Voith Diwa.3 Trouble Shooting

5SPVCMF 4IPPUJOH
5SBOTNJTTJPOT %*8"
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Voith. 55.6293.31 / 2002-03
*NQPSUBOU TBGFUZ JOTUSVDUJPOT

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 ensure that his personal safety or that of other persons is not at risk.
*NQPSUBOU JOGPSNBUJPO
Note! in conjunction with the symbol on the left denotes information that is particularly
important.
"EEJUJPOBM OPUFT
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 described in detail in the Customer service letters.
Furthermore, all work must be performed in accordance with Voith requirements to prevent damage to parts and tools.
Voith. Trouble Shooting
5SPVCMF 4IPPUJOH
What is it for?
The manual serves the following purpose:
n Special fault tracing in electrical transmission components or parts using the Voith PCbased diagnostic program DIWAGNOSIS.
n Assistance in commissioning, maintenance, and repair of DIWA.3 and DIWA.3E transmissions.
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.:
Brochure
Part No.
for
transmission
Technical Manual
55.6354. ..
55.6356. ..
DIWA.3
DIWA.3E
Function description of the transmission, transmission data, installation

instructions, design and dimensional
data for transmission assemblies
Servicing Schedule
55.6373. ..
All
DIWA
Maintenance of DIWA transmissions
Lists of Lubricants
55.6335. ..
55.6336. ..
All
DIWA
List of the lube oils that are approved

by Voith for DIWA transmissions
Fault Finding
55.6302. ..
DIWA.3,
DIWA.3E
General fault tracing, analysis, and

repair
Driving Instructions
55.6290. ..
DIWA.3,
DIWA.3E
Brief description of transmission operation for the bus driver
Diagnostic Manual
55.6263. ..
DIWA.3,
DIWA.3E
Use of the Voith PC-based diagnostic

program DIWAGNOSIS
Spare Parts Catalogs
55.6600. ..
55.6601. ..
55.6602. ..
55.6603. ..
D 851.3E
D 854.3E
D 863.3E
D 864.3E
Illustration and designation of transmission parts for spare parts ordering
Repair Manual
55.6320. ..
55.6704. ..
DIWA.3
DIWA.3E
Description of transmission disassembly and assembly of 3- and 4speed transmissions
Technical Description with

Oil and Control Circuit
Diagrams
55.6308. ..
55.6310. ..
DIWA.3
DIWA.3E
Representation of the oil circuits for

the various transmission gear shifts
Purpose
All of the above brochures are available from department "ant" or "anv".
This documentation is protected by copyright
Subject to change
Who is it for?
n Service technicians (e.g. testing, acceptance, etc.)

n Automobile mechanics and electricians
II
)PX UP QSPDFFE JO DBTF PG

USBOTNJTTJPO NBMGVODUJPOT
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
III
IV
$POUFOUT
Page
Differences between DIWA.3 and DIWA.3E in terms of trouble-shooting................................VII
A.
Introduction ......................................................................................................................... 1
1.
Control and diagnosis ......................................................................................................... 3

1.1
1.2
2.
Faulty component: Voltage supply to control unit ..................................................... 3

Faulty component: Diagnosis connection ................................................................ 4
Sensors............................................................................................................................... 5
2.1
2.2
Faulty component: Inductive pick-up N2.................................................................. 6
2.3
Faulty component: Inductive pick-up N3.................................................................. 7
2.4
3.
Faulty component: Inductive pick-up N1................................................................... 5
Faulty component: Oil temperature transmitter ....................................................... 8
Solenoids ............................................................................................................................ 9
3.1
Solenoids with measuring coil .................................................................................. 9

3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.2
Solenoids without measuring coil .......................................................................... 15

3.2.1
3.2.2
3.2.3
3.2.4
4.
Faulty component: EK solenoid................................................................... 9

Faulty component: TB solenoid ................................................................. 10
Faulty component: PB solenoid................................................................. 11
Faulty component: DK solenoid ................................................................ 12
Faulty component: SK solenoid................................................................. 13
Faulty component: RBK solenoid .............................................................. 14
Faulty component: RBG solenoid.............................................................. 15

Faulty component: WP solenoid for DIWA.3 ............................................. 16
Faulty component: WP solenoid for DIWA.3E........................................... 17
Faulty component: WR solenoid ............................................................... 18
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
4.5.2
4.6
Faulty component: Central warning light (ZW) ...................................................... 25

4.6.1
4.6.2
4.7
Faulty component: Stop brake relay dHSB ............................................... 23

Faulty component: Stop brake actuation ................................................... 24
Faulty component: ZW relay ..................................................................... 25

Faulty component: ZW bulb ...................................................................... 26
Faulty component: Voltage supply to solenoid valves ........................................... 27

4.7.1
4.7.2
Faulty component: Control relay dS .......................................................... 27

Faulty component: Solenoid valve voltage ................................................ 28
5.
Controllers.........................................................................................................................29
5.1
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
6.
Faulty component: Push-button switch ...................................................................29
Faulty component: Kickdown switch ...................................................................... 39
Signal conductors to motor control units ...........................................................................41

6.1
6.2
Faulty component: MB FMR .................................................................................. 42
6.3
Faulty component: CAN-Bus ................................................................................. 43
6.4
7.
Faulty component: BOSCH electronic throttle control EMS 3.3 B/G ...................... 41
Faulty component: dNEUTR output ....................................................................... 44
Other switches and warning lights ....................................................................................45

7.1
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
8.
Faulty component: ABS connection........................................................................45
Faulty component: ANS activation switch.............................................................. 49
Cables and plugs ..............................................................................................................51

8.1
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
9.
Connection of cable 1 to control unit.......................................................................51
Level converter 56.4219.10 ................................................................................... 55
Appendices ....................................................................................................................... 57
1 Circuit diagram DIWA.3
1 Circuit diagram DIWA.3E
VI
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JO UFSNT PG USPVCMFTIPPUJOH
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 diagram DIWA.3 55.3705.20 and Circuit diagram DIWA.3E 55.6168.10), however, the differences
in fault-tracing procedures are minor, too.
See also:
n Chap. 3.2.2 and Chap. 3.2.3,

n Chap. 8.1,
n Chap. 8.2,
n Chap. 8.4
VII
VIII
" *OUSPEVDUJPO
Purpose
The purpose of this manual is to enable the service engineer to systematically search for defective 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. mostly 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 troubleshooting can begin:
n Connect a suitable PC (laptop) to the transmission control via the cable (level converter) provided for this purpose
n Start the diagnostic program
n Start communication
n Read fault memory (function B)
n Test faulty components individually once again (functions C, D, E, F, G, H and J). This is to
find out whether the fault still exists.
How to proceed with the "Trouble Shooting"

The trouble-shooting procedure is as follows:
1. Switch off vehicle ignition for all measurements unless you are expressly instructed at some
point in this manual not to do so.
2. Open plug connection between control unit and cable 1 or cable 2. This is where the test measurements 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 designations may differ.
After completion of "Trouble Shooting"

Erase fault memory after repair of the defect by pressing function key B (see "Diagnostic Manual").
$POUSPM BOE EJBHOPTJT

1.1 Faulty component: Voltage supply to control unit
Relay
"control"
Electronic control unit

E 200
G6
D
69
Utarget = approx. 24 V
Rtarget = 0

69
Rtarget =
Vehicle
supply
system
)
Rtarget = 0
; 8=
< 8%
Connection cable
Cable 2
69
Step
Activity and location
Fuse, pins or contacts
1.
Switch on ignition.
If control unit E 200 does not operate properly, check
whether 8 A fuse F1 in connection cable to vehicle supply 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 .

4.

19 and the conductor in connection cable to fuse F1. Rtarget = 0 .
5.

21 and vehicle earth. Rtarget = 0 .
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 .
7.
Measure resistance between contact Y (-UB) of earthing cable (M) and vehicle earth. The number of Y is
shown in the circuit diagram. Rtarget = 0 .
8.
SV.2: Measure resistance between contact 19 and earth. Rtarget = .
9.
SV.19: Measure resistance between contact X (+UZ) and earth. Rtarget = .

1. Control and diagnosis
1.2 Faulty component: Diagnosis connection

E 200

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

V
Utarget = approx. 24 V
Step
1.
2.
3.
Level converter
(see Chap. 8.)
Pins or contacts
Switch on ignition.
SV.31
Open plug connection SV.31 (cable 2).
Measure voltage between contacts 1
and 2 (earth).
Utarget = approx. 24 V.
Open plug connections SV.2 (cable 2). SV.2

Measure resistance between
contacts 16 (SV.2) and 10 (SV.31),
contacts 52 (SV.2) and 8 (SV.31).
Rtarget = 0 .
SV.2: Measure resistance between
contacts 16, 19, 21, and 52 (cable 2)
and vehicle earth. Rtarget = .

