Voith Diwa3 Trouble Shooting PDF

5SPVCMF4IPPUJOH
5SBOTNJTTJPOT%*8"
%*8"&
Voith. 55.6293.31 / 2002-03

*NQPSUBOUTBGFUZJOTUSVDUJPOT
It is your responsibility to familiarize yourself with the warnings and precautions described in this
manual.
Danger! in conjunction with the symbol on the left is used if personal injury or danger to
life may result if work is not carried out carefully.
This manual only contains the most important information, however. It is impossible to describe
all conceivable mistakes and danger conditions.
Therefore, everybody who performs installation, repair or service work must very carefully en-
sure that his personal safety or that of other persons is not at risk.
*NQPSUBOUJOGPSNBUJPO
Note! in conjunction with the symbol on the left denotes information that is particularly
important.
"EEJUJPOBMOPUFT
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.
Voith. Trouble Shooting I

5SPVCMF4IPPUJOH
What is it for?
The manual serves the following purpose:
n Special fault tracing in electrical transmission components or parts using the Voith PC-
based diagnostic program DIWAGNOSIS.
n 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.:
for
Brochure Part No. Purpose
transmission
Technical Manual 55.6354. .. DIWA.3 Function description of the transmis-
55.6356. .. DIWA.3E sion, transmission data, installation
instructions, design and dimensional
data for transmission assemblies
Servicing Schedule 55.6373. .. All Maintenance of DIWA transmissions
DIWA
Lists of Lubricants 55.6335. .. All List of the lube oils that are approved
55.6336. .. DIWA by Voith for DIWA transmissions
Fault Finding 55.6302. .. DIWA.3, General fault tracing, analysis, and
DIWA.3E repair
Driving Instructions 55.6290. .. DIWA.3, Brief description of transmission op-
DIWA.3E eration for the bus driver
Diagnostic Manual 55.6263. .. DIWA.3, Use of the Voith PC-based diagnostic
DIWA.3E program DIWAGNOSIS
Spare Parts Catalogs 55.6600. .. D 851.3E
55.6601. .. D 854.3E Illustration and designation of trans-
55.6602. .. D 863.3E mission parts for spare parts ordering
55.6603. .. D 864.3E
Repair Manual 55.6320. .. DIWA.3 Description of transmission disas-
55.6704. .. DIWA.3E sembly and assembly of 3- and 4-
speed transmissions
Technical Description with 55.6308. .. DIWA.3 Representation of the oil circuits for
Oil and Control Circuit 55.6310. .. DIWA.3E the various transmission gear shifts
Diagrams
All of the above brochures are available from department "ant" or "anv".
This documentation is protected by copyright
Subject to change
Who is it for?
n Service technicians (e.g. testing, acceptance, etc.)
n Automobile mechanics and electricians
II Voith. Trouble Shooting

)PXUPQSPDFFEJODBTFPG
USBOTNJTTJPONBMGVODUJPOT
If transmission malfunctions occur, fault may be present in
a) the control unit records,

b) in the electrical or
c) mechanical part of electromechanical or
d) purely mechanical components.
In the case of faults in a) and b), use of "Diagnostic Manual" and "Trouble Shooting", if required,
alone may be sufficient for repair. However, since malfunctions in c) and d) are not detected by
the control and/or diagnosis, it is recommended to refer to the appropriate Voith documentation
and programs for transmission malfunction repairs in the following order, for example:
Read out the fault memory of the transmission control unit by means of the diagnostic program
DIWAGNOSIS:
Diagnostic Manual
Malfunction analysis and information about possible remedies, if required, information about
transmission design and function in the "Technical Manuals" and in the "Technical Descriptions
with Oil and Control Circuit Diagrams" for DIWA.3 and DIWA.3E:
Fault Finding
Use of the diagnostic program for fault tracing:
Diagnostic Manual
Tracing of possible faults in the electrical system of DIWA.3 and DIWA.3E transmissions:
Trouble Shooting
Transmission repair and spare parts ordering:
Repair Manual,
Spare Parts Catalogs
Voith. Trouble Shooting III

IV Voith. Trouble Shooting
$POUFOUT
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................................................................... 9
3.1.2 Faulty component: TB solenoid ................................................................. 10
3.1.3 Faulty component: PB solenoid................................................................. 11
3.1.4 Faulty component: DK solenoid ................................................................ 12
3.1.5 Faulty component: SK solenoid................................................................. 13
3.1.6 Faulty component: RBK solenoid .............................................................. 14
3.2 Solenoids without measuring coil .......................................................................... 15
3.2.1 Faulty component: RBG solenoid.............................................................. 15
3.2.2 Faulty component: WP solenoid for DIWA.3 ............................................. 16
3.2.3 Faulty component: WP solenoid for DIWA.3E........................................... 17
3.2.4 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 ............................................... 23
4.5.2 Faulty component: Stop brake actuation ................................................... 24
4.6 Faulty component: Central warning light (ZW) ...................................................... 25
4.6.1 Faulty component: ZW relay ..................................................................... 25
4.6.2 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
Voith. Trouble Shooting V

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 or
EMR 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
VI Voith. Trouble Shooting

%JGGFSFODFTCFUXFFO%*8"BOE%*8"&
JOUFSNTPGUSPVCMFTIPPUJOH
As mentioned in the next chapter, only parts or components that can be accessed by the Voith
diagnostic system are concerned here, i. e. mainly electrical parts.
The decisive reference is the circuit diagram. Since there are hardly any fundamental differences
between 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 differences
in fault-tracing procedures are minor, too.
See also:
n Chap. 3.2.2 and Chap. 3.2.3,
n Chap. 8.1,
n Chap. 8.2,
n Chap. 8.4
Voith. Trouble Shooting VII

VIII Voith. Trouble Shooting
" *OUSPEVDUJPO
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 manual
only covers parts or components that can be tested using the Voith diagnostic system, i. e. most-
ly electrical parts.
Before trouble-shooting
Danger! Always apply the parking brake before proceeding with diagnosis at vehicle
standstill.
The following preparations described in the "Diagnostic Manual" are necessary before trouble-
shooting can begin:
n Connect a suitable PC (laptop) to the transmission control via the cable (level converter) pro-
vided for this purpose
n Start the diagnostic program
n Start communication
n Read fault memory (function B)
n Test faulty components individually once again (functions C, D, E, F, G, H and J). This is to
find 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 some
point 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 parts
or components by proceeding with the next step.With regard to relay and plug designs and their
contact designations the circuit diagrams 55.3705.20 for DIWA.3 and 55.6168.10 for DIWA.3E
are used, provided that the respective components were shown in it.
Note! In the case of other circuit diagrams, relay and plug designs and their contact des-
ignations may differ.
After completion of "Trouble Shooting"

Erase fault memory after repair of the defect by pressing function key B (see "Diagnostic Manu-
al").
Voith. Trouble Shooting 1

2 Voith. Trouble Shooting
$POUSPMBOEEJBHOPTJT
1.1 Faulty component: Voltage supply to control unit
Relay
"control" Electronic control unit
G6 E 200
D 69
69
Utarget = approx. 24 V
Rtarget = 0 Ω Rtarget = ∞ Ω
V
Ω Ω
Vehicle ) Rtarget = 0 Ω
supply ; 8=
system
Connection cable < 8% Ω
Cable 2
69
Step Activity and location Fuse, pins or contacts

1. Switch on ignition.
If control unit E 200 does not operate properly, check
whether 8 A fuse F1 in connection cable to vehicle sup-
ply system is blown.
2. Open connection SV.2. SV.2
Measure voltage between contacts 19
and 21 (cable 2). Utarget = approx. 24 V.
Switch off ignition.
3. Measure resistance between contact
19 and the conductor to contact 30 (dS
relay). Rtarget = 0 Ω.

