150 00024013 Repair Manual 2011 02 03 PDF

Voith Turbo
Repair Manual
DIWA.5
Repair Level
152.00024013_EN
2011-02-02
Translation of the original Operation Manual

Keep for future use!
Document Change History
Revision no. Author Date Reason for revision / contents of revision
Preface
This manual is intended for the maintenance staff.
The maintenance staff must read, understand and observe the manual. We would like
to point out that we do not assume any liability for damage or operational malfunctions
resulting from non-observance of the manual.
Copyright
The copyright in this manual remains with Voith Turbo. The instructions and drawings
contained herein may neither be reproduced or disseminated nor used or communicated
to others for competitive purposes in whole or in part without authorization.
Manufacturer
Voith Turbo GmbH und 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 GmbH & Co. KG Table of Contents
Table of Contents
Chapter 1 Preliminary Remarks on this Manual 1-1
1.1 Description of the warnings, symbols and signs 1-1

1.1.1 Warnings 1-1
1.1.2 Symbols and signs 1-2
Chapter 2 Safety 2-1
2.1 Safety instructions for DIWA.5 2-1

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

3.1.1 Standard tools 3-1
3.1.2 Other tools 3-2
3.1.3 Special tools for cable connectors 3-3
3.1.4 Other special tools 3-6
3.1.5 Auxiliary tools 3-11
3.1.6 Measuring cover 3-14
3.1.7 Measuring cable 3-15
3.1.8 Adapter for measuring cable 3-15
2011-02-02 I
3.2 Service accessories 3-16

3.2.1 Set level converter with RS232 interface with ALADIN software 3-16
3.2.2 Set level converter with RS232 interface with DIWAgnosis software 3-16
3.2.3 ALADIN software separately on CD-ROM 3-17
3.2.4 Set level converter with USB interface with ALADIN software 3-17
3.2.5 DIWAgnosis software separately on CD-ROM 3-18
3.2.6 Voith Analyzer on CD-ROM 3-18
3.2.7 Set DIWA BlueCom K-line interface with DIWAgnosis CD 3-19
3.2.8 Set DIWA BlueCom K-line interface with ALADIN CD 3-19
3.2.9 DIWA BlueCom K-line interface 3-20
3.2.10 NEOMAN-specific adapter cable 3-21
3.2.11 Forced download plug 3-21
3.2.12 Diagnostic adapter cable without CAN bus port 3-22
3.2.13 Diagnostic adapter cable with CAN bus port 3-22
3.2.14 Diagnostic adapter OBD2 3-23
3.3 Dismounting the transmission 3-24

3.3.1 Suspension points 3-24
3.3.2 Cleaning 3-25
3.3.3 Sealing elements 3-25
3.3.4 Hose lines 3-25
3.3.5 Storage 3-25
Chapter 4 Maintenance 4-1
4.1 Draining the transmission oil 4-1

4.1.1 Draining the transmission oil from the oil pan 4-2
4.1.2 Draining oil from the converter 4-3
4.1.3 Closing the oil drain hole 4-4
4.2 Preparations for work on the transmission 4-5
4.3 Dismounting the transmission 4-6
4.4 Dismounting the hydrodamp 4-8

4.4.1 Checking the oil level 4-9
4.4.2 Wear check at the hub 4-10
2011-02-02 II
4.5 Faults 4-11

4.5.1 Vehicle does not start driving 4-11
4.5.2 Vehicle does not drive in reverse 4-12
4.5.3 Shifting jerk when engaging a gear 4-13
4.5.4 Poor acceleration in all gears 4-13
4.5.5 Poor acceleration in first gear 4-14
4.5.6 Vehicle drives in 1st gear only 4-15
4.5.7 Vehicle does not shift into 3rd gear 4-16
4.5.8 Engine is reduced considerably in reverse gear 4-16
4.5.9 No retarder operation 4-17
4.5.10 Hard activation of the retarder 4-17
4.5.11 Braking force in 2nd, 3rd and 4th gear too high 4-18
4.5.12 Braking force too low 4-18
4.6 Disassembling the transmission into assemblies 4-19

