Voith Diwa3 Trouble Shooting

 
 

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.
21 and vehicle earth. Rtarget = 0 Ω.
If R = Rtarget for all of measurements 3
to 5, proceed with step 8.
6. Open SV.19. SV.19; variant
Measure resistance between contact 19 (cable 2) and
contact X (+UZ) of the connection cable to the vehicle
supply system. The number of X is shown in the circuit                  
              
diagram. Rtarget = 0 Ω.
 
7. Measure resistance between contact Y (-UB) of earth-

ing cable (M) and vehicle earth. The number of Y is
shown in the circuit diagram. Rtarget = 0 Ω.
8. SV.2: Measure resistance between contact 19 and earth. Rtarget = ∞ Ω.
9. SV.19: Measure resistance between contact X (+UZ) and earth. Rtarget = ∞ Ω.

1. Control and diagnosis
1.2 Faulty component: Diagnosis connection
Electronic control unit

E 200
       
 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.  


 
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.

 
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

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.

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

10 and 29 of cable 1.    
Rtarget = 800-1400 Ω.    

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

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

2. Sensors
DIWA.3/.3E


Cable harness
with connection
for inductive
Rtarget = ∞ Ω pick-up N3
Ω    
   
   
   

Inductive
E 200 pick-up N3

28 and 46 of cable 1.    
Rtarget = 800-1400 Ω.    

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

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

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

2. Sensors
2.4 Faulty component: Oil temperature transmitter
DIWA.3/.3E
Cable harness


Ω
   
 
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]

8 and 44 of cable 1.    
For Rtarget see chart above.    

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

Open SV.4. Measure resistance between contacts 3 and 4 of the
connector for the oil temperature transmitter.
4. Remove oil sump. SV.9

Open SV.9.
On TB accumulator: measure resistance between pins of oil temper-
ature transmitter.
6. Open SV.3. Measure resistance between contact Z and earth. Rtarget = ∞ Ω.
7. Open SV.4. Measure resistance between contact 4 and earth. Rtarget = ∞ Ω.

 
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

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

Measure resistance between contacts 15 and 19. Rtarget = ∞ Ω.
5. Open SV.3. Measure resistance between contact c (or EKM) and earth. Rtarget = ∞ Ω.
Measure resistance between contacts c (or EKM) and L (or EK). Rtarget = ∞ Ω.
6. Open SV.10. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω.

3. Solenoids
3.1.2 Faulty component: TB solenoid
Cable 1 DIWA.3/.3E
transmission




Cable harness


Ω Rtarget = ∞ Ω    
Ω
Coil + TB solenoid
   
           
Rtarget Coil only

cable 1
   
Working coil 11 - 20 [Ω] 11±0,7 [Ω]

    
Measuring
ing coil coil
E 200

cable 1.    
Rtarget = 11-20 Ω.    

Rtarget = 5-10 Ω.
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.
Open SV.11.
a) Working coil: Measure resistance between pins 1 and 2 of the TB
 
TB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.  

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

3. Solenoids
3.1.3 Faulty component: PB solenoid
Cable 1 DIWA.3/.3E
transmission




Cable harness


Ω Rtarget = ∞ Ω    
Ω
Coil + PB solenoid
   
          
Rtarget Coil only

cable 1
   
Working coil 11 - 20 [Ω] 11±0,7 [Ω]

    
Measuring
ing coil coil
E 200

between contacts 2 and 52 or 53 of ca-
ble 1.    
Rtarget = 11-20 Ω.    

Rtarget = 5-10 Ω.
between contacts M and A or B (cable 
harness) or PB and – UB (measuring   
cable). 
Rtarget = 11-20 Ω. 
  

   
between contacts d and h or j (cable

harness) or PBM and SENSE (measur-     

ing cable).
Rtarget = 5-10 Ω.
Open SV.12.
a) Working coil: Measure resistance between pins 1 and 2 of the PB
 
PB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.  

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

3. Solenoids
3.1.4 Faulty component: DK solenoid
Cable 1 DIWA.3/.3E
transmission




Cable harness


Ω Rtarget = ∞ Ω    
Ω
Coil + DK solenoid
   
           
Rtarget Coil only

cable 1
   
Working coil 11 - 20 [Ω] 11±0,7 [Ω]

    
Measuring
ing coil coil
E 200

cable 1.    
Rtarget = 11-20 Ω.    

