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 
 


Voith. 55.6293.31 / 2002-03


 

  

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.

 

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

 

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


 

 

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.:

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?

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

  Automobile mechanics and electricians

II Voith. Trouble Shooting


 

     


 

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


 



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


 

    


   

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:

   Chap. 3.2.2 and Chap. 3.2.3,

   Chap. 8.1,

   Chap. 8.2,

   Chap. 8.4

Voith. Trouble Shooting VII


 

VIII Voith. Trouble Shooting


 

 

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:

 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 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


 

   

1.1 Faulty component: Voltage supply to control unit

Relay 
"control"  Electronic control unit
 E 200 

             

      

     
     

Utarget = approx. 24 V

Rtarget = 0 Ω Rtarget = ∞ Ω


V
Ω Ω
Vehicle  Rtarget  = 0 Ω
supply  
   

system 
Connection cable  
    Ω
Cable 2 
      

 

 
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.   
  

4. Measure resistance between contact   


  

19 and the conductor in connection ca-


ble to fuse F1. Rtarget = 0 Ω.
5. Measure resistance between contact
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.

Voith. Trouble Shooting 3


 

1. Control and diagnosis

1.2 Faulty component: Diagnosis connection

Electronic control unit 


E 200 

           

 Diagnosis-PC 

Rtarget = ∞ Ω Rtarget = 0 Ω

Ω Ω

   

 

   

 

        

 

        

  

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.    

Switch off ignition.


 

  

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


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

4 Voith. Trouble Shooting


 

 

2.1 Faulty component: Inductive pick-up N1

Cable 1 DIWA.3/.3E
transmission 

 

 

Cable harness 

     
   

Ω Rtarget = ∞ Ω      

Ω Rtarget = 800-1400 Ω Connection for in- 


     
ductive pick-up N1
     

     

Inductive 
Electronic control unit  pick-up N1
E 200 

Step Activity and location Pins or contacts


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.)


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.

Voith. Trouble Shooting 5


 

2. Sensors

2.2 Faulty component: Inductive pick-up N2

DIWA.3/.3E
Cable 1 transmission 

 

 

Cable harness 
Ω Rtarget = ∞ Ω
     
with connection 
for inductive pick- 
up N2 
Ω Rtarget = 800-1400 Ω
     

     

     

Inductive 
Electronic control unit  pick-up N2 
E 200 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
Measure resistance between contacts
10 and 29 of cable 1.      

Rtarget = 800-1400 Ω.      

If R = Rtarget continue with step 4.    

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


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.
  
 

 

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.

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


5. Open SV.3. Measure resistance between contact F and earth. Rtarget = ∞ Ω.
6. Open SV.7. Measure resistance between a contact and earth. Rtarget = ∞ Ω.

6 Voith. Trouble Shooting


 

2. Sensors

2.3 Faulty component: Inductive pick-up N3

DIWA.3/.3E
Cable 1 transmission 

 

 

Cable harness 
with connection 
for inductive 
Rtarget = ∞ Ω pick-up N3 
Ω      

Ω Rtarget = 800-1400 Ω
     

     

     

Electronic control unit


Inductive 
E 200  pick-up N3 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
Measure resistance between contacts
28 and 46 of cable 1.      

Rtarget = 800-1400 Ω.      

If R = Rtarget continue with step 4.    

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


Measure resistance between pins G 56.4461.12
and 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. SV.8


Open SV.8. Measure resistance between pins of pick-up N3.
Rtarget = 800-1400 Ω.

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


5. Open SV.3. Measure resistance between contact H and earth. Rtarget = ∞ Ω.
6. Open SV.8. Measure resistance between a contact and earth. Rtarget = ∞ Ω.

Voith. Trouble Shooting 7


 

2. Sensors

2.4 Faulty component: Oil temperature transmitter

DIWA.3/.3E
Cable 1 transmission 
Cable harness 
 

 


     
   

Rtarget = ∞ Ω      
     

  Connection for oil 


Oil temp. ϑ Rtarget


 

Ω temperature 
     
    
0 [°C] 810 [Ω] transmitter 
20 [°C] 950 [Ω]
70 [°C] 1360 [Ω]   

     

90 [°C] 1550 [Ω] Oil temperature 


Electronic control unit    

120 [°C] 1860 [Ω] transmitter 


E 200 
140 [°C] 2090 [Ω]

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
Measure resistance between contacts
8 and 44 of cable 1.      

For Rtarget see chart above.      

If R = Rtarget continue with step 5.    

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


Measure resistance between pins a 56.4461.12
and Z of cable harness or the N1-con-
tacts of the measuring cable.
For Rtarget see chart above.
  

   

3. Remove control cover. SV.4


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

4. Remove oil sump. SV.9


Open SV.9.
On TB accumulator: measure resistance between pins of oil temper-
ature transmitter.
For Rtarget see chart above.
5. Measure resistance between contact 44 and vehicle earth. Rtarget = ∞ Ω.
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.
8. Open SV.9. Measure resistance between a contact and earth. Rtarget = ∞ Ω.

