Operating Instructions DIWA Transmission DIWA.6, DIWA.5, DIWA.3E, DIWA.3

Voith Turbo
Operating Instructions DIWA Transmission

DIWA.6, DIWA.5, DIWA.3E, DIWA.3
150.00321911_EN
2013-05-02
Translation of the original Operation Manual

Keep for future use!
Preface
These operating instructions are directed at the drivers and the operator of buses which are equipped
with Voith automatic transmissions.
Please read the information summarised for you in these operating instructions before you get behind
the wheel of the vehicle. You will received important notes about vehicle operation that allow you to
take full advantage of the technical benefits of the Voith automatic transmission. In addition, you will
receive important information about safety, responsibility of the driver and economical driving, which
serve the purposes of operational and traffic safety as well as an efficient and ecologically-friendly
operation of your vehicle.
These operating instructions describe all equipment that Voith offers for the automatic transmission.
Please understand that they also contain information about equipment variants that you may not have
in your vehicle. Possible differences are easy to trace since all optional equipment is marked with an
asterisk (*).
As the driver, you always bear full responsibility for the traffic safety and safe operation of the vehicle.
Copyright
The copyright for this manual remains with Voith Turbo. The specifications and drawings it contains
may not be duplicated, either in whole or in part, disseminated, or used without authorisation for
competitive purposes or communicated to other people. ©2013
Document change history
Revision No. Prepared by Date Reason for revision/contents of revision
2.0 KaSg-arattk 2013-01-11 DIWA.6 added

Manufacturer
Voith Turbo GmbH & Co. KG
Alexanderstrasse 2
D-89522 Heidenheim
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 1-1

1.1.1 Symbols and signs in the text 1-1
Chapter 2 Driving instruction 2-1
2.1 Starting the engine 2-1
2.2 Blink codes 2-3
2.3 Drive forward 2-7
2.4 Braking 2-15
2.5 Stopping 2-20
2.6 ANS activation 2-21
2013-05-02 I
Table of Contents Voith Turbo
2.7 Limp home function for DIWA.5 and DIWA.6* 2-22
2.8 Driving in reverse 2-23
2.9 Stopping 2-26
2.10 Towing 2-27
2.11 Environmental information 2-29
II 2013-05-02
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

Operating Instructions DIWA Transmission - DIWA.6, DIWA.5, DIWA.3E, DIWA.3
1.1.1 Symbols and signs in the text
Symbol Insert Explanation

KaSg-arattk - TeXML v.turbo-latex-121214b - 2013-05-02
Ö Action instruction Step

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
©2013 Voith Turbo GmbH & Co. KG
machine or accidents.
Please pay special –
attention!
• Listing with two stages Listings do not imply any activities
–
Tab. 1-1 Symbols in the text 1/3
2013-05-02 1-1
About this Manual / Symbols and signs Voith Turbo
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.

Hazard ...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.
1-2 2013-05-02
Voith Turbo About this Manual / Symbols and signs
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.

2013-05-02 1-3
1-4
About this Manual / Symbols and signs
2013-05-02
Voith Turbo

Voith Turbo Driving instruction
2 Driving instruction
2.1 Starting the engine
CAUTION
Danger of damaging the vehicle.
Secure the vehicle.

Ö Apply the parking brake.
When starting the engine, the gear range selector must be in the neutral position.
Ö Press the N button on the gear range selector
2BDnn002
Fig. 2-1 Starting the engine -- neutral position
2013-05-02 2-1
Driving instruction / Starting the engine Voith Turbo
The N button lights up.
Ö Ignition on.

2BDnn001

Fig. 2-2 Starting the engine

2-2 2013-05-02
Voith Turbo Driving instruction / Blink codes
2.2 Blink codes

Through the blinking of the gear range selector lamps, the driver is made aware of an error. The
various blink codes provide information about the type and priority of the error.
',:$( ZLWK ( ',:$ ',:$

Error type Blink duration Blinking buttons Blink frequency Action/remedy
on the blink switch
CAN error Until ignition off All 1x per second Limp home function
(Î Page 2-22, Chap-
CAN connection be-
ter 2.7)
tween gear range
selector and transmis- Contact Voith customer
sion control device is service.

interrupted.
2013-05-02 2-3
Driving instruction / Blink codes Voith Turbo

on the blink switch
Severe error 10 seconds All 2x per second Stop the vehicle imme-
The roadworthiness diately.
and/or safety are im- Bring vehicle to the
paired workshop immediately.

