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Voith Diwa3 Trouble Shooting
Voith Diwa3 Trouble Shooting
Voith Diwa3 Trouble Shooting
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.
What is it for?
Special fault tracing in electrical transmission components or parts using the Voith PC-
based diagnostic program DIWAGNOSIS.
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".
Subject to change
Who is it for?
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
Diagnostic Manual
Tracing of possible faults in the electrical system of DIWA.3 and DIWA.3E transmissions:
Trouble Shooting
Repair Manual,
Spare Parts Catalogs
Page
A. Introduction ......................................................................................................................... 1
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
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
9. Appendices .......................................................................................................................57
1 Circuit diagram DIWA.3
1 Circuit diagram DIWA.3E
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. 8.1,
Chap. 8.2,
Chap. 8.4
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 communication
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.
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.
Relay
"control" Electronic control unit
E 200
Utarget = approx. 24 V
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.
diagram. Rtarget = 0 Ω.
Diagnosis-PC
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.
Rtarget = 0 Ω.
3. SV.2: Measure resistance between
contacts 16, 19, 21, and 52 (cable 2)
and vehicle earth. Rtarget = ∞ Ω.
Cable 1 DIWA.3/.3E
transmission
Cable harness
Ω Rtarget = ∞ Ω
Inductive
Electronic control unit pick-up N1
E 200
Rtarget = 800-1400 Ω.
2. Sensors
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
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.
2. Sensors
DIWA.3/.3E
Cable 1 transmission
Cable harness
with connection
for inductive
Rtarget = ∞ Ω pick-up N3
Ω
Ω Rtarget = 800-1400 Ω
Rtarget = 800-1400 Ω.
2. Sensors
DIWA.3/.3E
Cable 1 transmission
Cable harness
Ω
Rtarget = ∞ Ω
Ω temperature
0 [°C] 810 [Ω] transmitter
20 [°C] 950 [Ω]
70 [°C] 1360 [Ω]
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
Measuring
5 - 10 [Ω] 5,2±0,3 [Ω] Measur- Working
Electronic control unit coil
ing coil coil
E 200
Rtarget = 11-20 Ω.
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.
3. Solenoids
Cable 1 DIWA.3/.3E
transmission
Cable harness
Ω Rtarget = ∞ Ω
Ω
Coil + TB solenoid
Measuring
5 - 10 [Ω] 5,2±0,3 [Ω] Measur- Working
Electronic control unit coil
ing coil coil
E 200
Rtarget = 11-20 Ω.
cable).
Rtarget = 11-20 Ω.
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.
3. Solenoids
Cable 1 DIWA.3/.3E
transmission
Cable harness
Ω Rtarget = ∞ Ω
Ω
Coil + PB solenoid
Measuring
5 - 10 [Ω] 5,2±0,3 [Ω] Measur- Working
Electronic control unit coil
ing coil coil
E 200
Rtarget = 11-20 Ω.
cable).
Rtarget = 11-20 Ω.
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.
3. Solenoids
Cable 1 DIWA.3/.3E
transmission
Cable harness
Ω Rtarget = ∞ Ω
Ω
Coil + DK solenoid
Measuring
5 - 10 [Ω] 5,2±0,3 [Ω] Measur- Working
Electronic control unit coil
ing coil coil
E 200
Rtarget = 11-20 Ω.
cable).
Rtarget = 11-20 Ω.
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.
3. Solenoids
Cable 1 DIWA.3/.3E
transmission
Cable harness
Ω Rtarget = ∞ Ω
Ω
Coil + SK solenoid
Measuring
5 - 10 [Ω] 5,2±0,3 [Ω] Measur- Working
Electronic control unit coil
ing coil coil
E 200
Rtarget = 11-20 Ω.
cable).
Rtarget = 11-20 Ω.
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.
3. Solenoids
DIWA.3/.3E
Cable 1
transmission
Cable harness
Ω Rtarget = ∞ Ω
Ω
Coil + RBK solenoid
Measuring Measur-
5 - 10 [Ω] 5,2±0,3 [Ω] Working
Electronic control unit coil
ing coil
coil
E 200
Rtarget = 11-20 Ω.
cable).
Rtarget = 11-20 Ω.
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
3. Solenoids
DIWA.3/.3E
transmission
Cable 1
Cable harness
Coil +
Rtarget Coil only
Ω cable 1
11 - 20 [Ω] 11±0,7 [Ω]
Ω
Rtarget = ∞ Ω
RBG solenoid
Rtarget = 11-20 Ω.
3. Solenoids
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
Rtarget = 11-20 Ω.
Rtarget = 11-20 Ω.
3. Solenoids
DIWA.3E
transmission
Cable 1
Cable harness
Coil +
Rtarget = ∞ Ω
Ω WP solenoid
Rtarget = 11-20 Ω.
Rtarget = 11-20 Ω.
3. Solenoids
DIWA.3/.3E
transmission
Cable 1
Cable harness
Coil +
Rtarget Coil only
Ω cable 1
11 - 20 [Ω] 11±0,7 [Ω]
Ω
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].