Rtarget = 5-10 Ω.
between contacts K and A or B (cable 
harness) or DK and – UB (measuring   
cable).
Rtarget = 11-20 Ω.   

between contacts b and h or j (cable
  
harness) or DKM and SENSE (mea- 

    
suring cable). 

Rtarget = 5-10 Ω.
Open SV.13.
a) Working coil: Measure resistance between pins 1 and 2 of the DK
 
DK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.  

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

3. Solenoids
3.1.5 Faulty component: SK solenoid
Cable 1 DIWA.3/.3E
transmission




Cable harness


Ω Rtarget = ∞ Ω    
Ω
Coil + SK solenoid
   
           
Rtarget Coil only

cable 1
   
Working coil 11 - 20 [Ω] 11±0,7 [Ω]

    
Measuring
ing coil coil
E 200

cable 1.    
Rtarget = 11-20 Ω.    

Rtarget = 5-10 Ω.
between contacts U and A or B (cable 
harness) or SK and – UB (measuring

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

between contacts g and h or j (cable
  
harness) or SKM and SENSE (measur-     
ing cable).

Rtarget = 5-10 Ω.
Open SV.14.
a) Working coil: Measure resistance between pins 1 and 2 of the SK
 
SK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.  

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

3. Solenoids
3.1.6 Faulty component: RBK solenoid
DIWA.3/.3E
Cable 1
transmission




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
ing coil
coil
E 200

cable 1.    
Rtarget = 11-20 Ω.    

Rtarget = 5-10 Ω.
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.
Open SV.15.
a) Working coil: Measure resistance between pins 1 and 2 of the
RBK solenoid flat pin connector. Rtarget = 11±0,7 Ω.
 
RBK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω  

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

3. Solenoids
3.2 Solenoids without measuring coil
3.2.1 Faulty component: RBG solenoid
DIWA.3/.3E
transmission
Cable 1

Cable harness


   
Coil +
Rtarget Coil only
Ω cable 1
   
     
11 - 20 [Ω] 11±0,7 [Ω]
Ω
 
Rtarget = ∞ Ω
    
RBG solenoid

E 200

17 and 52 or 53 of cable 1.    
Rtarget = 11-20 Ω.    

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

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

3. Solenoids
3.2.2 Faulty component: WP solenoid for DIWA.3
DIWA.3
transmission
Cable 1

Cable harness


   
Coil +
Rtarget Coil only
Ω cable 1
   
    
11 - 20 [Ω] 11±0,7 [Ω]
 
Rtarget = ∞ Ω Ω
    
WP solenoid

E 200

3 and 52 or 53 of cable 1.    
Rtarget = 11-20 Ω.    

N and A or B (cable harness) or WP 
and – UB (measuring cable).    

  

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

3. Solenoids
3.2.3 Faulty component: WP solenoid for DIWA.3E
DIWA.3E
transmission
Cable 1

Cable harness


Coil +    
Rtarget Coil only

cable 1
Ω
    
11 - 20 [Ω] 11±0,7 [Ω]
   
Rtarget = ∞ Ω  
Ω WP solenoid
    

E 200

3 and 52 or 53 of cable 1.    
Rtarget = 11-20 Ω.    

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

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

3. Solenoids
3.2.4 Faulty component: WR solenoid
DIWA.3/.3E
transmission
Cable 1

Cable harness


   
Coil +
Rtarget Coil only
Ω cable 1
   
     
11 - 20 [Ω] 11±0,7 [Ω]
 
Ω
    
Rtarget = ∞ Ω WR solenoid

E 200

35 and 52 or 53 of cable 1.    
Rtarget = 11-20 Ω.    

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

    
4.1 Faulty component: Converter brake relay dW
Converter
brake relay

E 200
          


Ω Rtarget = 0 Ω  
Rtarget = 285-310 Ω
 Ω

Connection cable Cable 2

 


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.
 
 

Measure resistance at pin X (dW) of
the connection cable to the dW relay.
                 
The number of contact X can be found                 
in the circuit diagram.