• Transmission may Towing (Î Page 2-27,
switch to the neutral Chapter 2.10)
position
• Driving to the work-

shop is possible but
the functions might
be restricted.

Severe error Until ignition off All 2x per second Stop the vehicle imme-
A serious error has diately.
occurred that impairs Bring vehicle to the
the safety. workshop.
Transmission switches Towing (Î Page 2-27,
to the neutral position. Chapter 2.10)
2-4 2013-05-02
Voith Turbo Driving instruction / Blink codes

on the blink switch
Note Until ignition off N button 1x per second Further driving is pos-
The transmission is or error or over sible, but there may
operated outside of temperature no be limitations on the
the optimal range, longer present retarder
e.g. with increased oil

temperature
The transmission As long as button Pressed button 1x per second Drive forward
control unit refuses pressed or until (Î Page 2-7,
to accept the gear gear is accepted Chapter Fig. 2-3).

2013-05-02 2-5
Driving instruction / Blink codes Voith Turbo
',:$ DQG ',:$( ZLWK (

Cause Effect Gear range Transmission Central warning
selector active oil temperature lamp (if present)
button warning lamp
Operating error No gear accepted Lamp off Lamp off Lamp off
Severe error Transmission in neutral posi- Permanent blink- – Permanent blink-

tion Further driving is possible ing ing
after ignition off/on or after
pressing the N button and
engaging the gear again.

Slight fault Further driving is possible Blinking for 10 – Permanent blink-
but the functions might be seconds ing
restricted.
Over temperature Further driving is possible with – Lamp on –

indicator limitations, limited retarder
operation
Ignition on Transmission electronics are Lamp on Lamp on for 3 Lamp on for 3
being initialised. seconds, then off seconds, then off
2-6 2013-05-02
Voith Turbo Driving instruction / Drive forward
2.3 Drive forward

2BDnn003
Fig. 2-3 Drive forward
If your vehicle is equipped with a safeguard against undesired engaging of the gears, you must first
activate this safeguard, e.g. step on the brake pedal.
1. Please inform yourself about the functioning of the gear safeguard * in the operating instructions
for the vehicle.
2. Step on the brake pedal.
2013-05-02 2-7
Driving instruction / Drive forward Voith Turbo

2BDnn004
3. When the vehicle is at a standstill and the motor is idling, press the D button until it snaps in

audibly.

2BDnn005
4. Now release the brake.

The vehicle starts to drive.
2-8 2013-05-02
The vehicle does not start to drive

Possible causes:
When applying a gear, gas was given.
The gear release was not activated
Ö Please inform yourself about this in the operating instructions for the vehicle.
DANGER
D button does not snap in audibly
If the D button does not snap in audibly, this means that it is not pressed
completely, then no forward gear can be accepted. This can cause rolling
back on slopes, stopping of the vehicle in dangerous places and thus

accidents.
Ö When pressing the D button, always make sure that it is pressed all the
way and that it snaps in audibly.
2013-05-02 2-9
WARNING
Pressing the N button while driving!
If, while the vehicle is driving, the N button is pressed and then another
forward gear is applied, there is danger of blocking the drive wheels.
Furthermore, the engine and transmission can be damaged severely.

Ö While driving, only press the N button in absolute
emergency situations.

2-10 2013-05-02
WARNING
Starting forward on inclines!
The vehicle can roll backwards unintentionally.

Ö Press the D button all the way until it snaps in audibly.

Ö When starting to drive on a hill, give some gas before releasing the
brake so that the vehicle does not roll backwards.
Ö If the vehicle nevertheless rolls backwards unintentionally, it must be
braked immediately with the foot brake.

