Voith Diwa.3 Trouble Shooting
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Description
5SPVCMF4IPPUJOH 5SBOTNJTTJPOT%*8" %*8"&
Voith. 55.6293.31 / 2002-03
*NQPSUBOUTBGFUZJOTUSVDUJPOT It is your responsibility to familiarize yourself with the warnings and precautions described in this manual. Danger! in conjunction with the symbol on the left is used if personal injury or danger to life may result if work is not carried out carefully. This manual only contains the most important information, however. It is impossible to describe all conceivable mistakes and danger conditions. Therefore, everybody who performs installation, repair or service work must very carefully ensure that his personal safety or that of other persons is not at risk.
*NQPSUBOUJOGPSNBUJPO Note! in conjunction with the symbol on the left denotes information that is particularly important.
"EEJUJPOBMOPUFT When replacing parts, always pay attention to the instructions in the spare parts catalog! Design improvements which should be taken into account during transmission overhauls are 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
I
5SPVCMF4IPPUJOH What is it for? The manual serves the following purpose:
n Special fault tracing in electrical transmission components or parts using the Voith 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
Voith. Trouble Shooting
)PXUPQSPDFFEJODBTFPG USBOTNJTTJPONBMGVODUJPOT If transmission malfunctions occur, fault may be present in a) the control unit records, b) in the electrical or c) mechanical part of electromechanical or d) purely mechanical components. In the case of faults in a) and b), use of "Diagnostic Manual" and "Trouble Shooting", if required, alone may be sufficient for repair. However, since malfunctions in c) and d) are not detected by the control and/or diagnosis, it is recommended to refer to the appropriate Voith documentation and programs for transmission malfunction repairs in the following order, for example: Read out the fault memory of the transmission control unit by means of the diagnostic program DIWAGNOSIS:
Diagnostic Manual
Malfunction analysis and information about possible remedies, if required, information about transmission design and function in the "Technical Manuals" and in the "Technical Descriptions with Oil and Control Circuit Diagrams" for DIWA.3 and DIWA.3E:
Fault Finding
Use of the diagnostic program for fault tracing:
Diagnostic Manual
Tracing of possible faults in the electrical system of DIWA.3 and DIWA.3E transmissions:
Trouble Shooting
Transmission repair and spare parts ordering:
Repair Manual, Spare Parts Catalogs
Voith. Trouble Shooting
III
IV
Voith. Trouble Shooting
$POUFOUT Page Differences between DIWA.3 and DIWA.3E in terms of trouble-shooting................................VII A.
Introduction ......................................................................................................................... 1
1.
Control and diagnosis ......................................................................................................... 3
2.
3.
1.1
Faulty component: Voltage supply to control unit ..................................................... 3
1.2
Faulty component: Diagnosis connection ................................................................ 4
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
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
Voith. Trouble Shooting
V
5.
6.
7.
8.
9.
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
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
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
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
Appendices ....................................................................................................................... 57 1 Circuit diagram DIWA.3 1 Circuit diagram DIWA.3E
VI
Voith. Trouble Shooting
%JGGFSFODFTCFUXFFO%*8"BOE%*8"& JOUFSNTPGUSPVCMFTIPPUJOH As mentioned in the next chapter, only parts or components that can be accessed by the Voith diagnostic system are concerned here, i. e. mainly electrical parts. The decisive reference is the circuit diagram. Since there are hardly any fundamental differences between the circuit diagrams of DIWA.3 and DIWA.3E transmissions (see chap. 9. Circuit 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
Voith. Trouble Shooting
VII
VIII
Voith. Trouble Shooting
" *OUSPEVDUJPO Purpose The purpose of this manual is to enable the service engineer to systematically search for 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").
Voith. Trouble Shooting
1
2
Voith. Trouble Shooting
$POUSPMBOEEJBHOPTJT 1.1 Faulty component: Voltage supply to control unit Relay "control"
Electronic control unit E 200
G6
D
69
Utarget = approx. 24 V Rtarget = 0 Ω
69
Rtarget = ∞ Ω
V
Ω
Ω Vehicle supply system
)
Rtarget = 0 Ω
; 8= < 8%
Connection cable
Ω Cable 2
69
0
Step
Activity and location
Fuse, pins or contacts
1.
Switch on ignition. If control unit E 200 does not operate properly, check whether 8 A fuse F1 in connection cable to vehicle supply system is blown.
2.
Open connection SV.2. SV.2 Measure voltage between contacts 19 and 21 (cable 2). Utarget = approx. 24 V. Switch off ignition.
3.
Measure resistance between contact 19 and the conductor to contact 30 (dS relay). Rtarget = 0 Ω.
4.
Measure resistance between contact 19 and the conductor in connection cable to fuse F1. Rtarget = 0 Ω.
5.
Measure resistance between contact 21 and vehicle earth. Rtarget = 0 Ω. If R = Rtarget for all of measurements 3 to 5, proceed with step 8.
6.
Open SV.19. SV.19; variant Measure resistance between contact 19 (cable 2) and contact X (+UZ) of the connection cable to the vehicle supply system. The number of X is shown in the circuit diagram. Rtarget = 0 Ω.
7.
Measure resistance between contact Y (-UB) of earthing cable (M) and vehicle earth. The number of Y is shown in the circuit diagram. Rtarget = 0 Ω.
8.
SV.2: Measure resistance between contact 19 and earth. Rtarget = ∞ Ω.
9.
SV.19: Measure resistance between contact X (+UZ) and earth. Rtarget = ∞ Ω. Voith. Trouble Shooting
3
1. Control and diagnosis
1.2 Faulty component: Diagnosis connection
Electronic control unit E 200
69
Diagnosis-PC
Rtarget = 0 Ω
Rtarget = ∞ Ω
Ω
Ω
8= 8% ',$*1. ',$*1/
69
V Utarget = approx. 24 V Step 1.
2.
3.
4
Level converter (see Chap. 8.)
Activity and location
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. Switch off ignition.
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. SV.2: Measure resistance between contacts 16, 19, 21, and 52 (cable 2) and vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
4FOTPST 2.1 Faulty component: Inductive pick-up N1
DIWA.3/.3E transmission
Cable 1 ' &
Ω 69
69
Rtarget = ∞ Ω
Ω
Cable harness
69
Rtarget = 800-1400 Ω
Connection for inductive pick-up N1
69
Inductive pick-up N1
Electronic control unit E 200
Step 1.
2.
Activity and location 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.)
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 Ω.
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 Ω.
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 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.
SV.5
Voith. Trouble Shooting
5
2. Sensors
2.2 Faulty component: Inductive pick-up N2
DIWA.3/.3E transmission
Cable 1 ( )
Ω
69
Rtarget = ∞ Ω
Ω
Cable harness with connection for inductive pickup N2
69
Rtarget = 800-1400 Ω
69
Inductive pick-up N2
Electronic control unit E 200
Step 1.
2.
6
Activity and location Open plug connection SV.1. SV.1 Measure resistance between contacts 10 and 29 of cable 1. Rtarget = 800-1400 Ω. If R = Rtarget continue with step 4.
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 Ω.
SV.3; Measuring cable 56.4461.12
( )
3.
On transmission output side: remove cap from above pick-up N2. SV.7 Open SV.7. Measure resistance between pins of pick-up N2. Rtarget = 800-1400 Ω.
4.
Measure resistance between contact 29 and vehicle earth. Rtarget = ∞ Ω.
5.
Open SV.3. Measure resistance between contact F and earth. Rtarget = ∞ Ω.
6.
Open SV.7. Measure resistance between a contact and earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
Q
2. Sensors
2.3 Faulty component: Inductive pick-up N3
DIWA.3/.3E transmission
Cable 1 * +
Ω
69
Rtarget = ∞ Ω
Ω
Cable harness with connection for inductive pick-up N3
69
Rtarget = 800-1400 Ω
69
Electronic control unit E 200
Step 1.