8 Voith. Trouble Shooting


 

 
3.1 Solenoids with measuring coil
3.1.1 Faulty component: EK solenoid

Cable 1 DIWA.3/.3E
transmission 
 

 

 

 

Cable harness 
 

 

Ω Rtarget = ∞ Ω      

Ω  
Coil + EK solenoid 
     
                

Rtarget Coil only


cable 1
     

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 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
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.
If R = Rtarget continue with step 4.
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.    

b) Measuring coil: Measure resistance  


between contacts c and h or j (cable

   

harness) or EKM and SENSE (measur-



ing cable).       


Rtarget = 5-10 Ω.
3. Remove control cover. SV.10
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.  

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.

Voith. Trouble Shooting 9


 

3. Solenoids

3.1.2 Faulty component: TB solenoid

Cable 1 DIWA.3/.3E
transmission 
 

 

 

 

Cable harness 
 

 

Ω Rtarget = ∞ Ω      

Ω  
Coil + TB solenoid 
     
               

Rtarget Coil only


cable 1
     

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 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
a) Working coil: Measure resistance
between contacts 20 and 52 or 53 of
cable 1.      

Rtarget = 11-20 Ω.      

b) Measuring coil: Measure resistance    

between contacts 50 and 31 or 49.


Rtarget = 5-10 Ω.
If R = Rtarget continue with step 4.
2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable
a) Working coil: Measure resistance 56.4461.12
between contacts S and A or B (cable 
harness) or TB and  – UB (measuring     

cable).  
Rtarget = 11-20 Ω.    

b) Measuring coil: Measure resistance


between contacts f and h or j (cable
   

harness) or TBM and SENSE (measur-       

ing cable). 
Rtarget = 5-10 Ω.
3. Remove control cover. SV.11
Open SV.11.
a) Working coil: Measure resistance between pins 1 and 2 of the TB
solenoid flat pin connector. Rtarget = 11±0,7 Ω.
 
b) Measuring coil: Measure resistance between pins 3 and 4 of the
TB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.  

4. Measure resistance between contact 50 and vehicle earth. Rtarget = ∞ Ω.


Measure resistance between contacts 50 and 20. Rtarget = ∞ 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.
6. Open SV.11. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω.
Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.

10 Voith. Trouble Shooting


 

3. Solenoids

3.1.3 Faulty component: PB solenoid

Cable 1 DIWA.3/.3E
transmission 
 

 

 

 

Cable harness 
 

 

Ω Rtarget = ∞ Ω      

Ω  
Coil + PB solenoid 
     
               

Rtarget Coil only


cable 1
     

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 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
a) Working coil: Measure resistance
between contacts 2 and 52 or 53 of ca-
ble 1.      

Rtarget = 11-20 Ω.      

b) Measuring coil: Measure resistance    

between contacts 14 and 31 or 49.


Rtarget = 5-10 Ω.
If R = Rtarget continue with step 4.
2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable
a) Working coil: Measure resistance 56.4461.12
between contacts M and A or B (cable 
harness) or PB and  – UB (measuring    

cable). 
Rtarget = 11-20 Ω.  
   

b) Measuring coil: Measure resistance


    

between contacts d and h or j (cable


harness) or PBM and SENSE (measur-       


ing cable).
Rtarget = 5-10 Ω.
3. Remove control cover. SV.12
Open SV.12.
a) Working coil: Measure resistance between pins 1 and 2 of the PB
solenoid flat pin connector. Rtarget = 11±0,7 Ω.
 
b) Measuring coil: Measure resistance between pins 3 and 4 of the
PB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.  

4. Measure resistance between contact 14 and vehicle earth. Rtarget = ∞ Ω.


Measure resistance between contacts 14 and 2. Rtarget = ∞ 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.
6. Open SV.12. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω.
Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.

Voith. Trouble Shooting 11


 

3. Solenoids

3.1.4 Faulty component: DK solenoid

Cable 1 DIWA.3/.3E
transmission 
 

 

 

 

Cable harness 
 

 

Ω Rtarget = ∞ Ω      

Ω  
Coil + DK solenoid 
     
                 

Rtarget Coil only


cable 1
     

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 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
a) Working coil: Measure resistance
between contacts 37 and 52 or 53 of
cable 1.      

Rtarget = 11-20 Ω.      

b) Measuring coil: Measure resistance    

between contacts 51 and 31 or 49.


Rtarget = 5-10 Ω.
If R = Rtarget continue with step 4.
2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable
a) Working coil: Measure resistance 56.4461.12
between contacts K and A or B (cable 
harness) or DK and  – UB (measuring    

cable).
Rtarget = 11-20 Ω.    

b) Measuring coil: Measure resistance


between contacts b and h or j (cable
   

harness) or DKM and SENSE (mea- 


      

suring cable). 

Rtarget = 5-10 Ω.
3. Remove control cover. SV.13
Open SV.13.
a) Working coil: Measure resistance between pins 1 and 2 of the DK
solenoid flat pin connector. Rtarget = 11±0,7 Ω.
 
b) Measuring coil: Measure resistance between pins 3 and 4 of the
DK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.  

4. Measure resistance between contact 51 and vehicle earth. Rtarget = ∞ Ω.


Measure resistance between contacts 51 and 37. Rtarget = ∞ 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.
6. Open SV.13. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω.
Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.

