RepAnleitungVoithDIWA3 E [PDF]

Zitiervorschau

Repair Manual DIWA Transmissions D 851.3E / D 863.3E D 854.3E / D 864.3E

Voith. Repair Manual DIWA.3E 55.6704.13 / 2003-01 © by Voith Turbo 2002

Copyright This document is protected by copyright. All rights reserved. All types of copying and distributing, including partially and for other purposes than those agreed - especially that of further commercial or private use are forbidden and will be prosecuted. © 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:

Version

Date

Changes

55.6704.12

02-12

Included page describing changes.

55.6704.13

03-01

Output flange Bolted connection 3x M10x50-10.9 : tightening torque changed from 67 Nm to 72 Nm.

Important Notes You are responsible for familiarizing yourself with the warning notes and precautionary measures 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. This document describes the transmission as originally delivered. Subject to change due to technical progress.

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, maintenance, or repair of the transmission.

Voith. Repair Manual DIWA.3E

I

Notes on Safety at Work and Product Safety Only genuine Voith parts may be used! 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 disassembly. Cleanliness must be ensured when the transmission is assembled. When replacing larger components, make sure they are carefully attached to the hoists and secured. Storage and useful life of heat exchanger hoses: Even if stored properly and under permissible stress, hoses and hose lines are subject to natural ageing. This also limits their useful lives. DIN 20066 recommends: the useful life of a hose line, including its storage time, should not exceed 6 years. 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 transmission overhauls are described in the ”Service Bulletins“. Work must be carried out properly to prevent damage to parts and tools. Voith recommends always replacing all the parts printed in bold-italics. All the other parts must be examined individually and replaced when necessary.

II

Voith. Reparaturanleitung DIWA.3E

Malfunctions 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 transmission 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... .

Consequences of coolant or oil loss, treatment of used oil DANGER! If oil leaks because the piping, seals or O-rings are not properly installed or have become leaky over time, accidents may occur.

Disposal of used oil ENVIRONMENT: Do not pollute the environment with oil or coolant! Used oil must be disposed of in accordance with applicable laws. Do not contaminate earth or sewers.

Who is allowed to repair Only trained automobile mechanics or workers with similar skills. 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 person.

Voith. Repair Manual DIWA.3E

III

IV

Voith. Repair Manual DIWA.3E

Differences between 3 and 4-Speed Transmissions Externally, the two variants can be distinguished by an intermediate housing between cover and body on the input drive side.

Most parts of the transmission variants are identical. Where this is not so the difference is marked by symbols in the illustrations and text. See illustrations for 3-speed and 4-speed version.

D 851.3 / D 863.3: 3-speed transmissions

3-speed

D 854.3 / D 864.3: 4-speed transmissions

4-speed

Voith. Repair Manual DIWA.3E

V

VI

Voith. Repair Manual DIWA.3E

Contents Page Important Notes ....................................................................................................................I Differences between 3 and 4-Speed Transmissions ....................................................... V Contents ..............................................................................................................................1 1

Tools ..............................................................................................................................3 1.1 Standard Tools .................................................................................................... 3 1.2 Special Tools .................................................................................................... 4-7 1.3 Auxiliary Tools ............................................................................................... 8-10

2

Transmission Removal ..............................................................................................11

3

Removal of Torsional Vibration Damper ..................................................................12 3.1 Hydrodamp .........................................................................................................12 3.2 Check of Hydrodamp Hub for Wear....................................................................13

4

Removal of Electronic Control Unit .........................................................................15

5

Removal of Assemblies from Transmission..........................................................17 5.1 Heat Exchanger .................................................................................................17 5.2 Valve Blocks ................................................................................................. 18-19 5.3 Cable Harness ....................................................................................................20 5.4 Output Drive........................................................................................................21 5.5 Turbine Gear, Stator and Turbine Wheel...................................................... 22-23 5.6 Input Drive ..........................................................................................................24 5.7 Suction Strainer ..................................................................................................25 5.8 Gear Pump .........................................................................................................25 5.9 Converter Drain Valve ........................................................................................26 5.10 Working Pressure Valve .....................................................................................26 5.11 Oil Filter ..............................................................................................................27 5.12 Impeller Brake............................................................................................... 28-30

6

Dismantling and Assembly of Subassemlies...........................................................31 6.1 Disassembly of Input Differential .................................................................. 31-40 6.2 Disassembly of Planet Gear Carriers .................................................................41 6.3 Assembly of Planet Gear Carriers ......................................................................41 6.4 Assembly of Input Differential ....................................................................... 42-54 6.5 Disassembly of Impeller Brake ..................................................................... 55-57 6.6 Assembly of Impeller Brake .......................................................................... 58-61 6.7 Disassembly of Stator and Turbine Wheel .........................................................62 6.8 Assembly of Stator and Turbine Wheel ....................................................... 63-64 6.9 Disassembly of Turbine Gear ....................................................................... 65-66 6.10 Assembly of Turbine Gear ..................................................................................67 6.11 Disassembly of Output Drive and Reverse Gear.......................................... 68-69 6.12 Disassembly and Assembly of Working Pressure Valve ....................................70 6.13 Disassembly of Gear Pump with Inductive Pick-up N1.......................................71 6.14 Assembly of Gear Pump with Inductive Pick-up N1 ..........................................72 6.15 Disassembly and Assembly of Converter Drain Valve .......................................73 6.16 Disassembly and Assembly of Valve Blocks ............................................... 74-76

Voith. Repair Manual DIWA.3E

1

Page 7

Installation of Assemblies in Transmission ............................................................ 77 7.1 Impeller Brake............................................................................................... 77-80 7.2 Working Pressure Valve .................................................................................... 81 7.3 Converter Drain Valve........................................................................................ 81 7.4 Oil Filter.............................................................................................................. 82 7.5 Valve Plate......................................................................................................... 83 7.6 Gear Pump......................................................................................................... 83 7.7 Suction Strainer ................................................................................................. 84 7.8 Input Drive.......................................................................................................... 85 7.9 Stator and Turbine Wheel .................................................................................. 86 7.10 Turbine Gear................................................................................................. 87-88 7.11 Reverse Gear in Output Drive............................................................................ 89 7.12 Measurement and Adjustment of Disc Clearance for Reverse Gear ................. 90 7.13 Output Drive ................................................................................................. 91-93 7.14 Inductive Pick-Ups ............................................................................................. 94 7.15 Cable Harness ................................................................................................... 94 7.16 Valve Blocks ................................................................................................. 95-96 7.17 Installation Examples for Heat Exchanger ......................................................... 97

8

Installation of Transmission in the Vehicle ............................................................. 98 8.1 Bolt Hydrodamp to Engine Flywheel.................................................................. 98 8.2 Installing the Transmission ................................................................................ 99

9

Checks ...................................................................................................................... 100 9.1. Check of Working Pressure and Converter Pressure .............................. 100-101 9.2 Further Checks ............................................................................................... 101

10 Transmission Weights............................................................................................. 103 11 Tightening Torques.................................................................................................. 105

2

Voith. Repair Manual DIWA.3E

1 Tools 1.1 Standard Tools Bit holder Voith part no. 02.0112.04

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

Torque wrench 0 - 150 Nm

Forcing bolt 2x M6 Forcing bolt 2x M8 Forcing bolt 2x M12

Voith part no. 50.0677.10 Voith part no. 50.0682.10 Voith part no. 50.0684.10

Circlip pliers for inner circlips Pliers J1 Circlip 8 - 25 mm dia. J2 19 - 60 mm dia. J3 40 - 100 mm dia.

Circlip pliers for outer circlips Pliers A1 Circlip 10 - 25 mm dia. A2 19 - 60 mm dia. A3 40 - 100 mm dia.

Voith. Repair Manual DIWA.3E

3

1 Tools

1.2 Special Tools The following special tools are required for disassembly and assembly. You can make them yourself, or you may order them from Voith - see following sketches. Special tool no.1 Extractor for input cover Voith part no. 58.2736.11

Manufactured from M16x100 DIN 933

Welded 30x30

Special tool no. 2 Forcing bolt M10 Voith part no. 58.2740.10

M10x350 Hardened

Special tool no. 3 Tool for removal and installation of spring clips. Voith part no. 50.7692.10

4

Voith. Repair Manual DIWA.3E

1 Tools Special tool no. 4 Screwdriver with socket wrench Voith part no. 59.0842.10

Lock washer B 8 DIN 127

Special tool no. 5 for removing the plugs from solenoids. Voith part no. 68.1535.10

M4x10 DIN 912-10.9

Length approx. 150

Voith. Repair Manual DIWA.3E

5

1 Tools Special tool no. 6 for removing the plugs from the cable harness, inductive pick-up N1, and temperature sensor. Voith part no. 68.1534.10

10

Pliers DIN 5254-A40-gl

14

Pliers DIN 5254-A40-gl

Ø2.5

16

5 2.

20°

5 2.5

R

15 8

15 13.1+0.1

5

Hard-soldered

Screwdriver DIN 5265-C-A0.5x3 Point removed

Special tool no. 7 for installing plugs on inductive pick-ups. Voith part no. 68.1532.10

Hard-soldered

8

7 10

5.5

R

1.5

3

8

Ø 3.2

13

9.5

2.5

3

Special tool no. 8 for installing plugs on cable harness, inductive pick-up N1, and temperature sensor. Voith part no. 68.1533.10 Pliers DIN 5256-C40-gl

5

4 Ø 2.5° 5X45°

17 10

1x45°

1x45°

14.5

9 13.2 17

6

18.5

Voith. Repair Manual DIWA.3E

Hard-soldered

1 Tools Special tool no. 9 for installing the shaft seal of the output drive cover. Voith part no. 64.1436.10

Special tool no. 10 for installing the shaft seal of the input drive cover. Voith part no. 64.1437.10

Voith. Repair Manual DIWA.3E

7

1 Tools

1.3 Auxiliary Tools These tools are not available from Voith. Auxiliary tool no. 1 Sleeve for mounting the input shaft bearing

Auxiliary tool no. 2 Sleeve for mounting the EK disc carrier bearing Ø 73

90

90

100

100

Ø 60

Ø 52

Auxiliary tool no. 3 Sleeve for mounting the turbine gear clutch and pump brake bearings

Ø 62

Auxiliary tool no. 4 Disc for forcing off the ring gear of input differential

120

130

Ø 41

Ø 60

Ø 84,5

10 16

Ø 76

8

Voith. Repair Manual DIWA.3E

1 Tools Auxiliary tool no. 6 for installing the needle bushings in the gear pump.

R 1,5

2 x 45°

2 x 30°

8

5

Ø 40

Ø 60 Ø 68,5 Ø 80

5

2 x 30°

Ø 21,9 Ø 27,9

Auxiliary tool no. 5 for installing the inner ring and ball bearing. on the turbine shaft.

