Maintenance Manual DIWA.6: Voith Turbo

Voith Turbo
Maintenance Manual
DIWA.6
Diagnostic level
150 01050112 ENX
2014-03-19
Translation of the original Operation Manual

Keep for future use!
Document Change History
Revision no. Author Date Reason for revision / contents of revision
2.0 kasg 2013-07-01 Î Page 3-1, Chapter 3.1.3 added

Î Page 3-2, Chapter 3.1.4 new
3.0 kasg 2014-02-19 Î Page 3-1, Chapter 3.1.2 changed
Preface
This manual is intended for the maintenance staff.
The maintenance staff must read, understand and observe the manual. We would like
to point out that we do not assume any liability for damage or operational malfunctions
resulting from non-observance of the manual.
Copyright
The copyright in this manual remains with Voith Turbo. The instructions and drawings
contained herein may neither be reproduced or disseminated nor used or communicated
to others for competitive purposes in whole or in part without authorization.
Manufacturer
Voith Turbo GmbH & Co. KG
Alexanderstrasse 2
89522 Heidenheim
Germany
Tel. +49 73 21 37 0
Fax +49 73 21 37 7618
service-diwa@voith.com
www.voithturbo.com
Voith Turbo Table of Contents
Table of Contents
Chapter 1 About this Manual 1-1
1.1 Symbols and signs in the text 1-1
Chapter 2 Safety 2-1
2.1 Safety instructions for DIWA Transmissions 2-1

2.1.1 General information 2-1
2.1.2 State of the art 2-1
2.1.3 Intended use 2-1
2.1.4 Conditions for usage 2-2
2.1.5 Staff qualification 2-2
2.1.6 Responsibilities 2-2
2.1.7 Unsafe instructions 2-2
2.1.8 Hoisting devices 2-2
2.1.9 Risk of burning 2-2
2.1.10 Risk of accidents caused by oil 2-3
2.1.11 Spare parts 2-3
2.1.12 Work on the transmission 2-3
2.1.13 Cleaning the transmission 2-3
2.1.14 Conversion or modification of the transmission 2-4
2.1.15 Disposal 2-4
2.1.16 Towing 2-4
Chapter 3 Maintenance 3-1
3.1 Maintenance schedule 3-1

3.1.1 Checking the oil level 3-1
3.1.2 Changing oil and oil filters 3-1
3.1.3 General restrictions 3-1
3.1.4 Extension of the oil change intervals for old vehicles 3-2
3.2 Position of the oil dipstick 3-3
3.3 Checking the oil level 3-4
3.4 Draining the transmission oil 3-5

3.4.1 Draining the transmission oil from the oil pan 3-6
3.4.2 Draining oil from the converter 3-7
3.4.3 Closing the oil drain hole 3-8
2014-03-19 I
Voith Turbo Table of Contents
3.5 Draining the transmission oil with the flush module 3-8
3.6 Position of the oil filler hole 3-9

3.6.1 Oil filler lateral 3-9
3.6.2 Oil filler on top 3-9
3.7 Filling the transmission with oil 3-10
3.8 Changing the oil filter 3-11
3.9 Cooling water quality 3-13

3.9.1 Water quality requirements 3-13
3.9.2 Mixing ratio 3-13
2014-03-19 II
Maintenance Manual
Voith Turbo About this Manual
1 About this Manual

This manual uses symbols and characters that help you to find information quickly.
Please read the comments on the symbols in the section below.
Special attention is to be paid to all safety instructions in this manual.
1.1 Symbols and signs in the text

Symbol Use Explanation
Ö Action instruction You have to do something here

1. Action instruction com- Action instructions have to be carried out in the given order.
2. prising several steps Deviations from the given order may cause damage to the
machine or accidents.
Please pay special –
attention!
• Listing with two stages Listings do not imply any activities
–
Î Cross reference References to pictures, tables, other chapters or other
manuals
Note Indicates information about the understanding of the
machine/system or about optimised operational flows.
Environmental Points out a potentially

harmful situation for the environment owing to operation,
maintenance or repair of the transmission.
Problem Indicates a situation that can possibly become dangerous.
Danger ...identifies an immediate threat to a person’s life or health.