4.6.1 Dismounting the heat exchanger 4-19
4.6.2 Dismounting the control block cover 4-20
4.6.3 Speed sensors 4-21
4.6.4 TIM - Transmission Identification Module 4-22
4.6.5 Converter temperature sensor 4-23
4.6.6 Dismounting the control blocks 4-24
4.6.7 Dismounting the cable harness 4-26
4.6.8 Dismounting the oil pan 4-29
4.6.9 Dismounting the temperature sensor / oil level sensor 4-31
4.6.10 Dismounting the output assembly 4-33
4.6.11 Dismounting the turbine transmission 4-36
4.6.12 Dismounting the drive unit 4-39
4.6.13 Dismounting the suction screen 4-39
4.6.14 Dismounting the gear pump 4-40
4.6.15 Dismounting the converter outlet valve 4-41
4.6.16 Dismounting the operating pressure valve 4-43
4.6.17 Dismounting the pump brake 4-45
4.7 Dismounting and mounting assemblies 4-46

4.7.1 Dismounting the input differential 4-46
4.7.2 Dismounting the planet carrier 4-57
4.7.3 Mounting the planet carrier 4-58
4.7.4 Mounting the input differential 4-59
4.7.5 Dismounting the pump brake 4-75
4.7.6 Mounting the pump brake 4-79
4.7.7 Dismounting the stator - turbine wheel 4-86
2011-02-02 III
4.7.8 Mounting the stator - turbine wheel 4-88

4.7.9 Dismounting the turbine transmission 4-94
4.7.10 Mounting the turbine transmission 4-97
4.7.11 Dismounting the output and reverse gear 4-99
4.7.12 Dismounting the TB-RB disk carrier 4-100
4.7.13 Assembling the TB-RB disk carrier 4-103
4.7.14 Mounting and dismounting the operating pressure valve 4-106
4.7.15 Mounting and dismounting the converter outlet valve 4-110
4.7.16 Dismounting the control blocks 4-113
4.7.17 Mounting the control blocks 4-115
4.8 Assembling the transmission 4-118

4.8.1 General information 4-118
4.8.2 Checking and replacing parts 4-118
4.8.3 Mounting the screw plug 4-119
4.8.4 Mounting the pump brake 4-120
4.8.5 Mounting the operating pressure valve 4-124
4.8.6 Mounting the converter drain valve 4-126
4.8.7 Mounting the gear pump 4-128
4.8.8 Mounting the drive unit 4-130
4.8.9 Mounting the stator - turbine wheel 4-131
4.8.10 Mounting the turbine transmission 4-134
4.8.11 Mounting the reverse gear into the output unit 4-138
4.8.12 Measure and adjust the disk clearance of the reverse gear. 4-139
4.8.13 Mounting the output unit 4-141
4.8.14 Mounting the oil sump temperature sensor / oil level sensor 4-146
4.8.15 Mount the oil pan. 4-147
4.8.16 Mounting the speed sensors 4-150
4.8.17 Mounting the converter temperature sensor 4-151
4.8.18 Mounting the cable harness 4-152
4.8.19 Mounting the control blocks 4-158
4.8.20 Mounting the control block cover 4-159
4.8.21 Mounting the heat exchanger 4-160
4.9 Mounting the hydrodamp 4-161
4.10 Installing the transmission 4-162

4.10.1 Transmission 4-162
4.10.2 Drive shaft 4-162
4.10.3 Ports 4-163
4.11 Filling the transmission with oil 4-165
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4.12 Test drive 4-166
4.13 Measuring and testing 4-168

4.13.1 Measuring the stall point 4-168
4.13.2 Pump characteristic 4-169
4.13.3 Measuring pressures 4-170
Chapter 5 Standard lists 5-1
5.1 DIWA.5 tightening torques 5-1
2011-02-02 V
Repair Manual
Voith Turbo GmbH & Co. KG Preliminary Remarks on this Manual
1 Preliminary Remarks on 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.
Pay special attention to the safety instructions in this manual.
Safety instructions can be found in chapter 2 and always precede action instructions.
1.1 Description of the warnings, symbols and signs
1.1.1 Warnings
This manual uses warnings to prevent any personal injury or property damage.
Please always read and observe these warnings!
Warnings are marked by the following symbols:
Symbol Description
Imminent danger!
Non-observance will lead to death or
DANGER
severe injury.
Probable imminent danger!