4FOTPST
2.1 Faulty component: Inductive pick-up N1
DIWA.3/.3E
transmission
Cable 1
'
&
69
69
Rtarget =

Cable harness

69
Rtarget = 800-1400
Connection for inductive pick-up N1
69
Inductive
pick-up N1

E 200
Step
1.
2.

Open plug connection SV.1.
SV.1
Measure resistance between contacts
11 and 47 of cable 1.
Rtarget = 800-1400 .
If R = Rtarget continue with step 5.
(For the plug see Chap. 8.)
Pins or contacts

SV.3; Cable harness

Open SV.3.
Measure resistance between pins C
&
and D of cable harness or the N1-contacts of the measuring cable.
'
(For the plug see Chap. 8.)
Rtarget = 800-1400 .
SV.3; Measuring cable

56.4461.12
Q
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 .
4.
Remove oil sump.

Remove gear pump with inductive pick-up N1.
Open SV.5.
Measure resistance between pins of pick-up N1.
Rtarget = 800-1400 .
5.
Measure resistance between contact 47 and vehicle earth. Rtarget = .
6.
Open SV.3. Measure resistance between contact C and earth. Rtarget = .
7.
Open SV.4. Measure resistance between contact 2 and earth. Rtarget = .
8.
Open SV.5. Measure resistance between a contact and earth. Rtarget = .
SV.5
2. Sensors
DIWA.3/.3E
transmission
Cable 1
(
)
69
Rtarget =

Cable
harness
with connection
for inductive pickup N2
69
Rtarget = 800-1400
69
Inductive
pick-up N2

E 200
Step
1.
2.

SV.1
Rtarget = 800-1400 .
Pins or contacts

Open SV.3.
SV.3; Cable harness
Measure resistance between pins E
and F of cable harness or the N2-contacts of the measuring cable.
Rtarget = 800-1400 .

56.4461.12
(
)
3.
4.
5.
Open SV.3. Measure resistance between contact F and earth. Rtarget = .
6.
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 .
Q
2. Sensors
DIWA.3/.3E
transmission
Cable 1
*
+
69
Rtarget =

Cable harness
with connection
for
inductive
pick-up N3
69
Rtarget = 800-1400
69

E 200
Step
1.
2.
Inductive
pick-up N3

SV.1
Rtarget = 800-1400 .
Pins or contacts

Open SV.3.
SV.3; Cable harness
Measure resistance between pins G
and H of cable harness or the N3-contacts of the measuring cable.
Rtarget = 800-1400 .

56.4461.12
Q
*
+
3.
On transmission housing: remove cap from above pick-up N3.

Open SV.8. Measure resistance between pins of pick-up N3.
Rtarget = 800-1400 .
SV.8
4.
5.
Open SV.3. Measure resistance between contact H and earth. Rtarget = .
6.
2. Sensors
2.4 Faulty component: Oil temperature transmitter
DIWA.3/.3E
transmission
Cable 1
Cable harness
D
=

69


E 200
Step
1.
2.
69
Rtarget =
Oil temp.
0 [C]
20 [C]
70 [C]
90 [C]
120 [C]
140 [C]
ZV
69
VZ
Connection for oil

temperature
transmitter
Rtarget
810 []
950 []
1360 []
1550 []
1860 []
2090 []
69

Pins or contacts

SV.1
For Rtarget see chart above.

Open SV.3.
SV.3; Cable harness
Measure resistance between pins a
and Z of cable harness or the N1-contacts of the measuring cable.

56.4461.12
3.

SV.4
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 temperature transmitter.
5.
6.
Open SV.3. Measure resistance between contact Z and earth. Rtarget = .
7.
Open SV.4. Measure resistance between contact 4 and earth. Rtarget = .
8.
Oil temperature
transmitter
76
4PMFOPJET
3.1 Solenoids with measuring coil
3.1.1 Faulty component: EK solenoid
DIWA.3/.3E
transmission
Cable 1
M
K
F
/
69


E 200
Step
1.
2.
3.
Cable harness
%
$
Rtarget =
Rtarget
Working coil
Measuring
coil
69
EK solenoid
Coil +
cable 1
11 - 20 []
110,7 []
5 - 10 []
5,20,3 []
Coil only

SV.1
a) Working coil: Measure resistance
between contacts 19 and 52 or 53 of
cable 1.
Rtarget = 11-20 .
b) Measuring coil: Measure resistance
between contacts 15 and 31 or 49.
Rtarget = 5-10 .
69

Measuring coil
Working
coil
Pins or contacts

Open SV.3.
SV.3; Cable harness
$
between contacts L and A or B (cable
%
harness) or EK and UB (measuring
cable). Rtarget = 11-20 .
M
between contacts c and h or j (cable
F
harness) or EKM and SENSE (measur/
ing cable).
K
Rtarget = 5-10 .
SV.3; measuring cable

56.4461.12
(.
8%
(.0
6(16(

SV.10
Open SV.10.
a) Working coil: Measure resistance between pins 1 and 2 of the EK
solenoid flat pin connector. Rtarget = 110,7 .

b) Measuring coil: Measure resistance between pins 3 and 4 of the
EK solenoid flat pin connector. Rtarget = 5,20,3 .

4.

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

3. Solenoids
3.1.2 Faulty component: TB solenoid
DIWA.3/.3E
transmission
Cable 1
M
K
I
6
69


E 200
Step
1.
2.
3.
Cable harness
%
$
Rtarget =
Rtarget
Working coil
Measuring
coil
69
TB solenoid
Coil +
cable 1
11 - 20 []
110,7 []
5 - 10 []
5,20,3 []
Coil only

SV.1
cable 1.
Rtarget = 11-20 .
Rtarget = 5-10 .
69

Measuring coil
Working
coil
Pins or contacts

Open SV.3.
SV.3; Cable harness
between contacts S and A or B (cable
$
harness) or TB and UB (measuring
6
%
cable).
I
Rtarget = 11-20 .
M
between contacts f and h or j (cable
harness) or TBM and SENSE (measurK
ing cable).
Rtarget = 5-10 .

56.4461.12
7%
8%
7%0

SV.11
Open SV.11.
a) Working coil: Measure resistance between pins 1 and 2 of the TB

TB solenoid flat pin connector. Rtarget = 5,20,3 .

4.
5.
Open SV.3. Measure resistance between contact f (or TBM) and earth. Rtarget = .
Measure resistance between contacts f (or TBM) and S (or TB). Rtarget = .
6.
10


6(16(

3. Solenoids
3.1.3 Faulty component: PB solenoid
DIWA.3/.3E
transmission
Cable 1
M
K
G
0
69


E 200
Step
1.
2.
3.
Cable harness
%
$
Rtarget =
Rtarget
Working coil
Measuring
coil
69
PB solenoid
Coil +
cable 1
11 - 20 []
110,7 []
5 - 10 []
5,20,3 []
Coil only

SV.1
between contacts 2 and 52 or 53 of cable 1.
Rtarget = 11-20 .
Rtarget = 5-10 .
69

Measuring coil
Working
coil
Pins or contacts

Open SV.3.
SV.3; Cable harness
$
between contacts M and A or B (cable
%
harness) or PB and UB (measuring
G
cable).
M
Rtarget = 11-20 .
0
between contacts d and h or j (cable
harness) or PBM and SENSE (measurK
ing cable).
Rtarget = 5-10 .

56.4461.12
3%
8%
3%0
6(16(

SV.12
Open SV.12.
a) Working coil: Measure resistance between pins 1 and 2 of the PB

PB solenoid flat pin connector. Rtarget = 5,20,3 .

4.

5.
Open SV.3. Measure resistance between contact d (or PBM) and earth. Rtarget = .
Measure resistance between contacts d (or PBM) and M (or PB). Rtarget = .
6.

11
3. Solenoids
3.1.4 Faulty component: DK solenoid
DIWA.3/.3E
transmission
Cable 1
M
K
E
.
69


E 200
Step
1.
2.
3.
Cable harness
%
$
Rtarget =
Rtarget
Working coil
Measuring
coil
69
DK solenoid
Coil +
cable 1
11 - 20 []
110,7 []
5 - 10 []
5,20,3 []
Coil only

SV.1
cable 1.
Rtarget = 11-20 .
Rtarget = 5-10 .
69

Measuring coil
Working
coil
Pins or contacts

Open SV.3.
SV.3; Cable harness
$
between contacts K and A or B (cable
%
harness) or DK and UB (measuring
cable).
Rtarget = 11-20 .
M
between contacts b and h or j (cable
E
harness) or DKM and SENSE (meaK
suring cable).
.
Rtarget = 5-10 .