12 Voith. Trouble Shooting


 

3. Solenoids

3.1.5 Faulty component: SK solenoid

Cable 1 DIWA.3/.3E
transmission 
 

 

 

 

Cable harness 
 

 

Ω Rtarget = ∞ Ω      

Ω  
Coil + SK solenoid 
     
               

Rtarget Coil only


cable 1
     

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 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
a) Working coil: Measure resistance
between contacts 18 and 52 or 53 of
cable 1.      

Rtarget = 11-20 Ω.      

b) Measuring coil: Measure resistance    

between contacts 33 and 31 or 49.


Rtarget = 5-10 Ω.
If R = Rtarget continue with step 4.
2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable
a) Working coil: Measure resistance 56.4461.12
between contacts U and A or B (cable  

harness) or SK and  – UB (measuring


 

  
 

cable).
Rtarget = 11-20 Ω.  
 
   

b) Measuring coil: Measure resistance


between contacts g and h or j (cable
   

harness) or SKM and SENSE (measur-       

ing cable).
 

Rtarget = 5-10 Ω.
3. Remove control cover. SV.14
Open SV.14.
a) Working coil: Measure resistance between pins 1 and 2 of the SK
solenoid flat pin connector. Rtarget = 11±0,7 Ω.
 
b) Measuring coil: Measure resistance between pins 3 and 4 of the
SK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.  

4. Measure resistance between contact 33 and vehicle earth. Rtarget = ∞ Ω.


Measure resistance between contacts 33 and 18. Rtarget = ∞ 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.
6. Open SV.14. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω.
Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.

Voith. Trouble Shooting 13


 

3. Solenoids

3.1.6 Faulty component: RBK solenoid

DIWA.3/.3E
Cable 1
transmission 
 

 

 

 

Cable harness 
 

 

Ω Rtarget = ∞ Ω      

Ω  
Coil + RBK solenoid 
     
               

Rtarget Coil only


cable 1
     

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 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
a) Working coil: Measure resistance
between contacts 21 and 52 or 53 of
cable 1.      

Rtarget = 11-20 Ω.      

b) Measuring coil: Measure resistance    

between contacts 13 and 31 or 49.


Rtarget = 5-10 Ω.
If R = Rtarget continue with step 4.
2. Open SV.3. SV.3; Cable harness SV.3; Measuring cable
a) Working coil: Measure resistance 56.4461.12
between contacts P and A or B (cable 
harness) or RBK and – UB (measuring      

cable). 
Rtarget = 11-20 Ω.  
   

b) Measuring coil: Measure resistance      

between contacts e and h or j (cable


harness) or RBKM and SENSE (mea-       


suring cable).
Rtarget = 5-10 Ω.
3. Remove control cover. SV.15
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.
 
b) Measuring coil: Measure resistance between pins 3 and 4 of the
RBK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω  

4. Measure resistance between contact 13 and vehicle earth. Rtarget = ∞ Ω.


Measure resistance between contacts 13 and 21. Rtarget = ∞ 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.
6. Open SV.15. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω.
Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.

14 Voith. Trouble Shooting


 

3. Solenoids

3.2 Solenoids without measuring coil

3.2.1 Faulty component: RBG solenoid

DIWA.3/.3E
transmission 

Cable 1
 

Cable harness 
 

 

       

Coil +
Rtarget Coil only
Ω cable 1
     
        
11 - 20 [Ω] 11±0,7 [Ω]


  

Rtarget = ∞ Ω
      

RBG solenoid 

Electronic control unit


E 200 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
Measure resistance between contacts
17 and 52 or 53 of cable 1.      

Rtarget = 11-20 Ω.      

If R = Rtarget continue with step 4.    

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


Measure resistance between contacts  56.4461.12
R and A or B (cable harness) or RBG  
and – UB (measuring cable).
Rtarget = 11-20 Ω.
   

   

3. Remove control cover. SV.16


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

4. Measure resistance between contact 2 and vehicle earth. Rtarget = ∞ Ω.

Voith. Trouble Shooting 15


 

3. Solenoids

3.2.2 Faulty component: WP solenoid for DIWA.3

DIWA.3 
transmission 

Cable 1
 

Cable harness 
 

 

       

Coil +
Rtarget Coil only
Ω cable 1
     
       
11 - 20 [Ω] 11±0,7 [Ω]
  

Rtarget = ∞ Ω Ω
      

WP solenoid 

Electronic control unit 


E 200 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
Measure resistance between contacts
3 and 52 or 53 of cable 1.      

Rtarget = 11-20 Ω.      

If R = Rtarget continue with step 4.    

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


Measure resistance between contacts  56.4461.12
N and A or B (cable harness) or WP 
and – UB (measuring cable).      

Rtarget = 11-20 Ω.

   

3. Remove control cover. SV.17


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

4. Measure resistance between contact 2 and vehicle earth. Rtarget = ∞ Ω.

16 Voith. Trouble Shooting


 

3. Solenoids

3.2.3 Faulty component: WP solenoid for DIWA.3E

DIWA.3E 
transmission 

Cable 1

 
Cable harness 
 

   

Coil +      

Rtarget Coil only


cable 1

       
11 - 20 [Ω] 11±0,7 [Ω]
     

Rtarget = ∞ Ω   

Ω WP solenoid 
      

Electronic control unit


E 200 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
Measure resistance between contacts
3 and 52 or 53 of cable 1.      