19 and the conductor in connection ca-
ble to fuse F1. Rtarget = 0 Ω.
21 and vehicle earth. Rtarget = 0 Ω.
If R = Rtarget for all of measurements 3
to 5, proceed with step 8.
6. Open SV.19. SV.19; variant
Measure resistance between contact 19 (cable 2) and
contact X (+UZ) of the connection cable to the vehicle
supply system. The number of X is shown in the circuit

diagram. Rtarget = 0 Ω.
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
Electronic control unit

E 200
69 Diagnosis-PC
Rtarget = ∞ Ω Rtarget = 0 Ω
Ω Ω
69
8=
8%
',$*1.
',$*1/

V Level converter
(see Chap. 8.)
Utarget = approx. 24 V
Step Activity and location Pins or contacts

1. Switch on ignition. SV.31
Open plug connection SV.31 (cable 2).
Measure voltage between contacts 1
and 2 (earth).

Utarget = approx. 24 V.

2. Open plug connections SV.2 (cable 2). SV.2

Measure resistance between
contacts 16 (SV.2) and 10 (SV.31),

contacts 52 (SV.2) and 8 (SV.31).
Rtarget = 0 Ω.
3. SV.2: Measure resistance between
contacts 16, 19, 21, and 52 (cable 2)
and vehicle earth. Rtarget = ∞ Ω.

4FOTPST
2.1 Faulty component: Inductive pick-up N1
Cable 1 DIWA.3/.3E
transmission
'
& Cable harness
69
Ω Rtarget = ∞ Ω 69
Ω Rtarget = 800-1400 Ω Connection for in-

ductive pick-up N1
69
69
Inductive
Electronic control unit pick-up N1
E 200

1. Open plug connection SV.1. SV.1
Measure resistance between contacts

11 and 47 of cable 1.
Rtarget = 800-1400 Ω.

If R = Rtarget continue with step 5.
(For the plug see Chap. 8.)
2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable
Measure resistance between pins C 56.4461.12
and D of cable harness or the N1-con- &
tacts of the measuring cable. '
(For the plug see Chap. 8.)
Q
Rtarget = 800-1400 Ω.
3. Remove control cover. SV.4

Open SV.4.
Measure resistance between contacts 1 and 2 of the connector for
inductive pick-up N1. Rtarget = 800-1400 Ω.
4. Remove oil sump. SV.5
Remove gear pump with inductive pick-up N1.
Open SV.5.
Measure resistance between pins of pick-up N1.
Rtarget = 800-1400 Ω.
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
DIWA.3/.3E
Cable 1 transmission
(
)
Cable harness
with connection
for inductive pick-
up N2
Ω Rtarget = 800-1400 Ω
69

69
Inductive
Electronic control unit pick-up N2
E 200


Rtarget = 800-1400 Ω.


Measure resistance between pins E 56.4461.12
and F of cable harness or the N2-con-
tacts of the measuring cable.
Rtarget = 800-1400 Ω.
( Q
)
3. On transmission output side: remove cap from above pick-up N2. SV.7
Open SV.7.
Measure resistance between pins of pick-up N2.
Rtarget = 800-1400 Ω.

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

2. Sensors
DIWA.3/.3E
*
+
Cable harness
with connection
for inductive
pick-up N3
69
69
Electronic control unit Inductive

E 200 pick-up N3


Rtarget = 800-1400 Ω.


Measure resistance between pins G 56.4461.12
and H of cable harness or the N3-con-
Rtarget = 800-1400 Ω.
Q
*
+
3. On transmission housing: remove cap from above pick-up N3. SV.8
Open SV.8. Measure resistance between pins of pick-up N3.
Rtarget = 800-1400 Ω.

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

2. Sensors
2.4 Faulty component: Oil temperature transmitter
DIWA.3/.3E
Cable harness
D
=
Ω Rtarget = ∞ Ω
69
69 ZV VZ
Connection for oil

Ω Oil temp. ϑ Rtarget temperature
69 0 [°C] 810 [Ω] transmitter
20 [°C] 950 [Ω]
70 [°C] 1360 [Ω]
69
90 [°C] 1550 [Ω] Oil temperature
120 [°C] 1860 [Ω] transmitter
E 200
140 [°C] 2090 [Ω]

For Rtarget see chart above.


Measure resistance between pins a 56.4461.12
and Z of cable harness or the N1-con-
76
D =
Open SV.4. Measure resistance between contacts 3 and 4 of the
connector for the oil temperature transmitter.
4. Remove oil sump. SV.9

Open SV.9.
On TB accumulator: measure resistance between pins of oil temper-
ature transmitter.
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.

4PMFOPJET
3.1 Solenoids with measuring coil
3.1.1 Faulty component: EK solenoid
Cable 1 DIWA.3/.3E
transmission
M
K
F
/ Cable harness
%
$
Ω EK solenoid
Coil +
69 Rtarget Coil only
cable 1
69
Working coil 11 - 20 [Ω] 11±0,7 [Ω]
Measuring
5 - 10 [Ω] 5,2±0,3 [Ω] Measur- Working
Electronic control unit coil
ing coil coil
E 200

a) Working coil: Measure resistance
between contacts 19 and 52 or 53 of
cable 1.
Rtarget = 11-20 Ω.
b) Measuring coil: Measure resistance
between contacts 15 and 31 or 49.
Rtarget = 5-10 Ω.
2. Open SV.3. SV.3; Cable harness SV.3; measuring cable
a) Working coil: Measure resistance 56.4461.12
$
between contacts L and A or B (cable
harness) or EK and –UB (measuring % (.
cable). Rtarget = 11-20 Ω. 8%

b) Measuring coil: Measure resistance M
between contacts c and h or j (cable (.0
F
harness) or EKM and SENSE (measur-
ing cable). / 6(16(
K
Rtarget = 5-10 Ω.
Open SV.10.
a) Working coil: Measure resistance between pins 1 and 2 of the EK
solenoid flat pin connector. Rtarget = 11±0,7 Ω.

b) Measuring coil: Measure resistance between pins 3 and 4 of the
EK solenoid flat pin connector. Rtarget = 5,2±0,3 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.

3. Solenoids
3.1.2 Faulty component: TB solenoid
Cable 1 DIWA.3/.3E
transmission
M
K
I
6 Cable harness
%
$
Ω TB solenoid
Coil +
cable 1
69
Working coil 11 - 20 [Ω] 11±0,7 [Ω]
Measuring
ing coil coil
E 200

cable 1.
Rtarget = 5-10 Ω.
between contacts S and A or B (cable $
harness) or TB and –UB (measuring 6 % 7%
cable). I
Rtarget = 11-20 Ω. M
8%

7%0
between contacts f and h or j (cable
harness) or TBM and SENSE (measur- 6(16(
ing cable). K
Rtarget = 5-10 Ω.
Open SV.11.
a) Working coil: Measure resistance between pins 1 and 2 of the TB

TB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
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.