Ö Depending on the incline on which the vehicle is located, if may be
necessary to use the hand brake to start forward on the hill.
Optimising fuel consumption

Accelerate by pressing the accelerator all the way down to the desired final speed. Next, drive shortly
before reaching the final speed in the partial load range, that is, not at full throttle and with no kickdown.
This has a positive effect on the fuel consumption.
2013-05-02 2-11
Driving in kickdown*

2BDnn006

Fig. 2-6 Driving in kickdown
If a greater acceleration is required, press the accelerator to full throttle and keep pressing.

The transmission then shifts only at higher speeds.
Driving in kickdown
increases the fuel consumption.
2-12 2013-05-02
Driving while pressing the button 1, 2 or 3 down*

2BDnn007
Fig. 2-7 Driving while pressing the button 1, 2 or 3 down
The vehicle can be equipped with a 6-gear range selector. The buttons 1, 2 and 3 are gear blocking
buttons.
With a simultaneous selection of several buttons, the smallest gear blocking button is selected; for
example, with a simultaneous selection of the buttons 1, 2, 3 and D, the button 1 is active.
When button 1, 2 or 3 is pressed, shifting to the next gear is blocked.

Pressing the button No upshift to the gear/the gears
3 4
2 3 and 4
1 2, 3 and 4
2013-05-02 2-13
Driving while pressing the button 1, 2 or 3 down

increases the fuel consumption.
The blocking buttons 1, 2 and 3 are used only with repeated gear hunting on inclines to prevent a
shift up or when driving on incline stretches to prevent a shift up in order to be able to better use the
braking of the engine. In normal driving operation, the use of the blocking buttons 1, 2 and 3 does not

make any sense.
WARNING

Incomplete pressing of one of the blocking buttons
If a blocking button is not pressed all the way through until it snaps in
audibly, then all other buttons are unlocked and the transmission shifts to

neutral.
Ö Always press blocking buttons all the way through until they snap in
audibly.
2-14 2013-05-02
Voith Turbo Driving instruction / Braking
2.4 Braking
2BDnn008
Fig. 2-8 Braking
When activating the brake pedal or the retarder manual switch, the retarder is switched on. With
further pressing of the brake pedal, the service brake takes effect.
2013-05-02 2-15
Driving instruction / Braking Voith Turbo

2BDnn004
Fig. 2-9 Braking with the brake pedal

2BDnn009
Fig. 2-10 Braking with retarder manual switch
2-16 2013-05-02
Retarder regulation for DIWA.3E, DIWA.5 and DIWA.6
DANGER
Reduction of the braking power of the retarder due to high oil temperatures
when braking!
With high oil temperatures in the retarder (DIWA.5/DIWA.6) or in the sump,

(DIWA.3E, DIWA.5 and DIWA.6) the control unit automatically regulates
the retarder, that is, the braking effect of the retarder is reduced. This
operating state is indicated on the display of your vehicle.
Ö Please inform yourself about the display of this operating state in the
operating instructions for the vehicle.
If you have activated the retarder via the manual switch for the retarder:
Ö When this indicator appears, activate the brake pedal in order to also
activate the service brake.
2013-05-02 2-17
Driving instruction / Braking Voith Turbo
Slippery road
DANGER
Danger of loss of control over the vehicle!
When braking on a slippery road, heed that the retarder only affects the

drive wheels.
With vehicles without ABS, in poor street conditions such as ice, snow, sand
or gravel, you must switch off the retarder in order to prevent a blocking of
the rear wheels and thus a possible loss of control over the vehicle.

Ö Switch the retarder off with the off switch for the retarder, if present.
Off switch for the retarder

With the off switch for the retarder, the activation of the retarder on the brake pedal is switched off.
Depending on the vehicle type, with activated switch off for the retarder:
• when activating the retarder manual switch, the retarder is activated nevertheless
• when activating the retarder manual switch, the retarder is not activated.
Ö Please inform yourself about the functioning of the off switch for the retarder in the operating
instructions for the vehicle.
2-18 2013-05-02
ABS
Vehicles with ABS
For vehicles with ABS, the off switch for the retarder is usually not present since with activated ABS,
the retarder is deactivated automatically.
Please inform yourself about the position and operation of this switch in the operating instructions for
the vehicle.
2013-05-02 2-19
Driving instruction / Stopping Voith Turbo
2.5 Stopping

2BDnn010

Fig. 2-11 Stopping
1. For a short stop (traffic light, bus stop), leave the gear selection button pressed.