DANGER
Warning ...identifies a possibly dangerous situation for a person’s

WARNING
life or health.
Caution ...identifies a possibly dangerous situation for people, slight

CAUTION
injuries are possible.
Notice ...identifies a possibly dangerous situation for components,

NOTICE
property damage is possible.
- - TeXML v.turbo-latex-140225 - 2014-03-19
Tab. 1-1 Symbols in the text

©2014 Voith Turbo GmbH & Co. KG
Maintenance Manual - DIWA.6
2014-03-19 1-1
Maintenance Manual
Voith Turbo Safety
2 Safety
2.1 Safety instructions for DIWA Transmissions
2.1.1 General information

Operation, maintenance and repair of the transmission are always subject to the relevant
local safety and accident prevention regulations.
These regulations can apply to, for example, the handling of hazardous materials, the
provision and wearing of personal protective gear, or motor vehicle regulations.
Anyone operating the transmission or any persons involved in installation, repair or main-
tenance have to familiarize themselves with the warning notes and precautions described
in this document.
Anyone who operates the transmission or who carries out installation, repair or mainte-
nance work has to make sure that his/her personal safety or the safety of other people
is ensured.
2.1.2 State of the art
This transmission is designed and constructed according to the state of the art in technol-
ogy and acknowledged safety regulations. Nevertheless, risks to life and limb of people
or impairment of the transmission or other tangible assets might arise during installation,
repair or maintenance, if:
• the transmission is used improperly,

• the transmission is operated, maintained or repaired by untrained staff,
• the transmission is modified or rebuilt improperly, and/or
• the safety instructions are not observed.
2.1.3 Intended use
The intended use of the DIWA transmission is its application as an automatic transmis-
sion for buses.
Any use other than the one described above is considered improper. Voith Turbo GmbH
& Co. KG does not assume any liability for improper use. The risk lies solely with the
user.
The persons in charge, in particular the staff engaged in operation and maintenance,
must absolutely observe the guidelines for the proper and correct use of the transmission.
2014-03-19 2-1
Maintenance Manual
Voith Turbo Safety / Safety instructions for DIWA Transmissions
2.1.4 Conditions for usage

The transmission must be used only:
• in technically flawless condition,

• according to its prescribed use,
• with safety and risk awareness, observing the technical manual and other technical
documents.
Malfunctions that compromise safety must be eliminated immediately.
2.1.5 Staff qualification

Work on the transmission may only be carried out by staff who have been properly
trained, instructed and authorized by the operator. The statutory minimum age has to
be observed.
Maintenance and repair require special knowledge and training (e.g. Voith diagnostics
and repair training) and may only be carried out by staff qualified accordingly.
Staff that is currently being trained, instructed, introduced to a job or undergoes a general
training, may work on the transmission only under the permanent supervision of a person
assigned for this purpose.
2.1.6 Responsibilities
The responsibilities of the staff for work on the transmission have to be clearly defined
and observed.
Only such staff that is explicitly assigned, authorized and trained for this purpose is al-
lowed to work on the transmission.
Work on running gears, braking or steering systems must be carried out by trained staff
only.
2.1.7 Unsafe instructions
The staff working on the transmission must refuse to carry out unsafe instructions by
third parties.
2.1.8 Hoisting devices
Use only appropriate and technically flawless hoisting devices and load suspension de-
vices with sufficient load capacity.
When replacing the transmission, assemblies or individual parts, these must be carefully
attached to hoisting devices and secured so that they do not present any risk.
Never stay or work under suspended loads.
2.1.9 Risk of burning

The oil can become very hot - in extreme cases up to 130 °C.
Improper handling may cause burns to the skin.