2.
Inductive pick-up N3
Activity and location Open plug connection SV.1. SV.1 Measure resistance between contacts 28 and 46 of cable 1. Rtarget = 800-1400 Ω. If R = Rtarget continue with step 4.
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 Ω.
SV.3; Measuring cable 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 Ω.
SV.8
4.
Measure resistance between contact 46 and vehicle earth. Rtarget = ∞ Ω.
5.
Open SV.3. Measure resistance between contact H and earth. Rtarget = ∞ Ω.
6.
Open SV.8. Measure resistance between a contact and earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
7
2. Sensors
2.4 Faulty component: Oil temperature transmitter
DIWA.3/.3E transmission
Cable 1
Cable harness D =
Ω 69
Ω
Electronic control unit E 200
Step 1.
2.
69
Rtarget = ∞ Ω Oil temp. ϑ 0 [°C] 20 [°C] 70 [°C] 90 [°C] 120 [°C] 140 [°C]
VZ
Connection for oil temperature transmitter
Rtarget 810 [Ω] 950 [Ω] 1360 [Ω] 1550 [Ω] 1860 [Ω] 2090 [Ω]
69
Activity and location
Open plug connection SV.1. SV.1 Measure resistance between contacts 8 and 44 of cable 1. For Rtarget see chart above. If R = Rtarget continue with step 5.
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. For Rtarget see chart above.
SV.3; Measuring cable 56.4461.12
=
3.
Remove control cover. SV.4 Open SV.4. Measure resistance between contacts 3 and 4 of the connector for the oil temperature transmitter. For Rtarget see chart above.
4.
Remove oil sump. SV.9 Open SV.9. On TB accumulator: measure resistance between pins of oil temperature transmitter. For Rtarget see chart above.
5.
Measure resistance between contact 44 and vehicle earth. Rtarget = ∞ Ω.
6.
Open SV.3. Measure resistance between contact Z and earth. Rtarget = ∞ Ω.
7.
Open SV.4. Measure resistance between contact 4 and earth. Rtarget = ∞ Ω.
8.
Open SV.9. Measure resistance between a contact and earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
Oil temperature transmitter
Pins or contacts
D
8
ZV
69
76
4PMFOPJET 3.1 Solenoids with measuring coil 3.1.1 Faulty component: EK solenoid
DIWA.3/.3E transmission
Cable 1 M K F /
Ω 69
Electronic control unit E 200
Step 1.
2.
3.
Cable harness
% $
Rtarget = ∞ Ω
Ω Rtarget Working coil Measuring coil
69
EK solenoid
Coil + cable 1 11 - 20 [Ω]
11±0,7 [Ω]
5 - 10 [Ω]
5,2±0,3 [Ω]
Coil only
Activity and location Open plug connection SV.1. SV.1 a) Working coil: Measure resistance between contacts 19 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. b) Measuring coil: Measure resistance between contacts 15 and 31 or 49. Rtarget = 5-10 Ω. If R = Rtarget continue with step 4.
69
Measuring coil
Working coil
Pins or contacts
Open SV.3. SV.3; Cable harness a) Working coil: Measure resistance $ between contacts L and A or B (cable % harness) or EK and –UB (measuring cable). Rtarget = 11-20 Ω. M b) Measuring coil: Measure resistance between contacts c and h or j (cable F harness) or EKM and SENSE (measur/ ing cable). K Rtarget = 5-10 Ω.
SV.3; measuring cable 56.4461.12 (.
8%
(.0
6(16(
Remove control cover. SV.10 Open SV.10. a) Working coil: Measure resistance between pins 1 and 2 of the EK solenoid flat pin connector. Rtarget = 11±0,7 Ω. b) Measuring coil: Measure resistance between pins 3 and 4 of the EK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
4.
Measure resistance between contact 15 and vehicle earth. Rtarget = ∞ Ω. Measure resistance between contacts 15 and 19. Rtarget = ∞ Ω.
5.
Open SV.3. Measure resistance between contact c (or EKM) and earth. Rtarget = ∞ Ω. Measure resistance between contacts c (or EKM) and L (or EK). Rtarget = ∞ Ω.
6.
Open SV.10. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω. Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω. Voith. Trouble Shooting
9
3. Solenoids
3.1.2 Faulty component: TB solenoid
DIWA.3/.3E transmission
Cable 1 M K I 6
Ω 69
Electronic control unit E 200
Step 1.
2.
3.
10
Cable harness
% $
Rtarget = ∞ Ω
Ω Rtarget Working coil Measuring coil
69
TB solenoid
Coil + cable 1 11 - 20 [Ω]
11±0,7 [Ω]
5 - 10 [Ω]
5,2±0,3 [Ω]
Coil only
Activity and location Open plug connection SV.1. SV.1 a) Working coil: Measure resistance between contacts 20 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. b) Measuring coil: Measure resistance between contacts 50 and 31 or 49. Rtarget = 5-10 Ω. If R = Rtarget continue with step 4.
69
Measuring coil
Working coil
Pins or contacts
Open SV.3. SV.3; Cable harness a) Working coil: Measure resistance between contacts S and A or B (cable $ harness) or TB and –UB (measuring 6 % cable). I Rtarget = 11-20 Ω. M b) Measuring coil: Measure resistance between contacts f and h or j (cable harness) or TBM and SENSE (measurK ing cable). Rtarget = 5-10 Ω.
SV.3; Measuring cable 56.4461.12 7%
8%
7%0
Remove control cover. SV.11 Open SV.11. a) Working coil: Measure resistance between pins 1 and 2 of the TB solenoid flat pin connector. Rtarget = 11±0,7 Ω. b) Measuring coil: Measure resistance between pins 3 and 4 of the TB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
4.
Measure resistance between contact 50 and vehicle earth. Rtarget = ∞ Ω. Measure resistance between contacts 50 and 20. Rtarget = ∞ Ω.
5.
Open SV.3. Measure resistance between contact f (or TBM) and earth. Rtarget = ∞ Ω. Measure resistance between contacts f (or TBM) and S (or TB). Rtarget = ∞ Ω.
6.
Open SV.11. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω. Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.
Voith. Trouble Shooting
6(16(
3. Solenoids
3.1.3 Faulty component: PB solenoid
DIWA.3/.3E transmission
Cable 1 M K G 0
Ω 69
Electronic control unit E 200
Step 1.
2.
3.
Cable harness
% $
Rtarget = ∞ Ω
Ω Rtarget Working coil Measuring coil
69
PB solenoid
Coil + cable 1 11 - 20 [Ω]
11±0,7 [Ω]
5 - 10 [Ω]
5,2±0,3 [Ω]
Coil only
Activity and location Open plug connection SV.1. SV.1 a) Working coil: Measure resistance between contacts 2 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. b) Measuring coil: Measure resistance between contacts 14 and 31 or 49. Rtarget = 5-10 Ω. If R = Rtarget continue with step 4.
69
Measuring coil
Working coil
Pins or contacts
Open SV.3. SV.3; Cable harness a) Working coil: Measure resistance $ between contacts M and A or B (cable % harness) or PB and –UB (measuring G cable). M Rtarget = 11-20 Ω. b) Measuring coil: Measure resistance 0 between contacts d and h or j (cable harness) or PBM and SENSE (measurK ing cable). Rtarget = 5-10 Ω.
SV.3; Measuring cable 56.4461.12 3%
8%
3%0
6(16(
Remove control cover. SV.12 Open SV.12. a) Working coil: Measure resistance between pins 1 and 2 of the PB solenoid flat pin connector. Rtarget = 11±0,7 Ω. b) Measuring coil: Measure resistance between pins 3 and 4 of the PB solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
4.