25

41 54

Auxiliary tool no. 7 for installing the needle bushing in the gear pump housing.

15

Ø 60

Ø 34

Ø 27,9

1

16

Voith. Repair Manual DIWA.3E

9

10

Voith. Repair Manual DIWA.3E

2 Transmission Removal NOTE: The transmission should not be removed when hot, as the clutch housing centring is under increased pressure due to expansion. DANGER! Apply the parking brake, secure vehicle against rolling. Otherwise, there is a danger of accidents.

1

Press neutral button of push-button switch. Turn off engine: Turn off ignition to prevent damage to the electronics during further work. After that, disconnect the cable from the transmission housing (1/3). Disconnect tachometer cable from the adapter (1/4). Drain off coolant and dispose of it in an environmentally acceptable manner. Open drain plugs (1/6) and (1/7) and drain off transmission oil (approx. 26 litres). Dispose of the oil in an environmentally acceptable manner. DANGER! Hot coolant and/or oil may cause scalding! Suspend the transmission from a crane via suspension lugs. DANGER! Screw in eyebolts completely. Otherwise, they might break. The rope must have a sufficient carrying capacity. Transmission can weigh up to 450 kg! NOTE: If a lifting device is used, tie the transmission to it. All mechanical and electrical connections to the transmission, such as bolts (1/2) and cardan shaft (1/5), as well as coolant pipes and electrical cables must be removed. NOTE: In order to prevent damage to the Hydrodamp, move the transmission out for about 8 cm parallel to the engine until the pinion shaft (1/1) is free, then lower it. When removing the transmission, a small quantity of oil (up to 30 ml are permissible) may escape from the inside of the Hydrodamp seal.

Voith. Repair Manual DIWA.3E

11

3 Removal of Torsional Vibration Damper 3.1 Hydrodamp Handling NOTE: The Hydrodamp has been manufactured to close inside tolerances. External damage 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 remain in its original Voith packing. In case of defects, the Hydrodamp must be replaced complete. If oil traces are visible in the hub area, check the oil level.

Oil level check DANGER! Danger of scalding - do not remove the Hydrodamp while it is hot.

1

2

2

With the damper temperature lower than 50 °C (122 °F), turn the Hydrodamp - or hold it with a vice - so that the inspection holes (2/1 and 2/2) are located vertically one above the other. Wait for about three minutes, then remove the upper screw plug (2/1). Turn Hydrodamp clockwise about the hub axis by approx. 40° - 45°. If oil flows out while doing so, close borehole (2/1) again with a screw plug M10x1 and a new copper seal 10.5x16x2, VGN 3019 (special size, not DIN) using Loctite type 243 - tightening torque: 18 Nm. If no oil comes out, the oil level must have dropped below the minimum permissible quantity. Leaks may be a possible cause. Replace the Hydrodamp.

To facilitate removal: Remove 2 opposite bolts M10 from the outer pitch circle of Hydrodamp (3/2) and replace 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 12

Voith. Repair Manual DIWA.3E

3 Removal of Torsional Vibration Damper

3.2 Check of Hydrodamp Hub for Wear Check the circumferential backlash between drive shaft and hub of the Hydrodamp. Install Hydrodamp on a new shaft. If the circumferential backlash at the pitch circle dia. (approx. 410 mm) is greater than 2 mm, then replace the Hydrodamp completely

4

Voith. Repair Manual DIWA.3E

13

14

Voith. Repair Manual DIWA.3E

4 Removal of Electronic Control Unit For cable 1 and 2: open clamping lever (5/1) and pull off flat pin connector (5/2). Unscrew 4 fastening nuts M6 (5/3).

1 2 3 Cable 1 Cable 2 5

Voith. Repair Manual DIWA.3E

15

16

Voith. Repair Manual DIWA.3E

5 Removal of Assemblies from Transmission 5.1 Heat Exchanger Removal DANGER! Danger of scalding - there may still be hot oil in the heat exchanger. The heat exchanger is installed at various points of the transmission or in a separate location. Example: standard variant.

6

Heat exchanger attached to the output drive side at the bottom.

1

For removing the heat exchanger, first disconnect hoses (7/1, 7/2) and then the heat exchanger (7/3) itself. Screw off mounting plate, if any.

2

3 7

Voith. Repair Manual DIWA.3E

17

5 Removal of Assemblies from Transmission

5.2 Removal of Valve Blocks For one and two-piece covers.

one-piece

2

two-piece

One-piece: Unscrew 12 hex. bolts M8 (8/1) of control unit cover (8/2) and remove it. Remove gasket underneath.

1 8

3-speed Remove cable guard (9/1).

1

9

Pull plugs (10/4) off the solenoids using special tool no. 5 (see fig. 12).

1 2 3 4

NOTE: Do not pull the cables. Undo 12 socket-head bolts M8 (10/2) of valve blocks (10/1, 10/5) and remove the blocks. Remove connecting pipe (10/3).

2 5

10

18

Voith. Repair Manual DIWA.3E

5 Removal of Assemblies from Transmission

4-speed Remove cable guard (11/1).

1

11

Pull plugs (12/4) off the solenoids using special tool no. 5.

Special tool no. 5

1 2 3 4

1

NOTE: Do not pull the cables. Undo 12 socket-head bolts M8 (12/2) of valve blocks (12/1, 12/5) and remove the blocks. Remove connecting pipe (12/3).

2 5

12

Voith. Repair Manual DIWA.3E

19

5 Removal of Assemblies from Transmission

5.3 Removal of Cable Harness Disconnect earth cable (13/1). Open connection for inductive pick-up N1 and temperature sensor using special tool no. 6.

Special tool no. 6

1

13

1 2 3

4

56

Open union nuts (14/3, 14/5, 14/6) and undo 3 socket-head bolts M6 of multi-pin socket (14/7). Screw off cap (14/1) and pull off the contacts from the inductive pick-up N2. Screw out male union (14/2). Undo 3 socket-head bolts M8 of cap (14/4). Pull contacts off inductive pick-up N3. Remove cable harness from the transmission.

7

14

1

Unscrew inductive pick-ups N2 (15/1) and N3 (15/2). Pull 4 tubes (16/3) out of the transmission by using a screw M12.

2 3

15

20

Voith. Repair Manual DIWA.3E

5 Removal of Assemblies from Transmission

5.4 Removal of Output Drive 2

Set up the transmission with the output shaft at the top.

3

DANGER! Secure the transmission against toppling.

1

If the transmission has an angle drive on the output side, remove it - see special Repair Manual for angle drives.

4 5

Unscrew lubricating pipe (16/1). Remove 3 hex. bolts M10 (16/2) of output flange (16/3) and lift off with washer, adjusting discs and O-ring. 16

Unscrew 26 nuts M8 (16/4) of oil pan (16/5) and remove with gasket. NOTE: Oil may still run out.

Unscrew 12 hex. bolts M10 (17/2) of output cover (17/1) and lift off uniformly.

1

DANGER! If the RG planet carrier remaines in the output cover it may drop out when lifting the cover.

2

17

Remove ring gear R (18/1), inner and outer discs R (18/2), and key (18/3).

1

2 3

NOTE: Mark the position of the ring gear so that the same side will be seated during reinstallation.

18

Voith. Repair Manual DIWA.3E

21

5 Removal of Assemblies from Transmission

5.5 Removal of Turbine Gear, Stator and Turbine Wheel Special variant: Remove blocking oscillator (19/1).

1

19

Disconnect hose line (20/2) and male union (20/1).

1 2

20

Remove RG-TB disc carrier (21/1) from the transmission.

1

21

Remove turbine gear (22/1) using special tool no. 2.

Special tool no. 2

NOTE: The planet gear carrier shaft may jam.

1

22 22

Voith. Repair Manual DIWA.3E

5 Removal of Assemblies from Transmission Remove TB friction discs (23/2) and panet gear carrier shaft (23/1).

1 2

23

Undo 4 socket-head bolts M8 (24/5) of abutment ring (24/4). Remove abutment ring with brass disc and disc springs, large disc spring (24/3), and brake piston (24/2). Undo 12 socket-head bolts M8 (24/1), then press off and remove the stator together with the turbine wheel and shaft using special tool no. 2.

1 2 3 4 5

Set the transmission on its output side. 24

NOTE: Provisionally fix the oil pan to the housing with two nuts to protect the pipes.

Voith. Repair Manual DIWA.3E

23

5 Removal of Assemblies from Transmission

5.6 Removal of Input Drive

3-speed Input drive cover "B" (25/1): Undo 12 socket-head bolts M10. Force off cover using special tool no. 2. Remove cover together with input differential (25/2).

1 2

25

Input drive cover "A": Undo 12 socket-head bolts M10 of the connecting flange. Remove the flange. Undo 2 socket-head bolts M10. Force off cover using special tool no. 2. Remove cover together with input differential.

4-speed Input drive cover "B" or "D" (26/1): Undo 12 socket-head bolts M10. Force off cover using special tool no. 2. Remove cover together with input differential (26/2).

1

Remove adaptor housing (26/3).

2

3 26

Input drive cover "A" or "C": Undo 12 socket-head bolts M10 of the connecting flange. Remove the flange. Undo 2 socket-head bolts M10. Force off cover using special tool no. 2. Remove cover together with input differential. Remove adaptor housing (26/3).