Non-observance may lead to death or
WARNING severe injury.
Dangerous situation!
Non-observance may lead to minor injury.
CAUTION
Dangerous situation!
Non-observance may lead to damage to
CAUTION property.
Tab. 1-1 Identification of warnings

KaSg-arattk - TeXML v.110128 - 2011-02-02
©2011 Voith Turbo GmbH & Co. KG
Repair Manual - DIWA.5
2011-02-02 1-1
Repair Manual
Voith Turbo GmbH & Co. KG Preliminary Remarks on this Manual / Description of the warnings, symbols and signs
1.1.2 Symbols and signs

This manual uses symbols and signs to provide you with fast access to information.
Symbol Use Description
Note Indicates information on the proper handling

of the transmission. It does not identify any
dangerous situations.
Environment Points out a potentially harmful

situation for the environment owing to
operation, maintenance or repair of the
transmission.
Help in the event of Provides help if problems occur.
problems
Tab. 1-2 Symbols in the right text column
Symbol Use Description
Ö Action instruction You are required to do something here.

1. Action instruction com- Action instructions have to be carried out in
2. prising several steps the given order.
Deviations from the given order may cause
damage to the machine or accidents.
Please note especially! –

Listing with two stages Listings do not imply any activities.
•
–
Î Cross reference References to pictures, tables, other chap-
ters or other manuals
Tab. 1-3 Symbols in the text
2011-02-02 1-2
Repair Manual
Voith Turbo GmbH & Co. KG Safety
2 Safety
2.1 Safety instructions for DIWA.5
2.1.1 General information

Operation, maintenance and repair of the transmission are always subject to the relevant
local safety and accident prevention regulations.
These regulations can apply to, for example, the handling of hazardous materials, the
provision and wearing of personal protective gear, or motor vehicle regulations.
Anyone operating the transmission or any persons involved in installation, repair or main-
tenance have to familiarize themselves with the warning notes and precautions described
in this document.
Anyone who operates the transmission or who carries out installation, repair or mainte-
nance work has to make sure that his/her personal safety or the safety of other people
is ensured.
2.1.2 State of the art
This transmission is designed and constructed according to the state of the art in technol-
ogy and acknowledged safety regulations. Nevertheless, risks to life and limb of people
or impairment of the transmission or other tangible assets might arise during installation,
repair or maintenance, if:
• the transmission is used improperly,
• the transmission is operated, maintained or repaired by untrained staff,
• the transmission is modified or rebuilt improperly, and/or
• the safety instructions are not observed.
2.1.3 Intended use
The intended use of the DIWA transmission is its application as an automatic transmis-
sion for buses.
Any use other than the one described above is considered improper. Voith Turbo GmbH
& Co. KG does not assume any liability for improper use. The risk lies solely with the
user.
The persons in charge, in particular the staff engaged in operation and maintenance,
must absolutely observe the guidelines for the proper and correct use of the transmission.
2011-02-02 2-1
Repair Manual
Voith Turbo GmbH & Co. KG Safety / Safety instructions for DIWA.5
2.1.4 Conditions for usage

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

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

Therefore, let the transmission cool down to approx. 60 °C before changing the oil.
2011-02-02 2-2
Repair Manual
2.1.10 Risk of accidents caused by oil

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

Use only original spare parts for repair work since only these can guarantee that the
transmission complies with the road safety regulations and the technical state at delivery.
Always observe the notes in the spare parts catalogue when replacing parts.
Original spare parts are designed especially for the Voith transmission. We would like
to point out that original spare parts which are not supplied by Voith are neither tested
nor approved by Voith. The installation and/or use of non-original spare parts might
adversely affect the specified design characteristics of the transmission and thus com-
promise safety.
In case of any damage due to the use of non-original spare parts, Voith does not assume
any liability.
2.1.12 Work on the transmission
Before maintenance or control work on the installed transmission and during installation
or removal of the transmission, the engine of the bus must be secured against starting.
Prior to performing maintenance or inspection work on the installed transmission and
during installation and removal of the transmission, the bus must be secured in such a
way that it cannot be put in motion, neither deliberately nor accidentally (slope!).
The prescribed service work must be carried out regularly, on time and with the intended
fuels and fluids.
The work must be performed in accordance with the Voith provisions, e.g. the customer
service information describing improvements and modifications to the transmission, so
that no parts and tools take damage.
Work on the transmission requires appropriate service station equipment.
After work has been performed on the transmission, all transmission oil lines must be
checked for leaks, loose connections, chafing and damage. Any defects must be elimi-
nated immediately.
After work on the transmission has been performed, all joints must be checked for leak-
age.
All screwed connections loosened during work on the transmission must be tightened at
the tightening torques specified in the technical documents on the transmission.
2.1.13 Cleaning the transmission