3. Solenoids
3.1.3 Faulty component: PB solenoid
Cable 1 DIWA.3/.3E
transmission
M
K
G
0 Cable harness
%
$
Ω PB solenoid
Coil +
cable 1
69
Working coil 11 - 20 [Ω] 11±0,7 [Ω]
Measuring
ing coil coil
E 200

between contacts 2 and 52 or 53 of ca-
ble 1.
Rtarget = 5-10 Ω.
between contacts M and A or B (cable $
harness) or PB and –UB (measuring % 3%
cable). G
8%
0 3%0
between contacts d and h or j (cable
harness) or PBM and SENSE (measur- 6(16(
K
ing cable).
Rtarget = 5-10 Ω.
Open SV.12.
a) Working coil: Measure resistance between pins 1 and 2 of the PB

PB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
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
Cable 1 DIWA.3/.3E
transmission
M
K
E
. Cable harness
%
$
Ω DK solenoid
Coil +
cable 1
69
Working coil 11 - 20 [Ω] 11±0,7 [Ω]
Measuring
ing coil coil
E 200

cable 1.
Rtarget = 5-10 Ω.
between contacts K and A or B (cable $
harness) or DK and –UB (measuring % '.
cable).
8%

'.0
between contacts b and h or j (cable
harness) or DKM and SENSE (mea- E
6(16(
suring cable). K
.
Rtarget = 5-10 Ω.
Open SV.13.
a) Working coil: Measure resistance between pins 1 and 2 of the DK

DK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
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
Cable 1 DIWA.3/.3E
transmission
M
K
J
8 Cable harness
%
$
Ω SK solenoid
Coil +
cable 1
69
Working coil 11 - 20 [Ω] 11±0,7 [Ω]
Measuring
ing coil coil
E 200

cable 1.
Rtarget = 5-10 Ω.
between contacts U and A or B (cable
8 $
harness) or SK and –UB (measuring % 6.
cable).
Rtarget = 11-20 Ω. M J 8%

6.0
between contacts g and h or j (cable
harness) or SKM and SENSE (measur-
ing cable).
K 6(16(
Rtarget = 5-10 Ω.
Open SV.14.
a) Working coil: Measure resistance between pins 1 and 2 of the SK

SK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
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
DIWA.3/.3E
Cable 1
transmission
M
K
H
3 Cable harness
%
$
Ω RBK solenoid
Coil +
cable 1
69
Working coil 11 - 20 [Ω] 11±0,7 [Ω]
Measuring Measur-
5 - 10 [Ω] 5,2±0,3 [Ω] Working
Electronic control unit coil ing coil
coil
E 200

cable 1.
Rtarget = 5-10 Ω.
between contacts P and A or B (cable $
harness) or RBK and –UB (measuring H % 5%.
cable). 3
8%
b) Measuring coil: Measure resistance 5%.0
between contacts e and h or j (cable
harness) or RBKM and SENSE (mea- 6(16(
K
suring cable).
Rtarget = 5-10 Ω.
Open SV.15.
a) Working coil: Measure resistance between pins 1 and 2 of the
RBK solenoid flat pin connector. Rtarget = 11±0,7 Ω.

RBK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω
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
DIWA.3/.3E
transmission
Cable 1
5 Cable harness
%
$
69
Coil +
Ω Rtarget
cable 1
Coil only
69 11 - 20 [Ω] 11±0,7 [Ω]

Ω
69
Rtarget = ∞ Ω RBG solenoid

E 200

17 and 52 or 53 of cable 1.

Measure resistance between contacts $ 56.4461.12
R and A or B (cable harness) or RBG 5 %
and –UB (measuring cable).
5%*
8%

Open SV.16.
Measure resistance between pins 1 and 2 of the RBG solenoid flat
pin connector.
Rtarget = 11±0,7 [Ω].


3. Solenoids
3.2.2 Faulty component: WP solenoid for DIWA.3
DIWA.3
transmission
Cable 1
1 Cable harness
%
$
69
Coil +
Ω Rtarget
cable 1
Coil only
69 11 - 20 [Ω] 11±0,7 [Ω]

Ω
69
Rtarget = ∞ Ω WP solenoid

E 200


N and A or B (cable harness) or WP %
and –UB (measuring cable). :3
8%
1

Open SV.17.
Measure resistance between pins 1 and 2 of the WP solenoid flat pin
connector.
Rtarget = 11±0,7 [Ω].


3. Solenoids
3.2.3 Faulty component: WP solenoid for DIWA.3E
DIWA.3E
transmission
Cable 1
7 Cable harness
%
$
69
Coil +
Rtarget Coil only
Ω cable 1

11 - 20 [Ω] 11±0,7 [Ω]
69
Rtarget = ∞ Ω
Ω
69
WP solenoid

E 200


Measure resistance between contacts 7 $ 56.4461.12
T and A or B (cable harness) or WP %
and –UB (measuring cable). :3(
8%

Open SV.17.
Measure resistance between pins 1 and 2 of the WP solenoid flat pin
connector.
Rtarget = 11±0,7 [Ω].


3. Solenoids
3.2.4 Faulty component: WR solenoid
DIWA.3/.3E
transmission
Cable 1
- Cable harness
%
$
69
Coil +
Rtarget Coil only
Ω cable 1
69 11 - 20 [Ω] 11±0,7 [Ω]

Ω
69
Rtarget = ∞ Ω WR solenoid

E 200


J and A or B (cable harness) or WR %
and –UB (measuring cable).
Rtarget = 11-20 Ω. :5
8%
-
Open SV.18.
Measure resistance between pins 1 and 2 of the WR solenoid flat pin
connector.
Rtarget = 11±0,7 [Ω].


3FMBZTBOEQJMPUMJHIUT
4.1 Faulty component: Converter brake relay dW
Converter
brake relay
G:
E 200
D
69
Ω Rtarget = 0 Ω Rtarget = 285-310 Ω

69
0 Ω
69
Connection cable Cable 2
; G:

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

2. Open plug connector SV.2. SV.2

For the following steps, connect one
feeler of the ohmmeter to vehicle earth.
Measure resistance at contact 32 of
cable 2.

Measure resistance at pin X (dW) of
the connection cable to the dW relay.

The number of contact X can be found
in the circuit diagram.
4. Mounting plug SV.20: Measure resis- SV.20
tance at the cable to the start of the
dW
winding of the dW relay (pin 86).
5. SV.20: Measure resistance at the ca-
ble to the end of the winding of the dW
relay (pin 85) and earthing point M.
Rtarget = 0 Ω.

4. Relays and pilot lights
4.2 Faulty component: Speed switch relay dN
Speed switch
relay
G1
E 200
D
69
Ω Rtarget = 0 Ω Rtarget = 285-310 Ω 69
0 Ω
69
; G1

1. Replace dN relay by a new one or re-




cable 2.
Measure resistance at pin X (dN) of the
connection cable to the dN relay. The
number of contact X can be found in

the circuit diagram.

winding of the dN relay (pin 86). dN
ble to the end of the winding of the dN
Rtarget = 0 Ω.

4.3 Faulty component: Reversing light relay dR
Reversing light
relay
G5
E 200
D
69
Ω Rtarget = 0 Ω Rtarget = 285-310 Ω

69
0 Ω
69
; G5

1. Replace dR relay by a new one or re-




cable 2.
Measure resistance at pin X (dR) of the
connection cable to the dR relay. The

winding of the dR relay (pin 86). dR
5. SV. 20: Measure resistance at the ca-
ble to the end of the winding of the dR
Rtarget = 0 Ω.