56.4461.12
'.
8%
'.0
6(16(

SV.13
Open SV.13.
a) Working coil: Measure resistance between pins 1 and 2 of the DK

DK solenoid flat pin connector. Rtarget = 5,20,3 .

4.
5.
Open SV.3. Measure resistance between contact b (or DKM) and earth. Rtarget = .
Measure resistance between contacts b (or DKM) and K (or DK). Rtarget = .
6.
12



3. Solenoids
3.1.5 Faulty component: SK solenoid
DIWA.3/.3E
transmission
Cable 1
M
K
J
8
69


E 200
Step
1.
2.
3.
Cable harness
%
$
Rtarget =
Rtarget
Working coil
Measuring
coil
69
SK solenoid
Coil +
cable 1
11 - 20 []
110,7 []
5 - 10 []
5,20,3 []
Coil only

SV.1
cable 1.
Rtarget = 11-20 .
Rtarget = 5-10 .
69

Measuring coil
Working
coil
Pins or contacts

Open SV.3.
SV.3; Cable harness
between contacts U and A or B (cable
$
8
harness) or SK and UB (measuring
%
cable).
Rtarget = 11-20 .
J
M
between contacts g and h or j (cable
harness) or SKM and SENSE (measurK
ing cable).
Rtarget = 5-10 .

56.4461.12
6.
8%
6.0
6(16(

SV.14
Open SV.14.
a) Working coil: Measure resistance between pins 1 and 2 of the SK

SK solenoid flat pin connector. Rtarget = 5,20,3 .

4.

5.
Open SV.3. Measure resistance between contact g (or SKM) and earth. Rtarget = .
Measure resistance between contacts g (or SKM) and U (or SK). Rtarget = .
6.

13
3. Solenoids
3.1.6 Faulty component: RBK solenoid
DIWA.3/.3E
transmission
Cable 1
M
K
H
3
69


E 200
Step
1.
2.
3.
Cable harness
%
$
Rtarget =
Rtarget
Working coil
Measuring
coil
69
RBK solenoid
Coil +
cable 1
11 - 20 []
110,7 []
5 - 10 []
5,20,3 []
Coil only

SV.1
cable 1.
Rtarget = 11-20 .
Rtarget = 5-10 .
69

Measuring coil
Working
coil
Pins or contacts

Open SV.3.
SV.3; Cable harness
$
between contacts P and A or B (cable
H
%
harness) or RBK and UB (measuring
3
cable).
M
Rtarget = 11-20 .
between contacts e and h or j (cable
harness) or RBKM and SENSE (meaK
suring cable).
Rtarget = 5-10 .

56.4461.12
5%.
8%
5%.0
6(16(

SV.15
Open SV.15.
a) Working coil: Measure resistance between pins 1 and 2 of the
RBK solenoid flat pin connector. Rtarget = 110,7 .

RBK solenoid flat pin connector. Rtarget = 5,20,3

4.
5.
Open SV.3. Measure resistance between contact e (or RBKM) and earth. Rtarget = .
Measure resistance between contacts e (or RBKM) and P (or RBK). Rtarget = .
6.
14



3. Solenoids
3.2 Solenoids without measuring coil

3.2.1 Faulty component: RBG solenoid
DIWA.3/.3E
transmission
Cable 1
5
Cable harness
%
$
69

Rtarget
Coil +
cable 1
11 - 20 []
69
Coil only
110,7 []
Rtarget =
69
RBG solenoid

E 200
Step
1.
2.

SV.1
17 and 52 or 53 of cable 1.
Rtarget = 11-20 .
Pins or contacts

Open SV.3.
SV.3; Cable harness
$
R and A or B (cable harness) or RBG
5
%
and UB (measuring cable).
Rtarget = 11-20 .

56.4461.12
5%*
8%
3.

SV.16
Open SV.16.
Measure resistance between pins 1 and 2 of the RBG solenoid flat
pin connector.
Rtarget = 110,7 [].
4.
15
3. Solenoids
3.2.2 Faulty component: WP solenoid for DIWA.3
DIWA.3
transmission
Cable 1
1
Cable harness
%
$
69
Rtarget

69
Coil +
cable 1
11 - 20 []
Coil only
110,7 []
Rtarget =
69
WP solenoid

E 200
Step
1.
2.
Pins or contacts

SV.1
Rtarget = 11-20 .

Open SV.3.
SV.3; Cable harness
$
N and A or B (cable harness) or WP
%
Rtarget = 11-20 .

56.4461.12
:3
8%
3.

SV.17
Open SV.17.
Measure resistance between pins 1 and 2 of the WP solenoid flat pin
connector.
Rtarget = 110,7 [].
4.
16
3. Solenoids
3.2.3 Faulty component: WP solenoid for DIWA.3E
DIWA.3E
transmission
Cable 1
Cable harness
7
%
$
69

Rtarget
Coil +
cable 1
11 - 20 []
Coil only
69
110,7 []
Rtarget =
69
WP solenoid

E 200
Step
1.
2.

SV.1
Rtarget = 11-20 .
Pins or contacts

Open SV.3.
SV.3; Cable harness
7
$
T and A or B (cable harness) or WP
%
Rtarget = 11-20 .

56.4461.12
:3(
8%
3.

SV.17
Open SV.17.
Measure resistance between pins 1 and 2 of the WP solenoid flat pin
connector.
Rtarget = 110,7 [].
4.
17
3. Solenoids
3.2.4 Faulty component: WR solenoid
DIWA.3/.3E
transmission
Cable 1
-
Cable harness
%
$
69

Rtarget
Coil +
cable 1
11 - 20 []
69
Coil only
110,7 []
Rtarget =
69
WR solenoid

E 200
Step
1.
2.
Pins or contacts

SV.1
Rtarget = 11-20 .

Open SV.3.
SV.3; Cable harness
$
J and A or B (cable harness) or WR
%
Rtarget = 11-20 .

56.4461.12
:5
8%
3.

SV.18
Open SV.18.
Measure resistance between pins 1 and 2 of the WR solenoid flat pin
connector.
Rtarget = 110,7 [].
4.
18
3FMBZT BOE QJMPU MJHIUT

4.1 Faulty component: Converter brake relay dW
Converter
brake relay
G:

E 200
D
69
Rtarget = 0
Rtarget = 285-310
69
Connection cable
;
Step
69
Cable 2
G:
1.

Pins or contacts
Replace dW relay by a new one or remove relay and measure resistance directly between coil contacts 85 and 86.
Rtarget = 285-310 .

D

2.
3.
4.
5.
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 .

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

dW
SV.20: Measure resistance at the cable to the end of the winding of the dW
relay (pin 85) and earthing point M.
Rtarget = 0 .
19
4. Relays and pilot lights
4.2 Faulty component: Speed switch relay dN

Speed switch
relay
G1

E 200
D
69
Rtarget = 0

Rtarget = 285-310
69
Connection cable
;
Step
Cable 2
G1
1.
69
Pins or contacts
Replace dN relay by a new one or remove relay and measure resistance directly between coil contacts 85 and 86.
Rtarget = 285-310 .

D

2.
3.
4.
5.
20

SV.2
cable 2.
Rtarget = 285-310 .

SV.20: Measure resistance at the cable to the end of the winding of the dN
Rtarget = 0 .

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 .
winding of the dN relay (pin 86).
Rtarget = 285-310 .

dN
4.3 Faulty component: Reversing light relay dR

Reversing light
relay
G5

E 200
D
69
Rtarget = 0
Rtarget = 285-310
69
Connection cable
;
Step
69
Cable 2
G5
1.

Pins or contacts
Replace dR relay by a new one or remove relay and measure resistance directly between coil contacts 85 and 86.
Rtarget = 285-310 .

D

2.
3.
4.
5.

SV.2
cable 2.
Rtarget = 285-310 .

Open SV.19.
SV.19; variant
Measure resistance at pin X (dR) of the
connection cable to the dR relay. The
Rtarget = 285-310 .
winding of the dR relay (pin 86).
Rtarget = 285-310 .

dR
SV. 20: Measure resistance at the cable to the end of the winding of the dR
Rtarget = 0 .
21
4.4 Faulty component: Starter inhibitor relay

Starter inhibitor
relay
69
69
D

Rtarget = 0
Rtarget = 285-310
69
Vehicle
electrical
system
663
Connection cable
Cable 2
Step
Pins or contacts, relay
1.
Replace starter inhibitor relay by a new

one or measure resistance directly between winding contacts 85 and 86 after
removal of the relay.
Rtarget = 285-310 .