Before cleaning the transmission with water or steam jet (high-pressure cleaner) or other
cleaning agents, any openings into which no water, steam or cleaning agent must ingress
for reasons of safety and functioning must be sealed.
Outside oil hose lines must not be directly exposed to the jet of the high-pressure cleaner.
After cleaning, remove all covers/adhesives completely.
2011-02-02 2-3
Repair Manual
2.1.14 Conversion or modification of the transmission

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

Disconnect the connecting cable between control and transmission from the control unit.
In case of transmission damage: Remove the prop shaft or stub shaft of the rear axle.
If there is no transmission damage, the bus can also be towed by means of the prop
shaft:
• Max. permissible distance: 10 km
• Max. permissible speed: 30 km/h

For transmissions with angle drives it is in any case necessary to remove the prop shaft
or stub shaft of the rear axle.
If this is not possible, please contact the Voith customer service.
2011-02-02 2-4
Repair Manual
Voith Turbo GmbH & Co. KG Preparation of installation
3 Preparation of installation
3.1 Tools
3.1.1 Standard tools
Retainer for screwdriver bit
Order number H02.011204
2BAnn020
Fig. 3-1 Retainer for screwdriver bit
Screwdriver bit
2BAnn021
Fig. 3-2 Screwdriver bit
Version Order number

B-K 5x11 H02.011186
K-5 long H02.007820
B-K 6x11 H02.011187
B-K 8x11 H02.011188
B-K 10x11 H02.011189
B-K 12x11 H02.011190

Tab. 3-1 Screwdriver bit

2011-02-02 3-1
Repair Manual
Voith Turbo GmbH & Co. KG Preparation of installation / Tools
3.1.2 Other tools
Torque wrench
• Torque wrench 0-150 Nm
Forcing screws
• Forcing screw 2x M6
– Order number H50.067710

Pliers
Pliers for interior locking rings:
• Pliers J1 for locking rings ø 8-25 mm

Pliers for exterior locking rings:
• Pliers A1 for locking rings ø 10-25 mm

2011-02-02 3-2
Repair Manual
3.1.3 Special tools for cable connectors
Tool for loosening the cable connectors from the solenoid coils
Order number H68.1535XX
2BAnn030
Fig. 3-3 Tool for loosening the cable connectors from the solenoid coils
2011-02-02 3-3
Repair Manual
Tool for plugging the cable connectors at the solenoid coils
Order number 150.000145XX
2BAnn040
Fig. 3-4 Tool for plugging the cable connectors at the solenoid coils
1 Hard-soldered 3 Screwdriver DIN 5265-C-A 0,

2 Insert for assembly tool 8x4, tip removed
2011-02-02 3-4
Repair Manual
Tool for loosening the cable connectors from the cable harness
2BAnn050
Fig. 3-5 Tool for loosening the cable connectors for the temperature sensor from the cable harness
1 Hard-soldered 2 Pliers DIN 5254-A40-gl
Tool for plugging the cable connectors at the cable harness
2BAnn051
Fig. 3-6 Tool for plugging the cable connectors for the temperature sensor at the cable harness
1 Hard-soldered 2 Pliers DIN 5256-C40-gl

2011-02-02 3-5
Repair Manual
3.1.4 Other special tools
Tool for installing the shaft sealing ring in the output cover
2BAnn060
Fig. 3-7 Tool for installing the shaft sealing ring in the output cover
2011-02-02 3-6
Repair Manual
Tool for installing the shaft sealing ring in the drive cover
2BAnn070
Fig. 3-8 Tool for installing the shaft sealing ring in the drive cover
2011-02-02 3-7
Repair Manual
Puller for the drive cover
2BAnn070
Fig. 3-9 Puller for the drive cover
1 Made of M16x100 2 Fixedly welded 30x30

DIN EN ISO 4017
Forcing screw M10
Order number: H58.2740XX
2BAnn080
Fig. 3-10 Forcing screw M10
1 Threaded bolt AM10 4.6 2 Hex head nut M10 8 A3C

DIN 976-1, hardened DIN 934

2011-02-02 3-8
Repair Manual
Tool for disassembling and assembling the EK/DK piston carrier
Sheet plate
2BAnn080
Fig. 3-11 Tool for disassembling and assembling the EK/DK piston carrier sheet plate
Base plate