2. Stop the vehicle with the service or bus stop brake in order to activate the ANS (Î Page 2-21,
2.6)
2-20 2013-05-02
Voith Turbo Driving instruction / ANS activation
2.6 ANS activation

This means:
Automatic neutral position on standstill.
Despite the driving level set, the transmission goes into the neutral position if the following conditions
are fulfilled:
• The gas pedal is in idle position

• A brake signal is pending

• The speed of the vehicle is < 1 km/h
• A forward gear is applied.
The power flow between engine and transmission is interrupted.

This saves fuel.
2013-05-02 2-21
Driving instruction / Limp home function for DIWA.5 and DIWA.6* Voith Turbo
2.7 Limp home function for DIWA.5 and DIWA.6*

Your vehicle can be equipped with a switch for emergency operation, the limp home switch. The
emergency operation is only active if the gear range selector is defective.
Ö Please inform yourself about the position of this switch in the operating instructions for the vehicle.
For vehicles without limp home function, no driving is possible in case of a defective gear
range selector.

The limp home switch has three positions (neutral, forwards and reverse). It is activated as soon as
there are no signals emitted by the gear range selector.
After activation, the limp home switch must first be put into the neutral position for safety reasons. Only
then can it fulfil its function. From the neutral position, it is possible to shift to emergency operation

forwards (1st and 2nd gear) and emergency operation reverse.

2-22 2013-05-02
Voith Turbo Driving instruction / Driving in reverse
2.8 Driving in reverse
Ö Press the R button on the gear range selector.

2BDnn011
Fig. 2-12 Driving in reverse
DANGER
Danger of accident!
Ö When driving in reverse, heed the valid legal regulations of the country
in question.
2013-05-02 2-23
Driving instruction / Driving in reverse Voith Turbo
If your vehicle is equipped with a safeguard against undesired engaging of the gears, you must first
activate this safeguard.
Ö Please inform yourself about the functioning of the gear safeguard * in the operating instructions
for the vehicle.

2-24 2013-05-02
Voith Turbo Driving instruction / Driving in reverse
Shifting
Shifting from forward to reverse or vice versa is only possible after the N button.
1. Press the N button.

2. When the vehicle is at a standstill and the motor is idling, press the R button.
DANGER
Danger of accident!
Ö Never press the reverse gear button while driving forward.

2013-05-02 2-25
Driving instruction / Stopping Voith Turbo
2.9 Stopping
For a longer stop or to stop the engine:
1. Press the N button.

2BDnn002
Fig. 2-13 Stopping

2. Apply the parking brake.

2BDnn012
Fig. 2-14 Stopping
2-26 2013-05-02
Voith Turbo Driving instruction / Towing
2.10 Towing
2BDnn013
Fig. 2-15 Towing
1. Shift the transmission to idle position (N button).

2. Unplug the connecting cable between control and transmission from the control unit.
3. If the transmission is damaged: dismount the cardan shaft or stub shaft of the rear axle.
If no transmission damage is detected, the vehicle can also be towed with the cardan shaft:
• max. permissible distance: 10 km

• max. permissible speed: 30 km/h
2013-05-02 2-27
Driving instruction / Towing Voith Turbo
Angle drives
For transmissions with angle drives it is in any case necessary to remove the cardan shaft or stub
shaft of the rear axle.
Ö If this is not possible, please contact Voith customer service.

