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RepAnleitungVoithDIWA3 E
RepAnleitungVoithDIWA3 E
DIWA Transmissions
D 851.3E / D 863.3E
D 854.3E / D 864.3E
© 2002
Changes
The version of the documentation is noted on the cover sheet.
When revising the document, the number of version is increased of 1.
Changes are listed in the following table:
You are responsible for familiarizing yourself with the warning notes and precautionary meas-
ures described in these instructions.
However, these instructions only contain the most important information. It is not
possible to include all conceivable faults and hazardous circumstances.
Therefore, everybody who performs repairs or maintenance work must very carefully make sure
that his own personal safety and the safety of other persons is not endangered.
Symbol
DANGER!
This symbol warns of an immidiate threat to the life and health of persons.
Ignoring the instruction may result in severe injury or may even be fatal.
NOTE:
This symbol stands for information about the proper use of the Diwa transmission.
It does not imply any imminent danger.
ENVIRONMENT
This symbol warns of possible damage to the environment caused by operation, mainte-
nance, or repair of the transmission.
The instructions in the repair manual are based on the assumption that the design and function
of the DIWA transmission are known. Pertinent explanations are found in the ”Technical Manual
55.6357. ..“.
To ensure perfect operation of the transmission it is essential that the oil filter and oil is changed
after at least 5,000 km, when the transmission was overhauled or a service exchange unit was
installed.
During general overhauls of the transmission, the ball, roller and needle bearings of the
transmission must be checked and all sealing elements, hoses, inner friction discs and other
wear parts replaced.
Immerse inner friction discs in oil before installation.
Check TB inner discs and all outer discs for wear. Replace if overheated and/or deformed.
Very dirty transmissions must be cleaned prior to disassembly to keep out foreign objects (chips,
sand, etc.).
All parts including the heat exchanger must be cleaned and blown out carefully after disassem-
bly.
Cleanliness must be ensured when the transmission is assembled.
When replacing larger components, make sure they are carefully attached to the hoists and se-
cured.
Check running faces of piston rings for grooves and polish out light scores, if required.
Expand inside piston rings before installation.
Generally install piston rings with the groove toward the oil side.
Grease all sliding faces of piston rings and O-rings.
Oil or grease sliding surfaces of shaft seals.
Do not open circlips more than necessary when installing.
Do not remove or install inductive pick-ups using a slugging wrench.
NOTE: When removing the transmission from the vehicle, observe the instructions of the
vehicle’s manufacturer. This handbook does not contain instructions on removal of the
transmissions from the vehicle.
If the transmission is removed after an longer operating time (approx. 400,000 km or more),
check of Hydrodamp, chapter 3.2.
Rework, modifications and design improvements that should be taken into account in transmis-
sion overhauls are described in the ”Service Bulletins“.
Work must be carried out properly to prevent damage to parts and tools.
In case of malfunctions, the NOTEs and instructions in the brochures ”Diagnostic Manual
55.6264. ..“ and ”Fault Finding 55.6303. ..“ should be consulted first.
Towing
NOTE: Please pay attention to the following in order to avoid damage to the DIWA trans-
mission during towing.
Shift transmission to neutral and disconnect the electrical connector at the transmission
or electronic control unit.
If the transmission is damaged, remove the cardan shaft or stub shaft of the rear axle.If
transmission damage is not present, the vehicle may also be towed with the cardan shaft
installed, however, at most for a distance of 10 km. Allowed maximum speed: 30 km/h.
If the transmission has an angle drive, the cardan shaft or stub shaft must be removed in
any case.
Special issues must be observed for railroad vehicles, e.g. that the reversing axle gearbox
is shifted to neutral.
Observe instructions by the vehicle manufacturer.
NOTE: If a transmission is stored after repair without a test run, corrosion protection will
be required.
All transmission parts must be treated with ATF during assembly.
See also Voith’s List of Lubricants 55.6335..., 55.6336... .
DANGER! If oil leaks because the piping, seals or O-rings are not properly installed or
have become leaky over time, accidents may occur.