Therefore, let the transmission cool down to approx. 60 °C before changing the oil.
2014-03-19 2-2
Maintenance Manual
2.1.10 Risk of accidents caused by oil

Oil that escapes through lines, gaskets or O-rings which were not installed correctly or
which have become leaky after a longer time in operation can cause accidents.
The oil can be under high pressure in pipes and conduits or in the converter.
Shut off the drive motor before conducting maintenance work or repairs.
2.1.11 Spare parts

Use only original spare parts for repair work since only these can guarantee that the
transmission complies with the road safety regulations and the technical state at delivery.
Always observe the notes in the spare parts catalogue when replacing parts.
Original spare parts are designed especially for the Voith transmission. We would like
to point out that original spare parts which are not supplied by Voith are neither tested
nor approved by Voith. The installation and/or use of non-original spare parts might
adversely affect the specified design characteristics of the transmission and thus com-
promise safety.
In case of any damage due to the use of non-original spare parts, Voith does not assume
any liability.
2.1.12 Work on the transmission

Before maintenance or control work on the installed transmission and during installation
or removal of the transmission, the engine of the bus must be secured against starting.
Prior to performing maintenance or inspection work on the installed transmission and
during installation and removal of the transmission, the bus must be secured in such a
way that it cannot be put in motion, neither deliberately nor accidentally (slope!).
The prescribed service work must be carried out regularly, on time and with the intended
fuels and fluids.
The work must be performed in accordance with the Voith provisions, e.g. the customer
service information describing improvements and modifications to the transmission, so
that no parts and tools take damage.
Work on the transmission requires appropriate service station equipment.
After work has been performed on the transmission, all transmission oil lines must be
checked for leaks, loose connections, chafing and damage. Any defects must be elimi-
nated immediately.
After work on the transmission has been performed, all joints must be checked for leak-
age.
All screwed connections loosened during work on the transmission must be tightened at
the tightening torques specified in the technical documents on the transmission.
After work on installed transmissions, the maintenance flap must be closed again and
secured against unauthorised opening, e.g. by passengers.
2.1.13 Cleaning the transmission

Before cleaning the transmission with water or steam jet (high-pressure cleaner) or other
cleaning agents, any openings into which no water, steam or cleaning agent must ingress
for reasons of safety and functioning must be sealed.

Outside oil hose lines must not be directly exposed to the jet of the high-pressure cleaner.
After cleaning, remove all covers/adhesives completely.
2014-03-19 2-3
Maintenance Manual
2.1.14 Conversion or modification of the transmission

Any modifications, attachments or rebuildings of the transmission must not be imple-
mented without approval by Voith Turbo GmbH & Co. KG.
2.1.15 Disposal
Fluids and auxiliary substances (e.g. used oil) and disassembled parts must be disposed
of in a safe and environmentally sound manner.
The local regulations and laws on environmental protection and disposal of hazardous
materials must be observed.
2.1.16 Towing
Shift the transmission to idle position (N button).

Disconnect the connecting cable between control and transmission from the control unit.
In case of transmission damage: Remove the prop shaft or stub shaft of the rear axle.
If there is no transmission damage, the bus can also be towed by means of the prop
shaft:
• Max. permissible distance: 10 km

• Max. permissible speed: 30 km/h
For transmissions with angle drives it is in any case necessary to remove the prop shaft
or stub shaft of the rear axle.
If this is not possible, please contact the Voith customer service.
2014-03-19 2-4
Maintenance Manual
Voith Turbo Maintenance
3 Maintenance
3.1 Maintenance schedule
3.1.1 Checking the oil level
• monthly
3.1.2 Changing oil and oil filters
After every 60,000 km or after 2 years, whatever occurs first, with the following
requirement:
• Lubricant according to list of lubricants for normal oil change intervals H55.6335xx.
requirement:
• Lubricant according to list of lubricants for extended oil change intervals H55.6336xx,
with oil according to list of lubricants, Section 1.
requirements:
• Initial filling and refilling with lubricant according to list of lubricants for extended oil
change intervals H55.6336xx, with oil according to list of lubricants, Section 2.
• Vehicle weight ≤ 19 t
• Rear axle iA > 5,1
requirements:
• Initial filling and refilling with lubricant according to list of lubricants for extended oil
change intervals H55.6336xx, with oil according to list of lubricants, Section 3.
3.1.3 General restrictions
• Oil change intervals do not apply if internal transmission protection functions are
activated.
• Voith reserves the right to adjust the oil change intervals stated above in individual
cases depending on the usage conditions.
• As a basic requirement for the applicability of the specified oil change intervals, the
cooling system of the vehicle must be regularly maintained and fully functional.
2014-03-19 3-1
Maintenance Manual
Voith Turbo Maintenance / Maintenance schedule
3.1.4 Extension of the oil change intervals for old vehicles

In order to increase the oil change intervals for existing vehicles to 180,000 km, the
following procedures must be adhered to:
• Oil change with Shell Spirax S6 ATF VM Plus.