2BAnn081
Fig. 3-12 Tool for disassembling and assembling the EK/DK piston carrier base plate
2011-02-02 3-9
Repair Manual
Tool for installing the turbine transmission
2BAnn090
Fig. 3-13 Tool for installing the turbine transmission

2011-02-02 3-10
Repair Manual
3.1.5 Auxiliary tools
Sleeve for mounting the input shaft bearing
2BAnn100
Fig. 3-14 Sleeve for mounting the input shaft bearing
Sleeve for mounting the EK multi-disk carrier bearing
2BAnn101
Fig. 3-15 Sleeve for mounting the EK multi-disk carrier bearing

2011-02-02 3-11
Repair Manual
Sleeve for mounting the turbine and pump brake bearings
2BAnn102
Fig. 3-16 Sleeve for mounting the turbine and pump brake bearings
Disk for pulling off the outer rim of the input differential
2BAnn103
Fig. 3-17 Disk for pulling off the outer rim of the input differential
2011-02-02 3-12
Repair Manual
Tool for mounting the inner ring and roller bearing on the turbine shaft
2BAnn110
Fig. 3-18 Tool for mounting the inner ring and roller bearing on the turbine shaft
2011-02-02 3-13
Repair Manual
3.1.6 Measuring cover

2BAnn130
Fig. 3-19 Measuring cover
1 WR 7 Operating pressure
2 Converter pressure 8 DK
3 TB 9 EK
4 RG 10 PB
5 RK 11 WP
6 SK
Test port
• Quantity 11
Sealing ring
• Quantity 11
2011-02-02 3-14
Repair Manual
3.1.7 Measuring cable

2BAnn508
Fig. 3-20 Measuring cable
3.1.8 Adapter for measuring cable

2BAnn509
Fig. 3-21 Adapter for measuring cable

2011-02-02 3-15
Repair Manual
Voith Turbo GmbH & Co. KG Preparation of installation / Service accessories
3.2 Service accessories
3.2.1 Set level converter with RS232 interface with ALADIN software
The level converter with RS232 interface is the same as with DIWA.3 and DIWA.3E.
• Material number 151.001529XX
2BEnn001
Fig. 3-22 RS232 interface with ALADIN software
3.2.2 Set level converter with RS232 interface with DIWAgnosis software
The level converter with RS232 interface is the same as with DIWA.3 and DIWA.3E.
• Material number H59.2500XX
2BEnn010
Fig. 3-23 RS232 interface with DIWAgnosis software

2011-02-02 3-16
Repair Manual
3.2.3 ALADIN software separately on CD-ROM

For customers who already have a level converter.
2BEnn003
Fig. 3-24 ALADIN software separately on CD-ROM
3.2.4 Set level converter with USB interface with ALADIN software
2BEnn002
Fig. 3-25 USB interface with ALADIN software

2011-02-02 3-17
Repair Manual
3.2.5 DIWAgnosis software separately on CD-ROM
• Material number H59.2495XX
2BEnn013
Fig. 3-26 DIWAgnosis software separately on CD-ROM
3.2.6 Voith Analyzer on CD-ROM
2BEnn004
Fig. 3-27 Voith Analyzer on CD-ROM

2011-02-02 3-18
Repair Manual
3.2.7 Set DIWA BlueCom K-line interface with DIWAgnosis CD
2BEnn011
Fig. 3-28 Set DIWA BlueCom K-line interface with DIWAgnosis CD
3.2.8 Set DIWA BlueCom K-line interface with ALADIN CD
2BEnn012
Fig. 3-29 Set DIWA BlueCom K-line interface with ALADIN CD

2011-02-02 3-19
Repair Manual
3.2.9 DIWA BlueCom K-line interface
2BEnn012
Fig. 3-30 DIWA BlueCom K-line interface
This article is only intended for the Voith Service. It must not be passed on to the end
customer.
The article is not stated on the price list; price on request.
2011-02-02 3-20
Repair Manual
3.2.10 NEOMAN-specific adapter cable

New cable for DIWA.5.
From TEPS on
2BEnn005
Fig. 3-31 NEOMAN-specific adapter cable
3.2.11 Forced download plug

The forced download plug is required if no function software can be loaded after having
loaded the flash loader.
2BEnn006
Fig. 3-32 Forced download plug
customer.