Persons who already attended a Voith repair training course for DIWA transmission.
Untrained staff may only work on the DIWA transmission in the presence of an experiencer per-
son.
3-speed
4-speed
Contents ..............................................................................................................................1
1 Tools ..............................................................................................................................3
1.1 Standard Tools .................................................................................................... 3
1.2 Special Tools .................................................................................................... 4-7
1.3 Auxiliary Tools ............................................................................................... 8-10
Screwdriver bit
B-K 5x11 Voith part no. 02.0111.86
K-5 long Voith part no. 02.0078.20
B-K 6x11 Voith part no. 02.0111.87
B-K 8x11 Voith part no. 02.0111.88
B-K 10x11 Voith part no. 02.0111.89
B-K 12x11 Voith part no. 02.0111.90
Manufactured from
M16x100 DIN 933
Welded
30x30
M10x350
Hardened
10
14 Pliers DIN 5254-A40-gl
15 5 R
8 2.
2.5 5
20°
16
Ø2.5
15
5 Hard-soldered
13.1+0.1
Hard-soldered
5.5
10
7
8
3
2.5
9.5
13
1.5
Ø 3.2
R
3
4
1x45° Ø 2.5°
1x45°
5X45°
5
10
17
9 14.5 Hard-soldered
13.2 18.5
17
Ø 60 Ø 73
100
100
90
90
Ø 52 Ø 62
Ø 84,5
Ø 60
Ø 41
130
120
10
16
Ø 76
5 8
5
2 x 30°
Ø 21,9
Ø 27,9
Ø 68,5
Ø 40
Ø 60
Ø 80
R 1,5
25
2 x 45° 2 x 30°
41
54
1
Ø 27,9
Ø 34
Ø 60
15 16
3.1 Hydrodamp
Handling
NOTE: The Hydrodamp has been manufactured to close inside tolerances. External dam-
age may result in failure of the damper.
Important note for handling, storage and replacement: Do not lay down the Hydrodamp on
its hub.
For transportation, storage up to installation and sending back, the Hydrodamp must re-
main in its original Voith packing.
If oil traces are visible in the hub area, check the oil level.
To facilitate removal:
Remove 2 opposite bolts M10 from the ou-
ter pitch circle of Hydrodamp (3/2) and re-
place them by studs (3/1, length 100 mm).
Remove remaining 10 bolts from the outer
pitch circle but do not remove the short
hex. bolts of the damper.
Then force off the damper by means of
forcing bolts (special tool no. 2).
If the intermediate ring, if installed, comes
loose from the flywheel centring socket,
push the ring back.
3
3
Cable 1
Cable 2
5
Example:
standard variant.
one-piece two-piece
One-piece:
Unscrew 12 hex. bolts M8 (8/1) of control
unit cover (8/2) and remove it.
2 1 Remove gasket underneath.
8
3-speed
10
4-speed
11
2
1 5
12
13
14
15
17
18
19
20
Remove RG-TB disc carrier (21/1) from
the transmission.
21
22
23
3-speed
4-speed
27
28
29
30
31
32
33
34
35
3-speed
36
37
4-speed
38
39
3-speed
40
41
42
43
44
45
Remove springs,
spring cups,
bars and
outer discs.
46
47
48
2
49
1
2
50
51
53
4-speed
54
55
56
1
2
57
58
59
60
1
2
61
62
2
64
Remove springs,
spring sockets,
rods, and
guide plates.
65
66
67
1
2
68
69
70
3-speed
2
DANGER! Clips may come loose if
they are incorrectly installed.
74
1
2
75
76
78
79
2
81
82
83
84
85
86
4-speed
88
89
90
92
93
94
Remove rods.
DANGER of blocking!
97
98
3 2 Rod (99/1)
Lock washer(99/2)
Serrated cup washer (99/3)
6 Compression spring (99/4)
Spring sockets (99/5)
Compression spring (99/4)
Spring clip (99/6)
100
102
1
2 Install EK disc carrier (104/1) and deep
groove ball bearing 16012 DIN 625
(104/2) with auxiliary tool no. 2.