2-28 2013-05-02
Voith Turbo Driving instruction / Environmental information
2.11 Environmental information
Shift programs
Thanks to optimal shift programs, you can achieve optimal fuel consumption with the use of the DIWA
transmission.
Avoid driving in kickdown and while pressing buttons 1, 2 or 3 since this increases the fuel consump-
tion.
Retarder
Thanks to the use of the retarder, the life span of the service brake is increased by 2 to 3 times.
The off switch for the retarder should not be activated during normal street conditions.
Oil
The disposal effort and the environmental damage due to used oil are reduced sharply through the
use of oils with longer oil change intervals.
For the approved oils for Voith DIWA transmissions, see the lubricant lists H55.6335XX and
H55.6336XX
2013-05-02 2-29
Voith Turbo GmbH & Co. KG
Alexanderstrasse 2
D-89522 Heidenheim
+49 7321 37 0
+49 7321 37 7618
service-diwa@voith.com
www.voithturbo.com

Operating Instructions DIWA Transmission DIWA.6, DIWA.5, DIWA.3E, DIWA.3

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Operating Instructions DIWA Transmission DIWA.6, DIWA.5, DIWA.3E, DIWA.3

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Voith Turbo

Operating Instructions DIWA Transmission

Translation of the original Operation Manual

2.0 KaSg-arattk 2013-01-11 DIWA.6 added

1.1 Symbols and signs 1-1

Chapter 2 Driving instruction 2-1

2.1 Starting the engine 2-1

2.2 Blink codes 2-3

2.3 Drive forward 2-7

2.4 Braking 2-15

2.5 Stopping 2-20

2.6 ANS activation 2-21

2.7 Limp home function for DIWA.5 and DIWA.6* 2-22

2.8 Driving in reverse 2-23

2.9 Stopping 2-26

2.10 Towing 2-27

2.11 Environmental information 2-29

1 About this Manual

1.1 Symbols and signs

1.1.1 Symbols and signs in the text

Symbol Insert Explanation

Ö Action instruction Step

Symbol Insert Explanation

Î Cross-reference References to pictures, tables, other chapters or other

Operating Instructions DIWA Transmission - DIWA.6, DIWA.5, DIWA.3E, DIWA.3

KaSg-arattk - TeXML v.turbo-latex-121214b - 2013-05-02

©2013 Voith Turbo GmbH & Co. KG

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

Tab. 1-1 Symbols in the text 2/3

Symbol Insert Explanation

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

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

Tab. 1-1 Symbols in the text 3/3

©2013 Voith Turbo GmbH & Co. KG

Danger of damaging the vehicle.

Secure the vehicle.

Ö Apply the parking brake.

Ö Press the N button on the gear range selector

The N button lights up.

Operating Instructions DIWA Transmission - DIWA.6, DIWA.5, DIWA.3E, DIWA.3

KaSg-arattk - TeXML v.turbo-latex-121214b - 2013-05-02

©2013 Voith Turbo GmbH & Co. KG

2.2 Blink codes

',:$( ZLWK ( ',:$ ',:$

sion control device is service.

Error type Blink duration Blinking buttons Blink frequency Action/remedy

Operating Instructions DIWA Transmission - DIWA.6, DIWA.5, DIWA.3E, DIWA.3

KaSg-arattk - TeXML v.turbo-latex-121214b - 2013-05-02

©2013 Voith Turbo GmbH & Co. KG

Error type Blink duration Blinking buttons Blink frequency Action/remedy

e.g. with increased oil

to accept the gear gear is accepted Chapter Fig. 2-3).

',:$ DQG ',:$( ZLWK (

Severe error Transmission in neutral posi- Permanent blink- – Permanent blink-

Operating Instructions DIWA Transmission - DIWA.6, DIWA.5, DIWA.3E, DIWA.3

KaSg-arattk - TeXML v.turbo-latex-121214b - 2013-05-02

©2013 Voith Turbo GmbH & Co. KG

2.3 Drive forward

Fig. 2-3 Drive forward

Operating Instructions DIWA Transmission - DIWA.6, DIWA.5, DIWA.3E, DIWA.3

Fig. 2-4 Drive forward

KaSg-arattk - TeXML v.turbo-latex-121214b - 2013-05-02

©2013 Voith Turbo GmbH & Co. KG

',:$( ZLWK ( ',:$ ',:$

',:$ DQG ',:$( ZLWK (