0 21 (-UB) appr. 290

Ω

Ω


E 200

Manual switch

Rtarget = ∞ Ω


Connection cablemanual switch

Cable 2

Indicator light



5. Controllers


* = next to contact 1** = next to contact 4


3. Open SV.24.Select braking stage as per table 2 be-low according to the diagnostic fault in-

dication and measure resistances be-tween contacts.

SV.24

Table 2

Braking

stage

Measurement

between con-

tact

15 (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

15 (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

15 (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

15 (+HB) and:

Rtarget [Ω]

0 14 (HBA) ∞ 13 (HBB) ∞ 12 (HBC) ∞ 10 (-UB) ∞

1 14 (HBA) 0 13 (HBB) ∞ 12 (HBC) ∞ 10 (-UB) appr. 290

2 14 (HBA) 0 13 (HBB) 0 12 (HBC) ∞ 10 (-UB) appr. 290

3 14 (HBA) 0 13 (HBB) 0 12 (HBC) 0 10 (-UB) appr. 290


4. Open SV.26.Select braking stage as per table 3 be-low according to the diagnostic fault in-dication and measure resistances be-tween contacts.

SV.26

Table 3

Braking

stage

Measurement

between con-

tact

+* (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

+** (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

+** (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

X and:

Rtarget [Ω]

0 3 (HBA) ∞ 4 (HBB) ∞ 5 (HBC) ∞ Y appr. 290

1 3 (HBA) 0 4 (HBB) ∞ 5 (HBC) ∞ Y appr. 290

2 3 (HBA) 0 4 (HBB) 0 5 (HBC) ∞ Y appr. 290

3 3 (HBA) 0 4 (HBB) 0 5 (HBC) 0 Y appr. 290

Step Activity

5. SV.2: Measure resistance of contacts 7, 8, 21, 26 and 44 to earth. Rtarget = ∞ Ω.

6. Open SV.24. Measure resistance of contacts 10 and 12-15 to earth. Rtarget = ∞ Ω.





5. Controllers


* * = next to contact 1** = next to contact 4


3. Open SV.24.Measure resistances between con-tacts as per table 2 below.

SV.24

Table 2

Switch

Measurement

between con-

tact

15 (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

15 (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

15 (+HB) and:

Rtarget [Ω]

off 14 (HBA) ∞ 12 (HBC) ∞ 10 (-UB) ∞

on 14 (HBA) 0 12 (HBC) 0 10 (-UB) appr. 290


4. Open SV.26.Measure resistances between con-tacts as per table 3 below.

SV.26

Table 3

Switch

Measurement

between con-

tact

+* (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

+** (+HB) and:

Rtarget [Ω]

Measurement

between con-

tact

X and:

Rtarget [Ω]

off 3 (HBA) ∞ 5 (HBC) ∞ Y appr. 290

on 3 (HBA) 0 5 (HBC) 0 Y appr. 290

Step Activity

5. SV.2: Measure resistance of contacts 7, 8, 21, and 44 to vehicle earth. Rtarget = ∞ Ω.

6. Open SV.24. Measure resistance of contacts 10 and 12, 14 and 15 to earth. Rtarget = ∞ Ω.





5. Controllers



2. Open SV.27.Select braking stage as per table 2 be-low according to the diagnostic fault in-dication and measure resistances be-

tween contacts.

SV.27

Table 2

Braking

stage

Measurement

between con-

tact

5 (+FB) and:

Rtarget [Ω]

Measurement

between con-

tact

5 (+FB) and:

Rtarget [Ω]

Measurement

between con-

tact

5 (+FB) and:

Rtarget [Ω]

0 3 (FB1) ∞ 6 (FB2) ∞ 4 (FB3) ∞

1 3 (FB1) 0 6 (FB2) ∞ 4 (FB3) ∞

2 3 (FB1) 0 6 (FB2) 0 4 (FB3) ∞

3 3 (FB1) 0 6 (FB2) 0 4 (FB3) 0


3. Open SV.28.Select braking stage as per table 3 be-low according to the diagnostic fault in-dication and measure resistances be-tween contacts.