Measure resistance between contact 14 and vehicle earth. Rtarget = ∞ Ω. Measure resistance between contacts 14 and 2. Rtarget = ∞ Ω.
5.
Open SV.3. Measure resistance between contact d (or PBM) and earth. Rtarget = ∞ Ω. Measure resistance between contacts d (or PBM) and M (or PB). Rtarget = ∞ Ω.
6.
Open SV.12. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω. Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.
Voith. Trouble Shooting
11
3. Solenoids
3.1.4 Faulty component: DK solenoid
DIWA.3/.3E transmission
Cable 1 M K E .
Ω 69
Electronic control unit E 200
Step 1.
2.
3.
12
Cable harness
% $
Rtarget = ∞ Ω
Ω Rtarget Working coil Measuring coil
69
DK solenoid
Coil + cable 1 11 - 20 [Ω]
11±0,7 [Ω]
5 - 10 [Ω]
5,2±0,3 [Ω]
Coil only
Activity and location Open plug connection SV.1. SV.1 a) Working coil: Measure resistance between contacts 37 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. b) Measuring coil: Measure resistance between contacts 51 and 31 or 49. Rtarget = 5-10 Ω. If R = Rtarget continue with step 4.
69
Measuring coil
Working coil
Pins or contacts
Open SV.3. SV.3; Cable harness a) Working coil: Measure resistance $ between contacts K and A or B (cable % harness) or DK and –UB (measuring cable). Rtarget = 11-20 Ω. M b) Measuring coil: Measure resistance between contacts b and h or j (cable E harness) or DKM and SENSE (meaK suring cable). . Rtarget = 5-10 Ω.
SV.3; Measuring cable 56.4461.12 '.
8%
'.0
6(16(
Remove control cover. SV.13 Open SV.13. a) Working coil: Measure resistance between pins 1 and 2 of the DK solenoid flat pin connector. Rtarget = 11±0,7 Ω. b) Measuring coil: Measure resistance between pins 3 and 4 of the DK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
4.
Measure resistance between contact 51 and vehicle earth. Rtarget = ∞ Ω. Measure resistance between contacts 51 and 37. Rtarget = ∞ Ω.
5.
Open SV.3. Measure resistance between contact b (or DKM) and earth. Rtarget = ∞ Ω. Measure resistance between contacts b (or DKM) and K (or DK). Rtarget = ∞ Ω.
6.
Open SV.13. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω. Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.
Voith. Trouble Shooting
3. Solenoids
3.1.5 Faulty component: SK solenoid
DIWA.3/.3E transmission
Cable 1 M K J 8
Ω 69
Electronic control unit E 200
Step 1.
2.
3.
Cable harness
% $
Rtarget = ∞ Ω
Ω Rtarget Working coil Measuring coil
69
SK solenoid
Coil + cable 1 11 - 20 [Ω]
11±0,7 [Ω]
5 - 10 [Ω]
5,2±0,3 [Ω]
Coil only
Activity and location Open plug connection SV.1. SV.1 a) Working coil: Measure resistance between contacts 18 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. b) Measuring coil: Measure resistance between contacts 33 and 31 or 49. Rtarget = 5-10 Ω. If R = Rtarget continue with step 4.
69
Measuring coil
Working coil
Pins or contacts
Open SV.3. SV.3; Cable harness a) Working coil: Measure resistance between contacts U and A or B (cable $ 8 harness) or SK and –UB (measuring % cable). Rtarget = 11-20 Ω. J M b) Measuring coil: Measure resistance between contacts g and h or j (cable harness) or SKM and SENSE (measurK ing cable). Rtarget = 5-10 Ω.
SV.3; Measuring cable 56.4461.12 6.
8%
6.0
6(16(
Remove control cover. SV.14 Open SV.14. a) Working coil: Measure resistance between pins 1 and 2 of the SK solenoid flat pin connector. Rtarget = 11±0,7 Ω. b) Measuring coil: Measure resistance between pins 3 and 4 of the SK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω.
4.
Measure resistance between contact 33 and vehicle earth. Rtarget = ∞ Ω. Measure resistance between contacts 33 and 18. Rtarget = ∞ Ω.
5.
Open SV.3. Measure resistance between contact g (or SKM) and earth. Rtarget = ∞ Ω. Measure resistance between contacts g (or SKM) and U (or SK). Rtarget = ∞ Ω.
6.
Open SV.14. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω. Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.
Voith. Trouble Shooting
13
3. Solenoids
3.1.6 Faulty component: RBK solenoid
DIWA.3/.3E transmission
Cable 1 M K H 3
Ω 69
Electronic control unit E 200
Step 1.
2.
3.
14
Cable harness
% $
Rtarget = ∞ Ω
Ω Rtarget Working coil Measuring coil
69
RBK solenoid
Coil + cable 1 11 - 20 [Ω]
11±0,7 [Ω]
5 - 10 [Ω]
5,2±0,3 [Ω]
Coil only
Activity and location Open plug connection SV.1. SV.1 a) Working coil: Measure resistance between contacts 21 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. b) Measuring coil: Measure resistance between contacts 13 and 31 or 49. Rtarget = 5-10 Ω. If R = Rtarget continue with step 4.
69
Measuring coil
Working coil
Pins or contacts
Open SV.3. SV.3; Cable harness a) Working coil: Measure resistance $ between contacts P and A or B (cable H % harness) or RBK and –UB (measuring 3 cable). M Rtarget = 11-20 Ω. b) Measuring coil: Measure resistance between contacts e and h or j (cable harness) or RBKM and SENSE (meaK suring cable). Rtarget = 5-10 Ω.
SV.3; Measuring cable 56.4461.12 5%.
8%
5%.0
6(16(
Remove control cover. SV.15 Open SV.15. a) Working coil: Measure resistance between pins 1 and 2 of the RBK solenoid flat pin connector. Rtarget = 11±0,7 Ω. b) Measuring coil: Measure resistance between pins 3 and 4 of the RBK solenoid flat pin connector. Rtarget = 5,2±0,3 Ω
4.
Measure resistance between contact 13 and vehicle earth. Rtarget = ∞ Ω. Measure resistance between contacts 13 and 21. Rtarget = ∞ Ω.
5.
Open SV.3. Measure resistance between contact e (or RBKM) and earth. Rtarget = ∞ Ω. Measure resistance between contacts e (or RBKM) and P (or RBK). Rtarget = ∞ Ω.
6.
Open SV.15. Measure resistance of contacts 1 and 4 to earth. Rtarget = ∞ Ω. Measure resistance between contacts 1 and 4. Rtarget = ∞ Ω.
Voith. Trouble Shooting
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
Ω
Rtarget
Coil + cable 1 11 - 20 [Ω]
69
Coil only 11±0,7 [Ω]
Rtarget = ∞ Ω
Ω
69
RBG solenoid
Electronic control unit E 200
Step 1.
2.
Activity and location Open plug connection SV.1. SV.1 Measure resistance between contacts 17 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. If R = Rtarget continue with step 4.
Pins or contacts
Open SV.3. SV.3; Cable harness Measure resistance between contacts $ R and A or B (cable harness) or RBG 5 % and –UB (measuring cable). Rtarget = 11-20 Ω.
SV.3; Measuring cable 56.4461.12
5%*
8%
3.
Remove control cover. SV.16 Open SV.16. Measure resistance between pins 1 and 2 of the RBG solenoid flat pin connector. Rtarget = 11±0,7 [Ω].
4.
Measure resistance between contact 2 and vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
15
3. Solenoids
3.2.2 Faulty component: WP solenoid for DIWA.3
DIWA.3 transmission Cable 1 1
Cable harness
% $
69
Ω
Rtarget
69
Coil + cable 1 11 - 20 [Ω]
Coil only 11±0,7 [Ω]
Ω
Rtarget = ∞ Ω
69
WP solenoid
Electronic control unit E 200
Step 1.