24

Voith. Repair Manual DIWA.3E

5 Removal of Assemblies from Transmission

5.7 Removal of Suction Strainer Undo 2 hex. head bolts M10 (27/1) and remove the strainer (27/2).

2 1

27

5.8 Removal of Gear Pump To facilitate removal of the gear pump, unscrew 3 hex. bolts M8 (28/1) and remove the flange (28/2).

2 1

28

Pull out the plug-in tube (29/1).

1

29

NOTE: Remove all pipes. Unscrew 4 hex. bolts M10 (30/1). Remove gear pump (30/2). Pull off plug from inductive pick-up N1.

1 2

30 Voith. Repair Manual DIWA.3E

25

5 Removal of Assemblies from Transmission

5.9 Removal of Converter Drain Valve NOTE: Remove all pipes.

3 2

Unscrew 5 socket-head bolts M6 (31/1). Remove converter drain valve (31/2). Unscrew drain plug for converter oil (31/3).

1 2

1

31

5.10 Removal of Working Pressure Valve NOTE: Remove all pipes. Screw 4 hex. head bolts M8 (32/1) and 3 hex. head bolts M10 (32/2) out of valve plate (32/3). Pull valve plate out of plug-in tubes. Remove plug-in tubes. Remove working pressure valve.

3 2 1

32

26

Voith. Repair Manual DIWA.3E

5 Removal of Assemblies from Transmission

5.11 Removal of Oil Filter Unscrew cover (33/1).

1

33

Remove filter element (34/2).

2 1

34

Unscrew 5 hex. head bolts (35/1). Remove oil filter housing (34/1).

1

35

Voith. Repair Manual DIWA.3E

27

5 Removal of Assemblies from Transmission

5.12 Removal of Impeller Brake

3-speed Unscrew socket-head bolt M10 (36/2), remove and unrivet gear (36/1), press grooved ball bearing and abutment ring (36/3) out of the gear. NOTE: The gear can also be replaced complete.

1 2 3

Remove all pipes and pipe with cable.

36

Unscrew 11 hex. head bolts M10 (37/1). Force off impeller brake (37/2) using special tool no. 2 (figure 39) and remove.

1 2

37

28

Voith. Repair Manual DIWA.3E

5 Removal of Assemblies from Transmission

4-speed Unscrew socket-head bolt M10 (38/3), remove and unrivet gear (38/2), press grooved ball bearing and abutment ring (38/4) out of the gear.

1

NOTE: The gear can also be replaced complete.

2 3 4

Remove all pipes and pipe with cable. Unscrew 11 hex. head bolts M10 (38/1).

38

Remove impeller brake (39/1) using special tool no. 2.

Special tool no. 2

1

39

Voith. Repair Manual DIWA.3E

29

30

Voith. Repair Manual DIWA.3E

6 Dismantling and Assembly of Sub-Assemblies 6.1 Disassembly of Input Differential

3-speed

Remove circlip (40/1).

Special tool no. 2

Pull off input cover from input differential by means of special tools no. 1 and 2.

Special tool no. 1

1

40

Unscrew 12 hex. head bolts (41/2), remove input shaft (41/1). Unscrew 12 hex. head bolts (41/3).

1 2 3

41

Remove circlip (42/3), uniformly force off EK disc carrier (42/2) by means of two bolts M10 (42/1).

1 2 3

42

Voith. Repair Manual DIWA.3E

31

6 Dismantling and Assembly of Sub-Assemblies

Remove EK discs (43/1), planet gear carrier (43/2) with ring gear (43/3) from disc carrier.

1 2 3

43

Tap off DK disc carrier (44/1) using a plastic hammer.

1

44

Lift out DK discs (45/1).

1

45

Special tool no 3

Push off 12 spring clips (46/1) using special tool no. 3.

1

DANGER! The springs are under tension. They may spring off and cause injuries. Remove springs, spring cups, bars and outer discs.

46 32

Voith. Repair Manual DIWA.3E

6 Dismantling and Assembly of Sub-Assemblies

Remove pistons (47/1 and 47/2) from the EK-DK piston carrier and remove piston rings. Remove 4 O-rings (47/3).

1

3

2 47

NOTE: Check oil strainers (48/1) in EK-/DK piston carrier for damage. Replace if necessary.

1

48

Force ring gear (49/1) off planet gear carrier (49/2) using auxiliary tool no. 4 and special tools no. 1 and 2.

Special tool no. 2

NOTE: Spacer ring (49/3) will come off too. Special tool no. 1

3

Auxiliary tool no. 4

1 2 49

Voith. Repair Manual DIWA.3E

33

6 Dismantling and Assembly of Sub-Assemblies

Remove circlip (50/1) and grooved ball bearing (50/2) from ring gear.

1 2

50

Remove snap ring (51/1), supporting disc and driver (51/2) from ring gear.

1 2

51

If bush (52/1) of DK disc carrier is damaged due to wear of piston rings or gear, unscrew 6 socket-head bolts M8 (52/2) and press out bush.

1

The bore of the bush can be re-ground to a dimension of 85.120 mm, the permissible roughness is 1.6 microns.

2

52

To re-insert the bush, heat up the disc carrier to 120 °C (248 °F).

NOTE: Lube hole of bush must be in line with lube hole of DK disc carrier. After the DK disc carrier has cooled down, install inner gear (53/1) and secure with 6 hex. bolts M8x45-10.9 34 Nm.

1

53 34

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6 Dismantling and Assembly of Sub-Assemblies

4-speed Remove circlip (54/1).

Special tool no. 2

Pull off input cover with special tools no. 1 and 2.

Special tool no. 1

1

54

Unscrew 12 hex. bolts M12 (55/2). Lift off input shaft (55/1). Unscrew 12 hex. bolts M10 (55/3).

1 2 3

55

Remove circlip (56/3). Uniformly force off EK disc carrier (56/2) by means of two bolts M12 (56/1).

1

Lift off EK discs.

2 3

56

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6 Dismantling and Assembly of Sub-Assemblies

Special tool no. 2

Lift off ring gear (57/2) with auxiliary tool no. 4 and special tools no. 1 and no. 2.

Special tool no. 1

NOTE: Spacer ring (57/1) will come off too. Lift off complete EK-DK piston carrier (57/3).

Auxiliary tool no. 4

1 2 3 57

Lift off complete planet gear carrier (58/1) together with DK discs (58/2).

1 2

58

Lift off input cover disc (59/1).

1

59

36

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6 Dismantling and Assembly of Sub-Assemblies

NOTE: SK disc carrier is spring-loaded.

1 2

Uniformly unscrew hex. bolts M10 (61/1). Lift off SK disc carrier (60/2).

60

Lift off all SK discs (61/1), springs and spring sockets (61/2).

1 2

61

Take out piston (62/1) and remove piston rings. Remove 6 O-rings (62/2).

62

Voith. Repair Manual DIWA.3E

37

6 Dismantling and Assembly of Sub-Assemblies

Remove snap ring (63/1) from groove of SK planet gear carrier.

1 2 3

If sealing bush (63/2) of SK disc carrier is damaged due to wear of piston rings or gear, unscrew 6 socket-head bolts (63/3) and press out bush. The bore of the bush can be re-ground to a dimension of 85.120 mm, the permissible roughness is 1.6 microns. To re-insert the bush, heat up the disc carrier to 120 °C (248 °F). Install bush and secure with 6 socket-head bolts M8x25-10.9 - 34 Nm

63

Force off SK planet gear carrier (64/2) from disc carrier (64/1) by means of auxiliary tool no. 3 and special tools no. 1 and no. 2.

Special tool no. 2 Special tool no. 1

Auxiliary tool no. 3

1 2 64

38

Voith. Repair Manual DIWA.3E

NOTE: Lube hole of bush must be in line with lube hole of SK disc carrier.

6 Dismantling and Assembly of Sub-Assemblies

Special tool no. 3

Using special tool no. 3, push off 12 spring clips (65/1).

1

DANGER! The springs are under tension. They may spring off and cause injuries. Remove springs, spring sockets, rods, and guide plates.

65

Pull pistons (66/1, 66/2) out of EK/DK piston carrier and remove piston rings. Remove 4 O-rings (66/3).

1

3

2 66

NOTE: Check cylindrical sieves (67/1) on the EK/DK side and at the SK piston carrier for damage and replace, if necessary.

1

67

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6 Dismantling and Assembly of Sub-Assemblies

Remove circlip (68/1) and grooved ball bearing (68/2) from supporting disc.

1 2

68

Remove snap ring (69/1), supporting disc and driver (69/2) from ring gear.

1 2

69

40

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6 Dismantling and Assembly of Sub-Assemblies

6.2 Disassembly of Planet Gear Carriers NOTE: The procedure described here is basically the same for all types of planet gear carriers. Check all parts for wear and replace, if necessary. Remove dowel pin (70/2), axle (70/1), planet gear (70/4), spacer rings (70/3).

1 2 4 3 70

6.3 Assembly of Planet Gear Carriers NOTE: There are different bearing designs depending on the type of differential. The type of differential can be seen from the nameplate. The distinguishing features are:

1 2 3 71

Differential 3: 2 needle roller cages Differential 4: needle roller cage, ring, needle roller cage This also applies to the SK planet gear carrier. Planet gear carrier of turbine gear: 2 needle roller cages Planet gear carrier of reverse gear: 2 needle roller cages Insert oiled needle roller cages into planet gear (71/3). Assemble planet gear with spacer ring (71/2) on both sides. Press axle into the correct position and secure with dowel pin (71/1).

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6 Dismantling and Assembly of Sub-Assemblies

6.4 Assembly of Input Differential

3-speed Insert piston rings into EK and DK pistons (72/1 and 72/2) with the groove facing the oil pressure side.

Oil pressure side

3 1

Grease sliding surfaces in EK/DK piston carrier (72/3). Install both pistons (72/1 and 72/2) in the piston carrier. Make sure they are in the correct position.

2 72

1

Special tool no. 3

NOTE! In principle these instructions apply to the installation of all piston rings. Slightly expand inner piston rings before insertion. Pay attention to possible damage to sliding surfaces. Remachine, if necessary.