D

2.
3.
4.
5.
22
Open connection SV.24

SV.24
(see Chap. 5.1).
cable 2.
Rtarget = 285-310 .
If R = Rtarget, continue with step 5.
SV.19; variant
Open SV.19.
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 diagram.
Rtarget = 285-310 .
tance at the cable to the beginning of
the winding of the starter inhibitor relay
(pin contact 86).
Rtarget = 285-310 .
SV.20: Measure resistance at the cable to the end of the winding of the
starter inhibitor relay (pin contact 85)
and earthing point M.
Rtarget = 0 .

Starter
inhibitor
4.5 Faulty component: Stop brake

4.5.1 Faulty component: Stop brake relay dHSB
Stop brake
relay
G+6%
Stop brake
switch (HSB)
)

69


E 200
D
69
0
'
Rtarget = 0

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

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 removal of the relay.
Rtarget = 285-310 .

D

2.
3.
4.
5.

SV.2
For steps 1 to 5, connect one feeler of
the ohmmeter to vehicle earth. Measure resistance at contact 32 of cable
2.
Rtarget = 285-310 .

Open SV.19.
SV.19; variant
(dHSB) of the connection cable to the
dHSB relay. The number of contact X
is shown in the circuit diagram.
Rtarget = 285-310 .
the winding of the dHSB relay (pin contact 86).
Rtarget = 285-310 .

dHSB
SV.20: Measure resistance at the cable to the end of the winding of the
dHSB relay (pin contact 85) and earthing point M1.
Rtarget = 0 .
23
4.5.2 Faulty component: Stop brake actuation

Stop brake
relay
G+6%
Stop brake
switch (HSB)

SV.23
F2
D
SV.20
0
'

SV.22
Rtarget = 0

E 200
Rtarget = value

Rtarget = 0
or
MV

0
SV.19
+6%
<
Cable 2

SV.2
Rtarget =
G+6%
Connection cable
Step
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 = .
HSB switch closed: Rtarget = 0 .
Fuse, pins or contacts
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 = .
HSB switch closed: Rtarget = 0 .

9.
10.
Open SV.23. Measure resistance between contact 1 and 2.

HSB switch open: Rtarget = . HSB switch closed: Rtarget = 0 .
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 = .
12.
SV.20: Measure resistance between '+' conductor of the coil of solenoid valve (MV) and vehicle earth.
Rtarget = value.
13.
24
Open SV.22. Measure resistance between contact 1 and 2.

HSB switch open: Rtarget = . HSB switch closed: Rtarget = 0 .
Measure resistance between '' conductor MV coil and earth. Rtarget = 0 .
4.6 Faulty component: Central warning light (ZW)

4.6.1 Faulty component: ZW relay
Central warning
light relay
=:

E 200
69

D
0
Central warning light
Rtarget = 0
0

69
69
Connection cable
;
Step
Rtarget = 285-310
Cable 2
=:
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 removal of the relay.
Rtarget = 285-310 .

D

2.
3.
4.
5.

SV.2
For steps 1 to 5, connect one feeler of
the ohmmeter to vehicle earth. Measure resistance at contact 51 of cable
2.
Rtarget = 285-310 .

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.
Rtarget = 285-310 .
the winding of the ZW relay (pin contact 86).
Rtarget = 285-310 .

ZW
SV.20: Measure resistance at the cable to the end of the winding of the ZW
relay (pin contact 85) and earthing
point M1.
Rtarget = 0 .
25
4.6.2 Faulty component: ZW bulb

Central warning
light relay
=:
E 200
69
D
0 0
Rtarget = s.b.

Connection cable
Step
Rtarget = 0

69
Rtarget =
69
;
=:
Cable 2
6.
7.
Measure resistance between + and conductor of ZW.

With bulb: Rtarget = appr. 160 .
Without bulb: Rtarget = .
8.
Measure resistance of + and conductor ZW to vehicle earth. Rtarget = .
9.
26
If the central warning light always remains off,

replace the bulb.
SV.20: Measure resistance at earth conductor M2 of the ZW relay (pin contact 87). Rtarget = 0 .
4.7 Faulty component: Voltage supply to solenoid valves

4.7.1 Faulty component: Control relay dS
Control
relay

E 200
G6
69

D
Rtarget = 0

Rtarget = 285-310
69
Vehicle
electrical
system
69
<
;
)
8%
G6
8=
Connection cable
Cable 2
Step
1.
Replace dS relay by a new one or measure resistance directly between winding contacts 85 and 86 after removal of
the relay.
Rtarget = 285-310 .

D

2.
3.
4.
5.

SV.2
cable 2.
Rtarget = 285-310 .

Open SV.19.
SV.19; variant
(dS) of the connection cable to the dS
relay. The number of contact X is
Rtarget = 285-310 .
the winding of the dS relay (pin contact
86).
Rtarget = 285-310 .

dS
SV.20: Measure resistance at the cable to the end of the winding of the dS
relay (pin contact 85) and earthing
point M.
Rtarget = 0 .
If R = Rtarget continue with step 6 on the
opposite page.
27
4.7.2 Faulty component: Solenoid valve voltage

Control
relay

E 200
G6
69

D

Rtarget = 0
0
Vehicle
electrical
system
Step
<
;
)
8%
G6
8=
Cable 2
Connection cable
6.
Open SV.2.
SV.2
38 (+UB) and the supply line to contact
87 (dS relay).
Rtarget = 0 .
Pins or contacts
Test UZ line (see Chap. 1.1).
7.
8.
9.
28
Rtarget =
69
69

Open SV.19.
SV.19; variant
38 and Y (+UB). The number of contact
Y can be seen from the circuit diagram.
Rtarget = 0 .

SV.2: Measure resistance between contact 38 and vehicle earth. Rtarget = .
$POUSPMMFST
5.1 Faulty component: Push-button switch
6-button switch
'

E 200
Rtarget see tables 1, 2, 3

6
'
'
'
'

6
1
1
1
1
5
5
5
5

6
6

6
6
6
6
6
6
9
5
56
76
7/
1
8%
663
5)
56
5
6 6 6 6
Connections at 3, 4-,5and 6-button switches
69
69
8%

69
66695 1 +TS 56 7/

Reversing inhibitor
switch (Sp.Rg.)

Cable 2

Rtarget =
Connection cable
Push-button switch
to SV.19, contact X
(see Chap. 4.4)
Check 3, 4, and 5-button switches accordingly

Step
Pins or contacts
1.
If switch illumination is defective, replace 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
Button,
Switch
1
2
3
D
N
R
Sp.Rg.
SV.2:
Measurement
btw. contact 33
(TL) and:
21 (-UB)
21 (-UB)
21 (-UB)
21 (-UB)
21 (-UB)
21 (-UB)
Measurement
Rtarget []:
btw. SV.2, conButton depr./
tact 29 (TS)
not depressed
and SV.19:
appr. 580
X (SSP)
appr. 580
X (SSP)
appr. 580
X (SSP)
appr. 580
X (SSP)
appr. 580
X (SSP)
appr. 580
X (SSP)
appr. 580
Rtarget []:
Button depr.
(N depressed)
[not N depr.]
(0)
(0)
(0)
(0)
0 []
(0)
SV.2: Measurement btw.

contact 29 (TS)
and:
10 (/N)
10 (/N)
10 (/N)
10 (/N)
10 (/N)
10 (/N)
Rtarget []:
Button depr.
(N depressed)
[not N depr.]
0 ()
0 ()
0 ()
0 ()
[0]
0 ()
SV.2: MeaRtarget []:

surement btw.
Button depr.
contact 29 (TS)
(not depressed)
and:
27 (S1)
0 ()
45 (S2)
0 ()
9 (S3)
0 ()
28 (+V)
0 ()
46 (+R)
30 (RS)
0 ()
0*()*
* = Resistance when R-button is depressed too

29
5. Controllers
Step
3.
Pins or contacts
Open SV.24.
SV.24
between contacts.