2011-02-02 3-21
Repair Manual
3.2.12 Diagnostic adapter cable without CAN bus port

Connection directly at the E300/E300.1
2BEnn007
Fig. 3-33 Diagnostic adapter cable without CAN bus port
customer.
3.2.13 Diagnostic adapter cable with CAN bus port

Connection directly at the E300/E300.1
2BEnn008
Fig. 3-34 Diagnostic adapter cable with CAN bus port

customer.
2011-02-02 3-22
Repair Manual
3.2.14 Diagnostic adapter OBD2
2BEnn009
Fig. 3-35 Diagnostic adapter OBD2

2011-02-02 3-23
Repair Manual
Voith Turbo GmbH & Co. KG Preparation of installation / Dismounting the transmission
3.3 Dismounting the transmission
3.3.1 Suspension points
1 1
2BAnn010
Fig. 3-36 Suspension points
1 Eyebolts M12
Procedure
Ö Use only the suspension points (1) to attach the transmission to an appropriate lifting
device (Î Page 2-2, Chapter 2.1.8) that assures an even weight distribution.
2BAnn011
Fig. 3-37 Suspension points
Ö The eyebolts may only be subjected to vertical upward stress.

The maximum allowed to be attached to the eyebolts is the transmission with heat
exchanger and angle drive.
2011-02-02 3-24
Repair Manual
Voith Turbo GmbH & Co. KG Preparation of installation / Dismounting the transmission
It is not permitted to lift any additional loads at the eyebolts.
3.3.2 Cleaning
1. If the transmission is very dirty, clean it before repair

(Î Page 2-3, Chapter 2.1.13).
2. After dismounting, clean all parts.
3.3.3 Sealing elements

Replace all sealing elements that were removed.
Install all flat gaskets without using grease.
3.3.4 Hose lines

Even if they are stored properly and not stressed beyond the allowed limits, hoses and
hose lines are subject to a natural ageing process. Their service life is therefore limited.
DIN 20066: The service life of a hose line including storage must not exceed 6 years.
3.3.5 Storage
If a transmission is stored after repair without a test run, it has to be protected against
corrosion during storage.
2011-02-02 3-25
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance
4 Maintenance
4.1 Draining the transmission oil
WARNING
Risk of scalding due hot oil!
Direct skin contact with the hot transmission oil can cause
severe scalds.
Ö Take appropriate safety precautions when handling hot oil.
1. Shut off the engine.

2. Check the transmission oil temperature.
3. If the transmission oil temperature is below 60 °C, let the engine warm up to operating
temperature.
The oil must only be drained at operating temperature (at least 60 °C) because otherwise
there would remain too much residual oil in the transmission.
To determine the transmission oil temperature, you can use the cooling water tempera-
ture indicator inside the vehicle, since the temperature of the transmission oil is
almost identical to the temperature of the cooling water.
Environmental hazard due to oil!
The used oil must not leak out to the environment.
Collect the oil in an appropriate container.
Any oil must be disposed of in compliance with the respective local and state regulations.
2011-02-02 4-1
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Draining the transmission oil
4.1.1 Draining the transmission oil from the oil pan
2BAnn140
Fig. 4-1 Drain plug of the oil pan
1 Drain plug of the oil pan
Procedure
1. Loosen and remove the drain plug of the oil pan (1).
Use a hexagon socket wrench of size 12.
2. Drain the transmission oil.

2011-02-02 4-2
Repair Manual
4.1.2 Draining oil from the converter
The drain plug of the converter (2) is accessible via the oil drain hole of the oil pan (1).
2BAnn141
Fig. 4-2 Drain plug of the converter
1 Oil drain hole of the oil pan 2 Drain plug of the converter
Procedure
1. Loosen and remove the drain plug for the oil in the converter (2).
Use a hexagon socket wrench of size 12.
2. Drain the converter oil.

2011-02-02 4-3
Repair Manual
4.1.3 Closing the oil drain hole
1. Screw in the drain plug of the converter (2) with a new copper sealing ring 14 x 20.
2. Tighten the drain plug.
Tightening torque 50 Nm.
3. Screw in the drain plug of the oil pan (1) with a new copper sealing ring 26 x 34.
4. Tighten the drain plug.

2011-02-02 4-4
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Preparations for work on the transmission
4.2 Preparations for work on the transmission
DANGER
Risk of accident due to unsecured vehicle!
The vehicle can start to move accidentally and cause severe

accidents.
1. Apply the parking brake.