Rtarget = 11-20 Ω.      

If R = Rtarget continue with step 4.    

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


Measure resistance between contacts   56.4461.12
T and A or B (cable harness) or WP 
and – UB (measuring cable).       

Rtarget = 11-20 Ω.
   

3. Remove control cover. SV.17


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

4. Measure resistance between contact 2 and vehicle earth. Rtarget = ∞ Ω.

Voith. Trouble Shooting 17


 

3. Solenoids

3.2.4 Faulty component: WR solenoid

DIWA.3/.3E
transmission 

Cable 1

 

Cable harness 
 

 

       

Coil +
Rtarget Coil only
Ω cable 1
     
        
11 - 20 [Ω] 11±0,7 [Ω]
  


      

Rtarget = ∞ Ω WR solenoid 

Electronic control unit 


E 200 

Step Activity and location Pins or contacts


1. Open plug connection SV.1. SV.1
Measure resistance between contacts
35 and 52 or 53 of cable 1.      

Rtarget = 11-20 Ω.      

If R = Rtarget continue with step 4.    

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


Measure resistance between contacts  56.4461.12
J and A or B (cable harness) or WR 
and – UB (measuring cable).
Rtarget = 11-20 Ω.   

   


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

4. Measure resistance between contact 2 and vehicle earth. Rtarget = ∞ Ω.

18 Voith. Trouble Shooting


 

    

4.1 Faulty component: Converter brake relay dW

Converter
brake relay 


Electronic control unit 
E 200 

               




Ω Rtarget = 0 Ω   

Rtarget = 285-310 Ω
  Ω


Connection cable  Cable 2 


  

 

Step Activity and location Pins or contacts


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.    

     

  

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.
  

Rtarget = 285-310 Ω.
  

If R = Rtarget continue with step 5.


3. Open SV.19. SV.19; variant
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.


Rtarget = 285-310 Ω.
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).
Rtarget = 285-310 Ω.
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.

Voith. Trouble Shooting 19


 

4. Relays and pilot lights

4.2 Faulty component: Speed switch relay dN

Speed switch
relay 


Electronic control unit 
E 200 


               

Ω Rtarget = 0 Ω Rtarget = 285-310 Ω   




 



Connection cable  Cable 2 


  

 

Step Activity and location Pins or contacts


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. SV.2


For the following steps, connect one
feeler of the ohmmeter to vehicle earth.     

Measure resistance at contact 50 of      

cable 2.   
  

Rtarget = 285-310 Ω.
If R = Rtarget continue with step 5.
3. Open SV.19. SV.19; variant
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.


                           

Rtarget = 285-310 Ω.

4. Mounting plug SV.20: Measure resis- SV.20


tance at the cable to the start of the
winding of the dN relay (pin 86). dN
Rtarget = 285-310 Ω.
5. SV.20: Measure resistance at the ca-
ble to the end of the winding of the dN
relay (pin 85) and earthing point M.
Rtarget = 0 Ω.

20 Voith. Trouble Shooting


 

4. Relays and pilot lights

4.3 Faulty component: Reversing light relay dR

Reversing light
relay 


Electronic control unit 
E 200 

               




Ω Rtarget = 0 Ω Rtarget = 285-310 Ω
  

 


Connection cable  Cable 2 
  

 

Step Activity and location Pins or contacts


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. SV.2


For the following steps, connect one
feeler of the ohmmeter to vehicle earth.     

Measure resistance at contact 14 of      

cable 2.   
  

Rtarget = 285-310 Ω.
If R = Rtarget continue with step 5.
3. Open SV.19. SV.19; variant
Measure resistance at pin X (dR) of the
connection cable to the dR relay. The
number of contact X can be found in 


 

  
  

  

 
  


 

 


 

 


 

 

 
   

 
 

 
 

 
 

 

the circuit diagram.


Rtarget = 285-310 Ω.
4. Mounting plug SV.20: Measure resis- SV.20
tance at the cable to the start of the
winding of the dR relay (pin 86). dR
Rtarget = 285-310 Ω.
5. SV. 20: Measure resistance at the ca-
ble to the end of the winding of the dR
relay (pin 85) and earthing point M.
Rtarget = 0 Ω.

Voith. Trouble Shooting 21


 

4. Relays and pilot lights

4.4 Faulty component: Starter inhibitor relay

Starter inhibitor
relay 



               

  

Ω Rtarget = 0 Ω
Rtarget = 285-310 Ω
 




Vehicle    

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.    

Rtarget = 285-310 Ω.      

  

2. Open connection SV.24 SV.24


(see Chap. 5.1).
For the following steps, connect one
feeler of the ohmmeter to vehicle earth.                       