Table 2
Button,
Switch
1
2
3
D
N
R
Sp.Rg.
Measurement
btw. contact
8 (TL) and:
Rtarget []:
Button depr./
not depressed
Measurement
btw. contact
7 (TS) and:
10 (-UB)
10 (-UB)
10 (-UB)
10 (-UB)
10 (-UB)
10 (-UB)
appr. 580
appr. 580
appr. 580
appr. 580
appr. 580
appr. 580
16 (SSP)
16 (SSP)
16 (SSP)
16 (SSP)
16 (SSP)
16 (SSP)
Rtarget []:
Button depr.
(N depressed)
[not N depr.]
(0)
(0)
(0)
(0)
0 []
(0)
Measurement
btw. contact
7 (TS) and:
9 (/N)
9 (/N)
9 (/N)
9 (/N)
9 (/N)
9 (/N)
Rtarget []:
Button depr.
(N depressed)
[not N depr.]
0 ()
0 ()
0 ()
0 ()
[0]
0 ()
Measurement
Rtarget []:
btw. contact
Button depr.
7 (TS) and: (not depressed)
1 (S1)
2 (S2)
3 (S3)
4 (+V)
0 ()
0 ()
0 ()
0 ()
5 (+R)
6 (RS)
0 ()
0* ()*
Step
4.
Pins or contacts
Open SV.25.
SV.25
between contacts.

Table 3
Button,
Switch
1
2
3
D
N
R
Sp.Rg.
Measurement
btw. contact
8 (TL) and:
Rtarget []:
Button depr./
not depressed
Measurement
btw. contact
7 (TS) and:
Rtarget []:
Button depr.
(N depressed)
[not N depr.]
Measurement
btw. contact
7 (TS) and:
Rtarget []:
Button depr.
(N depressed)
[not N depr.]
10 (-UB)
10 (-UB)
10 (-UB)
10 (-UB)
10 (-UB)
10 (-UB)
appr. 580
appr. 580
appr. 580
appr. 580
appr. 580
appr. 580
11 (SSP)
11 (SSP)
11 (SSP)
11 (SSP)
11 (SSP)
11 (SSP)
(0)
(0)
(0)
(0)
0 []
(0)
9 (/N)
9 (/N)
9 (/N)
9 (/N)
9 (/N)
9 (/N)
0 ()
0 ()
0 ()
0 ()
[0]
0 ()
Measurement
btw. contact
7 (TS) and:
Rtarget []:
Button depr.
(not depressed)
1 (S1)
2 (S2)
3 (S3)
4 (+V)
0 ()
0 ()
0 ()
0 ()
5 (+R)
6 (RS)
0 ()
0* (*)

Step
Activity
5.
6.
30
Measure resistance to earth of SV.2, contacts 9, 10, 21, 27, 28, 29, 30, 33, 45, 46
and SV.19, contact X.
Rtarget = .
Open SV.24. Measure resistance of contacts 1-10 and 16 to earth. Rtarget = .
5. Controllers
5.2 Faulty component: Manual converter brake switch

E 200
Manual switch
Indicator light

8%
<

+%% +%
+%$ +%&
69

Rtarget =

8%
+%&
+%%
+%$
+%
Connection cable
manual switch
69
69
Step
1.
If indicator light is defective, replace

bulb.
2.

SV.2
Select braking stage as per table 1 below according to the diagnostic fault indication and measure resistances between contacts.
If R = Rtarget for all measurements,
Cable 2
Pins or contacts

Table 1
Braking
stage
0
1
2
3
Measurement
between contact
8 (+HB) and:
7 (HBA)
7 (HBA)
7 (HBA)
7 (HBA)
Rtarget []
0
0
0
Measurement
between contact
8 (+HB) and:
26 (HBB)
26 (HBB)
26 (HBB)
26 (HBB)
Rtarget []
0
0
Measurement
between contact
8 (+HB) and:
44 (HBC)
44 (HBC)
44 (HBC)
44 (HBC)
Rtarget []
Measurement
between contact
8 (+HB) and:
21 (-UB)
21 (-UB)
21 (-UB)
21 (-UB)
Rtarget []
appr. 290
appr. 290
appr. 290
31
5. Controllers
Step
3.
Pins or contacts
Open SV.24.
SV.24

Table 2
Braking
stage
0
1
2
3
Measurement
between contact
15 (+HB) and:
14 (HBA)
14 (HBA)
14 (HBA)
14 (HBA)
Step
4.
Rtarget []
0
0
0
Measurement
between contact
15 (+HB) and:
13 (HBB)
13 (HBB)
13 (HBB)
13 (HBB)
Measurement
between contact
15 (+HB) and:
12 (HBC)
12 (HBC)
12 (HBC)
12 (HBC)
Rtarget []
0
0
Measurement
between contact
15 (+HB) and:
10 (-UB)
10 (-UB)
10 (-UB)
10 (-UB)
Rtarget []
Rtarget []
appr. 290
appr. 290
appr. 290
Pins or contacts
Open SV.26.
SV.26
Table 3
Braking
stage
0
1
2
3
*
**
Measurement
between contact
+* (+HB) and:
3 (HBA)
3 (HBA)
3 (HBA)
3 (HBA)
Rtarget []
0
0
0
Measurement
between contact
+** (+HB) and:
4 (HBB)
4 (HBB)
4 (HBB)
4 (HBB)
Rtarget []
0
0
Measurement
between contact
+** (+HB) and:
5 (HBC)
5 (HBC)
5 (HBC)
5 (HBC)
Rtarget []
Measurement
between contact
X and:
Y
Y
Y
Y
= next to contact 1
= next to contact 4
Step
Activity
5.
6.
32
SV.2: Measure resistance of contacts 7, 8, 21, 26 and 44 to earth. Rtarget = .

Open SV.24. Measure resistance of contacts 10 and 12-15 to earth. Rtarget = .
Rtarget []
appr. 290
appr. 290
appr. 290
appr. 290
5. Controllers
5.3 Faulty component: Switch for converter braking stage 3
Electronic control unit E

200
Indicator light
Switch for converter braking

stage 3

8%
<
+%% +%
+%$ +%&
69

8%
+%&
+%%
+%$
+%
69
69

Connection cable
converter brake
Step
1.

SV.2
Measure resistances between contacts as per table 1 below.
Rtarget =

Cable 2
If indicator light is defective, replace

bulb.
2.
69
Pins or contacts

Table 1
Switch
off
on
Measurement
between contact
8 (+HB) and:
7 (HBA)
7 (HBA)
Rtarget []
Measurement
between contact
8 (+HB) and:
44 (HBC)
44 (HBC)
Rtarget []
Measurement
between contact
8 (+HB) and:
21 (-UB)
21 (-UB)
Rtarget []
appr. 290
33
5. Controllers
Step
3.
Pins or contacts
Open SV.24.
SV.24

Table 2
Switch
off
on
Measurement
between contact
15 (+HB) and:
14 (HBA)
14 (HBA)
Step
4.
Rtarget []
Measurement
between contact
15 (+HB) and:
12 (HBC)
12 (HBC)
Measurement
between contact
15 (+HB) and:
10 (-UB)
10 (-UB)
Rtarget []
Rtarget []
appr. 290
Pins or contacts
Open SV.26.
SV.26
Table 3
Switch
off
on
**
**
Measurement
between contact
+* (+HB) and:
3 (HBA)
3 (HBA)
Rtarget []
Measurement
between contact
+** (+HB) and:
5 (HBC)
5 (HBC)
Rtarget []
Measurement
between contact
X and:
Y
Y
Rtarget []
appr. 290
appr. 290
= next to contact 1
= next to contact 4
Step
Activity
5.
6.
34
SV.2: Measure resistance of contacts 7, 8, 21, and 44 to vehicle earth. Rtarget = .

Open SV.24. Measure resistance of contacts 10 and 12, 14 and 15 to earth. Rtarget = .
5. Controllers
5.4 Faulty component: Brake valve (service brake transmitter)

E 200
Brake valve

69
Rtarget =
69
69
)%
)%
)%
)%

Connection cable
brake valve
1.