Position outer friction disc (73/1) and secure it at two opposing points as follows: spring sockets (73/4), helical springs (73/5), rods (73/3) with spring clips (73/2).

2 DANGER! Clips may come loose if they are incorrectly installed. Hold rods and guide plate and turn piston carrier around.

5

4

Place the other guide plate (73/1), install spring sockets and springs.

3 73

Support rods (73/3), e. g. with a hammer. Using special tool no. 3, compress springs (73/5) and fit clips (73/2). Align the two guide plates. Install remaining rods, spring sockets, helical springs, and spring clips.

42

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6 Dismantling and Assembly of Sub-Assemblies

Install driver and supporting disc (74/2) in ring gear. Secure with snap ring B190 (74/1).

1 2

74

Press grooved ball bearing (75/2) into supporting disc and secure with circlip 95x3 (75/1).

1 2

75

1

2

Install ring gear (76/2) on planet gear carrier (76/3) and press grooved ball bearing onto planet gear carrier using suitable auxiliary tool no. 2.

3

Glue spacer ring (76/1) onto planet gear carrier neck using Loctite 270.

76

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6 Dismantling and Assembly of Sub-Assemblies

Transmission D 851.3E (see nameplate). Install and align 6 EK discs on the ring gear as follows (fig. 77): inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 2.0 mm thick.

77

1

2

Transmission D 863.3E (see nameplate). Install and align 8 EK discs on the ring gear as follows (fig. 77): inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 2.0 mm thick.

Install EK disc carrier (78/3) and grooved ball bearing 16012 DIN 625 (78/1), using auxiliary tool no. 2. Insert circlip (78/2).

3

Turn the assembly around.

78

Install complete EK/DK piston carrier (79/2). Install 4 O-rings 9x2 (79/1) in the piston carrier with grease.

1

2

79 44

Voith. Repair Manual DIWA.3E

6 Dismantling and Assembly of Sub-Assemblies

1

Transmission D 851.3E (see nameplate). Install and align 6 DK discs (80/1) in the EK-DK piston carrier as follows: inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 2.0 mm thick.

2

80

Transmission D 863.3E (see nameplate). Install and align 8 DK discs (80/1) in the EK-DK piston carrier as follows: inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 2.0 mm thick. Install DK disc carrier (80/2) on the assembly, align it with the dowel pin, and fasten. Turn the assembly around Secure EK disc carrier with 12 hex. head bolts M10x150-10.9 and washers B10.5 (81/1) - 55Nm.

1

2 81

1

Check for proper operation: Block off one of the holes (82/1 or 82/2) and blow compressed air into the opposite one. The pistons must move and compress the appropriate clutch packs.

2

NOTE: Air must escape from two relief bores (81/2) opposite each other.

82 Voith. Repair Manual DIWA.3E

45

6 Dismantling and Assembly of Sub-Assemblies

Measuring the input shaft (fig. 83) Measure tooth profile of the shaft at the wear points by means of balls or rollers of dia. 4 mm. If the dimension is less than 53.85 mm, replace the input shaft.

83

Put input shaft (84/1) on the input differential and secure with 12 hex. bolts M12x30-10.9 and spring washers B12 (84/2) - 115 Nm. Fit O-ring 45x2 (84/3) into the groove of the input shaft.

1 3 2

84

Install complete input drive cover (85/1) (with grooved ball bearing 6210C3, circlip 90x3, and shaft seal A60x78x10) on the input shaft using auxiliary tool no.1.

Auxiliary tool no. 1

NOTE: Visible surface of oiled shaft seal (87/2) should be 2 mm lower than the upper edge of the input cover.

1

85

1

2

Grease bush (86/1) on outside and inside and install it. Install circlip 50x2 (86/3).

3

86 46

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6 Dismantling and Assembly of Sub-Assemblies

4-speed Insert piston rings into SK piston (87/2) of SK piston carrier (87/1) with grooves towards the oil pressure side.

Oil pressure side

Grease sliding surfaces in piston carrier and insert piston.

87

NOTE: This procedure applies to all piston rings to be inserted. Expand inner piston rings slightly before insertion. Look for any possible damage to sliding surfaces of pistons and rectify, if necessary. Install 6 O-rings 9x2 (87/3) with grease in piston carrier.

Install snap ring B180 (88/2) on SK disc carrier (88/3). Inspect grooved ball bearing (88/1) and install it.

1 2 3

88

Install SK planet gear carrier (89/1) on the grooved ball bearing.

1

NOTE: Do not jam snap ring (89/2).

DANGER! The planet gear carrier may fall out of the grooved ball bearing when the assembly is turned around. 89

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6 Dismantling and Assembly of Sub-Assemblies

Insert snap ring B180 (90/1) into the groove of the SK planet gear carrier.

1

90

Transmission D 854.3E (see nameplate). Install and align 6 SK discs in the SK piston carrier as follows (fig. 91): outer disc 2.0 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc.

91

Transmission D 864.3E (see nameplate). Install and align 8 SK discs in the SK piston carrier as follows (fig. 91): outer disc 2.0 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc. Install 4 rods (92/1) with helical springs 1.6x8x65 (92/3), spring cups (92/2) and guide plate (92/4), at two points opposite each other.

1 2 3 4

92 48

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6 Dismantling and Assembly of Sub-Assemblies

Install SK piston carrier (93/1) on guide plate. NOTE: Pay attention to the location of the dowel.

1

93

Install remaining springs and spring cups. Fix them with rods (fig. 94). Press SK piston carrier (95/1) down.

94

Uniformly bolt piston carrier (95/1) and disc carrier (95/2) together using 12 hex. head bolts M10x30 - 8.8 and washers B 10.5 (95/3) - 46 Nm.

1

Remove rods. DANGER! The springs are under tension. They may spring off and cause injuries.

3

NOTE: Make sure the friction discs are working smoothly and the SK piston is correctly seated.

2 95

DANGER of blocking!

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6 Dismantling and Assembly of Sub-Assemblies

Place EK/DK planet gear carrier with mounted ring gear (96/1) onto the assembly.

1

96

Transmission D 854.3E (see nameplate). Install and align 6 DK discs in the SK piston carrier as follows (fig. 96): outer disc 2.0 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc. Transmission D 864.3E (see nameplate). Install and align 8 DK discs in the SK piston carrier as follows (fig. 96): outer disc 2.0 mm thick inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc.

Oil pressure side

3 Insert piston rings into EK and DK pistons (97/1 and 97/2) with the groove toward the oil pressure side. Grease sliding surfaces in EK/DK piston carrier (97/3). Install both pistons (97/1 and 97/2) in the piston carrier. Make sure they are correctly positioned.

1

2 97

Grease 4 O-rings 9x2 (98/1) and install them in the piston carrier.

1

98 50

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6 Dismantling and Assembly of Sub-Assemblies

3

2

Rod (99/1) Lock washer(99/2) Serrated cup washer (99/3) Compression spring (99/4) Spring sockets (99/5) Compression spring (99/4) Spring clip (99/6)

6

4

5

4

1 99

5 4 3 2

1

NOTE: Lock washer is secured by serrated cup washer.

Place guide plate (100/1) onto EK/DK piston carrier and assemble in the following order: Rods (100/5) - chamfer on O-ring side, spring sockets (100/2), springs 1.6x8x65 (100/3), and serrated cup washers (100/4). Turn the EK-DK piston carrier around, holding the rods.

100

Special tool no. 3

1 4

2 3

Install outer disc (101/1) and then assemble as follows: Spring sockets (101/2), helical springs (101/3), spring clips (101/4). Support rods (e. g. by putting a hammer underneath). Using special tool no.3, compress helical springs (101/3) and install spring clips (101/4). Align both outer discs.

101

Install remaining rods, spring sockets, helical springs, and spring clips. DANGER! Clips may come loose if incorrectly installed.

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6 Dismantling and Assembly of Sub-Assemblies

Auxiliary tool no. 2

1

Install EK/DK piston carrier (102/2) with guide pin suiting the SK piston carrier (102/3). Install ring gear (102/1) with auxiliary tool no. 2.

2 3

102

Install spacer ring (103/1) with Loctite 270.

1

103

Auxiliary tool no. 2

1 2

104 Voith. Repair Manual DIWA.3E

Transmission D 864.3E (see nameplate). Install and align 8 EK discs in the EK/DK piston carrier as follows (fig. 103): inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 2.0 mm thick.

Install EK disc carrier (104/1) and deep groove ball bearing 16012 DIN 625 (104/2) with auxiliary tool no. 2. Bolt disc carrier to EK/DK piston carrier (104/3) using 12 hex. bolts M10x15010.9 and washers B10.5 - 55 Nm.

3

52

Transmission D 854.3E (see nameplate). Install and align 6 EK discs in the EK/DK piston carrier as follows (fig. 103): inner disc, outer disc 3.5 mm thick, inner disc, outer disc 3.5 mm thick, inner disc, outer disc 2.0 mm thick.

6 Dismantling and Assembly of Sub-Assemblies

Tilt input differential through 90°. DANGER! Prevent differential from rolling away.

1

Knock onto the bearing again until the planet gear carrier abuts. Use auxiliary tool no. 2. Reinstall circlip 60x3 (105/1). 105

Set the input differential up again.

Input shaft measurement (fig. 106) Measure splined profile of the shaft at the wear points by means of balls or rollers of dia. 4 mm. If the dimension is less than 53.85 mm, replace the input shaft.

106

Place input shaft (107/1) onto the input differential and secure with 12 hex. bolts M12x30-10.9 and spring washers B12 (107/2) - 115 Nm. Insert O-ring 45x2 (107/3).

1 3

2

107

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6 Dismantling and Assembly of Sub-Assemblies

Auxiliary tool no. 1

1

Install complete input cover (108/1) (with ball bearing 6210C3, circlip 90x3 and shaft seal A60x78x10) on the input shaft by means of auxiliary tool no. 1. NOTE: Visible surface of oiled shaft seal (109/2) should be 2 mm lower than the upper edge of the input cover.