Measure resistance at contact 16 of                      

cable 2.
Rtarget = 285-310 Ω.
If R = Rtarget, continue with step 5.
3. Open SV.19. SV.19; variant
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.
Rtarget = 285-310 Ω.
4. Mounting plug SV.20: Measure resis- SV.20
tance at the cable to the beginning of
the winding of the starter inhibitor relay Starter
inhibitor 
(pin contact 86).
Rtarget = 285-310 Ω.
5. SV.20: Measure resistance at the ca-
ble to the end of the winding of the
starter inhibitor relay (pin contact 85)
and earthing point M.
Rtarget = 0 Ω.

22 Voith. Trouble Shooting


 

4. Relays and pilot lights

4.5 Faulty component: Stop brake

4.5.1 Faulty component: Stop brake relay dHSB

Stop brake
relay 
     

Electronic control unit 


Stop brake  E 200 
switch (HSB)                

Rtarget = 0 Ω

  
      

  

      
 
     
 

Rtarget = 285-310 Ω
   

             

  


Cable 2 
         

Connection cable   
   

     

 

Step Activity and location Pins or contacts


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.    

Rtarget = 285-310 Ω.      

  

2. Open connection SV.2. SV.2


For steps 1 to 5, connect one feeler of
the ohmmeter to vehicle earth. Mea-     

sure resistance at contact 32 of cable      

2.   
  

Rtarget = 285-310 Ω.
If R = Rtarget, continue with step 5.
3. Open SV.19. SV.19; variant
Measure resistance at pin contact X
(dHSB) of the connection cable to the
dHSB relay. The number of contact X 


 

  
  

  
  

 


 

 


 

 


 

 

 
   

 
 

 
 

 
 

 

is shown in the circuit diagram.


Rtarget = 285-310 Ω.
4. Mounting plug SV.20: Measure resis- SV.20
tance at the cable to the beginning of
dHSB
the winding of the dHSB relay (pin con-
tact 86).
Rtarget = 285-310 Ω.
5. SV.20: Measure resistance at the ca-
ble to the end of the winding of the
dHSB relay (pin contact 85) and earth-
ing point M1.
Rtarget = 0 Ω.

Voith. Trouble Shooting 23


 

4. Relays and pilot lights

4.5.2 Faulty component: Stop brake actuation

Stop brake
relay 
     

Electronic control unit 


Stop brake  E 200 
switch (HSB)                

F2 SV.20
Ω Rtarget = value
  

 
 

 
    
SV.2

Rtarget = 0 
 
 

SV.23   SV.22
 

MV or ∞ Ω Ω Ω
Rtarget = 0 Ω Ω

SV.19
  
Cable 2  Rtarget = ∞ Ω
   

 

     

 

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.


If R = Rtarget, continue with step 11.
8. Open SV.19. SV.19; variant
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: R target = 0 Ω.
10. Open SV.23. Measure resistance between contact 1 and 2.
HSB switch open: Rtarget = ∞ Ω. HSB switch closed: R target = 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.

24 Voith. Trouble Shooting


 

4. Relays and pilot lights

4.6 Faulty component: Central warning light (ZW)

4.6.1 Faulty component: ZW relay

Central warning
light relay 


Electronic control unit 
E 200 
               

      


  

Rtarget = 0 Ω Rtarget = 285-310 Ω   


     

Central warn- 
  

ing light        

Connection cable  Cable 2 


  

 

Step Activity and location Pins or contacts, relay


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.    

Rtarget = 285-310 Ω.      

  

2. Open connection SV.2. SV.2


For steps 1 to 5, connect one feeler of
the ohmmeter to vehicle earth. Mea-     

sure resistance at contact 51 of cable   


  

2.   
  

Rtarget = 285-310 Ω.
If R = Rtarget, continue with step 5.
3. Open SV.19 SV.19; variant
Measure resistance at pin contact X
(ZW) of the connection cable to the ZW
relay. The number of contact X is                             

shown in the circuit diagram.


                           

Rtarget = 285-310 Ω.

4. Mounting plug SV.20: Measure resis- SV.20


tance at the cable to the beginning of
ZW
the winding of the ZW relay (pin con-
tact 86).
Rtarget = 285-310 Ω.
5. SV.20: Measure resistance at the ca-
ble to the end of the winding of the ZW
relay (pin contact 85) and earthing
point M1.
Rtarget = 0 Ω.

Voith. Trouble Shooting 25


 

4. Relays and pilot lights

4.6.2 Faulty component: ZW bulb

Central warning
light relay 


Electronic control unit 
E 200 


               

Ω Rtarget = 0 Ω
     

  

Rtarget = s.b. Rtarget = ∞ Ω



  

 

Connection cable  Cable 2 


  

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.

26 Voith. Trouble Shooting


 

4. Relays and pilot lights

4.7 Faulty component: Voltage supply to solenoid valves

4.7.1 Faulty component: Control relay dS

Control
relay  Electronic control unit 
  
E 200 

               

      

Rtarget = 0 Ω               

Ω Rtarget = 285-310 Ω
 


      

Vehicle
   

 

  
  

electrical
 

   

system  Connection cable  Cable 2 

Step Activity and location Pins or contacts, relay


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.    

Rtarget = 285-310 Ω.      

  

2. Open connection SV.2. SV.2


For the following steps, connect one
feeler of the ohmmeter to vehicle earth.     

Measure resistance at contact 13 of   


  

cable 2.   
  