)% )% )% )%
Step

Cable 2
Pins or contacts

SV.2

Table 1
Braking
stage
0
1
2
3
Measurement
between contact
2 (+FB) and:
40 (FB1)
40 (FB1)
40 (FB1)
40 (FB1)
Rtarget []
0
0
0
Measurement
between contact
2 (+FB) and:
11 (FB2)
11 (FB2)
11 (FB2)
11 (FB2)
Rtarget []
0
0
Measurement
between contact
2 (+FB) and:
49 (FB3)
49 (FB3)
49 (FB3)
49 (FB3)
Rtarget []
35
5. Controllers
Step
2.
Pins or contacts
Open SV.27.
SV.27

Table 2
Braking
stage
0
1
2
3
Measurement
between contact
5 (+FB) and:
3 (FB1)
3 (FB1)
3 (FB1)
3 (FB1)
Step
3.
Rtarget []
0
0
0
Measurement
between contact
5 (+FB) and:
6 (FB2)
6 (FB2)
6 (FB2)
6 (FB2)
Measurement
between contact
5 (+FB) and:
4 (FB3)
4 (FB3)
4 (FB3)
4 (FB3)
Rtarget []
0
0
Rtarget []
Pins or contacts
Open SV.28.
SV.28
Table 3
Braking
stage
0
1
2
3
Measurement
between contact
3 (+FB) and:
1 (FB1)
1 (FB1)
1 (FB1)
1 (FB1)
Step
Rtarget []
0
0
0
Measurement
between contact
3 (+FB) and:
4 (FB2)
4 (FB2)
4 (FB2)
4 (FB2)
Rtarget []
0
0
Measurement
between contact
3 (+FB) and:
2 (FB3)
2 (FB3)
2 (FB3)
2 (FB3)
Rtarget []
Activity
4.
5.
Open SV.27. Measure resistance of contacts 3-6 to earth. Rtarget = .
6.
36
SV.2: Measure resistance of contacts 2, 11, 40, and 49 to earth. Rtarget = .

5. Controllers
5.5 Faulty component: Voith load transmitter or

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


Electronic control unit E

200
Step
1.
Pins or contacts

SV.1
Depress accelerator pedal as per table
1 below and measure resistance between contacts.

Table 1
Measurement
Accelera- between contor position
tact
5 (-LG) and:
0 throttle
41 (+LG)
Full throttle
41 (+LG)
Rtarget []
800-1500
800-1500
Measurement
between contact
5 (-LG) and:
24 (LGM)
24 (LGM)
Rtarget []
178-333
622-1667
37
5. Controllers
Step
2.
Pins or contacts

SV.30
Depress accelerator pedal as per table 2 below and measure resistance between contacts.
Table 2
Measurement
Accelera- between contor position
tact
3 (-LG) and:
0 throttle
1 (+LG)
Full throttle
1 (+LG)
Step
Rtarget []
800-1500
800-1500
Measurement
between contact
3 (-LG) and:
2 (LGM)
2 (LGM)
Rtarget []
178-333
622-1667
Activity
3.
4.
38
SV.2: Measure resistance of contacts 5, 24, and 41 to earth. Rtarget = .

5. Controllers
5.6 Faulty component: Kickdown switch

E 200

Kickdown switch (KD)
Rtarget = 0
or
69
2.
.'
8=
Connection cable Kickdown switch
1.
Rtarget =
69

Step
69
Cable 2

Open SV.2.
SV.2
4 and 19 (cable 2).
KD switch open (accelerator totally relieved): Rtarget = .
KD switch closed (accelerator fully depressed up to the final stop):
Rtarget = 0 .
Open SV.27.
SV.27
1 and 2.
KD switch open: Rtarget = .
KD switch closed: Rtarget = 0 .
Pins or contacts

3.
Open SV.32.
SV.32
Measure resistance between the two
contacts.
KD switch open: Rtarget = .
KD switch closed: Rtarget = 0 .
4.
SV.2: Measure resistance between contact 4 or 19 and vehicle earth with the KD switch closed.
Rtarget = .
5.
SV.27: Measure resistance between contact 1 or 2 and vehicle earth with the KD switch closed.
Rtarget = .
6.
SV.32: Measure resistance between one contact and earth with the KD switch closed.
Rtarget = .
39
5. Controllers
40
4JHOBM DPOEVDUPST UP NPUPS DPOUSPM VOJUT

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

E 200
69

Rtarget = 0
69
Bosch
EMS 3.3
;
<
=
1.
2.
'.93:0
'.(
Connection cable
Step
Rtarget =
'.5
Cable 2
Pins or contacts
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 .
SV.2: Measure resistance of contacts
5, 24, and 41 (cable 2) to vehicle earth.
Rtarget = .

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.

E 200

69
Rtarget = 0
Rtarget = 0
69
3:0,:$
Cable 2
Step
1.
2.
42
Pins or contacts
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 .
SV.2: Measure resistance of contact SV.21; variant MB FMR
41 (cable 2) to vehicle earth.
Rtarget = .
E.g.
MB FMR

6.3 Faulty component: CAN-Bus

E 200
Rtarget = 0

69
69
E.g.
EDC
Connection cable
Step
1.
2.
Rtarget =
CAN-H
&
% CAN-M
$ CAN-L

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 .
SV.33, variant
contacts 17, 36 and 37 (cable 2) and
vehicle earth.
Rtarget = .
Cabel 2
Pins or contacts

43
6.4 Faulty component: dNEUTR output

E 200
Rtarget = 0

69
RSoll =
69
E.g. E-Gas
Connection cable
Step
1.
2.
G1(875
Cable 2
Pins or contacts
Open plug connectors SV.2 and SV.2

SV.19.


55 and X (dNEUTR) of cable 2. The

Rtarget = 0 .
SV.19; variant
contact 55 and vehicle earth.
Rtarget = .

44

0UIFS TXJUDIFT BOE XBSOJOH MJHIUT

7.1 Faulty component: ABS connection

E 200
Rtarget = 0
Connection cable

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

Switch on ignition.
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.
Pins or contacts

2.

53 and the conductor of the connecting
cable leading to the ABS.
Rtarget = 0 .
3.
Open SV.19.
SV.19; variant
53 (SV.2) and 7 (SV.19).
Rtarget = 0 .
4.


53 and vehicle earth. Rtarget = .
45
7. Other switches and warning lights
7.2 Faulty component: Transmission oil warning light

E 200
Rtarget = 0
69

Connection cable

72(/
Rtarget =
or appr.160
Cable 2
69
+ 24V
Rtarget = 0
Transmission
oil warning light
Step
1.
Replace bulb of transmission oil warning light if defective.
2.
Open connector SV.2.

SV.2
15 (cable 2) and vehicle earth.
With bulb: Rtarget = approx. 160 .
Without bulb: Rtarget = .
Pins or contacts

3.

15 and the conductor to the transmission oil warning light.
Rtarget = 0 .
4.
Open SV.19.
SV.19; variant
15 (SV.2) and 17 (SV.19).
Rtarget = 0 .
5.
46
Measure resistance between the conductor of the warning light (M) and
earth.
Rtarget = 0 .

7.3 Faulty component: Converter brake release switch

E 200
Rtarget = 0
69

Connection cable
)%$86
Rtarget = 0
or
Cable 2
69
+ 24V
Rtarget = 0
Release switch
converter brake
Step
1.

SV.2
Switch open: Rtarget = .
Switch closed: Rtarget = 0 .
Pins or contacts

2.

31 and the conductor to the converter
brake release switch.
Rtarget = 0 .
3.
Open SV.19.
SV.19; variant
31 (SV.2) and 18 (SV.19).
Rtarget = 0 .
4.

Measure resistance between the conductor of the release switch (M) and
earth. Rtarget = 0 .
47
7.4 Faulty component: Gearshift inhibitor switch

E 200
Rtarget = 0
69

Connecting cable
$%6,&+
Rtarget = 0
or
Cable 2
69
+ 24V
Rtarget = 0
Gearshift inhibitor switch
Step
1.

SV.2
Measure resistance between contact 35 (cable 2) and vehicle earth.
Switch open (service brake released):
Rtarget = .
Switch closed (service brake applied):
Rtarget = 0 .
Pins or contacts

2.
Measure resistance between contact 35 and

the conductor to the gearshift inhibitor switch.
Rtarget = 0 .
3.
Open SV.19.
SV.19; variant
Measure resistance between contacts 35
(SV.2) and 20 (SV.19).

Rtarget = 0 .
4.
48

Measure resistance between the conductor

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

7.5 Faulty component: ANS activation switch

E 200
Rtarget = 0
69

Connecting cable
Rtarget = 0
or
%6

cable 2
69
+ 24V
Step
1.
Rtarget = 0
ANS activation
switch

SV.2
Switch open (service brake released):
Rtarget = .
Switch closed (service brake applied):
Rtarget = 0 .
Pins or contacts

2.

12 and the conductor to the EK disengagement switch.
Rtarget = 0 .
3.
Open SV.19.
SV.19; variant
12 (SV.2) and 21 (SV.19).
Rtarget = 0 .
4.