4.4 Faulty component: Starter inhibitor relay
Starter inhibitor
relay
D 69
69

Ω Rtarget = 0 Ω
Rtarget = 285-310 Ω
0
Ω
69
Vehicle 663
;
electrical
system Connection cable Cable 2
Step Activity and location Pins or contacts, relay

1. Replace starter inhibitor relay by a new
one or measure resistance directly be-
tween winding contacts 85 and 86 after
removal of the relay. D


2. Open connection SV.24 SV.24

(see Chap. 5.1).
cable 2.
If R = Rtarget, continue with step 5.
Measure resistance at pin contact X
(SSP) of the connection cable to the
starter inhibitor relay. The number of

contact X is shown in the circuit dia-
gram.
tance at the cable to the beginning of
the winding of the starter inhibitor relay Starter
inhibitor
(pin contact 86).
ble to the end of the winding of the
starter inhibitor relay (pin contact 85)
and earthing point M.
Rtarget = 0 Ω.

4.5 Faulty component: Stop brake
4.5.1 Faulty component: Stop brake relay dHSB
Stop brake
relay
G+6%
Stop brake E 200
switch (HSB) D
Rtarget = 0 Ω
Ω
) 69
0
' 69

Rtarget = 285-310 Ω
69 69
09
Ω
0 69
Cable 2
Connection cable < +6%
; G+6%

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 or
measure resistance directly between
winding contacts 85 and 86 after re-
moval of the relay. D



For steps 1 to 5, connect one feeler of

the ohmmeter to vehicle earth. Mea-

sure resistance at contact 32 of cable
2.
(dHSB) of the connection cable to the
dHSB relay. The number of contact X

is shown in the circuit diagram.
dHSB
the winding of the dHSB relay (pin con-
tact 86).
ble to the end of the winding of the
dHSB relay (pin contact 85) and earth-
ing point M1.
Rtarget = 0 Ω.

4.5.2 Faulty component: Stop brake actuation
Stop brake
relay
G+6%
Stop brake E 200
switch (HSB) D
F2 SV.20
Ω Rtarget = value
0
SV.2
'

Rtarget = 0
SV.23 SV.22
MV or ∞ Ω Ω Ω

Rtarget = 0 Ω Ω SV.19
0 +6%
Cable 2 Rtarget = ∞ Ω
<
; G+6%
Connection cable
Step Activity and location Fuse, pins or contacts

6. Check whether fuse F2 is blown.
7. Open SV.2. SV.2

Measure resistance between contact 1

of cable 2 and supply cable contact 30

(dHSB relay).
HSB switch open: Rtarget = ∞ Ω.
HSB switch closed: Rtarget = 0 Ω.
Measure resistance between contact Y
(HSB) and supply cable contact 30
(dHSB relay). The number of contact Y
is shown in the circuit diagram.
HSB switch open: Rtarget = ∞ Ω.
HSB switch closed: Rtarget = 0 Ω.
9. Open SV.22. Measure resistance between contact 1 and 2.
HSB switch open: Rtarget = ∞ Ω. HSB switch closed: Rtarget = 0 Ω.
10. Open SV.23. Measure resistance between contact 1 and 2.
HSB switch open: Rtarget = ∞ Ω. HSB switch closed: Rtarget = 0 Ω.
11. SV.2: Measure resistance between contact 1 of cable 2 and vehicle earth with HSB switch closed,
applying the '–' feeler of the ohmmeter to contact 1 (because of diode D).
Rtarget = ∞ Ω.
12. SV.20: Measure resistance between '+' conductor of the coil of solenoid valve (MV) and vehicle earth.
Rtarget = value.
13. Measure resistance between '–' conductor MV coil and earth. Rtarget = 0 Ω.

4.6 Faulty component: Central warning light (ZW)
4.6.1 Faulty component: ZW relay
Central warning
light relay
=:
E 200
D
69
0
Ω Rtarget = 0 Ω Rtarget = 285-310 Ω 69
Central warn-
0 Ω
69
ing light
; =:

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 or
measure resistance directly between
winding contacts 85 and 86 after re-
moval of the relay. D



For steps 1 to 5, connect one feeler of

the ohmmeter to vehicle earth. Mea-

sure resistance at contact 51 of cable
2.
3. Open SV.19 SV.19; variant
(ZW) of the connection cable to the ZW
relay. The number of contact X is

shown in the circuit diagram.

ZW
the winding of the ZW relay (pin con-
tact 86).
ble to the end of the winding of the ZW
relay (pin contact 85) and earthing
point M1.
Rtarget = 0 Ω.

4.6.2 Faulty component: ZW bulb
Central warning
light relay
=:
E 200
D
69
Ω Rtarget = 0 Ω
0 0
69
Rtarget = s.b. Rtarget = ∞ Ω
Ω
Ω 69
; =:
Central warn-
ing light
Step Activity and location

6. If the central warning light always remains off,
replace the bulb.
7. Measure resistance between + and –conductor of ZW.

With bulb: Rtarget = appr. 160 Ω.
Without bulb: Rtarget = ∞ Ω.
8. Measure resistance of + and –conductor ZW to vehicle earth. Rtarget = ∞ Ω.
9. SV.20: Measure resistance at earth conductor M2 of the ZW relay (pin contact 87). Rtarget = 0 Ω.

4.7 Faulty component: Voltage supply to solenoid valves
4.7.1 Faulty component: Control relay dS
Control
relay Electronic control unit
G6 E 200
D
69
Rtarget = 0 Ω 69
0
Ω
69
< 8%
Vehicle ) G6
; 8=
electrical

1. Replace dS relay by a new one or mea-
sure resistance directly between wind-
ing contacts 85 and 86 after removal of
the relay. D





cable 2.
(dS) of the connection cable to the dS
relay. The number of contact X is

the winding of the dS relay (pin contact dS
86).
ble to the end of the winding of the dS
relay (pin contact 85) and earthing
point M.
Rtarget = 0 Ω.
If R = Rtarget continue with step 6 on the
opposite page.

4.7.2 Faulty component: Solenoid valve voltage
Control
relay
G6 E 200
D
69
69
Rtarget = 0 Ω
Rtarget = ∞ Ω
0
Ω
69
Ω
< 8%
Vehicle ) G6
; 8=
electrical

6. Test UZ line (see Chap. 1.1).
7. Open SV.2. SV.2
Measure resistance between contact

38 (+UB) and the supply line to contact

87 (dS relay).
Rtarget = 0 Ω.

38 and Y (+UB). The number of contact
Y can be seen from the circuit diagram.

Rtarget = 0 Ω.
9. SV.2: Measure resistance between contact 38 and vehicle earth. Rtarget = ∞ Ω.

$POUSPMMFST
5.1 Faulty component: Push-button switch
6-button switch
' 1 5
E 200
Rtarget see tables 1, 2, 3

69

69
Ω 69
8% 66695 1 +TS 56 7/
6 6 6 6
6
6
6 Cable 2

9

5
56
76

7/

1

8%
663 Ω

6 5)
' 1 5
6 6 6 6 6 6
56

'
'
1
1
5
5
5
Rtarget = ∞ Ω
' 1 5
Connections at 3, 4-,5- Reversing inhibitor Connection cable to SV.19, contact X

and 6-button switches switch (Sp.Rg.) Push-button switch (see Chap. 4.4)
Check 3, 4, and 5-button switches accordingly

1. If switch illumination is defective, re-
place bulb.
2. Open connections SV.2 and SV.19. SV.2

SV.19 see Chap. 4.4 and contact X

see Chap. 9.

Operate button (switch) as per table 1
below according to the diagnostic fault
indication and measure resistances
between contacts.
If R = Rtarget for all measurements, SV.19, variant
continue with step 5.