SV.28

Table 3

Brakingstage

Measurement

between con-tact

3 (+FB) and:

Rtarget [Ω]

Measurement

between con-tact

3 (+FB) and:

Rtarget [Ω]

Measurement

between con-tact

3 (+FB) and:

Rtarget [Ω]

0 1 (FB1) ∞ 4 (FB2) ∞ 2 (FB3) ∞

1 1 (FB1) 0 4 (FB2) ∞ 2 (FB3) ∞

2 1 (FB1) 0 4 (FB2) 0 2 (FB3) ∞

3 1 (FB1) 0 4 (FB2) 0 2 (FB3) 0

Step Activity

4. SV.2: Measure resistance of contacts 2, 11, 40, and 49 to earth. Rtarget = ∞ Ω.

5. Open SV.27. Measure resistance of contacts 3-6 to earth. Rtarget = ∞ Ω.

6. Open SV.28. Measure resistance of contacts 1-4 to earth. Rtarget = ∞ Ω.



5. Controllers


5.5 Faulty component: Voith load transmitter orEMR with VDO load transmitter

Ω

Ω

Electronic control unit E200

Rtarget = ∞ Ω


Cable 1

Load transmitter


1. Open connection SV.1.Depress accelerator pedal as per table1 below and measure resistance be-tween contacts.If R = Rtarget for all measurements,continue with step 3.

SV.1

Table 1

Accelera-

tor position

Measurement

between con-

tact

5 (-LG) and:

Rtarget [Ω]

Measurement

between con-

tact

5 (-LG) and:

Rtarget [Ω]

0 throttle 41 (+LG) 800-1500 24 (LGM) 178-333

Full throttle 41 (+LG) 800-1500 24 (LGM) 622-1667





5. Controllers


5.6 Faulty component: Kickdown switch

Ω

Ω


E 200

Rtarget = ∞ ΩRtarget = 0or ∞Ω

Cable 2

Kickdown switch (KD)

Connection cable Kick-

down switch


1. Open SV.2.Measure resistance between contacts4 and 19 (cable 2).KD switch open (accelerator totally re-lieved): Rtarget = ∞ Ω.KD switch closed (accelerator fully de-pressed up to the final stop):Rtarget = 0 Ω.

If R = Rtarget continue with step 4.

SV.2

2. Open SV.27.Measure resistance between contacts1 and 2.KD switch open: Rtarget = ∞ Ω.KD switch closed: Rtarget = 0 Ω.

SV.27

3. Open SV.32.Measure resistance between the twocontacts.KD switch open: Rtarget = ∞ Ω.KD switch closed: Rtarget = 0 Ω.

SV.32

4. SV.2: Measure resistance between contact 4 or 19 and vehicle earth with the KD switch closed.Rtarget = ∞ Ω.

5. SV.27: Measure resistance between contact 1 or 2 and vehicle earth with the KD switch closed.Rtarget = ∞ Ω.

6. SV.32: Measure resistance between one contact and earth with the KD switch closed.Rtarget = ∞ Ω.



5. Controllers





6.1 Faulty component: BOSCH electronic throttle control EMS 3.3 B/G

Ω

Ω


E 200

Rtarget = ∞ Ω

Rtarget = 0 Ω

Cable 2

BoschEMS 3.3

Connection cable


1. Open plug-and-socket connectionsSV.2 and SV.19 (cable 2).Measure resistances between:contacts 5 and X (DKR),contacts 24 and Z (DKE),contacts 41 and Y (DKV/PWM).The numbers of contacts X, Y, and Zare shown in the circuit diagram.Rtarget = 0 Ω.

SV.2

SV.19; variant

2. SV.2: Measure resistance of contacts5, 24, and 41 (cable 2) to vehicle earth.Rtarget = ∞ Ω.



6. Signal conductors to motor control units


6.2 Faulty component: MB FMR

BOSCH-EDC M5/M7, VDO electronic throttle control, DDEC III similar.


1. Open plug-and-socket connectionsSV.2 and SV.21 (cable 2).Measure resistances between con-tacts 41 and X (PWM/IWA; variant MBFMR). The number of contact X isshown in the circuit diagram.Rtarget = 0 Ω.

SV.2

SV.21; variant MB FMR2. SV.2: Measure resistance of contact41 (cable 2) to vehicle earth.Rtarget = ∞ Ω.

Ω

Ω

Electronic control unitE 200

Rtarget = 0 Ω

Cable 2

E.g.

MB FMR

Rtarget = 0 Ω



6. Signal conductors to motor control units


6.3 Faulty component: CAN-Bus

Ω

Ω

CAN-HCAN-MCAN-L


E 200

Rtarget = 0 Ω

Cabel 2

Rtarget = ∞ Ω

Connection cable

E.g.