2.
Activity and location
Pins or contacts
Open plug connection SV.1. SV.1 Measure resistance between contacts 3 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. If R = Rtarget continue with step 4.
Open SV.3. SV.3; Cable harness Measure resistance between contacts $ N and A or B (cable harness) or WP % and –UB (measuring cable). Rtarget = 11-20 Ω.
SV.3; Measuring cable 56.4461.12 :3
8%
1
3.
Remove control cover. SV.17 Open SV.17. Measure resistance between pins 1 and 2 of the WP solenoid flat pin connector. Rtarget = 11±0,7 [Ω].
4.
16
Measure resistance between contact 2 and vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
3. Solenoids
3.2.3 Faulty component: WP solenoid for DIWA.3E
DIWA.3E transmission Cable 1 Cable harness
7 % $
69
Ω
Rtarget
Coil + cable 1 11 - 20 [Ω]
Coil only
69
11±0,7 [Ω]
Rtarget = ∞ Ω
Ω
69
WP solenoid
Electronic control unit E 200
Step 1.
2.
Activity and location Open plug connection SV.1. SV.1 Measure resistance between contacts 3 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. If R = Rtarget continue with step 4.
Pins or contacts
Open SV.3. SV.3; Cable harness Measure resistance between contacts 7 $ T and A or B (cable harness) or WP % and –UB (measuring cable). Rtarget = 11-20 Ω.
SV.3; Measuring cable 56.4461.12 :3(
8%
3.
Remove control cover. SV.17 Open SV.17. Measure resistance between pins 1 and 2 of the WP solenoid flat pin connector. Rtarget = 11±0,7 [Ω].
4.
Measure resistance between contact 2 and vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
17
3. Solenoids
3.2.4 Faulty component: WR solenoid
DIWA.3/.3E transmission Cable 1 -
Cable harness
% $
69
Ω
Rtarget
Coil + cable 1 11 - 20 [Ω]
69
Coil only 11±0,7 [Ω]
Ω
Rtarget = ∞ Ω
69
WR solenoid
Electronic control unit E 200
Step 1.
2.
Activity and location
Pins or contacts
Open plug connection SV.1. SV.1 Measure resistance between contacts 35 and 52 or 53 of cable 1. Rtarget = 11-20 Ω. If R = Rtarget continue with step 4.
Open SV.3. SV.3; Cable harness Measure resistance between contacts $ J and A or B (cable harness) or WR % and –UB (measuring cable). Rtarget = 11-20 Ω.
SV.3; Measuring cable 56.4461.12
:5
8%
-
3.
Remove control cover. SV.18 Open SV.18. Measure resistance between pins 1 and 2 of the WR solenoid flat pin connector. Rtarget = 11±0,7 [Ω].
4.
18
Measure resistance between contact 2 and vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
3FMBZTBOEQJMPUMJHIUT 4.1 Faulty component: Converter brake relay dW Converter brake relay
G:
Electronic control unit E 200
D
69
Ω 0
Rtarget = 0 Ω
Rtarget = 285-310 Ω
69
Connection cable ;
Step
Activity and location
1.
Replace dW relay by a new one or remove relay and measure resistance directly between coil contacts 85 and 86. Rtarget = 285-310 Ω.
69
Ω
Cable 2
G:
Pins or contacts
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 Ω. If R = Rtarget continue with step 5.
Open SV.19. SV.19; variant Measure resistance at pin X (dW) of the connection cable to the dW relay. The number of contact X can be found in the circuit diagram. Rtarget = 285-310 Ω. 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 Ω.
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 Ω.
Voith. Trouble Shooting
19
4. Relays and pilot lights
4.2 Faulty component: Speed switch relay dN Speed switch relay
G1
Electronic control unit E 200
D
69
Ω
Rtarget = 0 Ω
Rtarget = 285-310 Ω
Ω
0
69 Connection cable ;
Step
Activity and location
1.
Replace dN relay by a new one or remove relay and measure resistance directly between coil contacts 85 and 86. Rtarget = 285-310 Ω.
69
Cable 2
G1
Pins or contacts
D
2.
3.
4.
5.
20
Open plug connector SV.2. SV.2 For the following steps, connect one feeler of the ohmmeter to vehicle earth. Measure resistance at contact 50 of cable 2. Rtarget = 285-310 Ω. If R = Rtarget continue with step 5.
SV.20: Measure resistance at the cable to the end of the winding of the dN relay (pin 85) and earthing point M. Rtarget = 0 Ω.
Voith. Trouble Shooting
Open SV.19. SV.19; variant Measure resistance at pin X (dN) of the connection cable to the dN relay. The number of contact X can be found in the circuit diagram. Rtarget = 285-310 Ω. Mounting plug SV.20: Measure resis- SV.20 tance at the cable to the start of the winding of the dN relay (pin 86). Rtarget = 285-310 Ω.
dN
4. Relays and pilot lights
4.3 Faulty component: Reversing light relay dR Reversing light relay
G5
Electronic control unit E 200
D
69
Ω
Rtarget = 0 Ω
0
Rtarget = 285-310 Ω
69
Connection cable ;
Step
Activity and location
1.
Replace dR relay by a new one or remove relay and measure resistance directly between coil contacts 85 and 86. Rtarget = 285-310 Ω.
69
Ω
Cable 2
G5
Pins or contacts
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 14 of cable 2. Rtarget = 285-310 Ω. If R = Rtarget continue with step 5.
Open SV.19. SV.19; variant Measure resistance at pin X (dR) of the connection cable to the dR relay. The number of contact X can be found in the circuit diagram. Rtarget = 285-310 Ω. Mounting plug SV.20: Measure resis- SV.20 tance at the cable to the start of the winding of the dR relay (pin 86). Rtarget = 285-310 Ω.
dR
SV. 20: Measure resistance at the cable to the end of the winding of the dR relay (pin 85) and earthing point M. Rtarget = 0 Ω.
Voith. Trouble Shooting
21
4. Relays and pilot lights
4.4 Faulty component: Starter inhibitor relay Starter inhibitor relay
69
69
D
0
Ω
Rtarget = 0 Ω
Rtarget = 285-310 Ω
Ω
69 Vehicle electrical system
;
663
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 between winding contacts 85 and 86 after removal of the relay. Rtarget = 285-310 Ω.
D
2.
3.
4.
5.
22
Open connection SV.24 SV.24 (see Chap. 5.1). For the following steps, connect one feeler of the ohmmeter to vehicle earth. Measure resistance at contact 16 of cable 2. Rtarget = 285-310 Ω. If R = Rtarget, continue with step 5. 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 Ω. Mounting plug SV.20: Measure resis- SV.20 tance at the cable to the beginning of the winding of the starter inhibitor relay (pin contact 86). Rtarget = 285-310 Ω. 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 Ω.
Voith. Trouble Shooting
Starter inhibitor
4. Relays and pilot lights
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
Electronic control unit E 200
D 69
0 '
Ω
Rtarget = 0 Ω
Rtarget = 285-310 Ω
69 09
0
69
Connection cable
+6%
<
69
Ω
Cable 2
G+6%
;
Step
Activity and location
Pins or contacts
First, check whether the diagnosis shows a defect of the dHSB relay (a) or not (b). Case a: take steps 1 to 5. Case b: take steps 1 and 6 to 13 (see opposite page). 1.
Replace dHSB relay by a new one or measure resistance directly between winding contacts 85 and 86 after removal of the relay. Rtarget = 285-310 Ω.
D
2.
3.
4.
5.
Open connection SV.2. 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 Ω. If R = Rtarget, continue with step 5.