Table 1
SV.2: Measurement Rtarget [Ω]: SV.2: Mea- Rtarget [Ω]: SV.2: Mea-
Rtarget [Ω]: Rtarget [Ω]:
Button, Measurement btw. SV.2, con- Button depr. surement btw. Button depr. surement btw.
Button depr./ Button depr.
Switch btw. contact 33 tact 29 (TS) (N depressed) contact 29 (TS) (N depressed) contact 29 (TS)
not depressed (not depressed)
(TL) and: and SV.19: [not N depr.] and: [not N depr.] and:
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*(∞)*
* = Resistance when R-button is depressed too

5. Controllers

3. Open SV.24. SV.24

between contacts.
Table 2
Measurement Rtarget [Ω]: Measurement Measurement Measurement Rtarget [Ω]:
Button, Button depr. Button depr.
btw. contact Button depr./ btw. contact btw. contact btw. contact Button depr.
Switch (N depressed) (N depressed)
8 (TL) and: not depressed 7 (TS) and: 7 (TS) and: 7 (TS) and: (not depressed)
[not N depr.] [not N depr.]
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* (∞)*

between contacts.
Table 3
Measurement Rtarget [Ω]: Measurement Measurement Measurement Rtarget [Ω]:
Button, Button depr. Button depr.
btw. contact Button depr./ btw. contact btw. contact btw. contact Button depr.
Switch (N depressed) (N depressed)
8 (TL) and: not depressed 7 (TS) and: 7 (TS) and: 7 (TS) and: (not depressed)
[not N depr.] [not N depr.]
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, 46
and 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

E 200
Manual switch Indicator light

69
;
Ω 8% +%% +%

<
+%$ +%&
69
Rtarget = ∞ Ω

8%
+%&

Ω
+%%
+%$
+%
69
manual switch

1. If indicator light is defective, replace
bulb.

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,
Table 1
Measurement Measurement Measurement Measurement
Braking between con- between con- between con- between con-
Rtarget [Ω] Rtarget [Ω] Rtarget [Ω] Rtarget [Ω]
stage tact tact tact tact
8 (+HB) and: 8 (+HB) and: 8 (+HB) and: 8 (+HB) and:
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

5. Controllers


tween contacts.
Table 2
15 (+HB) and: 15 (+HB) and: 15 (+HB) and: 15 (+HB) and:
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

tween contacts.
Table 3
+* (+HB) and: +** (+HB) and: +** (+HB) and: X and:
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
* = next to contact 1
** = next to contact 4
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
5.3 Faulty component: Switch for converter braking stage 3
Electronic control unit E

200
Indicator light Rtarget see tables 1, 2, 3

69
;
Switch for con-
verter braking
Ω 8% +%% +%
<
+%$ +%&
stage 3
69 Rtarget = ∞ Ω

8%
+%&

Ω
+%%
+%$
+%
69 69
converter brake

1. If indicator light is defective, replace
bulb.

Measure resistances between con-

tacts as per table 1 below.

Table 1
Measurement Measurement Measurement
between con- between con- between con-
Switch Rtarget [Ω] Rtarget [Ω] Rtarget [Ω]
tact tact tact
8 (+HB) and: 8 (+HB) and: 8 (+HB) and:
off 7 (HBA) ∞ 44 (HBC) ∞ 21 (-UB) ∞
on 7 (HBA) 0 44 (HBC) 0 21 (-UB) appr. 290

5. Controllers


Table 2
tact tact tact
15 (+HB) and: 15 (+HB) and: 15 (+HB) and:
off 14 (HBA) ∞ 12 (HBC) ∞ 10 (-UB) ∞
on 14 (HBA) 0 12 (HBC) 0 10 (-UB) appr. 290


Table 3
tact tact tact
+* (+HB) and: +** (+HB) and: X and:
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
5.4 Faulty component: Brake valve (service brake transmitter)

E 200
Brake valve

69
Ω
)% )% )% )%
69
Rtarget = ∞ Ω
69
)%

Ω
)%

)%

)%
brake valve



tween contacts.
Table 1
Braking between con- between con- between con-
Rtarget [Ω] Rtarget [Ω] Rtarget [Ω]
stage tact tact tact
2 (+FB) and: 2 (+FB) and: 2 (+FB) and:
0 40 (FB1) ∞ 11 (FB2) ∞ 49 (FB3) ∞
1 40 (FB1) 0 11 (FB2) ∞ 49 (FB3) ∞
2 40 (FB1) 0 11 (FB2) 0 49 (FB3) ∞
3 40 (FB1) 0 11 (FB2) 0 49 (FB3) 0

5. Controllers

tween contacts.
Table 2
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

tween contacts.
Table 3
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.

5. Controllers
5.5 Faulty component: Voith load transmitter or

EMR with VDO load transmitter
Load transmitter
Cable 1 69
/*
Rtarget = ∞ Ω /*0
/*

Ω
Ω Rtarget see tables 1, 2, 3
69
Electronic control unit E

200

Depress accelerator pedal as per table
1 below and measure resistance be-
tween contacts.
Table 1
Measurement Measurement
Accelera- between con- between con-
Rtarget [Ω] Rtarget [Ω]
tor position tact tact
5 (-LG) and: 5 (-LG) and:
0 throttle 41 (+LG) 800-1500 24 (LGM) 178-333
Full throttle 41 (+LG) 800-1500 24 (LGM) 622-1667

5. Controllers

Depress accelerator pedal as per table 2 be-
low and measure resistance between con-
tacts.
Table 2
Measurement Measurement
Accelera- between con- between con-
Rtarget [Ω] Rtarget [Ω]
tor position tact tact
3 (-LG) and: 3 (-LG) and:
0 throttle 1 (+LG) 800-1500 2 (LGM) 178-333
Full throttle 1 (+LG) 800-1500 2 (LGM) 622-1667
Step Activity
3. SV.2: Measure resistance of contacts 5, 24, and 41 to earth. Rtarget = ∞ Ω.

5. Controllers
5.6 Faulty component: Kickdown switch

E 200
Kickdown switch (KD) 69
Rtarget = 0 Rtarget = ∞ Ω
or ∞Ω Ω
69 69 Ω
.'
8=
Connection cable Kick- Cable 2
down switch

1. Open SV.2. SV.2

4 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.
1 and 2.
KD switch open: Rtarget = ∞ Ω.
KD switch closed: Rtarget = 0 Ω.

Measure resistance between the two
contacts.
KD switch open: Rtarget = ∞ Ω.
KD switch closed: Rtarget = 0 Ω.
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

4JHOBMDPOEVDUPSTUPNPUPSDPOUSPMVOJUT
6.1 Faulty component: BOSCH electronic throttle control EMS 3.3 B/G

E 200
69
Rtarget = 0 Ω
Ω
69 Rtarget = ∞ Ω
'.5
Bosch
Ω
;
'.93:0
<
EMS 3.3 '.(
=
Cable 2
Connection cable

1. Open plug-and-socket connections SV.2
SV.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 Z
SV.19; variant
are shown in the circuit diagram.
Rtarget = 0 Ω.
2. SV.2: Measure resistance of contacts
5, 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.

E 200
69
Rtarget = 0 Ω
Rtarget = 0 Ω
Ω
Ω 69
E.g.
3:0,:$
;
MB FMR
Cable 2

1. Open plug-and-socket connections SV.2
SV.2 and SV.21 (cable 2).
tacts 41 and X (PWM/IWA; variant MB
FMR). The number of contact X is

Rtarget = 0 Ω.
2. SV.2: Measure resistance of contact SV.21; variant MB FMR
41 (cable 2) to vehicle earth.
Rtarget = ∞ Ω.