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

4. Relays and pilot lights
4.2 Faulty component: Speed switch relay dN
Speed switch
relay

E 200

          
Ω Rtarget = 0 Ω Rtarget = 285-310 Ω  



Ω


 


1. Replace dN relay by a new one or re-
Rtarget = 285-310 Ω.   
   
 

Measure resistance at contact 50 of    
cable 2.  
 
Measure resistance at pin X (dN) of the
connection cable to the dN relay. The
number of contact X can be found in                  
the circuit diagram.

                

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

4.3 Faulty component: Reversing light relay dR
Reversing light
relay

E 200
          


Ω Rtarget = 0 Ω Rtarget = 285-310 Ω
 

Ω

 


1. Replace dR relay by a new one or re-
Rtarget = 285-310 Ω.   
   
 

Measure resistance at contact 14 of    
cable 2.  
 
Measure resistance at pin X (dR) of the
connection cable to the dR relay. The
number of contact X can be found in 


 
 
 


 













 








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

4.4 Faulty component: Starter inhibitor relay
Starter inhibitor
relay


          
 
Ω Rtarget = 0 Ω

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).
feeler of the ohmmeter to vehicle earth.              
Measure resistance at contact 16 of             
cable 2.
If R = Rtarget, continue with step 5.
Measure resistance at pin contact X
(SSP) of the connection cable to the
starter inhibitor relay. The number of                  
                
contact X is shown in the circuit dia-

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

4.5 Faulty component: Stop brake
4.5.1 Faulty component: Stop brake relay dHSB
Stop brake
relay
   

Stop brake E 200
switch (HSB)           
Rtarget = 0 Ω
Ω
 
    
 
   

   

 
         
 
Ω
Cable 2
      
Connection cable 
  
   


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.    
 

For steps 1 to 5, connect one feeler of
the ohmmeter to vehicle earth. Mea-   
sure resistance at contact 32 of cable    
2.  
 
(dHSB) of the connection cable to the
dHSB relay. The number of contact X 


 
 
 
 















 







is shown in the circuit diagram.

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

4.5.2 Faulty component: Stop brake actuation
Stop brake
relay
   

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.

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.

4.6 Faulty component: Central warning light (ZW)
4.6.1 Faulty component: ZW relay
Central warning
light relay

E 200
          
    
Ω
 
Rtarget = 0 Ω Rtarget = 285-310 Ω  

   
Central warn-
 
Ω
ing light     

 


First, check whether the diagnosis shows a defect of the ZW relay (a) or not (b).
Case a: take steps 1 to 5.
Case b: take steps 1 and 6 to 9 (see opposite page).
1. Replace ZW relay by a new one or
measure resistance directly between
winding contacts 85 and 86 after re-  
moval of the relay.   
Rtarget = 285-310 Ω.    
 

For steps 1 to 5, connect one feeler of
the ohmmeter to vehicle earth. Mea-   
sure resistance at contact 51 of cable  

 
2.  
 
3. Open SV.19 SV.19; variant
(ZW) of the connection cable to the ZW
relay. The number of contact X is                  
shown in the circuit diagram.

                

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

4.6.2 Faulty component: ZW bulb
Central warning
light relay

E 200

          
Ω Rtarget = 0 Ω
   
 

Rtarget = s.b. Rtarget = ∞ Ω
Ω

Ω
 


 
Central warn-
ing light
Step Activity and location

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

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

4.7 Faulty component: Voltage supply to solenoid valves
4.7.1 Faulty component: Control relay dS
Control
relay Electronic control unit
 
E 200
          
    
Rtarget = 0 Ω          

Ω
    
Vehicle
  

 
 
electrical

  

1. Replace dS relay by a new one or mea-
sure resistance directly between wind-
ing contacts 85 and 86 after removal of  
the relay.   
Rtarget = 285-310 Ω.    
 

Measure resistance at contact 13 of  

 
cable 2.  
 
(dS) of the connection cable to the dS
relay. The number of contact X is 


 
 
 
 















 








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

4.7.2 Faulty component: Solenoid valve voltage
Control
relay
E 200
 
          
    
         
Rtarget = 0 Ω
Rtarget = ∞ Ω
Ω

    
Ω
  
Vehicle  

 
electrical

  

6. Test UZ line (see Chap. 1.1).
7. Open SV.2. SV.2
Measure resistance between contact
38 (+UB) and the supply line to contact   
87 (dS relay).  
 