Open SV.19. SV.19; variant Measure resistance at pin contact X (dHSB) of the connection cable to the dHSB relay. The number of contact X is shown in the circuit diagram. Rtarget = 285-310 Ω. Mounting plug SV.20: Measure resis- SV.20 tance at the cable to the beginning of the winding of the dHSB relay (pin contact 86). Rtarget = 285-310 Ω.
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 Ω.
Voith. Trouble Shooting
23
4. Relays and pilot lights
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 Ω
Electronic control unit E 200
Ω
Rtarget = value
Rtarget = 0 or ∞ Ω
Ω
MV
0
SV.19 +6%
<
Ω
Cable 2
SV.2
Ω Rtarget = ∞ Ω
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 = ∞ Ω. HSB switch closed: Rtarget = 0 Ω. If R = Rtarget, continue with step 11.
8.
24
Activity and location
Fuse, pins or contacts
Open SV.19. SV.19; variant Measure resistance between contact Y (HSB) and supply cable contact 30 (dHSB relay). The number of contact Y is shown in the circuit diagram. HSB switch open: Rtarget = ∞ Ω. HSB switch closed: Rtarget = 0 Ω.
9.
Open SV.22. Measure resistance between contact 1 and 2. HSB switch open: Rtarget = ∞ Ω. HSB switch closed: Rtarget = 0 Ω.
10.
Open SV.23. Measure resistance between contact 1 and 2. HSB switch open: Rtarget = ∞ Ω. HSB switch closed: Rtarget = 0 Ω.
11.
SV.2: Measure resistance between contact 1 of cable 2 and vehicle earth with HSB switch closed, applying the '–' feeler of the ohmmeter to contact 1 (because of diode D). Rtarget = ∞ Ω.
12.
SV.20: Measure resistance between '+' conductor of the coil of solenoid valve (MV) and vehicle earth. Rtarget = value.
13.
Measure resistance between '–' conductor MV coil and earth. Rtarget = 0 Ω.
Voith. Trouble Shooting
4. Relays and pilot lights
4.6 Faulty component: Central warning light (ZW) 4.6.1 Faulty component: ZW relay
Central warning light relay =:
Electronic control unit E 200 69
D
0
Central warning light
Ω
Rtarget = 0 Ω
0
69
Ω
69
Connection cable ;
Step
Rtarget = 285-310 Ω
Cable 2
=:
Activity and location
Pins or contacts, relay
First, check whether the diagnosis shows a defect of the ZW relay (a) or not (b). Case a: take steps 1 to 5. Case b: take steps 1 and 6 to 9 (see opposite page). 1.
Replace ZW relay by a new one or measure resistance directly between winding contacts 85 and 86 after removal of the relay. Rtarget = 285-310 Ω.
D
2.
3.
4.
5.
Open connection SV.2. 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 Ω. If R = Rtarget, continue with step 5.
Open SV.19 SV.19; variant Measure resistance at pin contact X (ZW) of the connection cable to the ZW relay. The number of contact X is shown in the circuit diagram. Rtarget = 285-310 Ω. Mounting plug SV.20: Measure resis- SV.20 tance at the cable to the beginning of the winding of the ZW relay (pin contact 86). Rtarget = 285-310 Ω.
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 Ω.
Voith. Trouble Shooting
25
4. Relays and pilot lights
4.6.2 Faulty component: ZW bulb Central warning light relay
=: Electronic control unit E 200 69
D
0 0
Rtarget = s.b.
Ω
Ω Central warning light
Connection cable
Step
26
Ω
Rtarget = 0 Ω
69
Rtarget = ∞ Ω 69 ;
=: Cable 2
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.
Voith. Trouble Shooting
4. Relays and pilot lights
4.7 Faulty component: Voltage supply to solenoid valves 4.7.1 Faulty component: Control relay dS
Control relay
Electronic control unit E 200
G6
69
D
Rtarget = 0 Ω
Ω
Rtarget = 285-310 Ω
0
Ω
69
Vehicle electrical system
69
< ;
)
8% G6 8=
Connection cable
Cable 2
Step
Activity and location
Pins or contacts, relay
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 Ω.
D
2.
3.
4.
5.
Open connection SV.2. SV.2 For the following steps, connect one feeler of the ohmmeter to vehicle earth. Measure resistance at contact 13 of cable 2. Rtarget = 285-310 Ω. If R = Rtarget, continue with step 5.
Open SV.19. SV.19; variant Measure resistance at pin contact X (dS) of the connection cable to the dS relay. The number of contact X is shown in the circuit diagram. Rtarget = 285-310 Ω. Mounting plug SV.20: Measure resis- SV.20 tance at the cable to the beginning of the winding of the dS relay (pin contact 86). Rtarget = 285-310 Ω.
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 Ω. If R = Rtarget continue with step 6 on the opposite page.
Voith. Trouble Shooting
27
4. Relays and pilot lights
4.7.2 Faulty component: Solenoid valve voltage Control relay
Electronic control unit E 200
G6
69
D
Rtarget = 0 Ω 0
Vehicle electrical system
Step
Cable 2
Connection cable
Activity and location Test UZ line (see Chap. 1.1).
7.
Open SV.2. SV.2 Measure resistance between contact 38 (+UB) and the supply line to contact 87 (dS relay). Rtarget = 0 Ω. If R = Rtarget continue with step 9.
9.
Ω
8% G6 8=
6.
8.
28
< ;
)
Rtarget = ∞ Ω
Ω 69
Pins or contacts
Open SV.19. SV.19; variant Measure resistance between contacts 38 and Y (+UB). The number of contact Y can be seen from the circuit diagram. Rtarget = 0 Ω.
SV.2: Measure resistance between contact 38 and vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
69
$POUSPMMFST 5.1 Faulty component: Push-button switch 6-button switch
'
1
5
Electronic control unit 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
Ω
69
8%
69
66695 1 +TS 56 7/
Reversing inhibitor switch (Sp.Rg.)
Cable 2
Ω
Rtarget = ∞ Ω
Connection cable Push-button switch
to SV.19, contact X (see Chap. 4.4)
Check 3, 4, and 5-button switches accordingly Step
Activity and location
Pins or contacts
1.
If switch illumination is defective, 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 [Ω]: 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 [Ω]: 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 [Ω]: Button depr. (N depressed) [not N depr.] 0 (∞) 0 (∞) 0 (∞) 0 (∞) ∞ [0] 0 (∞)
SV.2: MeaRtarget [Ω]: 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 Voith. Trouble Shooting
29
5. Controllers
Step 3.
Activity and location
Pins or contacts
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 Button, Switch 1 2 3 D N R Sp.Rg.
Measurement btw. contact 8 (TL) and:
Rtarget [Ω]: 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 [Ω]: 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 [Ω]: Button depr. (N depressed) [not N depr.] 0 (∞) 0 (∞) 0 (∞) 0 (∞) ∞ [0] 0 (∞)
Measurement Rtarget [Ω]: 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* (∞)*
* = Resistance when R-button is depressed too
Step 4.
Activity and location
Pins or contacts
Open SV.25. SV.25 Operate button (switch) as per table 3 below according to the diagnostic fault indication and measure resistances between contacts.
Table 3 Button, Switch
1 2 3 D N R Sp.Rg.
Measurement btw. contact 8 (TL) and:
Rtarget [Ω]: Button depr./ not depressed
Measurement btw. contact 7 (TS) and:
Rtarget [Ω]: Button depr. (N depressed) [not N depr.]
Measurement btw. contact 7 (TS) and:
Rtarget [Ω]: 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 [Ω]: Button depr. (not depressed)
1 (S1) 2 (S2) 3 (S3) 4 (+V)
0 (∞) 0 (∞) 0 (∞) 0 (∞)
5 (+R) 6 (RS)
0 (∞) 0* (∞*)
* = Resistance when R-button is depressed too Step
30
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.