2. Secure the vehicle against rolling.
Environmental hazard due to coolant!
The used coolant must not leak out to the environment.
Collect the coolant in an appropriate container.
Any coolant must be disposed of in compliance with the respective local and state reg-
ulations.
1. Press the N button on the gear range selector.

2. Shut down the engine.
3. Turn off the ignition of the vehicle.
4. Unplug Voith cable 1 at the control unit.
5. Drain the coolant.
2011-02-02 4-5
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Dismounting the transmission
4.3 Dismounting the transmission
WARNING
Risk of scalding due hot oil!
Direct skin contact with the hot transmission oil can cause
severe scalds.
Ö Take appropriate safety precautions when handling hot oil.
CAUTION
Damage to the flywheel housing!
When it is hot, the centering of the transmission flange to the

flywheel housing is under increased compression due to the
different expansion of the materials.
Ö If possible, do not dismount the transmission when it is hot.

If dismounting of the hot transmission cannot be avoided,
detach the flywheel housing and transmission flange very
carefully.
CAUTION
Danger of damaging the hydrodamp!
If the transmission is lowered without being moved outward,

the hydrodamp will be damaged.
Ö Before lowering the transmission, move it outward ca. 8

cm parallel to the engine until the pinion shaft is free.
1. Drain the transmission oil (Î Page 4-1, Chapter 4.1).

2. Dismount the transmission using a hoisting device (Î Page 3-24, Chapter 3.3.1).
3. Secure the transmission against dropping from the hoisting device, e.g. using fas-
tening straps.
4. Remove the screws between transmission flange and flywheel housing.

5. Dismount the drive shaft.

6. Dismount the coolant lines.
7. Dismount all cables.

8. Lower the transmission.
2011-02-02 4-6
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Dismounting the transmission
Oil loss at the hydrodamp
A small amount of oil can leak out at the internal sealing area of the hydrodamp.
An oil loss of max. 30 ml is allowed.
2011-02-02 4-7
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Dismounting the hydrodamp
4.4 Dismounting the hydrodamp
CAUTION
Danger of damaging the hydrodamp!
The hydrodamp is manufactured with tight tolerances. Exter-

nal damage can cause failure of the hydrodamp.
1. Do not place the hydrodamp on its projecting hub during

transport, storage or exchange.
2. Store or dispatch the hydrodamp in its original packing
only.
3. In case of repair, replace the hydrodamp only as a whole.
2BAnn150
Fig. 4-3 Dismounting the hydrodamp
1. Unscrew two opposite screws M10 (1) out of the external pitch circle of the hydrodamp
(2).
2. Insert stud bolts, length 100 mm, into these places.
3. Unscrew ten screws out of the external pitch circle (2).
Do not remove the hex head screws in the clutch.
4. Press off the hydrodamp using forcing screws (Î Page 3-8, Fig. 3-10).
There may be an intermediate ring on the flywheel. This can become loose during
removal. If this is the case, push the ring back to its position.
2011-02-02 4-8
Repair Manual
4.4.1 Checking the oil level
WARNING
Risk of burns due to hot oil!
Hot oil can escape from the hydrodamp. This can cause
burns.
1. Make sure that the temperature in the hydrodamp is below

50 °C.
2. Wear personal protection gear when removing and working
on the hydrodamp.
If oil traces are visible in the area of the hub, check the oil level in the hydrodamp.
2BAnn151
Fig. 4-4 Checking the oil level at the hydrodamp
Environmental hazard due to escaping oil!
The oil from the hydrodamp must not leak out to the environment.
Any oil that has escaped must be disposed of in compliance with the respective local
and state regulations.
2011-02-02 4-9
Repair Manual
1. Turn the hydrodamp so that the check bores (1) and (2) are perpendicular above each
other.
2. Wait three minutes.
3. Unscrew the upper screw plug (1).
4. Turn the hydrodamp clockwise by 40° to 45° around the hub axis.
If oil flows out of the bore, the oil level is OK.
5. Use a screw plug M10 x 1 and a new copper sealing ring
10.5 x 16 x 2 VGN 3019 (special dimensions, no DIN design).
6. Screw in the screw plug with type 243 Loctite.
7. Tighten the screw plug with a tightening torque of 15 Nm.
or
8. Execute steps 1 to 4.
If no oil flows out of the bore, the oil does not reach the minimum level.
This may be due to the hydrodamp having a leak.
9. Replace the hydrodamp.
4.4.2 Wear check at the hub
Ö Plug the hydrodamp onto a new transmission input shaft.