Rtarget = 0 Ω.  
 

38 and Y (+UB). The number of contact
Y can be seen from the circuit diagram. 


 
 
 


 













 







Rtarget = 0 Ω.
9. SV.2: Measure resistance between contact 38 and vehicle earth. Rtarget = ∞ Ω.

 
5.1 Faulty component: Push-button switch
6-button switch
     

E 200
Rtarget see tables 1, 2, 3
                 

   









Ω                +TS     
            
   
 
Cable 2

 
 
 


 


 


 


  


  


 
Ω


  
   
  
 
 
                     
 
 
    
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

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

SV.19 see Chap. 4.4 and contact X
see Chap. 9.   
Operate button (switch) as per table 1    
below according to the diagnostic fault  

 
indication and measure resistances

between contacts.
If R = Rtarget for all measurements, SV.19, variant
continue with step 5.
                 
            
   
Table 1
SV.2: Measurement Rtarget [Ω]: SV.2: Mea- Rtarget [Ω]: SV.2: Mea-
Rtarget [Ω]: Rtarget [Ω]:
Button, Measurement btw. SV.2, con- Button depr. surement btw. Button depr. surement btw.
Button depr./ Button depr.
Switch btw. contact 33 tact 29 (TS) (N depressed) contact 29 (TS) (N depressed) contact 29 (TS)
not depressed (not depressed)
(TL) and: and SV.19: [not N depr.] and: [not N depr.] and:
1 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 27 (S1) 0 (∞)
2 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 45 (S2) 0 (∞)
3 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 9 (S3) 0 (∞)
D 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 28 (+V) 0 (∞)
N 21 (-UB) appr. 580 X (SSP) 0 [∞] 10 (/N) ∞ [0]
R 21 (-UB) appr. 580 X (SSP) ∞ (0) 10 (/N) 0 (∞) 46 (+R) 0 (∞)
Sp.Rg. appr. 580 30 (RS) 0*( ∞)*
* = Resistance when R-button is depressed too

5. Controllers

3. Open SV.24. SV.24
Operate button (switch) as per table 2
below according to the diagnostic fault
indication and measure resistances
             
            
between contacts.
Table 2
Measurement Rtarget [Ω]: Measurement Measurement Measurement Rtarget [Ω]:
Button, Button depr. Button depr.
btw. contact Button depr./ btw. contact btw. contact btw. contact Button depr.
Switch (N depressed) (N depressed)
8 (TL) and: not depressed 7 (TS) and: 7 (TS) and: 7 (TS) and: (not depressed)
[not N depr.] [not N depr.]
1 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 1 (S1) 0 ( ∞)
2 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 2 (S2) 0 ( ∞)
3 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 3 (S3) 0 ( ∞)
D 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 4 (+V) 0 ( ∞)
N 10 (-UB) appr. 580 16 (SSP) 0 [ ∞] 9 (/N) ∞ [0]
R 10 (-UB) appr. 580 16 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 5 (+R) 0 ( ∞)
Sp.Rg. 6 (RS) 0* ( ∞)*

Operate button (switch) as per table 3
below according to the diagnostic fault       
indication and measure resistances       
between contacts.
Table 3
Measurement Rtarget [Ω]: Measurement Measurement Measurement Rtarget [Ω]:
Button, Button depr. Button depr.
btw. contact Button depr./ btw. contact btw. contact btw. contact Button depr.
Switch (N depressed) (N depressed)
8 (TL) and: not depressed 7 (TS) and: 7 (TS) and: 7 (TS) and: (not depressed)
[not N depr.] [not N depr.]
1 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 1 (S1) 0 ( ∞)
2 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 2 (S2) 0 ( ∞)
3 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 3 (S3) 0 ( ∞)
D 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 4 (+V) 0 ( ∞)
N 10 (-UB) appr. 580 11 (SSP) 0 [ ∞] 9 (/N) ∞ [0]
R 10 (-UB) appr. 580 11 (SSP) ∞ (0) 9 (/N) 0 ( ∞) 5 (+R) 0 ( ∞)
Sp.Rg. 6 (RS) 0* ( ∞*)
Step Activity
5. Measure resistance to earth of SV.2, contacts 9, 10, 21, 27, 28, 29, 30, 33, 45, 46
and SV.19, contact X.
Rtarget = ∞ Ω.
6. Open SV.24. Measure resistance of contacts 1-10 and 16 to earth. Rtarget = ∞ Ω.