Voith. Trouble Shooting
5. Controllers
5.2 Faulty component: Manual converter brake switch
Electronic control unit E 200 Manual switch
Indicator light
Rtarget see tables 1, 2, 3
;
Ω
<
8%
+%% +% +%$ +%&
69
Rtarget = ∞ Ω
8% +%& +%% +%$ +%
Ω
Connection cable manual switch
69
69
Step
Activity and location
1.
If indicator light is defective, replace bulb.
2.
Open connection SV.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, continue with step 5.
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 [Ω] ∞ 0 0 0
Measurement between contact 8 (+HB) and: 26 (HBB) 26 (HBB) 26 (HBB) 26 (HBB)
Rtarget [Ω] ∞ ∞ 0 0
Measurement between contact 8 (+HB) and: 44 (HBC) 44 (HBC) 44 (HBC) 44 (HBC)
Rtarget [Ω] ∞ ∞ ∞ 0
Measurement between contact 8 (+HB) and: 21 (-UB) 21 (-UB) 21 (-UB) 21 (-UB)
Rtarget [Ω] ∞ appr. 290 appr. 290 appr. 290
Voith. Trouble Shooting
31
5. Controllers
Step 3.
Activity and location
Pins or contacts
Open SV.24. SV.24 Select braking stage as per table 2 below according to the diagnostic fault indication and measure resistances between contacts.
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 [Ω] ∞ 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 [Ω] ∞ ∞ 0 0
Activity and location
Measurement between contact 15 (+HB) and: 10 (-UB) 10 (-UB) 10 (-UB) 10 (-UB)
Rtarget [Ω] ∞ ∞ ∞ 0
Rtarget [Ω] ∞ appr. 290 appr. 290 appr. 290
Pins or contacts
Open SV.26. SV.26 Select braking stage as per table 3 below according to the diagnostic fault indication and measure resistances between contacts.
Table 3 Braking stage 0 1 2 3
* **
Measurement between contact +* (+HB) and: 3 (HBA) 3 (HBA) 3 (HBA) 3 (HBA)
∞ 0 0 0
Rtarget [Ω] ∞ ∞ 0 0
Measurement between contact +** (+HB) and: 5 (HBC) 5 (HBC) 5 (HBC) 5 (HBC)
Rtarget [Ω] ∞ ∞ ∞ 0
Measurement between contact X and: Y Y Y Y
= next to contact 1 = next to contact 4
Step
32
Rtarget [Ω]
Measurement between contact +** (+HB) and: 4 (HBB) 4 (HBB) 4 (HBB) 4 (HBB)
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.
Voith. Trouble Shooting
Rtarget [Ω] 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
Rtarget see tables 1, 2, 3
;
Switch for converter braking stage 3
Ω
<
8%
+%% +% +%$ +%&
69
8% +%& +%% +%$ +%
69
69
Connection cable converter brake
Step
Activity and location
1.
If indicator light is defective, replace bulb.
2.
Open connection SV.2. SV.2 Measure resistances between contacts as per table 1 below. If R = Rtarget for all measurements, continue with step 5.
69
Rtarget = ∞ Ω
Ω Cable 2
Pins or contacts
Table 1 Switch off on
Measurement between contact 8 (+HB) and: 7 (HBA) 7 (HBA)
Rtarget [Ω] ∞ 0
Measurement between contact 8 (+HB) and: 44 (HBC) 44 (HBC)
Rtarget [Ω] ∞ 0
Measurement between contact 8 (+HB) and: 21 (-UB) 21 (-UB)
Rtarget [Ω] ∞ appr. 290
Voith. Trouble Shooting
33
5. Controllers
Step 3.
Activity and location
Pins or contacts
Open SV.24. SV.24 Measure resistances between contacts as per table 2 below.
Table 2 Switch off on
Measurement between contact 15 (+HB) and: 14 (HBA) 14 (HBA)
Step 4.
Rtarget [Ω] ∞ 0
Measurement between contact 15 (+HB) and: 12 (HBC) 12 (HBC)
Measurement between contact 15 (+HB) and: 10 (-UB) 10 (-UB)
Rtarget [Ω] ∞ 0
Activity and location
Rtarget [Ω] ∞ appr. 290
Pins or contacts
Open SV.26. SV.26 Measure resistances between contacts as per table 3 below.
Table 3 Switch off on
** **
Measurement between contact +* (+HB) and: 3 (HBA) 3 (HBA)
∞ 0
Rtarget [Ω] ∞ 0
Measurement between contact X and: Y Y
Rtarget [Ω] appr. 290 appr. 290
= next to contact 1 = next to contact 4
Step
34
Rtarget [Ω]
Measurement between contact +** (+HB) and: 5 (HBC) 5 (HBC)
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.
Voith. Trouble Shooting
5. Controllers
5.4 Faulty component: Brake valve (service brake transmitter)
Electronic control unit E 200 Brake valve
Rtarget see tables 1, 2, 3
Ω
69
Rtarget = ∞ Ω
69 69
)% )% )% )%
Ω
Connection cable brake valve
1.
)% )% )% )%
Step
Cable 2
Activity and location
Pins or contacts
Open connection SV.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, continue with step 4.
Table 1 Braking stage 0 1 2 3
Measurement between contact 2 (+FB) and: 40 (FB1) 40 (FB1) 40 (FB1) 40 (FB1)
Rtarget [Ω] ∞ 0 0 0
Measurement between contact 2 (+FB) and: 11 (FB2) 11 (FB2) 11 (FB2) 11 (FB2)
Rtarget [Ω] ∞ ∞ 0 0
Measurement between contact 2 (+FB) and: 49 (FB3) 49 (FB3) 49 (FB3) 49 (FB3)
Rtarget [Ω] ∞ ∞ ∞ 0
Voith. Trouble Shooting
35
5. Controllers
Step 2.
Activity and location
Pins or contacts
Open SV.27. SV.27 Select braking stage as per table 2 below according to the diagnostic fault indication and measure resistances between contacts.
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 [Ω] ∞ 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 [Ω] ∞ ∞ 0 0
Activity and location
Rtarget [Ω] ∞ ∞ ∞ 0
Pins or contacts
Open SV.28. SV.28 Select braking stage as per table 3 below according to the diagnostic fault indication and measure resistances between contacts.
Table 3 Braking stage 0 1 2 3
Measurement between contact 3 (+FB) and: 1 (FB1) 1 (FB1) 1 (FB1) 1 (FB1)
Step
36
Rtarget [Ω] ∞ 0 0 0
Measurement between contact 3 (+FB) and: 4 (FB2) 4 (FB2) 4 (FB2) 4 (FB2)
Rtarget [Ω] ∞ ∞ 0 0
Measurement between contact 3 (+FB) and: 2 (FB3) 2 (FB3) 2 (FB3) 2 (FB3)
Rtarget [Ω] ∞ ∞ ∞ 0
Activity
4.
SV.2: Measure resistance of contacts 2, 11, 40, and 49 to earth. Rtarget = ∞ Ω.
5.
Open SV.27. Measure resistance of contacts 3-6 to earth. Rtarget = ∞ Ω.
6.
Open SV.28. Measure resistance of contacts 1-4 to earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
5. Controllers
5.5 Faulty component: Voith load transmitter or EMR with VDO load transmitter Load transmitter Cable 1 /* /*0 /*
Rtarget = ∞ Ω
Ω Ω 69
69
Rtarget see tables 1, 2, 3
Electronic control unit E 200
Step 1.
Activity and location
Pins or contacts
Open connection SV.1. SV.1 Depress accelerator pedal as per table 1 below and measure resistance between contacts. If R = Rtarget for all measurements, continue with step 3.