Rtarget = 285-310 Ω.
If R = Rtarget, continue with step 5.
3. Open SV.19. SV.19; variant
Measure resistance at pin contact X
(dS) of the connection cable to the dS
relay. The number of contact X is 


 

  
  

  
  

 


 

 


 

 


 

 

 
   

 
 

 
 

 
 

 

shown in the circuit diagram.


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

Voith. Trouble Shooting 27


 

4. Relays and pilot lights

4.7.2 Faulty component: Solenoid valve voltage

Control
relay 
Electronic control unit 
E 200 
  

             

      

              

Rtarget = 0 Ω
Rtarget = ∞ Ω

 

      

   

Vehicle   
 

  

electrical
 

   

system  Connection cable  Cable 2 

Step Activity and location Pins or contacts


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.   
  

If R = Rtarget continue with step 9.

8. Open SV.19. SV.19; variant


Measure resistance between contacts
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.

28 Voith. Trouble Shooting


 

 

5.1 Faulty component: Push-button switch

6-button switch 
        

Electronic control unit


E 200 

Rtarget see tables 1, 2, 3
                        
 
     

 
 

 
 
 
 
 
 
 
Ω                     +TS       

                   

       
 

Cable 2 

  

   

  

 
 

  

 
 

  

 
 

  

 
 

   

 
 

   

 
 

  


 
 

   

     

   

 

  
                           

  
  

        

Rtarget = ∞ Ω
  

  
      

  

        
  

          

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

Step Activity and location Pins or contacts


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

Voith. Trouble Shooting 29


 

5. Controllers

Step Activity and location Pins or contacts


3. Open SV.24. SV.24
Operate button (switch) as per table 2
below according to the diagnostic fault
indication and measure resistances
                      

                     

between contacts.

Table 2
Rtarget [Ω]: Rtarget [Ω]:
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* ( ∞)*

* = Resistance when R-button is depressed too

Step Activity and location Pins or contacts


4. Open SV.25. SV.25
Operate button (switch) as per table 3
below according to the diagnostic fault       
indication and measure resistances       

between contacts.

Table 3
Rtarget [Ω]: Rtarget [Ω]:
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* ( ∞*)

* = Resistance when R-button is depressed too

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.

30 Voith. Trouble Shooting


 

5. Controllers

5.2 Faulty component: Manual converter brake switch

Electronic control unit


E 200 

Manual switch  Indicator light 


Rtarget see tables 1, 2, 3
        
       
    


     

 

Ω            

 

       

      

 

 
Rtarget = ∞ Ω
    


   

    

   

  
 

   

    

   

  
 

   

    

Connection cable Cable 2 


      

manual switch 

Step Activity and location Pins or contacts


1. If indicator light is defective, replace
bulb.

2. Open connection SV.2. 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.

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

Voith. Trouble Shooting 31


 

5. Controllers

Step Activity and location Pins or contacts


3. Open SV.24. SV.24
Select braking stage as per table 2 be-
low according to the diagnostic fault in-
dication and measure resistances be-
                      

                     

tween contacts.

Table 2
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
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

Step Activity and location Pins or contacts


4. Open SV.26. SV.26
Select braking stage as per table 3 be-
low according to the diagnostic fault in-    
 

dication and measure resistances be-


tween contacts.      

Table 3
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
+* (+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.

32 Voith. Trouble Shooting


 

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


  
         
     

 

Switch for con- 


verter braking 
Ω            

 

stage 3 
       

 
      

Rtarget = ∞ Ω
 

    


   

    

   

    

   

    

   

  
 

   

    

Connection cable Cable 2 


converter brake 
             

Step Activity and location Pins or contacts


1. If indicator light is defective, replace
bulb.

2. Open connection SV.2. SV.2


Measure resistances between con-
tacts as per table 1 below.     

If R = Rtarget  for all measurements,      

continue with step 5.   


  

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

Voith. Trouble Shooting 33


 

5. Controllers

Step Activity and location Pins or contacts


3. Open SV.24. SV.24
Measure resistances between con-
tacts as per table 2 below.                       

                     

Table 2
Measurement Measurement Measurement
between con- between con- between con-
Switch Rtarget [Ω]  Rtarget [Ω] Rtarget [Ω]
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

Step Activity and location Pins or contacts


4. Open SV.26. SV.26
Measure resistances between con-    
 

tacts as per table 3 below.


     

Table 3
Measurement Measurement Measurement
between con- between con- between con-
Switch Rtarget [Ω] Rtarget [Ω] Rtarget [Ω]
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

* * = next to contact 1


** = next to contact 4

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.

34 Voith. Trouble Shooting


 

5. Controllers

5.4 Faulty component: Brake valve (service brake transmitter)

Electronic control unit


E 200 
Brake valve 

Rtarget see tables 1, 2, 3


         

     

 Ω
               


 Rtarget = ∞ Ω
      


      

   

 
 

   

   

   

   

   

   

Connection cable Cable 2 


brake valve 

Step Activity and location Pins or contacts


1. Open connection SV.2. 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 4.

Table 1
Measurement Measurement Measurement
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

Voith. Trouble Shooting 35


 

5. Controllers

Step Activity and location Pins or contacts


2. Open SV.27. SV.27
Select braking stage as per table 2 be-
low according to the diagnostic fault in-           

dication and measure resistances be-          

tween contacts.