5. Controllers
5.2 Faulty component: Manual converter brake switch

E 200
Manual switch Indicator light

  
    
  

   

Ω         

     
    


Rtarget = ∞ Ω
  
Ω
  
  
  
 

  
  
  
 

  
  

    
manual switch

1. If indicator light is defective, replace
bulb.

Select braking stage as per table 1 be-
low according to the diagnostic fault in-   
dication and measure resistances be-    
tween contacts.  
 
If R = Rtarget for all measurements,

Table 1
Measurement Measurement Measurement Measurement
Braking between con- between con- between con- between con-
Rtarget [Ω] Rtarget [Ω] Rtarget [Ω] Rtarget [Ω]
stage tact tact tact tact
8 (+HB) and: 8 (+HB) and: 8 (+HB) and: 8 (+HB) and:
0 7 (HBA) ∞ 26 (HBB) ∞ 44 (HBC) ∞ 21 (-UB) ∞
1 7 (HBA) 0 26 (HBB) ∞ 44 (HBC) ∞ 21 (-UB) appr. 290
2 7 (HBA) 0 26 (HBB) 0 44 (HBC) ∞ 21 (-UB) appr. 290
3 7 (HBA) 0 26 (HBB) 0 44 (HBC) 0 21 (-UB) appr. 290

5. Controllers

low according to the diagnostic fault in-
dication and measure resistances be-
             
            
tween contacts.
Table 2
15 (+HB) and: 15 (+HB) and: 15 (+HB) and: 15 (+HB) and:
0 14 (HBA) ∞ 13 (HBB) ∞ 12 (HBC) ∞ 10 (-UB) ∞
1 14 (HBA) 0 13 (HBB) ∞ 12 (HBC) ∞ 10 (-UB) appr. 290
2 14 (HBA) 0 13 (HBB) 0 12 (HBC) ∞ 10 (-UB) appr. 290
3 14 (HBA) 0 13 (HBB) 0 12 (HBC) 0 10 (-UB) appr. 290

low according to the diagnostic fault in-   


tween contacts.    
Table 3
+* (+HB) and: +** (+HB) and: +** (+HB) and: X and:
0 3 (HBA) ∞ 4 (HBB) ∞ 5 (HBC) ∞ Y appr. 290
1 3 (HBA) 0 4 (HBB) ∞ 5 (HBC) ∞ Y appr. 290
2 3 (HBA) 0 4 (HBB) 0 5 (HBC) ∞ Y appr. 290
3 3 (HBA) 0 4 (HBB) 0 5 (HBC) 0 Y appr. 290
* = next to contact 1
** = next to contact 4
Step Activity
5. SV.2: Measure resistance of contacts 7, 8, 21, 26 and 44 to earth. Rtarget = ∞ Ω.
6. Open SV.24. Measure resistance of contacts 10 and 12-15 to earth. Rtarget = ∞ Ω.

5. Controllers
5.3 Faulty component: Switch for converter braking stage 3
Electronic control unit E

200
Indicator light Rtarget see tables 1, 2, 3

 
     
   

Switch for con-

verter braking
Ω         

stage 3
     

    
Rtarget = ∞ Ω

  
Ω
  
  
  
  
  
  
  
 

  
  

converter brake
         

1. If indicator light is defective, replace
bulb.

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

5. Controllers

Measure resistances between con-
tacts as per table 2 below.              
            
Table 2
tact tact tact
15 (+HB) and: 15 (+HB) and: 15 (+HB) and:
off 14 (HBA) ∞ 12 (HBC) ∞ 10 (-UB) ∞
on 14 (HBA) 0 12 (HBC) 0 10 (-UB) appr. 290

Measure resistances between con-   

tacts as per table 3 below.

   
Table 3
tact tact tact
+* (+HB) and: +** (+HB) and: X and:
off 3 (HBA) ∞ 5 (HBC) ∞ Y appr. 290
on 3 (HBA) 0 5 (HBC) 0 Y appr. 290
* * = 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.