6.3 Faulty component: CAN-Bus

E 200
Rtarget = 0 Ω 69
Ω Rtarget = ∞ Ω
69
CAN-H
E.g. &
% CAN-M Ω
EDC $ CAN-L
Connection cable Cabel 2

1. Open plug connectors SV.2 and SV.2
SV.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.33, variant
contacts 17, 36 and 37 (cable 2) and A B
vehicle earth.
Rtarget = ∞ Ω.
C

6.4 Faulty component: dNEUTR output

E 200
Rtarget = 0 Ω
69
Ω RSoll = ∞ Ω
69
E.g. E-Gas ; G1(875 Ω

1. Open plug connectors SV.2 and SV.2
SV.19.


55 and X (dNEUTR) of cable 2. The
Rtarget = 0 Ω.
SV.19; variant
contact 55 and vehicle earth.
Rtarget = ∞ Ω.


0UIFSTXJUDIFTBOEXBSOJOHMJHIUT
7.1 Faulty component: ABS connection

E 200
Rtarget = 0 Ω
Connection cable 69
Ω

$%6 Ω
Rtarget = ∞ Ω
Cable 2 V
69
Case 1: inactive P P
Case 2: active Utarget = ca. 24
or 0 V
+ 24V
0 0 0 0 0
ABS

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

Case 2 (high active):
ABS inactive: USoll = ca. 0 V.
ABS active: USoll = 24 V.
53 and the conductor of the connecting
cable leading to the ABS.
Rtarget = 0 Ω.
53 (SV.2) and 7 (SV.19).
Rtarget = 0 Ω.

53 and vehicle earth. Rtarget = ∞ Ω.

7. Other switches and warning lights
7.2 Faulty component: Transmission oil warning light

E 200
Rtarget = 0 Ω
69
Connection cable
Ω

72(/ Ω
Rtarget = ∞
or appr.160 Ω
Cable 2
69
P P
Ω Rtarget = 0 Ω
+ 24V
0 0 0 0 0
Transmission
oil warning light

1. Replace bulb of transmission oil warn-
ing light if defective.
2. Open connector SV.2. SV.2

15 (cable 2) and vehicle earth.
With bulb: Rtarget = approx. 160 Ω.
Without bulb: Rtarget = ∞ Ω.

15 and the conductor to the transmis-
sion oil warning light.
Rtarget = 0 Ω.
15 (SV.2) and 17 (SV.19).
Rtarget = 0 Ω.

5. Measure resistance between the –con-

ductor of the warning light (M) and
earth.
Rtarget = 0 Ω.

7.3 Faulty component: Converter brake release switch

E 200
Rtarget = 0 Ω
69
Connection cable
Ω
Ω
)%$86
Rtarget = 0
or ∞ Ω
Cable 2
69
P P
Ω Rtarget = 0 Ω
+ 24V
0 0 0 0 0
Release switch
converter brake

Switch open: Rtarget = ∞ Ω.
Switch closed: Rtarget = 0 Ω.

31 and the conductor to the converter
brake release switch.
Rtarget = 0 Ω.
31 (SV.2) and 18 (SV.19).
Rtarget = 0 Ω.


ductor of the release switch (M) and
earth. Rtarget = 0 Ω.

7.4 Faulty component: Gearshift inhibitor switch

E 200
Rtarget = 0 Ω
69
Connecting cable
Ω
Ω
$%6,&+ Rtarget = 0
or ∞ Ω
Cable 2
69
P P
Ω Rtarget = 0 Ω
+ 24V
0 0 0 0 0
Gearshift in-
hibitor switch

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.
2. Measure resistance between contact 35 and

the conductor to the gearshift inhibitor switch.
Rtarget = 0 Ω.
Measure resistance between contacts 35
(SV.2) and 20 (SV.19).
Rtarget = 0 Ω.
4. Measure resistance between the –conductor

of the gearshift inhibitor switch (M) and earth.
Rtarget = 0 Ω.

7.5 Faulty component: ANS activation switch

E 200
Rtarget = 0 Ω
69
Connecting cable Ω
Ω
Rtarget = 0
%6 or ∞ Ω
cable 2
3
69
3
Rtarget = 0 Ω
Ω
+ 24V
0 0 0 0 0
ANS activation
switch

Switch open (service brake released):
Rtarget = ∞ Ω.
Switch closed (service brake applied):
Rtarget = 0 Ω.
12 and the conductor to the EK disen-

gagement switch.
Rtarget = 0 Ω.
12 (SV.2) and 21 (SV.19).

Rtarget = 0 Ω.

ductor of the ANS activation switch (M)
and earth. Rtarget = 0 Ω.


$BCMFTBOEQMVHT
8.1 Connection of cable 1 to control unit
SV.1 Pin assignment for Pin assignment for
DIWA.3: DIWA.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 RBKM
14 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 DKM
52 -UB 52 -UB
53 -UB 53 -UB
54 - 54 -
55 - 55 -

8. Cables and plugs
8.2 Connection of cable 1 to transmission housing
Pin assignment for Pin assignment for

SV.3; pin insert cable harness
DIWA.3: DIWA.3E:
(transmission housing)
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
7 $ %
6 G N3B G N3B
5 H 8 9 &
H N3A H N3A
J WR J WR
3 G I : ' K DK K DK
M J
1 F ; ( L EK L EK
K M PB M PB
E
0 D = < ) N WP N -
P RBK P RBK
/ * R 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
SV.3; socket insert cable 1 a +TS a +TS
b DKM b DKM
c EKM c EKM
d PBM d PBM
e RBKM e RBKM
% $ 7 6
f TBM f TBM
g SKM g SKM
& 9 8 H 5 h SENSE h SENSE
j SENSE j SENSE
' : I G 3
J M
( ; F 1
K
E
) < = D 0
* /
+ - .

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
SV.3; identical to
socket insert cable 1
1200
80
50
(
3

(6
:
1(
8
% 6
Q
76
Q
Q
0.
5 .6 6
: . 0%
' 0
'. (. 0 0 * %7 7
.% .% %5
(. 3%

0
3
5 5
%
3 :

8. Cables and plugs
8.5 Level converter 56.4219.10
X View X; plug
enlarged

450
7 000

/.

View Y;
SV.31; plug
enlarged


8. Cables and plugs

"QQFOEJDFT
1 Circuit diagram DIWA.3
1 Circuit diagram DIWA.3E

9. Appendices

$
1
' 1 5 238 +UB 20 EK 119

38 19
202 +FB -UB
221 2 55
221.1 DK 137
37
221.3 -UB SK 118
21 18
-UB
D 39 54
REA0
3 36
RBG 117
17
240 FB1 22 -UB 153
53
204 KD 40 WR 135
35
204.1 KD -UB
4 16
-UB 152
23 52
F
DKV/PWM
E
241.1 -UB
41 34
$
205.1 DKR EKM 7
5 15
224.1 DKE DKM 8
S1 S2 S3 S2/1 S2/2 S3/2 S3/3 24 51
D N R SKM 3
42 33
PBM 6
2 D N R 6 14
200 TBM 4
1 2 D N R 25 50
1 2 3 D N R 43 32
207 HBA RBKM 5
7 13
226 HBB SENSE 1
26 49
244 HBC SENSE 2
S2/2
S3/2
S2/1
S3/3
208 +HB 44 31
-UB
S1 227 227 8 12
1 S1 -UB 148
S2 245 245 27 48
2 S2 -UB
S3 209 209 S3 45 30
3 N1A 111
+V 228 228 9 11
4 +V N1B 147
+R 246 246 28 47
5 +R N2A 129
RS 230 210 /N 46 29
+TS 6 N2B 110
229 229 +TS 10 10
7 N3A 146
+TL 233 29 46
8 N3B 128
/N 210 FB2 47 28
-UB 9 211
221 230 11 9
10 RS
SSP 200 30 45
11 248 PU -UB
RF 256 48 27
12 212 BS TS+ 9
RS 12 8
13 231 FBAUS TS- 10
+R 31 44
14 249 FB3 -UB
49 26
213 dS
13 7
% & '
232 dW
32 43
250 dN
50 25
214 dR IO9
14 6
233 +TL
33 42
251 ZW LGM 124
51 24
215 TOEL -LG 105
15 5
+LG 141
34 41
252 DIAGN-K IO3
52 23
252.1
216 DIAGN-L 4
]
16 40
227