Measure resistance between the conductor of the ANS activation switch (M)
and earth. Rtarget = 0 .
49
50
$BCMFT BOE QMVHT

8.1 Connection of cable 1 to control unit
SV.1

Pin assignment for

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

DIWA.3E:
Pin no.
Designation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
WP
PB
-LG
IO9
+TS
N2B
N1A
RBKM
PBM
EKM
RBG
SK
EK
TB
RBK
IO3
LGM
N3B
N2A
SENSE
SKM
WR
REA0
DK
+LG
-TS
N3A
N1B
SENSE
TBM
DKM
-UB
-UB
-
51
8. Cables and plugs
8.2 Connection of cable 1 to transmission housing
SV.3; pin insert cable harness

(transmission housing)
7 $ %
5
H 8 9 &
3 G
I : '
J
M
; (
1 F
K
E
D = < )
0
*
/
+
.
6
SV.3; socket insert cable 1
% $ 7 6
& 9 8 H 5
G 3
' : I
J
M
( ;
F 1
K
E
0
) < = D
*
/
+ .
52
Pin assignment for

DIWA.3:
Pin no.
Designation
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
-UB
-UB
N1B
N1A
N2B
N2A
N3B
N3A
WR
DK
EK
PB
WP
RBK
RBG
TB
-TS
+TS
DKM
EKM
PBM
RBKM
TBM
SKM
SENSE
SENSE
Pin assignment for

DIWA.3E:
Pin no.
Designation
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
-UB
-UB
N1B
N1A
N2B
N2A
N3B
N3A
WR
DK
EK
PB
RBK
RBG
TB
WP
SK
-TS
+TS
DKM
EKM
PBM
RBKM
TBM
SKM
SENSE
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
53
8. Cables and plugs
8.4 Measuring cable 56.4461.12
50
80
1200
SV.3; identical to
socket insert cable 1
(

3
:
(6
1(
6
%
8
Q
76
Q

Q
5
: .
'
54
0
. .
' (
0
.
(
%
3
0
%
3

3
:
.
%
5
0 *
. %
% 5
5
%
7
0
%
7
.
6
0
.
6
8. Cables and plugs
8.5 Level converter 56.4219.10
View X; plug
enlarged

7 000
450

/.

View Y;
SV.31; plug
enlarged

55
8. Cables and plugs
56
"QQFOEJDFT
1 Circuit diagram DIWA.3
1 Circuit diagram DIWA.3E
57
9. Appendices
58
+UB
+FB
238
202
221
221.1
221.3
D
240
204
204.1
S3/2
S3/3
S2/1
S2/2
D
2 D
1 2 D
1 2 3 D
S1
S2
S3
+V
+R
RS
+TS
+TL
/N
-UB
SSP
RF
RS
+R
1
2
3
4
5
6
7
8
9
10
11
12
13
14
S1
N
N
N
N
S2
241.1
205.1
224.1
S3 S2/1 S2/2 S3/2 S3/3
R
R
R
R
200
207
226
244
208
227
245
209
228
246
210
229
227
245
209
228
246
230
229
233
210
221
200
256
211
230
248
212
231
249
&
213
232
250
214
233
251
215
252
221.2
6
5
4
-UB
HBC
HBB
HBA
+HB
244
226
207
208
3
2
1
1
2
3
4
5
6
7
8
0
0
1
1
0
1
1
1
1
1
1
1
-UB
HBC
HBB
HBA
+HB
244
226
207
208
SSP
RF
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
227
245
209
228
246
230
229
233
210
221
235
253
217
236
237
255
219
REA0
RBG
WR
-UB
-UB
-UB
4
23
41
5
24
42
6
25
43
HBA
7
HBB
26
HBC
44
+HB
8
S1
27
S2
45
S3
9
+V
28
+R
46
/N
10
+TS
29
47
FB2
11
RS
30
PU
48
BS
12
FBAUS
31
FB3
49
dS
13
dW
32
dN
50
dR
14
+TL
33
ZW
51
TOEL
15
34
DIAGN-K
52
252.1
DIAGN-L
16
216.1
ABSICH
35
ABS
53
CAN-H
17
CAN-M
36
54
18
CAN-L
37
dNEUTR
55
DKV/PWM
DKR
DKE
+UZ
219.1
244
226
207
208
200
-UB
219.2
219.2
221.3
252.1
216.1
EKM
DKM
SKM
PBM
TBM
RBKM
SENSE
SENSE
-UB
-UB
-UB
N1A
N1B
N2A
N2B
N3A
N3B
-UB
TS+
TS-UB
'
1
2
3
4
K
30 86
-UB
WP
-UB
RBK
PB
-UB
TB
PA
50e 50f D+
D-
Y
Z
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
+UZ
-UB
DIAGN-K
DIAGN-L
150
217
237
236
sw CAN-H
ge CAN-M
CAN-L
ABS
+ 24V
141
124
105
1
2
148
111
147
129
110
146
128
9
10
124
105
141
103
121
102
120
101
+LG
LGM
-LG
238
213
219.1
214
232
251
253
250
255
252
216
200
205.1
224.1
241.1
204.1
215
231
248
235
212
221.1
+UB
dS
+UZ
dR
dW
ZW
ABS
dN
dNEUTR
DIAGN-K
DIAGN-L
SSP
DKR
DKE
DKV/PWM
KD
TOEL
FBAUS
PU
ABSICH
BS
-UB
ws
sw
+
-
ws
sw
n1
EK
PB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
5
1
2
C D
E F
G H
J K L M N P R S T U V WX Y Z a b c d e f g h j
bl
bl
4
3
bl
bl
rt
sw
ge
bl
rt
sw
ge
bl
rt
sw
ge
bl
rt
sw
WP
A Push-button switch
B Connection cable for
push-button switch and
converter brake
C Cable 2
D E 200 control unit
E Connection: level converter and diagnostic PC
F Cable 1
G Load transmitter
H Speed and temperature
sensors
J Solenoid valves
K Connection cable
for vehicle wiring
L
M
N
O
P
Q
R
S
T
U
rt
1
2
4
3
1
2
4
3
1
2
4
3
1
2
2
1
ws
sw
br
br
ge
gn
bl
bl
2
4
3
1
n3
ws
sw
DKR
DKE
DKV/PWM
inactive
3
4
DK
7
8
3
6
4
A B
85 87 87a
sw
D+
152
WR
30 86
117
153
135
1
2
8
10
P
85 87 87a
137
118
19
dN
on
61
30 86
O
dR
119
204
219
240
249
202
211
10
C
B
A
N
dW
85 87 87a
1
2
3
4
5
6
7
8
9
T VW
dS
204
219
240
249
202
211
KD
+UZ
FB1
FB3
+FB
FB2
240
249
202
211
CAN-H
CAN-M
CAN-L
IO9
LGM
-LG
+LG
IO3

gn/ge
bl
sw
br
227
245
209
228
246
230
229
233
210
221
221.2
244
226
207
208
200
256
-UB
204
219

0
0
0
1
HBC
HBB
HBA
+HB
S1
S2
S3
+V
+R
RS
+TS
+TL
/N
-UB
21
39
3
22
40
FB1
KD
KD
19
55
37
18
54
36
17
53
35
16
52
34
15
51
33
14
50
32
13
49
31
12
48
30
11
47
29
10
46
28
9
45
27
8
44
26
7
43
25
6
42
24
5
41
23
4
40
22
3
39
21
2
38
20
1
DK
SK

EK
-UB
152
153
+HB
1
1
1
216
221.2
off
HBA
1
2
3
4
5
6
7
8
0
0
1

HBC
HBC
HBA
+HB

-UB
1
20
38
2
148
10
9
8
7
6
5
4
3
2
1
'
135
137
119
102
103
121
117
120
101
118
128
146
147
111
110
129
n2
sw
ge
bl
rt
SK
sw
ge
bl
rt
TB
br
ge
gn
bl
br
ge
gn
bl
br
ge
gn
bl
br
ge
gn
bl
br
2
4
3
1
sw
2
bl
RBG
rt
br
br
ge
gn
bl
bl
Switches and warning

light transmission oil
Engine control
Vehicle electrical system non-committal representation
Relays
CAN bus
Connection cable for
brake valve and
kickdown switch
Kickdown switch
Brake valve
Manual switch for
converter brake
Switch for converter
brake; stage no. 3
a
b
c
d
e
f
g
h
i
j
k
Inhibitor switch for reverse gear

Connections
Bridges
Warning light transm. oil
Cut-out switch for conv.
brake;
only for brake valve
Pressure switch for
gearshift inhibitor
Pressure switch for
ANS activation
Relay for control unit
Relay for starter inhibitor
Relay for centr. warn. light
Relay for converter brake
l
m
n
o
p
q
r
s
st
t
u
v
w
x
y
z
Relay for reversing light