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

E 200
Brake valve

      
   
 Ω
           

 Rtarget = ∞ Ω
    
Ω
    
  


  
 
  
 
  
 

brake valve

low according to the diagnostic fault in-   
dication and measure resistances be-    
tween contacts.  
 
If R = Rtarget for all measurements,

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

5. Controllers

low according to the diagnostic fault in-      
dication and measure resistances be-     
tween contacts.
Table 2
0 3 (FB1) ∞ 6 (FB2) ∞ 4 (FB3) ∞
1 3 (FB1) 0 6 (FB2) ∞ 4 (FB3) ∞
2 3 (FB1) 0 6 (FB2) 0 4 (FB3) ∞
3 3 (FB1) 0 6 (FB2) 0 4 (FB3) 0

low according to the diagnostic fault in-
tween contacts.
Table 3
0 1 (FB1) ∞ 4 (FB2) ∞ 2 (FB3) ∞
1 1 (FB1) 0 4 (FB2) ∞ 2 (FB3) ∞
2 1 (FB1) 0 4 (FB2) 0 2 (FB3) ∞
3 1 (FB1) 0 4 (FB2) 0 2 (FB3) 0
Step Activity
4. SV.2: Measure resistance of contacts 2, 11, 40, and 49 to earth. Rtarget = ∞ Ω.
5. Open SV.27. Measure resistance of contacts 3-6 to earth. Rtarget = ∞ Ω.

5. Controllers
5.5 Faulty component: Voith load transmitter or

EMR with VDO load transmitter
Load transmitter
Cable 1 
  
Rtarget = ∞ Ω   


  

Ω Rtarget see tables 1, 2, 3
     
Electronic control unit E

200

Depress accelerator pedal as per table
1 below and measure resistance be-    
tween contacts.
   
If R = Rtarget for all measurements,   
Table 1
Measurement Measurement
Accelera- between con- between con-
Rtarget [Ω] Rtarget [Ω]
tor position tact tact
5 (-LG) and: 5 (-LG) and:
0 throttle 41 (+LG) 800-1500 24 (LGM) 178-333
Full throttle 41 (+LG) 800-1500 24 (LGM) 622-1667

5. Controllers

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

5. Controllers
5.6 Faulty component: Kickdown switch

E 200
Kickdown switch (KD)

  

Rtarget = 0 Rtarget = ∞ Ω

or ∞Ω Ω
  Ω
 

  

Connection cable Kick- Cable 2

down switch

1. Open SV.2. SV.2
4 and 19 (cable 2).   
KD switch open (accelerator totally re-  

 
lieved): Rtarget = ∞ Ω.  
 
KD switch closed (accelerator fully de-

pressed up to the final stop):
Rtarget = 0 Ω.
1 and 2.              
KD switch open: Rtarget = ∞ Ω.             
KD switch closed: R target = 0 Ω.

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.

5. Controllers

      
6.1 Faulty component: BOSCH electronic throttle control EMS 3.3 B/G

E 200
    

Rtarget = 0 Ω
Ω
 Rtarget = ∞ Ω
Bosch
  
Ω

      
EMS 3.3 
  

Cable 2
Connection cable

1. Open plug-and-socket connections SV.2
SV.2 and SV.19 (cable 2).
Measure resistances between:   
contacts 5 and X (DKR),    
contacts 24 and Z (DKE),  

 
contacts 41 and Y (DKV/PWM).

The numbers of contacts X, Y, and Z
SV.19; variant
are shown in the circuit diagram.
Rtarget = 0 Ω.
2. SV.2: Measure resistance of contacts          
5, 24, and 41 (cable 2) to vehicle earth.          
Rtarget = ∞ Ω.

6. Signal conductors to motor control units
6.2 Faulty component: MB FMR
BOSCH-EDC M5/M7, VDO electronic throttle control, DDEC III similar.

E 200
 

Rtarget = 0 Ω
Rtarget = 0 Ω
Ω
Ω 
      
E.g.
MB FMR

Cable 2

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

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

6.3 Faulty component: CAN-Bus

E 200
Rtarget = 0 Ω      

Ω Rtarget = ∞ Ω

CAN-H
E.g. 
CAN-M Ω
EDC 

CAN-L
Connection cable Cabel 2

1. Open plug connectors SV.2 and SV.2
SV.33.
Measure resistance between:   
contact 17 und contact C (CAN-H)  

 
contact 36 und contact A (CAN-L)  

 
contact 37 und contact B (CAN-M).