Table 1 Measurement Accelera- between contor position tact 5 (-LG) and: 0 throttle 41 (+LG) Full throttle 41 (+LG)
Rtarget [Ω] 800-1500 800-1500
Measurement between contact 5 (-LG) and: 24 (LGM) 24 (LGM)
Rtarget [Ω] 178-333 622-1667
Voith. Trouble Shooting
37
5. Controllers
Step 2.
Activity and location
Pins or contacts
Open connection SV.30. 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
38
Rtarget [Ω] 800-1500 800-1500
Measurement between contact 3 (-LG) and: 2 (LGM) 2 (LGM)
Rtarget [Ω] 178-333 622-1667
Activity
3.
SV.2: Measure resistance of contacts 5, 24, and 41 to earth. Rtarget = ∞ Ω.
4.
Open SV.30. Measure resistance of contacts 1-3 to earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
5. Controllers
5.6 Faulty component: Kickdown switch
Electronic control unit E 200
Kickdown switch (KD)
Rtarget = 0 or ∞Ω 69
2.
Ω
.' 8=
Connection cable Kickdown switch
1.
Rtarget = ∞ Ω
Ω
69
Step
69
Cable 2
Activity and location Open SV.2. SV.2 Measure resistance between contacts 4 and 19 (cable 2). KD switch open (accelerator totally relieved): Rtarget = ∞ Ω. KD switch closed (accelerator fully depressed up to the final stop): Rtarget = 0 Ω. If R = Rtarget continue with step 4. Open SV.27. SV.27 Measure resistance between contacts 1 and 2. KD switch open: Rtarget = ∞ Ω. KD switch closed: Rtarget = 0 Ω.
Pins or contacts
3.
Open SV.32. SV.32 Measure resistance between the two contacts. KD switch open: Rtarget = ∞ Ω. KD switch closed: Rtarget = 0 Ω.
4.
SV.2: Measure resistance between contact 4 or 19 and vehicle earth with the KD switch closed. Rtarget = ∞ Ω.
5.
SV.27: Measure resistance between contact 1 or 2 and vehicle earth with the KD switch closed. Rtarget = ∞ Ω.
6.
SV.32: Measure resistance between one contact and earth with the KD switch closed. Rtarget = ∞ Ω.
Voith. Trouble Shooting
39
5. Controllers
40
Voith. Trouble Shooting
4JHOBMDPOEVDUPSTUPNPUPSDPOUSPMVOJUT 6.1 Faulty component: BOSCH electronic throttle control EMS 3.3 B/G
Electronic control unit E 200
69
Rtarget = 0 Ω
Ω 69 Bosch EMS 3.3
; < =
1.
2.
Ω
'.93:0 '.(
Connection cable
Step
Rtarget = ∞ Ω
'.5
Activity and location
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 Ω. SV.2: Measure resistance of contacts 5, 24, and 41 (cable 2) to vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
41
6. Signal conductors to motor control units
6.2 Faulty component: MB FMR BOSCH-EDC M5/M7, VDO electronic throttle control, DDEC III similar.
Electronic control unit E 200
69
Rtarget = 0 Ω Rtarget = 0 Ω
Ω
Ω
69
3:0,:$
;
Cable 2
Step 1.
2.
Activity and location
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 shown in the circuit diagram. Rtarget = 0 Ω. SV.2: Measure resistance of contact SV.21; variant MB FMR 41 (cable 2) to vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
E.g. MB FMR
6. Signal conductors to motor control units
6.3 Faulty component: CAN-Bus
Electronic control unit E 200
Rtarget = 0 Ω
69
Ω 69 E.g. EDC Connection cable
Step 1.
2.
Rtarget = ∞ Ω
CAN-H
& % CAN-M $ CAN-L
Activity and location 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 SV.2: Measure resistance between contacts 17, 36 and 37 (cable 2) and vehicle earth. Rtarget = ∞ Ω.
Ω Cabel 2
Pins or contacts
A
B
C
Voith. Trouble Shooting
43
6. Signal conductors to motor control units
6.4 Faulty component: dNEUTR output
Electronic control unit E 200
Rtarget = 0 Ω
69
Ω
RSoll = ∞ Ω
69 E.g. E-Gas
;
Connection cable
Step 1.
2.
Activity and location
Ω
G1(875
Cable 2
Pins or contacts
Open plug connectors SV.2 and SV.2 SV.19. Measure resistance between contacts 55 and X (dNEUTR) of cable 2. The number of contact X can be found in the circuit diagram. Rtarget = 0 Ω. SV.19; variant SV.2: Measure resistance between contact 55 and vehicle earth. Rtarget = ∞ Ω.
44
Voith. Trouble Shooting
0UIFSTXJUDIFTBOEXBSOJOHMJHIUT 7.1 Faulty component: ABS connection
Electronic control unit E 200
Rtarget = 0 Ω Connection cable
69
Ω
Ω
$%6
Rtarget = ∞ Ω
Case 1: inactive Case 2: active
69
P
P
V
Cable 2
Utarget = ca. 24 or 0 V + 24V
ABS
Step 1.
0
0
0
0
0
Activity and location Switch on ignition. SV.2 Open connection SV.2. Measure voltage between contact 53 (cable 2) and vehicle earth. Case 1 (low active): ABS inactive: Utarget = approx. 24 V ABS active: Utarget = 0 V. Case 2 (high active): ABS inactive: USoll = ca. 0 V. ABS active: USoll = 24 V. Switch off ignition.
Pins or contacts
2.
Measure resistance between contact 53 and the conductor of the connecting cable leading to the ABS. Rtarget = 0 Ω. If R = Rtarget continue with step 4.
3.
Open SV.19. SV.19; variant Measure resistance between contacts 53 (SV.2) and 7 (SV.19). Rtarget = 0 Ω.
4.
Measure resistance between contact 53 and vehicle earth. Rtarget = ∞ Ω.
Voith. Trouble Shooting
45
7. Other switches and warning lights
7.2 Faulty component: Transmission oil warning light
Electronic control unit E 200
Rtarget = 0 Ω 69
Ω
Connection cable
Ω
72(/
Rtarget = ∞ or appr.160 Ω Cable 2 69
P
P
Ω
+ 24V
0
0
0
0
Rtarget = 0 Ω
0
Transmission oil warning light
Step
Activity and location
1.
Replace bulb of transmission oil warning light if defective.
2.
Open connector SV.2. SV.2 Measure resistance between contact 15 (cable 2) and vehicle earth. With bulb: Rtarget = approx. 160 Ω. Without bulb: Rtarget = ∞ Ω.
Measure resistance between contact 15 and the conductor to the transmission oil warning light. Rtarget = 0 Ω. If R = Rtarget continue with step 5.
4.
Open SV.19. SV.19; variant Measure resistance between contacts 15 (SV.2) and 17 (SV.19). Rtarget = 0 Ω.
Measure resistance between the –conductor of the warning light (M) and earth. Rtarget = 0 Ω.
Voith. Trouble Shooting
3.
5.
46
Pins or contacts
7. Other switches and warning lights
7.3 Faulty component: Converter brake release switch
Electronic control unit E 200
Rtarget = 0 Ω 69
Ω
Connection cable
Ω
)%$86
Rtarget = 0 or ∞ Ω Cable 2 69
P
P
Ω
+ 24V
0
0
0
0
Rtarget = 0 Ω
0
Release switch converter brake
Step 1.
Activity and location Open connector SV.2. SV.2 Measure resistance between contact 31 (cable 2) and vehicle earth. Switch open: Rtarget = ∞ Ω. Switch closed: Rtarget = 0 Ω.
Pins or contacts
2.