EDC


1. Open plug connectors SV.2 andSV.33.Measure resistance between:contact 17 und contact C (CAN-H)contact 36 und contact A (CAN-L)contact 37 und contact B (CAN-M).Rtarget = 0 Ω.

SV.2

SV.33, variant

2. SV.2: Measure resistance betweencontacts 17, 36 and 37 (cable 2) and

vehicle earth.Rtarget = ∞ Ω.

A B

C






7.1 Faulty component: ABS connection

VP

P

+ 24V

Ω

Ω


E 200

Rtarget = ∞ Ω

Rtarget = 0 Ω

Cable 2 Case 1: inactive

Case 2: active

Connection cable

Utarget = ca. 24or 0 V

ABS


1. Switch on ignition.

Open connection SV.2.Measure voltage between contact 53(cable 2) and vehicle earth.Case 1 (low active):ABS inactive: Utarget = approx. 24 VABS active: Utarget = 0 V.Case 2 (high active):ABS inactive: USoll = ca. 0 V.ABS active: USoll = 24 V.Switch off ignition.

SV.2

2. Measure resistance between contact53 and the conductor of the connecting

cable leading to the ABS.Rtarget = 0 Ω.If R = Rtarget continue with step 4.

3. Open SV.19.Measure resistance between contacts53 (SV.2) and 7 (SV.19).Rtarget = 0 Ω.

SV.19; variant

4. Measure resistance between contact53 and vehicle earth. Rtarget = ∞ Ω.



7. Other switches and warning lights


7.2 Faulty component: Transmission oil warning light

+ 24V

Ω

Ω

Ω

P P


E 200

Rtarget = ∞ or appr.160 Ω

Rtarget = 0 Ω

Cable 2

Connection cable

Rtarget = 0 Ω

Transmissionoil warning light


1. Replace bulb of transmission oil warn-ing light if defective.

2. Open connector SV.2.Measure resistance between contact15 (cable 2) and vehicle earth.With bulb: Rtarget = approx. 160 Ω.Without bulb: Rtarget = ∞ Ω.

SV.2

3. Measure resistance between contact15 and the conductor to the transmis-sion oil warning light.Rtarget = 0 Ω.If R = Rtarget continue with step 5.

4. Open SV.19.Measure resistance between contacts15 (SV.2) and 17 (SV.19).Rtarget = 0 Ω.

SV.19; variant

5. Measure resistance between the – con-ductor of the warning light (M) andearth.Rtarget = 0 Ω.





7.3 Faulty component: Converter brake release switch

+ 24V

Ω

Ω

Ω

P P


E 200

Rtarget = 0or ∞ Ω

Rtarget = 0 Ω

Cable 2

Connection cable

Rtarget = 0 Ω

Release switch

converter brake


1. Open connector SV.2.Measure resistance between contact

31 (cable 2) and vehicle earth.Switch open: Rtarget = ∞ Ω.Switch closed: Rtarget = 0 Ω.

SV.2

2. Measure resistance between contact31 and the conductor to the converterbrake release switch.Rtarget = 0 Ω.If R = Rtarget continue with step 4.

3. Open SV.19.Measure resistance between contacts31 (SV.2) and 18 (SV.19).

Rtarget = 0 Ω.

SV.19; variant

4. Measure resistance between the – con-ductor of the release switch (M) andearth. Rtarget = 0 Ω.





7.4 Faulty component: Gearshift inhibitor switch

+ 24V

Ω

Ω

Ω

P P


E 200


Rtarget = 0 Ω

Cable 2

Connecting cable

Rtarget = 0 Ω

Gearshift in-

hibitor switch


1. Open connector SV.2.Measure resistance between contact 35 (ca-

ble 2) and vehicle earth.Switch open (service brake released):Rtarget = ∞ Ω.Switch closed (service brake applied):Rtarget = 0 Ω.

SV.2

2. Measure resistance between contact 35 andthe conductor to the gearshift inhibitor switch.Rtarget = 0 Ω.If R = Rtarget continue with step 4.

3. Open SV.19.Measure resistance between contacts 35

(SV.2) and 20 (SV.19).Rtarget = 0 Ω.