Rtarget = 0 Ω.
SV.33, variant
contacts 17, 36 and 37 (cable 2) and A B
vehicle earth.
Rtarget = ∞ Ω.
C

6.4 Faulty component: dNEUTR output

E 200
Rtarget = 0 Ω
 

Ω
RSoll = ∞ Ω

E.g. E-Gas

     
Ω

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  

 

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

     
7.1 Faulty component: ABS connection

E 200
Rtarget = 0 Ω
Connection cable    
 
Ω

  
Ω
Rtarget = ∞ Ω
Cable 2 V
Case 1: inactive P P
    
Case 2: active Utarget = ca. 24

or 0 V
+ 24V
ABS     

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

Case 2 (high active):
 
 
ABS inactive: USoll = ca. 0 V.

ABS active: USoll = 24 V.
53 and the conductor of the connecting
cable leading to the ABS.
Rtarget = 0 Ω.
53 (SV.2) and 7 (SV.19).                  
Rtarget = 0 Ω.                 

53 and vehicle earth. Rtarget = ∞ Ω.

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

E 200
Rtarget = 0 Ω
 
   
Ω
Connection cable
 
   
Ω
Rtarget = ∞
or appr.160 Ω
Cable 2
P P     
Ω Rtarget = 0 Ω
+ 24V
 
  
Transmission
oil warning light

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

15 (cable 2) and vehicle earth.
With bulb: Rtarget = approx. 160 Ω.   
Without bulb: Rtarget = ∞ Ω.    

 
15 and the conductor to the transmis-

sion oil warning light.
Rtarget = 0 Ω.
15 (SV.2) and 17 (SV.19).
Rtarget = 0 Ω. 


 
 
 


 



  





 







 
5. Measure resistance between the – con-

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

7.3 Faulty component: Converter brake release switch

E 200
Rtarget = 0 Ω
 
   
Ω
Connection cable
    
Ω
 
Rtarget = 0
or ∞ Ω
Cable 2
P P     
Ω Rtarget = 0 Ω
+ 24V
    
Release switch
converter brake

Switch open: Rtarget = ∞ Ω.   
Switch closed: Rtarget = 0 Ω.  

 

 
31 and the conductor to the converter

brake release switch.
Rtarget = 0 Ω.
31 (SV.2) and 18 (SV.19).
Rtarget = 0 Ω.                  
                

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

7.4 Faulty component: Gearshift inhibitor switch

E 200
Rtarget = 0 Ω
 
   
Ω
Connecting cable
 
     
Rtarget = 0
or ∞ Ω
Cable 2
P P
    
Ω Rtarget = 0 Ω
+ 24V
    
Gearshift in-
hibitor switch

Measure resistance between contact 35 (ca-
ble 2) and vehicle earth.
Switch open (service brake released):
Rtarget = ∞ Ω.   
Switch closed (service brake applied):    
Rtarget = 0 Ω.  
 
2. Measure resistance between contact 35 and

the conductor to the gearshift inhibitor switch.
Rtarget = 0 Ω.
Measure resistance between contacts 35
(SV.2) and 20 (SV.19).                  
Rtarget = 0 Ω.                 
4. Measure resistance between the – conductor

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

7.5 Faulty component: ANS activation switch

E 200
Rtarget = 0 Ω
 
   
Connecting cable Ω
Ω
Rtarget = 0
 
 
or ∞ Ω
cable 2
 
    
Rtarget = 0 Ω
Ω
+ 24V
 
  
ANS activation
switch

Switch open (service brake released):
Rtarget = ∞ Ω.
Switch closed (service brake applied):   
Rtarget = 0 Ω.    

 
12 and the conductor to the EK disen-

gagement switch.
Rtarget = 0 Ω.

12 (SV.2) and 21 (SV.19).
           
Rtarget = 0 Ω.
     