108

1

2

3

Grease inside and outside of bush (109/1). Install the bush and fit circlip 50x2 (109/3).

109

54

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6 Dismantling and Assembly of Sub-Assemblies

6.5 Disassembly of Impeller Brake

1

Remove circlip (110/1), lift off guide ring (110/2), pump impeller (110/3), and sheet metal disc (110/4).

2 3 4 5

Uniformly unscrew and remove 3 sockethead bolts M8 (110/5). NOTE: Disc carrier is spring-loaded.

110

7 6

1 2 3 4

5

Lift the following parts off one after the other from the piston carrier: thrust plate (111/1), PB discs (111/2), springs (111/3), spring sockets (111/4), guide plate (111/5), sealing ring (111/6), Inner PB disc carrier (111/7).

111

Pull PB piston (112/1) out of the piston carrier using 2 bolts M8. Unscrew 6 socket-head bolts M8 (112/2) and uninstall carrier by means of a plastic hammer or a press.

1 2

112

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6 Dismantling and Assembly of Sub-Assemblies

3-speed

Remove circlip (113/1). Lift piston ring carrier (113/2) off impeller shaft (113/4).

2 1

NOTE: To remove the rectangularsection rings (113/3), press one end in and unhook. 2 bores are provided for removal of the cylindrical roller bearings. Clean all parts thoroughly and inspect them for wear. Replace if necessary.

3 4 113

Remove double ring (114/1), ring (114/2), and sealing bush (114/3) from the impeller shaft.

1

2

3 114

56

Voith. Repair Manual DIWA.3E

6 Dismantling and Assembly of Sub-Assemblies

4-speed

Remove circlip (115/1). Lift piston ring carrier (115/2) off impeller shaft (115/4).

2 1

NOTE: To remove the rectangularsection rings (115/3), press one end in and unhook. 2 bores are provided for removal of the cylindrical roller bearing. Clean all parts thoroughly and inspect them for wear. Replace if necessary.

3 4

115

Remove double ring (116/1), ring (116/2), and rectangular-section ring (116/3) from the impeller shaft.

4

3

2 1

NOTE: If Teflon bush (116/4) is damaged, remove it using a suitable tool.

116

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6 Dismantling and Assembly of Sub-Assemblies

6.6 Assembly of Impeller Brake

3-speed

Insert sealing bush (117/3), ring (117/2), and double ring (117/1) into impeller shaft.

2

1

3 117

Install rectangular-section rings (118/3) in piston ring carrier (118/2). Then slide piston ring carrier over impeller shaft (118/4) while slightly compressing the rectangular-section rings.

2 1

Install circlip (118/1).

3 4 118

4 3

2

1

Inspect grooved ball bearing (119/1). Replace it if necessary. Stick gasket (119/4) on piston ring carrier (119/3) by applying a little grease at some points. Install PB piston carrier (119/2) on piston ring carrier (119/3).

5 119

58

Voith. Repair Manual DIWA.3E

NOTE: Make sure when assembling that the bore holes (119/5) are on the same side.

6 Dismantling and Assembly of Sub-Assemblies

4-speed

Install rectangular-section rings (120/ 3), bush (120/2), and double ring (120/1).

3

4

2 1

NOTE: If Teflon bush (120/4) was removed, press in a new one until it is flush.

120

Insert rectangular-section rings (121/3) into piston ring carrier (121/2). Then slide the piston ring carrier over impeller shaft (121/4) while slightly compressing the rectangular-section rings.

2 1

Install circlip (121/1).

3 4

121

3

4

2

1

Inspect deep groove ball bearing (122/1) and replace it, if necessary. Stick gasket (122/4) to piston ring carrier (122/3).

Install PB piston carrier (122/2) on piston ring carrier (122/3). NOTE: Make sure when assembling that bore holes (122/5) are on the same side.

5 122 Voith. Repair Manual DIWA.3E

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6 Dismantling and Assembly of Sub-Assemblies

Tighten 6 socket-head bolts M8x20-10.9 with washers B8 (123/1) in a criss-cross manner - 33 Nm.

2

NOTE: Grease sliding surfaces of piston rings.

3

Insert piston rings (123/2) into PB piston (123/3) with the groove toward the pressure side and install in PB piston carrier (123/4).

1

4 123

7 6

1 2 3 4

5

124

Insert the following parts into the piston carrier: inner PB disc carrier (124/7), O-ring (124/6) (greased and centred), guide plate (124/5), 10 spring sockets (124/4), 10 helical springs (124/3), 1 inner disc (124/2), 2 outer discs (124/2), 1 inner disc (124/2), thrust plate (124/1). NOTE: Align outer discs with guide plate.

Place PB disc carrier (125/1) on piston carrier.

1

3

2

NOTE: Pay attention to the bore hole of locating pin (125/3) and the spring seats when assembling. Secure disc carrier with 3 socket-head bolts M8x20-10.9 (125/2) - 33 Nm.

125

60

Voith. Repair Manual DIWA.3E

NOTE: Make sure when tightening that the guide tongues can be introduced into the friction discs without jamming.

6 Dismantling and Assembly of Sub-Assemblies

Install the following parts one after the other: Install sheet metal disc (126/4), pump impeller (126/3), guide ring (126/2), and circlip (126/1).

2 3 4

1

NOTE: Do not open circlip more than necessary when installing.

126

Measure end play of pump impeller: If it exceeds 0.1 mm, compensate by fitting a suitable shim (127/1).

1

NOTE: Place shim (127/1) underneath impeller (126/3).

127

Function check: Close hole (128/1) manually and apply compressed air max. 2bar to PB piston via hole (128/2).

1 2

128

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6 Dismantling and Assembly of Sub-Assemblies

6.7 Disassembly of Stator and Turbine Wheel Remove 2 snap rings and circlip (129/1) from turbine wheel (129/2).

1 2 3

Lift off turbine wheel and (129/3) from turbine shaft.

129

NOTE: Do not remove core ring (130/ 1). Replace stator complete in case of damage.

1

130

1 2

3

4

5

6

Press turbine shaft (131/1) out of deep groove ball bearing (131/3) and inner ring (131/2). Remove double ring (131/6), ring (131/5), and packing bush (131/4) from shaft. 131

62

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6 Dismantling and Assembly of Sub-Assemblies

6.8 Assembly of Stator and Turbine Wheel Check that stator bush (132/1) and dowel pin (132/2) are firmly seated.

2 The inner diameter must not be greater than 68.200.

1

132

If the stator bush (133/1) needs to be replaced, see Service Bulletin No. 156.

1

133

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6 Dismantling and Assembly of Sub-Assemblies

1

2 3

4

Install sealing bush (134/2), ring (134/3), and double ring (134/4) in turbine shaft (134/1).

134

1

2

3

Press deep groove ball bearing with installed double ring and inner ring (135/3) onto turbine shaft using auxiliary tool no. 5. Place distance washer (135/1) on ball bearing.

4

135

1 2

136

64

Voith. Repair Manual DIWA.3E

Place stator (136/4) and turbine wheel (136/1) onto turbine shaft and secure by means of circlip A58x2 and two snap rings B73 (136/2).

6 Dismantling and Assembly of Sub-Assemblies

6.9 Disassembly of Turbine Gear Screw out 6 hex. bolts M8 (137/1). Remove double ring (137/2).

1 2

137

Press inner gear (138/1) off planet gear carrier using special tool no. 2. Remove T ring gear (138/2).

Special tool no. 2

1 2 138

Remove spacing plate (139/1), circlip (139/2), and ring (139/3).

1 3 2

139

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6 Dismantling and Assembly of Sub-Assemblies

Uniformly force off retaining ring (140/2) and ball bearing (140/1) from planet gear carrier by means of 2 forcing bolts M8. NOTE: Forcing bolts must not press onto an axle.

1 2 3 140

Inspect deep groove ball bearing (141/1), replace if necessary, and install with Loctite 270.

1

NOTE: Dismantling and assembly of the T planet gear carrier is described in chapters 6.2 and 6.3.

141

66

Voith. Repair Manual DIWA.3E

6 Dismantling and Assembly of Sub-Assemblies

6.10 Assembly of Turbine Gear Place retaining ring (142/1) onto planet gear carrier (142/6) with the recess at the top.

3

4

2 1

Install grooved ball bearing with circlip (142/2) onto the planet gear carrier using auxiliary tool no. 5.

5 6

142

Install spacer ring (142/5), circlip A80x2,5 (142/4), and spacing plate (142/3).

Install inner gear (143/1) on ring gear (143/2). Install double ring (143/3), replace if necessary.

1 2 3

143

Install inner gear with ring gear on the planet gear carrier and secure it using 6 hex. head bolts M8x16-8.8 and spring washers B8 (144/1) - 23 Nm.

1

NOTE: With transmission models R2 the inner gear and ring gear are two pieces (see rating plate).

144

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6 Dismantling and Assembly of Sub-Assemblies

6.11 Disassembly of Output Drive and Reverse Gear Force the R planet gear carrier (145/1) off the output cover (145/2) by means of special tool no. 2.

Special tool no. 2

1 2

145

Remove 6 socket-head bolts (146/1). Force off abutment ring (146/2) by means of 2 forcing bolts M8. Remove disc spring (146/3), brake piston (146/4), and shim behind.

1 2 3 4 146

Remove abutment ring (147/1), ring (147/2), gear rim (147/3), and speedometer drive gear (147/4) from output cover (147/5).

1 2 3 4 5

147

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Voith. Repair Manual DIWA.3E

6 Dismantling and Assembly of Sub-Assemblies

Remove hex. screw (148/3) and speedometer flange (148/2). Remove shaft seal (148/1).

1

NOTE: The reverse gear and output drive are reassembled only after measurement of the reverse gear disc play.

2 3 148

Disassemble, inspect, and reassemble R planet gear carrier (149/1) as described in chapters 6.2 and 6.3.