Table 2
Measurement Measurement Measurement
Braking between con- between con- between con-
Rtarget [Ω] Rtarget [Ω] Rtarget [Ω]
stage tact tact tact
5 (+FB) and: 5 (+FB) and: 5 (+FB) and:
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

Step Activity and location Pins or contacts


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

Table 3
Measurement Measurement Measurement
Braking between con- between con- between con-
Rtarget [Ω]  Rtarget [Ω] Rtarget [Ω]
stage tact tact tact
3 (+FB) and: 3 (+FB) and: 3 (+FB) and:
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.

36 Voith. Trouble Shooting


 

5. Controllers

5.5 Faulty component: Voith load transmitter or


EMR with VDO load transmitter

Load transmitter 

Cable 1 
   

Rtarget = ∞ Ω    
 

 

   

 

Ω Rtarget see tables 1, 2, 3

        

Electronic control unit E


200 

Step Activity and location Pins or contacts


1. Open connection SV.1. SV.1
Depress accelerator pedal as per table
1 below and measure resistance be-      

tween contacts.
     

If R = Rtarget  for all measurements,    

continue with step 3.

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

Voith. Trouble Shooting 37


 

5. Controllers

Step Activity and location Pins or contacts


2. Open connection SV.30. SV.30
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.
4. Open SV.30. Measure resistance of contacts 1-3 to earth. Rtarget = ∞ Ω.

38 Voith. Trouble Shooting


 

5. Controllers

5.6 Faulty component: Kickdown switch

Electronic control unit


E 200 

Kickdown switch (KD)


    


Rtarget = 0 Rtarget = ∞ Ω


or ∞Ω Ω
  Ω
  

 

   

 

Connection cable Kick-  Cable 2 


down switch 

Step Activity and location Pins or contacts


1. Open SV.2. SV.2
Measure resistance between contacts
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.
If R = Rtarget continue with step 4.
2. Open SV.27. SV.27
Measure resistance between contacts
1 and 2.                       

KD switch open: Rtarget = ∞ Ω.                      

KD switch closed: R target = 0 Ω.

3. Open SV.32. SV.32


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

Voith. Trouble Shooting 39


 

5. Controllers

40 Voith. Trouble Shooting


 

      

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

Electronic control unit 


E 200 

      

Rtarget = 0 Ω


 Rtarget = ∞ Ω
Bosch
   


 

        

EMS 3.3   

   

 

Cable 2 
Connection cable

Step Activity and location Pins or contacts


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.

Voith. Trouble Shooting 41


 

6. Signal conductors to motor control units

6.2 Faulty component: MB FMR

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

Electronic control unit


E 200 

  



Rtarget = 0 Ω
Rtarget = 0 Ω

Ω 
        
E.g.
MB FMR 
 

Cable 2 

Step Activity and location Pins or contacts


1. Open plug-and-socket connections SV.2
SV.2 and SV.21 (cable 2).
Measure resistances between con-     

tacts 41 and X (PWM/IWA; variant MB      

FMR). The number of contact X is


shown in the circuit diagram.
  
  

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

   

42 Voith. Trouble Shooting


 

6. Signal conductors to motor control units

6.3 Faulty component: CAN-Bus

Electronic control unit


E 200 

Rtarget = 0 Ω         


Ω Rtarget = ∞ Ω

CAN-H
E.g.  

CAN-M Ω
EDC   

 
CAN-L
Connection cable  Cabel 2 

Step Activity and location Pins or contacts


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
2. SV.2: Measure resistance between
contacts 17, 36 and 37 (cable 2) and A B

vehicle earth.
Rtarget = ∞ Ω.
C

Voith. Trouble Shooting 43


 

6. Signal conductors to motor control units

6.4 Faulty component: dNEUTR output

Electronic control unit


E 200 

Rtarget = 0 Ω
  



RSoll = ∞ Ω


E.g. E-Gas 
 
       

Connection cable  Cable 2 

Step Activity and location Pins or contacts


1. Open plug connectors SV.2 and SV.2
SV.19.
Measure resistance between contacts     

55 and X (dNEUTR) of cable 2. The   


  

number of contact X can be found in   


  

the circuit diagram.


Rtarget = 0 Ω.
SV.19; variant
2. SV.2: Measure resistance between
contact 55 and vehicle earth.
Rtarget = ∞ Ω.          
         

44 Voith. Trouble Shooting


 

     

7.1 Faulty component: ABS connection

Electronic control unit


E 200 

Rtarget = 0 Ω
Connection cable       
  


 
   

Rtarget = ∞ Ω

Cable 2  V
Case 1: inactive  P P
      

Case 2: active  Utarget = ca. 24


or 0 V
+ 24V

ABS         

Step Activity and location Pins or contacts


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.
Switch off ignition.
2. Measure resistance between contact
53 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. SV.19; variant
Measure resistance between contacts
53 (SV.2) and 7 (SV.19).                             

Rtarget = 0 Ω.                            

4. Measure resistance between contact


53 and vehicle earth. Rtarget = ∞ Ω.