                

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


   

8.1 Connection of cable 1 to control unit
SV.1 Pin assignment for Pin assignment for

DIWA.3: DIWA.3E:
Pin no. Designation Pin no. Designation
1 PA 1 WP
2 PB 2 PB
3 WP 3 -
4 - 4 -
5 -LG 5 -LG
6 IO9 6 IO9
7 - 7 -
8 +TS 8 +TS
9 - 9 -
10 N2B 10 N2B
11 N1A 11 N1A
12 - 12 -
13 RBKM 13 RBKM
14 PBM 14 PBM
15 EKM 15 EKM
 16 - 16 -
  
  17 RBG 17 RBG
18 SK 18 SK
19 EK 19 EK
20 TB 20 TB
21 RBK 21 RBK
22 - 22 -
23 IO3 23 IO3
24 LGM 24 LGM
25 - 25 -
26 - 26 -
27 - 27 -
28 N3B 28 N3B
29 N2A 29 N2A
30 - 30 -
31 SENSE 31 SENSE
32 - 32 -
33 SKM 33 SKM
34 - 34 -
35 WR 35 WR
36 REA0 36 REA0
37 DK 37 DK
38 - 38 -
39 - 39 -
40 - 40 -
41 +LG 41 +LG
42 - 42 -
  43 - 43 -
 
 44 -TS 44 -TS
45 - 45 -
46 N3A 46 N3A
47 N1B 47 N1B
48 - 48 -
49 SENSE 49 SENSE
50 TBM 50 TBM
51 DKM 51 DKM
52 -UB 52 -UB
53 -UB 53 -UB
54 - 54 -
55 - 55 -

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

SV.3; pin insert cable harness
DIWA.3: DIWA.3E:
(transmission housing)
Pin no. Designation Pin no. Designation
A -UB A -UB
B -UB B -UB
C N1B C N1B
D N1A D N1A
E N2B E N2B
F N2A F N2A
   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
    
 
   


    
 
 


8. Cables and plugs
8.3 Connection of cable 2 to control unit
Pin assignment as per circuit diagrams for DIWA.3 and DIWA.3E
SV.2

 
 

 
 


8. Cables and plugs
8.4 Measuring cable 56.4461.12

SV.3; identical to
socket insert cable 1
0
0
2
1
0
8

0
5






 


 






















   
 



  
   
 

 
 



 


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
  
 

  
  
  
   
  


8. Cables and plugs

 
1 Circuit diagram DIWA.3
1 Circuit diagram DIWA.3E

9. Appendices

Voith Turbo GmbH & Co. KG

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

Voith Diwa3 Trouble Shooting

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Voith. 55.6293.31 / 2002-03

  

Voith. Trouble Shooting I

The manual serves the following purpose:

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

Additional DIWA.3 and DIWA.3E documentation

This documentation is protected by copyright

 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,

Use of the diagnostic program for fault tracing:

Transmission repair and spare parts ordering:

Voith. Trouble Shooting III

IV Voith. Trouble Shooting

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

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

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

Voith. Trouble Shooting V

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

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

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

VI Voith. Trouble Shooting

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

 Chap. 3.2.2 and Chap. 3.2.3,

Voith. Trouble Shooting VII

VIII Voith. Trouble Shooting

 Start the diagnostic program

 Read fault memory (function B)

How to proceed with the "Trouble Shooting"

After completion of "Trouble Shooting"

Voith. Trouble Shooting 1

2 Voith. Trouble Shooting

   

1.1 Faulty component: Voltage supply to control unit

Rtarget = 0 Ω Rtarget = ∞ Ω

4. Measure resistance between contact  

19 and the conductor in connection ca-

7. Measure resistance between contact Y (-UB) of earth-

Voith. Trouble Shooting 3

1. Control and diagnosis

1.2 Faulty component: Diagnosis connection

Electronic control unit

Rtarget = ∞ Ω Rtarget = 0 Ω

Switch off ignition.

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

contacts 19 (SV.2) and 1 (SV.31),    

contacts 21 (SV.2) and 2 (SV.31),

4 Voith. Trouble Shooting

2.1 Faulty component: Inductive pick-up N1

Ω Rtarget = 800-1400 Ω Connection for in-

Step Activity and location Pins or contacts

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

(For the plug see Chap. 8.)

tacts of the measuring cable. 

(For the plug see Chap. 8.)

3. Remove control cover. SV.4

Voith. Trouble Shooting 5

2.2 Faulty component: Inductive pick-up N2

Step Activity and location Pins or contacts

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