1 Change rectangular-section rings (149/2).

2

149

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6 Dismantling and Assembly of Sub-Assemblies

6.12 Dismantling and Assembly of Working Pressure Valve Dismantle working pressure valve. NOTE: Do not remove grub screw and hex. nut (150/6) for working pressure. Bracket (150/4) and cover (150/12) are spring-loaded. Check pistons/spools and bores for damage and replace if necessary. NOTE: Pay attention to the installation position and ease of motion of the spools and pistons.

150

151

Install the following parts one after the other: (150/1) housing, (150/2) washer, (150/3) piston, (150/4) bracket, (150/5) 3 socket-head bolts CV84 6x20 - 14 Nm, (150/7) 1 helical spring 3.2x21.0x101 (150/8) 1 helical spring 2.0x15.5x76.5, (150/9) selector piston, (150/10) spool, (150/11) piston with circlip, (150/12) cover, (150/13) 4 hex. bolts M6x45 - 8.8 - 9 Nm 4 spring washers B6

Location of spools/pistons and springs (figure 151).

Install the following parts one after the other: (152/1) valve plate, (152/2) cover, (152/3) 2 socket-head bolts CV84 M6x20 - 14 Nm, (152/4) piston, (152/5) helical spring 3.0x20.0x31.6, (152/6) cover, (152/7) 2 socket-head bolts CV84 M6x20 - 14 Nm. 152

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6 Dismantling and Assembly of Sub-Assemblies

6.13 Disassembly of Gear Pump with Inductive Pick-up N1

153

Remove the following parts one after the other: (153/12) inductive pick-up, (153/1) 7 hex. bolts M8, (153/2) 2 straight pins, (153/3) cover, (153/15) gearwheel, (153/16) gearwheel, (153/14) needle bush (153/18) driver, (153/17) intermediate plate, (153/5) gearwheel, (153/6) hex. nut, (153/7) washer, (153/8) drive gearwheel out of the (154/4) housing by using a copper punch, (153/9) remove cylindrical gear, (153/10, /11) press out needle bushes (153/13) and axle.

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6 Dismantling and Assembly of Sub-Assemblies

6.14 Assembly of Gear Pump with Inductive Pick-up N1 If a new pin (154/13) is installed in housing (154/4) the housing must be heated to 120° C. Press needle bush (154/19) into housing (155/4) using auxiliary tool no. 6. Press needle bush (154/10) into cover (154/3) using auxiliary tool no. 7. Press needle bush (154/11) into gear wheel (154/5) using auxiliary tool no. 6.

154

NOTE: One side of the needle bearing is lettered. It must be up when the bearing is pressed in.

Install the following parts one after the other: (154/9) cylindrical gear, (154/8) gear shaft, (154/7) washer, (154/6) insert hex. nut BM16x1.5 with Loctite 270 - 100 Nm, (154/5) gearwheel, (154/17) intermediate plate, (154/18) driver, (154/16) gearwheel, (154/15) gearwheel, (154/14) needle bush (154/3) cover, (154/2) 2 straight pins 10x40, (154/1) 7 hex. bolts M8x40 - 8.8 - 23 Nm, (154/12) inductive pick-up - 30 Nm.

NOTE: The cover, intermediate plate and housing are marked with the same number and must not be confused.

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6 Dismantling and Assembly of Sub-Assemblies

6.15 Dismantling and Assembly of Converter Drain Valve Dismantle converter drain valve. Check spools/pistions and bores for wear, replace if necessary.

NOTE: Pay attention to the installation position and ease of motion of the spools and pistons.

Tighten all bolts to 10 Nm. 155

Install the following parts one after the other: (155/1) housing, (155/2) plate, (155/13) 2 socket-head bolts M6x50 - 8.8, (155/3) spool, (155/4) cover, (155/11) 3 socket-head bolts M6x16 - 8.8, (155/7) 2 spools, (155/8) 2 helical springs 0.9x10.5x31, (155/9) piston, (155/10) cover (155/11) 2 socket-head bolts M6x16 - 8.8, (155/17) 1 piston, (155/8) 1 helical spring 0.9x10.5x31, (155/16) cover, (155/12) 3 socket-head bolts M6x55 - 8.8, (155/5) piston, (155/6) cover, (155/15) 4 socket-head bolts M6x30 - 8.8.

Location of spools, pistons, and springs (fig. 156).

156

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6 Dismantling and Assembly of Sub-Assemblies

6.16 Dismantling and Assembly of Valve Blocks

3-speed Dismantle valve block. NOTE: Screw WP screw plug M10 (157/23) with sealing washer (157/24) out of housing (157/20). Otherwise the spool (157/26) cannot be removed.

NOTE: Pay attention to the installation position and ease of motion of the spools.

157

158

74

Voith. Repair Manual DIWA.3E

Install the following parts one after the other: (157/31) 4 solenoids (connection at the top), (157/30) 10 socket-head bolts M5x12 -CV84 - 5 Nm, (157/26) spool, (157/25) helical spring 1.7x13x12.7 (157/29) 3 spool, (157/28) 3 control pin, (157/27) 3 helical spring 1.3x12.5x19, (157/22) cover, (157/21) 5 hex. bolts M6x12-8.8 - 9Nm, (157/24) sealing washer, (157/23) screw plug WP M10x1 - 15 Nm.

6 Dismantling and Assembly of Sub-Assemblies

4-speed

Dismantle valve block. NOTE: Screw WP screw plug M10 (160/23) with sealing washer (160/24) out of housing (160/20). Otherwise the spool (160/26) cannot be removed. NOTE: Pay attention to the installation position and ease of motion of the spools.

159

Install the following parts one after the other: (159/31) 5 solenoids (Anschluß nach oben, (159/30) 10 socket-head bolts M5x12 -CV84 - 5 Nm, (159/26) spool, (159/25) helical spring 1.7x13x12.7 (159/29) 4 spool, (159/28) 4 control pin, (159/27) 4 helical spring 1.3x12.5x19, (159/22) cover, (159/21) 5 hex. bolts M6x12-8.8 - 9 Nm, (159/24) sealing washer, (159/23) screw plug WP M10x1 - 15 Nm.

160

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6 Dismantling and Assembly of Sub-Assemblies

3-speed

4-speed Dismantle valve block. NOTE: Screw TB, RG, and WR screw plugs M10 (161/2) with sealing washers (161/3) out of housing (161/1). Otherwise the spools (161/13 and 15) cannot be removed.

161

NOTE: Pay attention to the installation position and ease of motion of the spools.

Install the following parts one after the other: (161/19) solenoids (connection at the top),

162

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Voith. Repair Manual DIWA.3E

(161/18) 8 socket-head bolts M5x12 CV84 - 5Nm, (161/10) insert (note installation position), (161/8) O-rings, (161/9) ball, (161/7) valve body, (161/6) circlip, (161/17) spool, (161/12) control pin, (161/11) helical spring 1.3x12.5x19, (161/13) spool, (161/12) control pin, (161/11) helical spring 1.3x12.5x19, (161/15) 2 spool, (161/14) 2 helical spring 1.7x13.0x12,7, (161/5) cover, (161/4) 4 hex. bolts M6x12-8.8 - 9Nm, (161/3) sealing washers A10x13.5, (161/2) TB, RG and WR screw plugs M10x1 - 15 Nm.

7 Installation of Assemblies in Transmission

3-speed Install insert (163/1), washer (163/2), screw plug (163/3) in transmission housing (fig. 164).

3 2 1 163

NOTE: Tighten screw plug (164/3) 1. at least until it is flush with the housing, 2. tightening torque 30 Nm.

164

7.1 Installation of Impeller Brake Place transmission housing on output side. Expand O-ring 275x2.65 (165/1) a little, grease it and place it in the housing groove.

1

165

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7 Installation of Assemblies in Transmission

Install impeller brake assembly (166/1) by means of special tool no. 2 (fig. 173). Align impeller brake with centring pin.

1 3

Tighten 10 hex. bolts M10x65 - 8.8 - and 10 spring washers B1 (166/2) - 46 Nm. Position (166/3) remains open.

2

166

7 8

6 5

NOTE: Install greased O-rings 12x2 and 29.2x3 to plug-in tubes before installing the tubes.

9 1

Install plug-in tubes (167/7 to 167/9).

2

Fix pipes in this order: pipe with cable (167/1), pipes (167/2, /3, /5, /6), pipe (167/4) with banjo bolt M14x1.5x32 - 38 Nm.

3 NOTE: Install all banjo bolts with copper seals on both sides.

4 167

Fix pipe with cable (168/2) using hex. bolt M8x10 (168/1) - 15 Nm.

1 2

168

1 2 3

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Voith. Repair Manual DIWA.3E

Install deep groove ball bearing in gearwheel (169/3), place discs on both sides and rivet. Install abutment ring (169/1), tighten socket-head bolt M10x30 - 10.9 and spring washer B10x18 (169/2) - 67Nm.

7 Installation of Assemblies in Transmission

4-speed Install insert (170/1), washer (170/2), screw plug (170/3) in transmission housing (fig. 171).

3 2 1 170

NOTE: Tighten screw plug (170/3) 1. at least until it is flush with the housing, 2. tightening torque 30 Nm.

171

Place transmission housing on output side. Expand O-ring 275x2.65 (172/1) a little, grease it and place it in the housing groove.

1

172

Install impeller brake assembly (173/1) by means of special tool no. 2. Align impeller brake with centring pin.

Special tool no. 2

1

173 Voith. Repair Manual DIWA.3E

79

7 Installation of Assemblies in Transmission

Tighten 10 hex. bolts M10x65 - 8.8 - and 10 spring washers B10 (174/1) - 46 Nm. Position (174/2) remains open.

2 1

174

8

NOTE: Place greased O-rings 12x2 or 29.2x3 on plug-in tubes before inserting the tubes.

9 10 11

1 7 6 5

2 3 4 175

Install plug in tubes (175/9 to 175/11) with the thread upward. Install pipes in this order: pipe with cable (175/1), pipes (175/2, /3, /5, /6), tighten 1 hexagon bolt M10x65 - 8.8 with spring washer B10 (175/7) to 46 Nm, pipe (175/4) with banjo bolt M14x1.5x32 - 38 Nm, pipe (175/8) with banjo bolt M16x1.5x28 - 42 Nm. NOTE: Install all banjo bolts with copper seals on both sides.