Converter
brake relay
Electronic control unit
E 200
Ω Rtarget = 0 Ω
Rtarget = 285-310 Ω
Ω
Rtarget = 285-310 Ω.
cable 2.
Rtarget = 285-310 Ω.
Speed switch
relay
Electronic control unit
E 200
Ω
Rtarget = 285-310 Ω.
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
Rtarget = 285-310 Ω.
Reversing light
relay
Electronic control unit
E 200
Ω Rtarget = 0 Ω Rtarget = 285-310 Ω
Ω
Connection cable Cable 2
Rtarget = 285-310 Ω.
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
Starter inhibitor
relay
Ω Rtarget = 0 Ω
Rtarget = 285-310 Ω
Ω
Vehicle
electrical
Rtarget = 285-310 Ω.
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
Stop brake
relay
Rtarget = 0 Ω
Ω
Rtarget = 285-310 Ω
Ω
Cable 2
Connection cable
Rtarget = 285-310 Ω.
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
Stop brake
relay
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
(dHSB relay).
Central warning
light relay
Electronic control unit
E 200
Ω
Central warn-
Ω
ing light
Rtarget = 285-310 Ω.
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
Rtarget = 285-310 Ω.
Central warning
light relay
Electronic control unit
E 200
Ω Rtarget = 0 Ω
Rtarget = s.b. Rtarget = ∞ Ω
Ω
Ω
Central warn-
ing light
Control
relay Electronic control unit
E 200
Rtarget = 0 Ω
Ω Rtarget = 285-310 Ω
Ω
Vehicle
electrical
the relay.
Rtarget = 285-310 Ω.
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
Control
relay
Electronic control unit
E 200
Rtarget = 0 Ω
Rtarget = ∞ Ω
Ω
Ω
Vehicle
electrical
87 (dS relay).
Rtarget = 0 Ω.
Rtarget = 0 Ω.
6-button switch
Rtarget see tables 1, 2, 3
Ω +TS
Cable 2
Ω
Rtarget = ∞ Ω
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*( ∞)*
5. Controllers
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* ( ∞)*
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* ( ∞*)
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
Ω
Rtarget = ∞ Ω
Ω
manual switch
tween contacts.
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
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
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.
5. Controllers
stage 3
Rtarget = ∞ Ω
Ω
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
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
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
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
Ω
Rtarget = ∞ Ω
Ω
tween contacts.
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
5. Controllers
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
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.
5. Controllers
Load transmitter
Cable 1
Rtarget = ∞ Ω
Ω Rtarget see tables 1, 2, 3
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
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.
5. Controllers
lieved): Rtarget = ∞ 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
6.1 Faulty component: BOSCH electronic throttle control EMS 3.3 B/G
Rtarget = 0 Ω
Ω
Rtarget = ∞ Ω
Bosch
Ω
EMS 3.3
Cable 2
Connection cable
Rtarget = 0 Ω
Rtarget = 0 Ω
Ω
Ω
E.g.
MB FMR
Cable 2
Rtarget = 0 Ω.
2. SV.2: Measure resistance of contact SV.21; variant MB FMR
41 (cable 2) to vehicle earth.
Rtarget = ∞ Ω.
Rtarget = 0 Ω
Ω Rtarget = ∞ Ω
CAN-H
E.g.
CAN-M Ω
EDC
CAN-L
Connection cable Cabel 2
vehicle earth.
Rtarget = ∞ Ω.
C
Rtarget = 0 Ω
Ω
RSoll = ∞ Ω
E.g. E-Gas
Ω
Connection cable Cable 2
Rtarget = 0 Ω
Connection cable
Ω
Ω
Rtarget = ∞ Ω
Cable 2 V
Case 1: inactive P P
ABS
Rtarget = 0 Ω.
Rtarget = 0 Ω
Ω
Connection cable
Ω
Rtarget = ∞
or appr.160 Ω
Cable 2
P P
Ω Rtarget = 0 Ω
+ 24V
Transmission
oil warning light
Rtarget = 0 Ω
Ω
Connection cable
Ω
Rtarget = 0
or ∞ Ω
Cable 2
P P
Ω Rtarget = 0 Ω
+ 24V
Release switch
converter brake
Rtarget = 0 Ω
Ω
Connecting cable
Rtarget = 0
or ∞ Ω
Cable 2
P P
Ω Rtarget = 0 Ω
+ 24V
Gearshift in-
hibitor switch
Rtarget = 0 Ω.
Rtarget = 0 Ω.
Rtarget = 0 Ω
Connecting cable Ω
Ω
Rtarget = 0
or ∞ Ω
cable 2
Rtarget = 0 Ω
Ω
+ 24V
ANS activation
switch
Rtarget = 0 Ω.
Rtarget = 0 Ω.
SV.2
SV.3; identical to
socket insert cable 1
0
0
2
1
0
8
0
5
X View X; plug
enlarged
0
5
4
0
0
0
7
View Y;
SV.31; plug
enlarged
9. Appendices