SV.19; variant

4. Measure resistance between the – conductorof the gearshift inhibitor switch (M) and earth.Rtarget = 0 Ω.





7.5 Faulty component: ANS activation switch


1. Open connector SV.2.Measure resistance between contact

12 (cable 2) and vehicle earth.Switch open (service brake released):Rtarget = ∞ Ω.Switch closed (service brake applied):Rtarget = 0 Ω.

SV.2

2. Measure resistance between contact12 and the conductor to the EK disen-gagement switch.Rtarget = 0 Ω.If R = Rtarget continue with step 4.

3. Open SV.19.

Measure resistance between contacts12 (SV.2) and 21 (SV.19).Rtarget = 0 Ω.

SV.19; variant

4. Measure resistance between the – con-ductor of the ANS activation switch (M)and earth. Rtarget = 0 Ω.

+ 24V

Ω

Ω

Ω


E 200


Rtarget = 0 Ω

cable 2

Connecting cable

Rtarget = 0 Ω

ANS activation

switch








8.1 Connection of cable 1 to control unit

SV.1 Pin assignment forDIWA.3:

Pin assignment forDIWA.3E:

Pin no. Designation Pin no. Designation

1 PA 1 WP

2 PB 2 PB

3 WP 3 -

4 - 4 -

5 -LG 5 -LG

6 IO9 6 IO9

7 - 7 -

8 +TS 8 +TS

9 - 9 -

10 N2B 10 N2B

11 N1A 11 N1A

12 - 12 -

13 RBKM 13 RBKM14 PBM 14 PBM

15 EKM 15 EKM

16 - 16 -

17 RBG 17 RBG

18 SK 18 SK

19 EK 19 EK

20 TB 20 TB

21 RBK 21 RBK

22 - 22 -

23 IO3 23 IO3

24 LGM 24 LGM

25 - 25 -

26 - 26 -27 - 27 -

28 N3B 28 N3B

29 N2A 29 N2A

30 - 30 -

31 SENSE 31 SENSE

32 - 32 -

33 SKM 33 SKM

34 - 34 -

35 WR 35 WR

36 REA0 36 REA0

37 DK 37 DK

38 - 38 -39 - 39 -

40 - 40 -

41 +LG 41 +LG

42 - 42 -

43 - 43 -

44 -TS 44 -TS

45 - 45 -

46 N3A 46 N3A

47 N1B 47 N1B

48 - 48 -

49 SENSE 49 SENSE

50 TBM 50 TBM

51 DKM 51 DKM52 -UB 52 -UB

53 -UB 53 -UB

54 - 54 -

55 - 55 -



8. Cables and plugs


8.2 Connection of cable 1 to transmission housing

SV.3; socket insert cable 1

SV.3; pin insert cable harness

(transmission housing)

Pin assignment forDIWA.3:

Pin assignment forDIWA.3E:

Pin no. Designation Pin no. Designation

A -UB A -UB

B -UB B -UB

C N1B C N1B

D N1A D N1A

E N2B E N2B

F N2A F N2A

G N3B G N3B

H N3A H N3A

J WR J WR

K DK K DK

L EK L EK

M PB M PB

N WP N -

P RBK P RBKR RBG R RBG

S TB S TB

T - T WP

U - U SK

V - V -

W - W -

X - X -

Y - Y -

Z -TS Z -TS

a +TS a +TS

b DKM b DKM

c EKM c EKM

d PBM d PBM

e RBKM e RBKM

f TBM f TBM

g SKM g SKM

h SENSE h SENSE

j SENSE j SENSE



8. Cables and plugs


8.3 Connection of cable 2 to control unit

Pin assignment as per circuit diagrams for DIWA.3 and DIWA.3E

SV.2



8. Cables and plugs


8.4 Measuring cable 56.4461.12

5 0

8 0

1 2 0 0

SV.3; identical to

socket insert cable 1



8. Cables and plugs


8.5 Level converter 56.4219.10

4 5 0

7

0 0 0

Y

X View X; plug

enlarged

View Y;

SV.31; plug

enlarged



8. Cables and plugs





1 Circuit diagram DIWA.3

1 Circuit diagram DIWA.3E



9. Appendices








Voith Turbo GmbH & Co. KG

Produktgruppe Nutzfahrzeuggetriebe

Alexanderstraße 2

D-89522 Heidenheim

T l h ( )

Documents

Voith Diwa.3 Trouble Shooting