Measure resistance between contact 31 and the conductor to the converter brake release switch. Rtarget = 0 Ω. If R = Rtarget continue with step 4.
3.
Open SV.19. SV.19; variant Measure resistance between contacts 31 (SV.2) and 18 (SV.19). Rtarget = 0 Ω.
4.
Measure resistance between the –conductor of the release switch (M) and earth. Rtarget = 0 Ω.
Voith. Trouble Shooting
47
7. Other switches and warning lights
7.4 Faulty component: Gearshift inhibitor switch
Electronic control unit E 200
Rtarget = 0 Ω 69
Ω
Connecting cable
Ω $%6,&+
Rtarget = 0 or ∞ Ω Cable 2
69
P
P
Ω
+ 24V
0
0
0
0
Rtarget = 0 Ω
0
Gearshift inhibitor switch
Step 1.
Open connector SV.2. SV.2 Measure resistance between contact 35 (cable 2) and vehicle earth. Switch open (service brake released): Rtarget = ∞ Ω. Switch closed (service brake applied): Rtarget = 0 Ω.
Pins or contacts
3.
Open SV.19. SV.19; variant Measure resistance between contacts 35 (SV.2) and 20 (SV.19). Rtarget = 0 Ω.
Voith. Trouble Shooting
Measure resistance between contact 35 and the conductor to the gearshift inhibitor switch. Rtarget = 0 Ω. If R = Rtarget continue with step 4.
Measure resistance between the –conductor of the gearshift inhibitor switch (M) and earth. Rtarget = 0 Ω.
2.
4.
48
Activity and location
7. Other switches and warning lights
7.5 Faulty component: ANS activation switch
Electronic control unit E 200
Rtarget = 0 Ω 69
Ω
Connecting cable
Ω Rtarget = 0 or ∞ Ω
%6
cable 2
3
3
69
Ω
+ 24V
0
Step 1.
0
0
0
Rtarget = 0 Ω
0
ANS activation switch
Activity and location Open connector SV.2. SV.2 Measure resistance between contact 12 (cable 2) and vehicle earth. Switch open (service brake released): Rtarget = ∞ Ω. Switch closed (service brake applied): Rtarget = 0 Ω.
Pins or contacts
2.
Measure resistance between contact 12 and the conductor to the EK disengagement switch. Rtarget = 0 Ω. If R = Rtarget continue with step 4.
3.
Open SV.19. SV.19; variant Measure resistance between contacts 12 (SV.2) and 21 (SV.19). Rtarget = 0 Ω.
4.
Measure resistance between the –conductor of the ANS activation switch (M) and earth. Rtarget = 0 Ω.
Voith. Trouble Shooting
49
7. Other switches and warning lights
50
Voith. Trouble Shooting
$BCMFTBOEQMVHT 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 -
Voith. Trouble Shooting
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
Voith. Trouble Shooting
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
Voith. Trouble Shooting
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
Voith. Trouble Shooting
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
X
View X; plug enlarged
7 000
450
/.
View Y; SV.31; plug enlarged
Y
Voith. Trouble Shooting
55
8. Cables and plugs
56
Voith. Trouble Shooting
"QQFOEJDFT 1 Circuit diagram DIWA.3 1 Circuit diagram DIWA.3E
Voith. Trouble Shooting
57
9. Appendices
58
Voith. Trouble Shooting
5
+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
E
S2
F
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
[
+HB
7
1 1 1
6 5 4
-UB HBC HBB HBA +HB
244 226 207 208
3 2 1
1 2 3 4 5 6 7 8
[
HBC HBB HBA +HB
2
3
0 0 0 1
0 0 1 1
0 1 1 1
1 1 1 1
-UB HBC HBB HBA +HB
244 226 207 208
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
235 253 217 236
237 255 219
-UB
22 40
-UB
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
21 39 3
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
2
1
K 30 86
-UB WP -UB RBK PB -UB TB PA
50e 50f D+
U
D-
Y Z
0
85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
+UZ -UB DIAGN-K DIAGN-L
G
150
217 237 236
sw CAN-H ge CAN-M CAN-L
-
ϑ
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
ABS
H
P
P
I
J
/
141 124 105
1 2
7 8 3 6 4 5 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
EK
ws sw
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
ws sw
+ -
n1
PB
DKR DKE DKV/PWM
+ 24V
3 4
DK
R
inactive
+
85 87 87a
.
G
1
2
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
3
1 2 3 4 5 6 7 8 9
Q
X
T VW
M
L
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
*
4
0
W
1
gn/ge bl sw br
S
0
S1 S2 S3 +V +R RS +TS +TL /N -UB
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
204 219
M
\
FB1 KD KD
EK -UB
5
6
V
216
]
221.2
off
HBA
1 2 3 4 5 6 7 8
0 0 1
+
HBC
HBC HBA +HB
+
8
\
-UB
1 20 38 2
L M N
O P Q
R S T U
rt
2
1 2 4 3 1 2 4 3 1 2 4 3 1 2
1
A B
C D
E F
G H
148 10 9 8 7 6 5 4 3 2 1
1
135 137 119 102 103 121 117 120 101 118
'
128 146
147 111
110 129
152 153
$
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
2 1
br
br ge gn bl
bl
2 4 3 1
ws sw
n3
ws sw
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
1
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 Central warning light 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
5
+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
E
S2
F
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
] [
HBA
+HB
1 2 3 4 5 6 7 8
\
0 0 1
7
1 1 1
6 5 4
-UB HBC HBB HBA +HB
244 226 207 208
]
221.2
+
HBC
HBC HBA +HB
3 2 1
+
8
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
1
2
3
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
K
2
1
KD +UZ FB1 FB3 +FB FB2
240 249 202 211
0 85 87 87a
30 86
85 87 87a
30 86
85 87 87a
30 86
O
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 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
30 86
TS+ TS-UB
' -UB -UB
RBK PB -UB TB WP
30 86
+UZ -UB DIAGN-K DIAGN-L
U
Y Z
G
150
R
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 ABS
G inactive
+ 24V
H
P
P
I
J
/
117 153 135 152 7 8 3 6 4 5 1 2 148 111 147 129 110 146 128
9 10
124 105 141
103 121 102 120 101
(
1 2 8 10
217 237 236
sw CAN-H ge CAN-M CAN-L
+
) 1
2 3 4
141 124 105
+LG LGM -LG
ϑ
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
1 2
+ -
ws sw ws sw
n1
4 3 2 1
A B
C D
E F
G H
J K L MN P R S T U V WX Y Z a b c d e f g h j
bl bl bl bl
ws sw
n3
ws sw
-
.
137 118
19
SK
sw ge bl rt
DK
sw ge bl rt
EK
sw ge bl rt
PB
sw ge bl rt
85 87 87a
D+
119
204 219 240 249 202 211
10
off
50e 50f D+
X
D-
on
61
IO9 LGM -LG +LG IO3
dN
85 87 87a
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
P
dR
85 87 87a
1 2 3 4 5 6 7 8 9
C B A
N dW
204 219 240 249 202 211
3
CAN-H CAN-M CAN-L
M
L
dS
30 86
T VW W
REA0 RBG -UB
35 53 17 36 54 18 CAN-L 37 dNEUTR 55
237
Q S
-UB
*
4
gn/ge bl sw br
M
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
5
6
V
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
1
135 137 119 102 103 121 117 120 101 118
'
128 146
110 129
147 111
152 153
$
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
1
br
br ge gn bl
2
n2 sw
WR bl
br ge gn bl br ge gn bl
br ge gn bl
br ge gn bl
br
bl
1
2 4 3 1
rt
sw ge bl rt
TB
sw 2
1
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 Central warning light 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 Alexanderstraße 2 D-89522 Heidenheim Telephone(07321) 37-0 Telefax (07321) 37 7618
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