• Renewed oil change with Shell Spirax ATF VM Plus after elapsing of the previously-
shortened interval.
• Starting with the second oil change with Shell Spirax S6 ATF VM Plus, the interval
can be extended to 180,000 km taking into consideration Chapter 3.1.3.
2014-03-19 3-2
Maintenance Manual
Voith Turbo Maintenance / Position of the oil dipstick
3.2 Position of the oil dipstick
2IBnn511
Fig. 3-1 Oil dipstick lateral
2IBnn512
Fig. 3-2 Oil dipstick on top

2014-03-19 3-3
Maintenance Manual
Voith Turbo Maintenance / Checking the oil level
3.3 Checking the oil level
1. Place the vehicle in horizontal position.

2. Apply the parking brake.
3. Press the N button.
NOTICE
Damage to the transmission due to missing oil
If the engine is started when there is no oil in the transmission yet, e.g. after repair
of the transmission, severe damage to the transmission might ensue.
Ö After repair of the transmission, check the oil level when the engine is not running.
Ö If there is an insufficient quantity or no oil at all in the transmission: Fill in oil.
Measuring conditions
In order to determine the correct value for operating conditions, the oil level must be
checked when the engine is running and the operating temperature (at least 60 °C) has
been reached.
the transmission oil temperature, you can use the cooling water temperature indicator
inside the vehicle, since the temperature of the transmission oil is almost identical to the
temperature of the cooling water.
1. Start the engine.

2. Let the engine idle.
If the transmission oil temperature is below 60 °C:
3. Let the engine warm up to operating temperature.
max.
min.
2BAnn513
Fig. 3-3 Oil dipstick

4. Pull out the oil dipstick.

5. Clean the oil dipstick.
The oil dipstick can be located to the side or on top of the transmission.
2014-03-19 3-4
Maintenance Manual
Voith Turbo Maintenance / Draining the transmission oil
6. Insert the oil dipstick briefly and pull it out again.

7. Read the oil level.
The oil level must lie between the "min" and "max" markings of the oil dipstick.
The difference in amount between the two markings is approx. 2.5 l.
8. If there is insufficient oil in the transmission, refill some oil.
3.4 Draining the transmission oil
WARNING
Risk of scalding due hot oil!
Direct skin contact with the hot transmission oil can cause
severe scalds.
Ö Take appropriate safety precautions when handling hot

oil.
1. Shut off the engine.

2. Check the transmission oil temperature.
3. If the transmission oil temperature is below 60 °C, let the engine warm up to operating
temperature.
The oil must only be drained at operating temperature (at least 60 °C) because otherwise
there would remain too much residual oil in the transmission.
To determine the transmission oil temperature, you can use the cooling water tempera-
ture indicator inside the vehicle, since the temperature of the transmission oil is almost
identical to the temperature of the cooling water.
Environmental hazard due to oil!