Relay for speed
Fuse 8A
Relay for battery
Switch box
Starter inhibitor relay
Starter
Start button
Battery
Overvoltage protection
Generator
Regulator
Connections
Position
Stage no.
2
4
3
1
sw
ge
bl
rt
RBK
Circuit diagram
DIWA.3
55.3705.20
+UB
+FB
238
202
221
221.1
221.3
-UB
D
240
204
204.1
S3/2
S3/3
S2/1
S2/2
D
2 D
1 2 D
1 2 3 D
S1
S2
S3
+V
+R
RS
+TS
+TL
/N
-UB
SSP
RF
RS
+R
1
2
3
4
5
6
7
8
9
10
11
12
13
14
S1
N
N
N
N
S2
S3 S2/1 S2/2 S3/2 S3/3
R
R
R
R
200
207
226
244
208
227
245
209
228
246
210
229
227
245
209
228
246
230
229
233
210
221
200
256
211
230
248
212
231
249
&
213
232
250
214
233
251
215
252
]
[
+HB
0
0
1
1
1
1
6
5
4
-UB
HBC
HBB
HBA
+HB
244
226
207
208
221.2
3
2
1
1
2
3
4
5
6
7
8
244
226
207
208
216
HBC
HBB
HBA
+HB
S1
S2
S3
+V
+R
RS
+TS
+TL
/N
-UB

0
0
0
0
1
0
0
1
1
0
1
1
1
1
1
1
1
-UB
HBC
HBB
HBA
+HB
SSP
RF
227
245
209
228
246
230
229
233
210
221
221.2
244
226
207
208
200
256
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
227
245
209
228
246
230
229
233
210
221
235
253
204
219

1
2
3
4
KD
+UZ
FB1
FB3
+FB
FB2
240
249
202
211
0
K
-UB
-UB
-UB
4
23
41
5
24
42
6
25
43
HBA
7
HBB
26
HBC
44
+HB
8
S1
27
S2
45
S3
9
+V
28
+R
46
/N
10
+TS
29
47
FB2
11
RS
30
PU
48
BS
12
FBAUS
31
FB3
49
dS
13
dW
32
dN
50
dR
14
+TL
33
ZW
51
TOEL
15
DIAGN-K 34
52
252.1
DIAGN-L
16
216.1
255
219
+UZ
219.1
244
226
207
208
200
EKM
DKM
SKM
PBM
TBM
RBKM
SENSE
SENSE
-UB
-UB
-UB
N1A
N1B
N2A
N2B
N3A
N3B
219.2
219.2
221.3
252.1
216.1
204
219
240
249
202
211
CAN-H
CAN-M
CAN-L
1
2
3
4
5
6
7
8
9
TS+
TS-UB
'
IO9
LGM
-LG
+LG
IO3
-UB
-UB
RBK
PB
-UB
TB
WP
dW
dS
30 86
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
+UZ
-UB
DIAGN-K
DIAGN-L
50e 50f D+
D-
Y
Z
30 86
2
3
4
217
237
236
sw CAN-H
ge CAN-M
CAN-L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
DKR
DKE
DKV/PWM
0
P
G
inactive
+ 24V
5
1
2
148
111
147
129
110
146
128
9
10
124
105
141
103
121
102
120
101
141
124
105
+LG
LGM
-LG
1
2
238
213
219.1
214
232
251
253
250
255
252
216
200
205.1
224.1
241.1
204.1
215
231
248
235
212
221.1
ws
sw
ws
sw
n1
sw
ge
bl
rt
sw
ge
bl
rt
EK
sw
ge
bl
rt
PB
+UB
dS
+UZ
dR
dW
ZW
ABS
dN
dNEUTR
DIAGN-K
DIAGN-L
SSP
DKR
DKE
DKV/PWM
KD
TOEL
FBAUS
PU
ABSICH
BS
-UB
+
-
4
3
2
1
C D
E F
G H
J K L MN P R S T U V WX Y Z a b c d e f g h j
bl
bl
bl
bl
ws
sw
n3
ws
sw
ABS
7
8
3
6
4
A B
sw
ge
bl
rt
85 87 87a
D+
150
152
SK
off
61
on
T VW
117
153
135
1
2
8
10
dN
85 87 87a
137
118
19
dR
119
204
219
240
249
202
211
10
C
B
A
47
29
10
46
28
9
45
27
8
44
26
7
43
25
6
42
24
5
41
23
4
40
22
3
39
21
2
38
20
1
-UB
35
53
17
36
54
18
CAN-L
37
dNEUTR
55
237
WR
DK
1
S
REA0
RBG
-UB

gn/ge
bl
sw
br
-UB
21
39
3
22
40
ABSICH
ABS
CAN-H
CAN-M
217
236
19
55
37
18
54
36
17
53
35
16
52
34
15
51
33
14
50
32
13
49
31
12
48
30
11
DK
SK
152
153
HBA
1
2
3
4
5
6
7
8

HBC
HBC
HBA
+HB

EK
-UB
241.1 DKV/PWM
205.1
DKR
224.1
DKE
%
221.2
FB1
KD
KD
1
20
38
2
148
10
9
8
7
6
5
4
3
2
1
'
135
137
119
102
103
121
117
120
101
118
128
146
110
129
147
111
sw
WP
A Push-button switch
B Connection cable for
push-button switch and
converter brake
C Cable 2
D E 200 control unit
E Connection: level converter and diagnostic PC
F Cable 1
G Load transmitter
H Speed and temperature
sensors
J Solenoid valves
K Connection cable
for vehicle wiring
L Switches and warning
light transmission oil
rt
2
4
3
1
2
4
3
1
2
4
3
1
2
4
3
1
2
br
br
ge
gn
bl
n2
sw
WR
bl
br
ge
gn
bl
br
ge
gn
bl
br
ge
gn
bl
br
ge
gn
bl
br
bl
2
4
3
1
rt
sw
ge
bl
rt
TB
sw
2
rt
RBG
sw
ge
bl
rt
RBK
br
br
ge
gn
bl
bl
M Engine control
N Vehicle electrical system non-committal representation
O Relays
P CAN Bus
Q Connection cable for
brake valve and
kickdown switch
R Kickdown switch
S Brake valve
T Manual switch for
converter brake
U Switch for converter
brake; stage no. 3
a
b
c
d
e
f
g
h
i
j
k
Inhibitor switch for reverse gear

Connections
Bridges
Warning light transm. oil
Cut-out switch for conv.
brake;
only for brake valve
Pressure switch for
gearshift inhibitor
Pressure switch for
ANS activation
Relay for control unit
Relay for starter inhibitor
Relay for centr. warn. light
Relay for converter brake
l
m
n
o
p
q
r
s
st
t
u
v
w
x
y
z
Relay for reversing light

Relay for speed
Fuse 8A
Relay for battery
Switch box
Starter inhibitor relay
Starter
Start button
Battery
Overvoltage protection
Generator
Regulator
Connections
Position
Stage no.
2
4
3
1
Circuit diagram
DIWA.3E
55.6168.10
Voith Turbo GmbH & Co. KG

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

Voith Diwa.3 Trouble Shooting

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Voith Diwa.3 Trouble Shooting

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5SPVCMF 4IPPUJOH

Voith. 55.6293.31 / 2002-03

*NQPSUBOU TBGFUZ JOTUSVDUJPOT

Voith. Trouble Shooting

Function description of the transmission, transmission data, installation

Maintenance of DIWA transmissions

List of the lube oils that are approved

General fault tracing, analysis, and

Brief description of transmission operation for the bus driver

Use of the Voith PC-based diagnostic

Spare Parts Catalogs

Illustration and designation of transmission parts for spare parts ordering

Description of transmission disassembly and assembly of 3- and 4speed transmissions

Technical Description with

Representation of the oil circuits for

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

Voith. Trouble Shooting

)PX UP QSPDFFE JO DBTF PG

Use of the diagnostic program for fault tracing:

Transmission repair and spare parts ordering:

Voith. Trouble Shooting

Voith. Trouble Shooting

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

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

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

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

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

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

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

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

Faulty component: EK solenoid................................................................... 9

Faulty component: RBG solenoid.............................................................. 15

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

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

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

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

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

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

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

Faulty component: Stop brake relay dHSB ............................................... 23

Faulty component: ZW relay ..................................................................... 25

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

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

Voith. Trouble Shooting

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

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

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

Faulty component: Voith load transmitter or

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

%JGGFSFODFT CFUXFFO %8" BOE %8"&

$POUSPM BOE EJBHOPTJT