3 Bolt disc carrier to EK/DK piston carrier
(104/3) using 12 hex. bolts M10x150-
10.9 and washers B10.5
- 55 Nm.
104
106
107
108
109
110
111
112
3-speed
1 2 3
114
4-speed
116
3-speed
1 2 3
117
118
4-speed
121
4 3 2 1
Inspect deep groove ball bearing
(122/1) and replace it, if necessary.
1 4
123
126
127
Function check:
Close hole (128/1) manually and apply
compressed air max. 2bar to PB piston
via hole (128/2).
1
2
128
129
130
Remove
double ring (131/6),
ring (131/5), and
packing bush (131/4) from shaft.
131
132
133
134
135
136
1
2
137
138
3
2
139
3
140
141
2
3
143
144
145
2
3
146
4
5
147
3
148
149
152
156
3-speed
4-speed
160
3-speed 4-speed
161
3-speed
Install insert (163/1),
washer (163/2),
3 screw plug (163/3) in transmission hous-
ing (fig. 164).
2
NOTE: Tighten screw plug (164/3)
1. at least until it is flush with the hou-
1 sing,
163 2. tightening torque 30 Nm.
164
165
166
168
169
4-speed
171
172
173
2
1
174
176
177
1 11 10 9 8
179
180
2
3
2
182
183
184
186
Secure flange with gasket (187/2) using
3 hex. head bolts M8x30 - 8.8 and spring
washers B8 (187/1) - 23 Nm.
2
1
187
188
189
3-speed
4-speed
194
195
196
197
198
3
4
199
200
Special variant:
Install blocking oscillator (201/1)
- 27 Nm.
201
202
2
203
204
Example: A = 5.5 mm
B = 1.0 mm
206
207
4
208
209
210
211
214
215
1
2
216
217
218
219
221
3-speed
Assemble as follows:
Fix valve block (222/6) using 6 socket-
head bolts M8x50 (222/2).
1 Connect plugs (222/5) to solenoids.
2
3 NOTE: Plugs (222/5) for valve block
(222/6) are marked with black rubber
4
rings or black spiral wrap.
5
Install connecting pipe (222/3) with
2 O-rings 12x2.
6 Fasten valve block (222/1) using 6 so-
cket-head bolts M8x50 (222/2).
Connect plugs (222/4) to solenoids.
222
NOTE: Do not squeeze the cables.
223
1
2
224
4-speed
Assemble as follows:
1 Fix valve block (225/6) using 6 socket-
head bolts M8x50 (225/2).
2 Connect plugs (225/5) to solenoids.
3
NOTE: Plugs (225/5) for valve block
4 (225/6) are marked with black rubber
5 rings or black spiral wrap.
226
227
228
grease
229
230
233
Test point for converter pressure
(233/2):
With an oil temperature toil of about 80-
90 °C, a forward gear engaged, the par-
king brake applied, and the engine idling
(500 ± 50 rev/min), the converter pressu-
re must be at least pW ≥ 2 bar.
234
235
Recommendation: If oil is dirty (caused by parts not being cleaned in a professional man-
ner), the oil and oil filter should be changed.
Voith recommends to change oil and oil filter at the latest 5,000km after a repair.
3-speed
D 851.3E D 863.3E
4-speed
D 854.3E D 864.3E
M4 8.8 3
M4 10.9 4
M5 8.8 5
M5 10.9 8
M6 8.8 9
M6 10.9 14
M8 8.8 23
M8 10.9 33
M 10 8.8 46
M 10 10.9 72
M 10x1 8.8 51
M 10x1 10.9 75
M 12 8.8 78
M 12 10.9 115
Stator M10x35 50 Nm
Tightening torque in Nm
NOTE: For sizes marked * the sealing washer and bolt must be oiled slightly.
In all other cases, the washers and bolts must remain dry.