The used oil must not leak out to the environment.
Collect the oil in an appropriate container.
Any oil must be disposed of in compliance with the respective local and state regulations
2014-03-19 3-5
Maintenance Manual
3.4.1 Draining the transmission oil from the oil pan
2BAnn140
Fig. 3-4 Drain plug of the oil pan
1 Drain plug of the oil pan
Procedure
1. Loosen and remove the drain plug of the oil pan (1).
Use a hexagon socket wrench of size 12.
2. Drain the transmission oil.
2014-03-19 3-6
Maintenance Manual
3.4.2 Draining oil from the converter
The drain plug of the converter (2) is accessible via the oil drain hole of the oil pan (1).
2BAnn141
Fig. 3-5 Drain plug of the converter
1 Oil drain hole of the oil pan 2 Drain plug of the converter
Procedure
1. Loosen and remove the drain plug for the oil in the converter (2).
Use a hexagon socket wrench of size 12.
2. Drain the converter oil.
2014-03-19 3-7
Maintenance Manual
Voith Turbo Maintenance / Draining the transmission oil with the flush module
3.4.3 Closing the oil drain hole
1. Screw in the drain plug of the converter (2) with a new copper sealing ring 14 x 20.
2. Tighten the drain plug.
Tightening torque 50 Nm.
3. Screw in the drain plug of the oil pan (1) with a new copper sealing ring 26 x 34.
4. Tighten the drain plug.
3.5 Draining the transmission oil with the flush module
2BAnn142
Fig. 3-6
If there is a quick-drain valve (1) on the oil pan, then while emptying the oil pan the oil in
the converter must be drained into the oil pan using the flush module.
With the flush module, the oil in the converter can be drained into the oil pan with the
touch of a button without having to unscrew the converter drain plug (Î flush module
operating instructions 150.00383610).
To drain the transmission oil using the quick-drain valve see the documentation of the
system manufacturer VIVA SYSTÈME.
2014-03-19 3-8
Maintenance Manual
Voith Turbo Maintenance / Position of the oil filler hole
3.6 Position of the oil filler hole
3.6.1 Oil filler lateral
2IBnn514
Fig. 3-7 Oil filler lateral
3.6.2 Oil filler on top

2IBnn515
Fig. 3-8 Oil filler on top
2014-03-19 3-9
Maintenance Manual
Voith Turbo Maintenance / Filling the transmission with oil
3.7 Filling the transmission with oil
NOTICE
Damage to the transmission due to incorrect oil level!
Insufficient oil can lead to transmission malfunctions and cause damage (disk dam-
age).
Excess oil can cause increased fuel consumption and may result in oil leakage at the
air breather filter.
Ö It is imperative to check the transmission oil level before starting the engine for
the first time after the transmission has been installed.
Ö Fill ATF oil into the transmission.

The oil filler can be located laterally or on top of the transmission.
Oil quantity
• For an oil change: 24 - 25 l.

• For a complete refill, e.g. after repair of the transmission: approx. 31 l.
• If oil was filled at the manufacturing plant, no additional oil filling is required.
• After short operation of the transmission, the oil level must be checked again
(Î Page 3-4, Chapter 3.3) and corrected, if necessary.
The oil level must range between the "min" and "max" markings of the oil dipstick.
Oil quality
The transmission may only be filled with oil types that are specified in the current version
of the Voith lubricant lists H55.6335.. and H55.6336..
Ö Check the oil level after having filled in the oil and examine the transmission for leaks.
2014-03-19 3-10
Maintenance Manual
Voith Turbo Maintenance / Changing the oil filter
3.8 Changing the oil filter
WARNING
Risk of scalding due hot oil!
When unscrewing the oil filter cover, a small quantity of

transmission oil leaks out, which can be very hot.
Direct skin contact with the hot transmission oil can cause
severe scalds.
Ö Take appropriate safety precautions when handling hot

oil.
For changing the oil filter of DIWA.6, the transmission oil does not have to be drained.
Environmental hazard due to oil!

The used oil must not leak out to the environment.
Collect the oil in an appropriate container.
Any oil must be disposed of in compliance with the respective local and state regulations.
2BAnn516
Fig. 3-9 Oil filter cover
Ö Remove the soiled oil filter.

Degree of oil filter soiling

If the used oil filter is very dirty, this is an indicator of advanced wear of the transmission
components.
In this case, the transmission should be checked by a Voith service technician.
2014-03-19 3-11
Maintenance Manual
Voith Turbo Maintenance / Changing the oil filter
NOTICE
Wrong oil filter
It is possible to install a DIWA.3E oil filter into a DIWA.6 transmission. Both housings
have the same fitting for accommodating the oil filter.
Ö It must be ensured that the oil filter for the DIWA.6 is mounted.
If a DIWA.3E filter is mounted in a DIWA.6 transmission:

– there will be no filter effect anymore.
– a pressure loss might occur in the transmission.
The material number for the servicing kit with DIWA.6 oil filter is 151.003837XX.
previous design new design
1 2 2
2BAen517
Fig. 3-10 Difference between the DIWA.3E and DIWA.6 oil filter
1 DIWA.3E oil filter 2 DIWA.6 oil filter