1 2

Fix pipe with cable (176/2) by means of hex. bolt M8x10 (176/1) - 15 Nm.

176

1 2 3

177 80

Voith. Repair Manual DIWA.3E

Install deep groove ball bearing in gearwheel (177/3), place discs on both sides and rivet. Install abutment ring (177/1), tighten socket-head bolt M10x30 - 10.9 and spring washer A10x18 (177/2) - 67Nm.

7 Installation of Assemblies in Transmission

7.2 Installation of Working Pressure Valve NOTE: Pipe (178/3) is only present from transmission no. 825 408. Refer to fig. 189 for a better overview of the piping.

5 4

Install the following one after the other: Working pressure valve (178/1), plug-in tube (178/2). Connect pipes (178/3, /4, /5) to working pressure valve by means of banjo bolts.

3 2 1 178

7.3 Installation of Converter Drain Valve Proceed in the following order: Secure converter drain valve (179/1) using 5 socket-head bolts M6x40 - 10.9 (179/4) - 14 Nm.

6 7

Connect pipes (179/2, /3, /5, /8, /9, /10,/ 11) to converter drain valve by means of banjo bolts.

5 4

Fix pipe (179/7) to the transmission using hex. bolt M8x10 - 8.8 (179/6) - 23 Nm.

3 2

1

11 10 9

8 179

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7 Installation of Assemblies in Transmission

7.4 Installation of Oil Filter Screw in two auxiliary bolts (180/1) for locating the gasket. Place gasket (180/2) on top of oil filter housing (180/3).

1 2 3

180

Install filter housing (181/1) in the transmission. Install flange and gasket (182/1) and secure with 3 hex. head bolts M8x65-8.8 (182/3).

1

Remove auxiliary bolts (180/1). Fit 2 hex. head bolts M8x65-8.8 (182/2).

2

NOTE: Tighten all hex. head bolts to - 23 Nm. 181

Install plug-in pipe (181/2).

1

2 3

2 182

Insert filter element into filter housing. Secure cover (183/1) SW36 - 25 Nm .

1

183

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7 Installation of Assemblies in Transmission

7.5 Installation of Valve Plate Proceed in the following order: Press valve plate (184/4) onto plug-in tubes. Bolt to working pressure valve using 3 hex. head bolts (184/3) M10x65 - 8.8 - 46 Nm, and 4 hex. head bolts (184/2) M8x60 8.8 - 23 Nm. Tighten drain plug (184/1) for converter oil - 50 Nm.

4 3 2 1

NOTE: Tighten all banjo bolts and screw plugs.

184

7.6 Installation of Gear Pump Connect inductive pick-up N1.

10

1 2

9 2

3 4 5 6 7 8 185

Install gear pump (185/1), fasten with 2 hex. bolts M10x45-8.8 and spring washers B10 (185/2). Fasten strap (185/4) by means of 1 hex. head bolt M10x45 - 8.8 and spring washer B10 (185/3). Install pipe (185/10) with O-ring and secure it by means of 1 hex. head bolt M10x45 - 8.8 and spring washer B10 (185/9). Fasten pipe (185/5) and temperature sensor (185/6) to plate (185/7) using 2 hex. head bolts M10x20 - 8.8 (185/8). NOTE: Tighten all hex. head bolts to - 46 Nm.

1

Insert plug-in tube (186/1) for gear pump.

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

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7 Installation of Assemblies in Transmission

7.7 Installation of Suction Strainer Bolt on suction strainer (188/2) using 2 hex. bolts M10x20 - 8.8 with spring washers B10 (188/1) - 46 Nm.

2 1 188

Fig. 189: Overview of piping

189

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7 Installation of Assemblies in Transmission

7.8 Installation of Input Drive

3-speed

1

2

190

NOTE: Slightly roughen contact areas of gaskets on Transmission housing and adaptor housing. Place gasket onto the transmission housing. Constantly turning the shaft (190/1), lower the input differential (190/2) and align it with the dowel pin. Secure input cover "A" by means of 2 socket-head bolts M10x25 - 46 Nm. Screw tight connection flange with 12 hex. bolts M10x50 - 8.8 with spring washers B10 - 46 Nm. Secure input cover "B" (fig. 190) by means of 13 hex. bolts M10x50 - 8.8 and 13 spring washers B10 - 46 Nm.

4-speed Place gasket onto the transmission housing. Align adaptor housing (191/3) with dowel pin and place on the transmission housing. Place gasket onto intermediate housing. Constantly turning the shaft (191/1), lower the input differential (191/2) and align it with the dowel pin.

1

2 3

NOTE: Make sure the gears of the driveline engage properly. 191

Secure input cover "A" by means of 2 socket-head bolts M10x100 - 46 Nm. Screw tight connection flange with 12 hex. bolts M10x130 - 8.8 with lock washers A10 - 46 Nm. Secure input cover "B" by means of 13 hex. bolts M10x130 - 8.8 and 13 spring washers B10 - 46 Nm.

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7 Installation of Assemblies in Transmission

7.9 Installation of Stator and Turbine Wheel Install stator with turbine wheel and turbine shaft (192/1) in the transmission housing using special tool no. 2.

1

NOTE: The projection on the stator must be aligned with the groove in the housing.

Special tool no. 2 192

Insert throttle with O-ring 12x2 into the hole in the transmission housing (valve block side).

Secure the stator using 12 socket-head bolts M10x35 and washers B10.5 (193/1) - 50 Nm.

1 2 3 4 5

Install piston rings in T brake piston (193/2) with the groove on the pressure side. Install piston.

6

Install disc spring (193/3) and abutment ring (193/4). Screw in 4 socket-head bolts (193/6) M8x30 -10.9 with Loctite 242 - 33 Nm. 193

Install 2 disc springs and 1 brass disc (193/5) in abutment ring. NOTE: Insert disc springs in X configuration.

Insert planet gear carrier shaft (194/1) with double ring (194/2) and introduce into the gearing by turning

1

2

194 86

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7 Installation of Assemblies in Transmission

7.10 Installation of Turbine Gear Special tool no. 2

Install turbine gear (195/1) in the transmission housing by means of special tool no. 2.

1

195

Alternately install 4 TB outer discs with marks and 3 inner discs (196/1) and align them. Start with an outer disc.

1 Mark in outer disc

196

Install RG-TB disc carriers (197/1) with abutment ring (197/2) with the keyway facing the key.

1

2

NOTE: Avoid canting of the disc carrier. The disc carrier must be seated on the stator.

197

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7 Installation of Assemblies in Transmission

Install male union (198/1) with hose (198/3). Connect hose to converter drain valve via banjo bolt and sealing washer A10x16 (198/2).

1 2 3

198

Install two O-rings 12x3 (199/1) and key (199/2).

1 Special tool no. 2

Install R ring gear (199/3) in disc carrier.

2

Install R planet gear carrier (199/4) using special tool no. 2.

3 4

199

Install 6 outer and 5 inner R discs (200/1). Start with an outer one.

1

200

Special variant: Install blocking oscillator (201/1) - 27 Nm.

1

201 88

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7 Installation of Assemblies in Transmission

7.11 Installation of Reverse Gear in Output Drive 2 mm

1

Press oiled shaft seal (202/1) into output cover (202/2) using special tool no. 10.

2

NOTE: Shaft seal should be recessed 2 mm below upper edge of output cover.

202

Install complete speedometer flange with new O-ring (203/1) in output cover. Secure with socket-head bolt M6x20 8.8 and spring washer B6 (203/2) - 9 Nm.

1 2 203

Install the following parts in output cover (205/5) one after the other: speedometer drive gear (205/4) - paying attention to orientation, gear rim (205/3), ring (205/2), abutment ring (205/1).

1 2 3 4 5

NOTE: Inspect abutment ring (205/1) for wear and replace it, if necessary.

204

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7 Installation of Assemblies in Transmission

7.12 Measurement and Adjustment of Disc Clearance for Reverse Gear NOTE: Insert brake piston without piston rings into output cover. Discs and piston must be in contact during measurement see figure (205/1 and /2). Do not compress the discs. Measure dimension "A" and dimension "B". NOTE: Dimension B must not be smaller than 0.1 mm. Example: A = 5.5 mm B = 1.0 mm Dimension "A" minus dimension "B" is the measured disc clearance.

205

Example: 5.5 - 1.0 = 4.5 mm disc clearance. Determine shim thickness: Available sizes are 0.5 mm, 1.0 mm, and 1.5 mm. Example: minus equals

4.5 mm clearance (measured) 1.5 mm shim 3.0 mm clearance (adjusted)

NOTE: The target clearance is 2.7 3.2 mm.

Remove brake piston from output cover. Install piston rings with groove (206/1 und /3) toward the pressure side and piston rings without groove (206/2) in the brake piston.

Install brake piston in output cover.

206

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7 Installation of Assemblies in Transmission

7.13 Installation of Output Drive Inspect deep groove ball bearing 6215 (207/1), replace if necessary.

1

207

Install disc spring (208/1) and ring (208/2) in the output cover. Secure by means of 6 socket-head bolts M8x30 - 10.9 and 6 spring washers A8 (208/3) - 33 Nm.

1 2 3

4 208

NOTE: Slightly roughen contact areas of gasket on Transmission housing.

1

Place gasket (209/1) on transmission housing.

209

Install output cover (210/1) by means of special tool no. 2. Special tool no. 2

1

210 Voith. Repair Manual DIWA.3E

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7 Installation of Assemblies in Transmission

NOTE: Care must be taken not to cant the speedometer drive gear, gear rim, and ring or damage the shaft seal (fig. 211) when lowering the output cover.

211

Special tool no. 2

Locate output cover and gasket using special tool no. 2. Install output flange (212/1). Knock onto the output flange with a plastic hammer until the cover is properly seated on the transmission housing.