Voith. Trouble Shooting 45


 

7. Other switches and warning lights

7.2 Faulty component: Transmission oil warning light

Electronic control unit


E 200 

Rtarget = 0 Ω
  
     


Connection cable 

  
     

Rtarget = ∞ 
or appr.160 Ω
Cable 2 
P P       

Ω Rtarget = 0 Ω
+ 24V

   
     

Transmission
oil warning light 

Step Activity and location Pins or contacts


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

2. Open connector SV.2. SV.2


Measure resistance between contact
15 (cable 2) and vehicle earth.
With bulb: Rtarget = approx. 160 Ω.     

Without bulb: Rtarget = ∞ Ω.      

3. Measure resistance between contact   


  

15 and the conductor to the transmis-


sion oil warning light.
Rtarget = 0 Ω.
If R = Rtarget continue with step 5.
4. Open SV.19. SV.19; variant
Measure resistance between contacts
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.

46 Voith. Trouble Shooting


 

7. Other switches and warning lights

7.3 Faulty component: Converter brake release switch

Electronic control unit 


E 200 

Rtarget = 0 Ω
  
     


Connection cable 

      

  

Rtarget = 0
or ∞ Ω
Cable 2 
P P       

Ω Rtarget = 0 Ω
+ 24V

         

Release switch
converter brake 

Step Activity and location Pins or contacts


1. Open connector SV.2. SV.2
Measure resistance between contact
31 (cable 2) and vehicle earth.
Switch open: Rtarget = ∞ Ω.     

Switch closed: Rtarget = 0 Ω.   


  

2. Measure resistance between contact   


  

31 and the conductor to the converter


brake release switch.
Rtarget = 0 Ω.
If R = Rtarget continue with step 4.
3. Open SV.19. SV.19; variant
Measure resistance between contacts
31 (SV.2) and 18 (SV.19).
Rtarget = 0 Ω.                             

                           

4. Measure resistance between the – con-


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

Voith. Trouble Shooting 47


 

7. Other switches and warning lights

7.4 Faulty component: Gearshift inhibitor switch

Electronic control unit


E 200 

Rtarget = 0 Ω
  
     


Connecting cable 

  
       
Rtarget = 0
or ∞ Ω
Cable 2 
P P
      

Ω Rtarget = 0 Ω
+ 24V

        

Gearshift in- 
hibitor switch 

Step Activity and location Pins or contacts


1. Open connector SV.2. 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.   
  

2. Measure resistance between contact 35 and


the conductor to the gearshift inhibitor switch.
Rtarget = 0 Ω.
If R = Rtarget continue with step 4.
3. Open SV.19. SV.19; variant
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.

48 Voith. Trouble Shooting


 

7. Other switches and warning lights

7.5 Faulty component: ANS activation switch

Electronic control unit


E 200 

Rtarget = 0 Ω
  
     

Connecting cable  Ω


Rtarget = 0
  
  

or ∞ Ω
cable 2 

   
      

Rtarget = 0 Ω

+ 24V

   
     

ANS activation
switch 

Step Activity and location Pins or contacts


1. Open connector SV.2. 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.      

2. Measure resistance between contact   


  

12 and the conductor to the EK disen-


gagement switch.
Rtarget = 0 Ω.
If R = Rtarget continue with step 4.

3. Open SV.19. SV.19; variant


Measure resistance between contacts
12 (SV.2) and 21 (SV.19).
                   

Rtarget = 0 Ω.
        

                           

4. Measure resistance between the – con-


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

Voith. Trouble Shooting 49


 

7. Other switches and warning lights

50 Voith. Trouble Shooting


 

   


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 -

Voith. Trouble Shooting 51


 

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
   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 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
f TBM f TBM
    g SKM g SKM
     h SENSE h SENSE
 j SENSE j SENSE
     
  
   

  
     
 
   

52 Voith. Trouble Shooting


 

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 

        
                 
                 

        
                 
           
        

Voith. Trouble Shooting 53


 

8. Cables and plugs

8.4 Measuring cable 56.4461.12

 
SV.3; identical to
socket insert cable 1

   0
   0
   2
   1

   0
   8
 

   0
   5
 

 

 
 

 
 

    

 

 

   

 
 

 

 

 

 

 

 

 

 

 

 
 

 
 
 
 
 
 

 
 
 

       
   
 
 
 
     
       
   

 
   
   
 
 

 
   
 

54 Voith. Trouble Shooting


 

8. Cables and plugs

8.5 Level converter 56.4219.10

X View X; plug
enlarged 

      

         

     

   0
   5
   4

   0
   0
   0
 
   7

 
 

   

        

View Y;
SV.31; plug
enlarged 

    

  

 
    

    

    

      

    

 

Voith. Trouble Shooting 55


 

8. Cables and plugs

56 Voith. Trouble Shooting


 

 

1 Circuit diagram DIWA.3

1 Circuit diagram DIWA.3E

Voith. Trouble Shooting 57


 

9. Appendices

58 Voith. Trouble Shooting


 

Voith Turbo GmbH & Co. KG


Produktgruppe Nutzfahrzeuggetriebe
Alexanderstraße 2
D-89522 Heidenheim
Telephone(07321) 37-0
Telefax (07321) 37 7618

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