1. Install a new oil filter.

2. Screw in the oil filter cover with a new sealing ring.

3. Tighten the oil filter cover.
2014-03-19 3-12
Maintenance Manual
Voith Turbo Maintenance / Cooling water quality
3.9 Cooling water quality
NOTICE
Damage to the heat exchanger through improper antifreeze and anticorrosive agents.
The heat exchanger might corrode and become leaky.
Ö Only use cooling water with a quality corresponding to the specifications below.
3.9.1 Water quality requirements
• No floating particles (especially with CU content) in the water

• Pure, completely demineralised water
• pH-value 6.5 t 8 at 20°C
• Chloride content max. 75 mg/l
• Sulphate content max. 50 mg/l
• Water hardness 3 to 10 °dH (German degrees of hardness)
• Nitrate content max. 50 mg/l
• Nitrite content 0 mg/l
Drinking water is suitable in most cases.
3.9.2 Mixing ratio
• Water ≤ 64%
• Antifreezer ≥ 35%
• Anticorrosive 1%
Ö Use ethylene-glycol based antifreezer.

2014-03-19 3-13
Voith Turbo GmbH & Co. KG
Alexanderstrasse 2
89522 Heidenheim
Germany
+49 7321 37 0
+49 7321 37 7618
service-diwa@voith.com
www.voithturbo.com

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Voith Turbo

Translation of the original Operation Manual

2.0 kasg 2013-07-01 Î Page 3-1, Chapter 3.1.3 added

1.1 Symbols and signs in the text 1-1

Chapter 2 Safety 2-1

2.1 Safety instructions for DIWA Transmissions 2-1

Chapter 3 Maintenance 3-1

3.1 Maintenance schedule 3-1

3.2 Position of the oil dipstick 3-3

3.3 Checking the oil level 3-4

3.4 Draining the transmission oil 3-5

3.6 Position of the oil ﬁller hole 3-9

3.7 Filling the transmission with oil 3-10

3.8 Changing the oil ﬁlter 3-11

3.9 Cooling water quality 3-13

1 About this Manual

1.1 Symbols and signs in the text

Ö Action instruction You have to do something here

Environmental Points out a potentially

Problem Indicates a situation that can possibly become dangerous.

Danger ...identiﬁes an immediate threat to a person’s life or health.

Warning ...identiﬁes a possibly dangerous situation for a person’s

Caution ...identiﬁes a possibly dangerous situation for people, slight

Notice ...identiﬁes a possibly dangerous situation for components,

Tab. 1-1 Symbols in the text

2.1.1 General information

2.1.2 State of the art

• the transmission is used improperly,

2.1.3 Intended use

2.1.4 Conditions for usage

• in technically ﬂawless condition,

Malfunctions that compromise safety must be eliminated immediately.

2.1.5 Staff qualiﬁcation

2.1.7 Unsafe instructions

2.1.8 Hoisting devices

2.1.9 Risk of burning

Improper handling may cause burns to the skin.

2.1.10 Risk of accidents caused by oil

2.1.11 Spare parts

2.1.12 Work on the transmission

2.1.13 Cleaning the transmission

for reasons of safety and functioning must be sealed.

2.1.14 Conversion or modiﬁcation of the transmission

Shift the transmission to idle position (N button).

• Max. permissible distance: 10 km

3.1.1 Checking the oil level

3.1.2 Changing oil and oil ﬁlters

3.1.3 General restrictions

3.1.4 Extension of the oil change intervals for old vehicles

• Oil change with Shell Spirax S6 ATF VM Plus.

3.2 Position of the oil dipstick

Fig. 3-1 Oil dipstick lateral

Fig. 3-2 Oil dipstick on top

3.3 Checking the oil level

1. Place the vehicle in horizontal position.

1. Start the engine.

Fig. 3-3 Oil dipstick

If a DIWA.3E ﬁlter is mounted in a DIWA.6 transmission:

Tightening torque 25 Nm.

Drinking water is suitable in most cases.