S1 227 216.1 -UB
]
1 22
S2 245 245 WP 103

235 ABSICH
\ 209 2 35 3
221.2 221.2 S3 209 253 ABS -UB
\ [
3 53 39
0 1 2 3 +V 228 228 217 CAN-H RBK 121
8 [ 7
246 4 17 21
+R 246 236 CAN-M PB 102
HBC 0 0 0 1 230 5 230 36 -UB 2
RS
6 54 38
HBC 0 1 HBB 0 0 1 1 +TS 229 229 TB 120
7 18 20
HBA 0 1 6 HBA 0 1 1 1 +TL 233 233 237 CAN-L PA 101
1 1 210 8 37 1
HBC +HB 1 1 5 +HB 1 1 1 1 /N 210 255 dNEUTR
2 2 221 9 55
4 -UB 221 219
3 3 -UB 221.2 10 +UZ
-UB 219.1
+
4 244 4 244 11 19
HBA HBC 3 244 HBC 244 219.2
5 226 HBB 5 226 HBB 226 12 226
2
6 207 6 207 13 207
HBA 1 207 HBA
+HB 7 208 +HB 7 208 +HB 208 14 208
8 + 8 SSP 200 15 200
RF 256 16
17
219.2
(
18 +UZ
)
221.3 -UB 1
252.1 DIAGN-K 2
216.1 DIAGN-L 8
10
6 5
*
141 +LG
1
124 LGM
2
204
219 3
105 -LG
4
4
128
146
152
153
147
111
110
129
135
137
119
102
103
121
117
120
101
118
9
148
4
3
1
10
2
6
5
KD 204 204
+UZ 219 1 219 A B C D E F G H J K L M N P R S T U V WX Y Z a b c d e f g h j
gn/ge FB1 240 2 240
240
1 FB3 249 3 249
bl 249
2 +FB 202 4 202
sw 202
3 5 211
br 211 FB2 211
4 6
ws bl
3
7 +
ϑ
1 4 bl
8 - sw
+
2 3
9
ws bl ws
10
n1 2 bl n3
0
sw sw
CAN-H 217 sw CAN-H 1
C
CAN-M 237 ge CAN-M
CAN-L B 236 CAN-L
A ws
sw n2
K L M N O P sw
2
br br
ge
2
sw
ge
2
dS dW dR dN WR gn
4
3
bl SK
rt bl bl rt
1 1
1
sw br
2 ge
30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a ge
4
DK bl
rt
3
gn
bl
1
sw br br sw
-
2 ge ge 2 ge
ge
TB
Q
4
EK bl
rt
3
gn
bl
gn
bl
4
3
bl
rt
1 1
V T VW X
.
sw br br sw
2 ge 2
ge
61 D- D+
PB bl 4 gn RBG
S
M rt 3 bl bl rt
Y R 1
238
213
+UB
dS
1 1
Z
50e 50f D+ 2 sw br br sw
U 150 219.1 +UZ 2 2

G
W
3 ge ge
4
214
232
dR
dW WP gn 4
3
bl RBK
5 rt bl bl rt
251 ZW 1 1
6 253 ABS
7 250 dN
8 255 dNEUTR
9 252 DIAGN-K A Push-button switch L Switches and warning a Inhibitor switch for re- l Relay for reversing light
10 216 DIAGN-L
11 200 SSP
B Connection cable for light transmission oil verse gear m Relay for speed
DKR 12
13
205.1 DKR push-button switch and M Engine control b Connections n Central warning light
DKE 224.1 DKE
DKV/PWM 14 241.1 DKV/PWM converter brake N Vehicle electrical system - c Bridges o Fuse 8A
0
15
16
204.1
215
KD
TOEL
C Cable 2 non-committal represen- d Warning light transm. oil p Relay for battery
17 231 FBAUS D E 200 control unit tation e Cut-out switch for conv. q Switch box
18 248 PU
19 235 ABSICH E Connection: level con- O Relays brake; r Starter inhibitor relay
20
21
212
221.1
BS
-UB
verter and diagnostic PC P CAN bus only for brake valve s Starter
F Cable 1 Q Connection cable for f Pressure switch for st Start button
off
on
22
ABS P P
G Load transmitter brake valve and gearshift inhibitor t Battery
H Speed and temperature kickdown switch g Pressure switch for u Overvoltage protection
G H I J sensors R Kickdown switch ANS activation v Generator
J Solenoid valves S Brake valve h Relay for control unit w Regulator
Circuit diagram
/
inactive
K Connection cable T Manual switch for i Relay for starter inhibitor x Connections
for vehicle wiring
U
converter brake
Switch for converter
j
k
Relay for centr. warn. light
Relay for converter brake
y
z
Position
Stage no.
DIWA.3
+ 24V
brake; stage no. 3 55.3705.20
$
1
' 1 5
20
238 +UB EK 119
38 19
202 +FB -UB
221 2 55 137
221.1 DK
221.3 -UB 37 118
SK
21 18
D
-UB
39 REA0 54
3 36 117
RBG
240 FB1 22 17 153
-UB
204 40 53 135
KD WR
204.1 KD 35
-UB
4 16 152
-UB
241.1 DKV/PWM 23 52
-UB
$ S1 S2
E F
S3 S2/1 S2/2 S3/2 S3/3
205.1
224.1
DKR
DKE
41
5
EKM
DKM
34
15
7
8
24 51 3
D N R SKM
42 33 6
PBM
2 D N R 6 14
200 TBM 4
1 2 D N R 25 50
1 2 3 D N R 43 32
207 HBA RBKM 5
226 HBB 7 SENSE 13 1
244 HBC 26 SENSE 49 2
S2/2
S3/2
S2/1
S3/3
208 44 31
+HB -UB
S1 227 227 8 12 148
1 S1 -UB
S2 245 27 48
2 245 S2 -UB
S3 209 45 30 111
3 209 S3 N1A 11
+V 228 9
4 228 +V N1B 147
+R 246 28 47
5 246 +R N2A 129
RS 230 46 29 110
6 210 /N N2B
+TS 229 10 10 146
7 229 +TS N3A
+TL 233 29 46
8 N3B 128
/N 210 FB2 47 28
9 211
-UB 221 230 11 9
10 RS
SSP 200 30 45
11 248 PU -UB
RF 256 48 27 9
12 212 BS TS+
RS FBAUS 12 8
13 231 TS- 10
+R FB3 31 44
14 249 -UB
dS 49 26
213
7
% & '
232 dW 13
32 43
250 dN
50 25
214 dR IO9
14 6
233 +TL
33 42 124
251 ZW LGM
51 24
215 TOEL -LG 105
15 +LG 5 141
41
252 DIAGN-K 34 IO3
52 23
252.1
216 DIAGN-L 4
] 227 16 -UB 40
S1 227 216.1