1

212

Fasten output cover: 11 hex. bolts M10x65 - 8.8, 1 hex. bolt M10x110 - 8.8 and spring washer B10 - 46 Nm.

1

Place disc (213/1) on shaft. Tighten 2 bolts (213/2) M10x50 - 10.9 to - 67 Nm. Measure spacing between shaft and flange.

2

The spacing must be 0.5 ± 0.1 mm (fig. 214). 213

If required, adjust by means of shims (215/2).

Remove disc and bolts (213/1 and /2).

0.5 ± 0.1 mm clearance adjusted by shims, with the bolts tightened.

214 92

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7 Installation of Assemblies in Transmission

Install O-ring 48x4.5 (215/1) and shim(s) (215/2) of calculated thickness.

215

Install disc (216/1), tighten 3 hex. bolts M10x50 - 10.9 and lock washers A10 (216/2) - 72 Nm.

1 2

216

1

Plug screw M14x1.5 with sealing ring A14x2 (217/1) into oil pan (217/2) - 38 Nm.

2

3

Bolt oil pan with gasket , Use 26 nuts M8 and washers B8.4 (217/3) - 25 Nm.

4

Install screw plug M26x1.5 with sealing ring A26x34 (217/4) - 100 Nm.

217

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7 Installation of Assemblies in Transmission

7.14 Installation of Inductive Pick-Ups 1

Tighten inductive pick-ups N2 (218/1) and N3 (218/2) to - 30 Nm.

2

218

7.15 Installation of Cable Harness Install cable harness (fig. 219) as described below. NOTE: Do not squeeze cables. Fasten cable harness with gasket (220/3) using 3 socket-head bolts M6x40 CV84 and spring washers B6 (220/4). 219

6 5

4 3

Fit connection for inductive pick-up N2 (220/5). Connect inductive pick-up N2 using special tool no. 7. Tighten cap with sealing ring (220/6) - 50 Nm.

2 1

Connect inductive pick-up N3 using special tool no. 7. Bolt on cap with gasket (220/3) using 3 socket-head bolts M8x30 CV84 with spring washers B8 (220/4) - 25 Nm. 220

NOTE: Tighten all bolts and fittings. Fasten earth cable (221/2) using hex. head bolt M8x10 and lock washer S8 (221/1) - 15 Nm.

1 2

Connect connection (221/3) for inductive pick-up N1 and temperature sensor using special tool no. 8.

3

221 94

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7 Installation of Assemblies in Transmission

7.16 Installation of Valve Blocks

3-speed

1 2 3 4 5 2 6

Assemble as follows: Fix valve block (222/6) using 6 sockethead bolts M8x50 (222/2). Connect plugs (222/5) to solenoids. NOTE: Plugs (222/5) for valve block (222/6) are marked with black rubber rings or black spiral wrap. Install connecting pipe (222/3) with O-rings 12x2. Fasten valve block (222/1) using 6 socket-head bolts M8x50 (222/2). Connect plugs (222/4) to solenoids.

222

NOTE: Do not squeeze the cables. Tighten 12 socket-head bolts M8x50 of valve blocks to 20 Nm.

Install cable guard (223/1).

1

223

Install control unit cover with gasket (224/1). Tighten 12 hex. bolts M8x30 - 8.8, spring washers B8, and washers B8.4 (224/2) - 23 Nm.

1 2

224 Voith. Repair Manual DIWA.3E

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7 Installation of Assemblies in Transmission

4-speed

1 2 3 4 5 2 6

Assemble as follows: Fix valve block (225/6) using 6 sockethead bolts M8x50 (225/2). Connect plugs (225/5) to solenoids. NOTE: Plugs (225/5) for valve block (225/6) are marked with black rubber rings or black spiral wrap. Install connecting pipe (225/3) with O-rings 12x2. Fasten valve block (225/1) using 6 socket-head bolts M8x50 (226/2). Connect plugs (225/4) to solenoids.

225

NOTE: Do not squeeze the cables. Tighten 12 socket-head bolts M8x50 of valve blocks to 20 Nm.

Install cable guard (226/1).

1

226

Install control unit cover with gasket (227/1). Tighten 12 hex. bolts M8x30 - 8.8, spring washers B8 and washers B8.4 (227/2) - 23 Nm .

1 2

227

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7 Installation of Assemblies in Transmission

Install lube oil pipe (228/1), tighten to 25 Nm. Insert dipstick (228/2).

2 1

228

7.17 Installation Examples for Heat Exchanger Standard position Fasten 2 hose lines (230/1) - 100 Nm.

1

NOTE: Grease friction surfaces of fittings. grease

229

NOTE: Different designs are possible. See also Spare Parts Catalogue No. 55.6603. ..

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97

8 Installation Vehicle

of

Transmission

in

the

8.1 Bolt Hydrodamp to Engine Flywheel Coat splines of Hydrodamp with molybdenum disulfide (paste or spray). Bolt Hydrodamp to engine flywheel.

230

12 11

Mounting the Hydrodamp on engine flywheel:

1

1. Suspend Hydrodamp from two assembly pins in positions 2 and 10 (on outer reference diameter, s. fig. 231) and slide it into the centring. 2. Tighten two bolts in a criss-cross manner. 3. Screw out assembly pins and replace them by bolts. 4. Tighten all 12 bolts M10-8.8 in a crisscross manner - 46 Nm.

2

10 b 9

3 a 8

4 7 6

5 231

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Voith. Repair Manual DIWA.3E

If centring is via locating pins at positions a and b (fig. 231), assembly is performed in an analogous way.

8 Installation of Transmission in the Vehicle

8.2 Installing the transmission NOTE! Prior to installing the transmission, it is absolutly necessary to treat the transmission input shaft with molybdenum disulfide (paste or spray). Make sure not to cant the input shaft when introducing it into the hub as this may damage the Hydrodamp!

Mount the transmission (232/2) and cardan shaft (232/5) . NOTE: Observe the tightening torques and installation regulations specified by the vehicle manufacturer. Connect cooling water pipes and tachometer (232/3 and /4). Fill in coolant and oil. Oil volume: approx. 26 litres. For transmissions with angle drive, the additional oil volume is indicated in the Repair Manual for the angle drive. 232

If the heat exchanger was drained, too, fill in about 2 l more. NOTE: Always use the dipstick to verify that the oil level is correct! The approved brands of oil are listed in the Lists of Lubricants 55.6335. .. and 55.6336. ...

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9 Checks 9.1 Check of Working Pressure and Coverter Pressure

1

Measure working pressure and converter pressure after every repair.

2

Test point for working pressure (233/1): The set point for working pressure is always pA = 8.5 bar. Tolerance: ± 0.2 bar. Only measure the pressure at an oil temperature of 80-90 °C (194 °F) immediately after shifting to 2nd gear, engine speed approx. 1,500 rev/min. Target value at idling speed: pA ≥ 3.5 bar 233

Test point for converter pressure (233/2): With an oil temperature toil of about 8090 °C, a forward gear engaged, the parking brake applied, and the engine idling (500 ± 50 rev/min), the converter pressure must be at least pW ≥ 2 bar. DANGER! Install or uninstall pressure gauge or measuring cover only with the engine stopped. Otherwise hot oil may result in scalding.

If a measuring cover (fig. 234) is used, the working pressure must be available at the measuring points for the clutches DK, EK, PB, WP, and SK.

234

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Voith. Repair Manual DIWA.3E

9 Checks The working pressure can be set at the grub screw of the working pressure valve through the oil filler neck (235/1).

1

If the required working pressure is not reached, check piping and other components for leaks.

235

9.2 Further Checks DANGER! All important transmission functions must be tested with the diagnostic program DIWAGNOSIS before driving the vehicle for the first time, as assembly errors can lead to transmission damage, or under some circumstances can cause an accident. Refer to "Diagnostic Manual" 55.6264. .. and, if necessary, "Fault Finding" 55.6303. ...

NOTE: Adaptation should be reset prior to a test ride by using DIWAGNOSIS. Before and after the test drive, check the transmission for oil leaks.

Recommendation: If oil is dirty (caused by parts not being cleaned in a professional manner), the oil and oil filter should be changed. Voith recommends to change oil and oil filter at the latest 5,000km after a repair.

Voith. Repair Manual DIWA.3E

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Voith. Repair Manual DIWA.3E

10 Transmission Weights

3-speed

Transmission without oil Transmission with oil Heat exchanger

D 851.3E

D 863.3E

275 kg 300 kg 25 kg

280 kg 305 kg 25 kg

D 854.3E

D 864.3E

310 kg 335 kg 25 kg

315 kg 340 kg 25 kg

4-speed

Transmission without oil Transmission with oil Heat exchanger

Voith. Repair Manual DIWA.3E

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Voith. Repair Manual DIWA.3E

11 Tightening Torques Tightening torques for hex. bolts and socket-head bolts.

Size

Strength

Tightening torque in Nm

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

Designation

Size

Tightening torque in Nm

Valve block

M8x50

20 Nm

Input differential

M10x150

55 Nm

Stator

M10x35

50 Nm

Output flange

M10x50-10.9

72 Nm

NOTE: Observe special cases.

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105

Tightening torques for screw plugs and banjo bolts with copper seals.

Tightening torque in Nm Size

Installation

Sealing washer

Steel / Al

M 10x1.5

10x13.5

13

X

Banjo bolt

M 10x1

10x13.5

15

X

Screw plug

M 12x1.5

12x15.5

20

X

Screw plug

M 14x1.5

14x18

38

X

Screw plug

M 18x1.5

18x22

45

X

Screw plug

M 26x1.5*

26x34

100

X

Screw plug

M 38x1.5*

38x44

150

X

Screw plug

M 48x1.5*

48x55

206

X

Screw plug

oiled

Designation

dry

NOTE: For sizes marked * the sealing washer and bolt must be oiled slightly. In all other cases, the washers and bolts must remain dry.

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Voith. Repair Manual DIWA.3E

Voith Turbo GmbH & Co. KG Commercial Vehicle Division Alexanderstraße 2 D-89522 Heidenheim Telephone (07321) 37-0 Telefax (07321) 37 7618