]
1 22
S2 245 245 235 ABSICH 103
\
221.2 221.2 S3 209 2 209 35 -UB 3
253 ABS
\ [ 0 1 2 3 3 53 39
7
+V 228 228 217 CAN-H RBK 121
[
8
4 17 21
+R 246 246 236 CAN-M PB 102
230 5 36 -UB 2
HBC 0 0 0 1 RS 230
HBC 0 1 229 6 54 TB 38
HBB 0 0 1 1 +TS 229 120
HBA 0 1 233 7 18 WP 20
6 HBA 0 1 1 1 +TL 233 237 CAN-L 101
1 1 8 37 1
HBC +HB 1 1 5 +HB 1 1 1 1 /N 210 210 255 dNEUTR
2 2 9 219 55
4 -UB 221 221
3 3 221.2 10 +UZ
-UB -UB 219.1
+
4 4 11 19
HBA 244 HBC 3 244 HBC 244 244 219.2
5 HBB 5 226 HBB 226 12 226
226 2
6 HBA 6 207 13 207
207 1 207 HBA
+HB 7 +HB 7 208 +HB 208 14 208
208
+
8 8 200 15
SSP 200
RF 256 16
17
18 219.2 +UZ
( )
221.3 -UB 1
252.1 DIAGN-K 2
216.1 DIAGN-L 8
10
6 5
*
141 +LG
1 124 LGM
204 2 105 -LG
219 3
4
4

128
146
152
153
147
111
110
129
135
137
119
102
103
121
117
120
101
118
9
148
4
3
1
10
2
6
5
KD 204 204
+UZ 1 219 A B C D E F G H J K L MN P R S T U V WX Y Z a b c d e f g h j
219
gn/ge 240 FB1 2 240
240
1 FB3 3
bl 249 249 249
sw 2 202 +FB 202 4 202
br 3 211 FB2 5 211
211
4 6
7 + ws bl
ϑ
3
1 - 4 bl
+
8 sw
2 3
9
10 ws bl ws
n1 sw
2 bl sw
n3
0
CAN-H 217 sw CAN-H 1
C
CAN-M 237 ge CAN-M
CAN-L B 236 CAN-L
A ws
sw n2
K L M N O P sw
2
br br
2
sw
ge ge
2
dS dW dR dN 4
SK bl
rt 3
gn
bl WR
1 bl rt
1
1
sw br
30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a 30 86 85 87 87a ge 2 ge
4 gn
DK bl
rt 3 bl
1
br br sw
-
sw
2 ge ge 2 ge
ge
Q
4 4
EK bl
rt 3
gn
bl
gn
bl 3
bl
rt
TB
1 1
V T VW X
.
sw br br sw
2 ge 2
ge
4
61 D- D+
PB bl gn
RBG
S
M rt
3 bl bl rt
Y R
238 +UB 1 1
1 213 dS br
Z
50e 50f D+ 2 sw
U
150 219.1 +UZ 2 br sw
W
G 3 214 dR 2
4
5
232 dW WP rt bl
ge
gn 4
ge
bl
RBK
251 ZW 1 3
6 bl rt
253 ABS 1
7 250 dN
8 255 dNEUTR
9
10
252 DIAGN-K A Push-button switch M Engine control a Inhibitor switch for re- l Relay for reversing light
216 DIAGN-L
11 200 SSP B Connection cable for N Vehicle electrical system - verse gear m Relay for speed
12 205.1
DKR
DKE 13 224.1
DKR
DKE
push-button switch and non-committal represen- b Connections n Central warning light
DKV/PWM 14
15
241.1 DKV/PWM converter brake tation c Bridges o Fuse 8A
204.1 KD
0
16 215 TOEL C Cable 2 O Relays d Warning light transm. oil p Relay for battery
17
18
231
248
FBAUS D E 200 control unit P CAN Bus e Cut-out switch for conv. q Switch box
PU
19
20
235 ABSICH E Connection: level con- Q Connection cable for brake; r Starter inhibitor relay
212 BS
21 221.1 -UB
verter and diagnostic PC brake valve and only for brake valve s Starter
off
on
22
F Cable 1 kickdown switch f Pressure switch for st Start button
ABS P P G Load transmitter R Kickdown switch gearshift inhibitor t Battery
H Speed and temperature S Brake valve g Pressure switch for u Overvoltage protection
G H I J sensors T Manual switch for ANS activation v Generator
/
J Solenoid valves converter brake h Relay for control unit w Regulator
inactive
K Connection cable U Switch for converter i Relay for starter inhibitor x Connections Circuit diagram
+ 24V
for vehicle wiring
L Switches and warning
brake; stage no. 3 j
k
Relay for centr. warn. light
Relay for converter brake
y
z
Position
Stage no.
DIWA.3E
light transmission oil 55.6168.10
Voith Turbo GmbH & Co. KG
Produktgruppe Nutzfahrzeuggetriebe
Alexanderstraße 2
D-89522 Heidenheim
Telephone(07321) 37-0
Telefax (07321) 37 7618

Voith Diwa3 Trouble Shooting PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Voith Diwa3 Trouble Shooting PDF

Uploaded by

Copyright:

Available Formats

5SPVCMF4IPPUJOH

Voith. 55.6293.31 / 2002-03

Voith. Trouble Shooting I

The manual serves the following purpose:

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

Additional DIWA.3 and DIWA.3E documentation

This documentation is protected by copyright

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

n Automobile mechanics and electricians

II Voith. Trouble Shooting

a) the control unit records,

Use of the diagnostic program for fault tracing:

Transmission repair and spare parts ordering:

Voith. Trouble Shooting III

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

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

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

Voith. Trouble Shooting V

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

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

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

VI Voith. Trouble Shooting

n Chap. 3.2.2 and Chap. 3.2.3,

Voith. Trouble Shooting VII

n Start the diagnostic program

n Read fault memory (function B)

How to proceed with the "Trouble Shooting"

After completion of "Trouble Shooting"

Voith. Trouble Shooting 1

1.1 Faulty component: Voltage supply to control unit

Step Activity and location Fuse, pins or contacts

4. Measure resistance between contact  

Voith. Trouble Shooting 3

1.2 Faulty component: Diagnosis connection

Electronic control unit

   69 Diagnosis-PC

Step Activity and location Pins or contacts

2. Open plug connections SV.2 (cable 2). SV.2

4 Voith. Trouble Shooting

2.1 Faulty component: Inductive pick-up N1

Ω Rtarget = 800-1400 Ω Connection for in-

Step Activity and location Pins or contacts

3. Remove control cover. SV.4

Voith. Trouble Shooting 5

2.2 Faulty component: Inductive pick-up N2

Step Activity and location Pins or contacts

2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable

4. Measure resistance between contact 29 and vehicle earth. Rtarget = ∞ Ω.

6 Voith. Trouble Shooting

2.3 Faulty component: Inductive pick-up N3

Electronic control unit Inductive

Step Activity and location Pins or contacts

2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable

4. Measure resistance between contact 46 and vehicle earth. Rtarget = ∞ Ω.

Voith. Trouble Shooting 7

2.4 Faulty component: Oil temperature transmitter

  Connection for oil

Step Activity and location Pins or contacts

For Rtarget see chart above.  

2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable

4. Remove oil sump. SV.9

8 Voith. Trouble Shooting

Step Activity and location Pins or contacts

4. Measure resistance between contact

69 Diagnosis-PC

Connection for oil

For Rtarget see chart above.

cable). Rtarget = 11-20 Ω. 8%

69 11 - 20 [Ω] 11±0,7 [Ω]

69 11 - 20 [Ω] 11±0,7 [Ω]

Ω Rtarget = 0 Ω Rtarget = 285-310 Ω 69