If the backlash at the bolt hole circle diameter between the input shaft and the hub is
greater than 2 mm, replace the entire hydrodamp.
2011-02-02 4-10
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Faults
4.5 Faults
4.5.1 Vehicle does not start driving
Vehicle does not start driving although:
• a gear is engaged,
• the parking brake is released,
• the accelerator pedal is applied.

Note: When stationary, the vehicle revs up to maximum speed
Possible causes Test option Elimination
EK solenoid coil Permanent flashing on gear range Check and, if required, replace the
selector coils and their cabling.
The transmission shifts to neutral.
Read out the ALADIN event mem-
ory.
Perform the ALADIN actuator test.
EK solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.
Disassemble the control block. polish, hone...) or replace it.
Check the valve for smooth running.

The EK disks are damaged. Check the oil condition. Repair or replace the transmission.
Unscrew the oil pan and check it
for dirt.
Check the disks for wear.
Operating pressure too low Measure the operating pressure Repair or replace the transmission.
and the converter pressure.
Î Page 4-170, Chapter 4.13.3
Cable harness, cable 1 Measuring cable Replace the cable harness.

Î Page 3-15, Chapter 3.1.7,
Î Page 4-26, Chapter 4.6.7 and
Adapter to measuring cable Î Page 4-152, Chapter 4.8.18
ECU defective Read out the ALADIN event mem- Replace the ECU.
ory.
2011-02-02 4-11
Repair Manual
4.5.2 Vehicle does not drive in reverse

Vehicle does not drive in reverse although:
• the reverse gear is engaged,
• the parking brake was released,
• the accelerator pedal is applied.

Note: No problem when starting forward.
RBG, RBK, WR solenoid coil Gear range selector flashes Check and, if required, replace
the coils and their cabling.
ory.
RBG, RBK, WR solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.
RG disks defective Check the oil condition. Repair or replace the transmission.
for dirt.
Converter leaks Measure the operating pressure If pressures are too low, repair or, if
and the converter pressure. required, replace the transmission.
Operating pressure too low

Adapter to measuring cable
2011-02-02 4-12
Repair Manual
4.5.3 Shifting jerk when engaging a gear

EK solenoid coil Gear range selector flashes Check and, if required, replace the
Measuring coil and/or solenoid coil and its cabling.
valve measuring coil GND ory.
EK solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.

EK disks damaged Check the oil condition. Repair or replace the transmission.
for dirt.
4.5.4 Poor acceleration in all gears

The engine output is insufficient Measure the stall point. Contact the vehicle manufacturer
Î Page 4-168, Chapter 4.13.1 or engine manufacturer.

2011-02-02 4-13
Repair Manual
4.5.5 Poor acceleration in first gear
Possible causes Checking options Elimination
EK and/or TB solenoid coil Gear range selector flashes Check and, if required, replace
Read out the ALADIN event mem- the coil and its cabling.
ory.
EK and/or TB solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.
EK and/or TB disks damaged Measure the stall point in 1st gear. Repair or replace the transmission.
Measure the stall point in R-gear.
Check the oil condition.
for dirt.
Pressures too low Measure the operating pressure Repair or replace the transmission.
and the converter pressure.
2011-02-02 4-14
Repair Manual
4.5.6 Vehicle drives in 1st gear only

Causes and remedy of fault apply accordingly to all lockings of the individual gears and
retarder (RB).
Possible causes Test options Elimination
Speed sensor N2 Gear range selector flashes Check and, if required, replace the
Read out the ALADIN event mem- speed sensor and its cabling.
ory.
Perform the ALADIN function test.
PRmax. reached Gear range selector flashes Repair or replace the transmission.
Disk slip detected Read out the ALADIN event mem-
ory.
Check the oil condition.
Measure the pressures.
for dirt.
PB solenoid coil Gear range selector flashes Check and, if required, replace the
coil and its cabling.
ory.
PB solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.
Gear range selector Perform the ALADIN function test Check and, if required, replace the
for the gear range selector. gear range selector.

2011-02-02 4-15
Repair Manual
4.5.7 Vehicle does not shift into 3rd gear

PRmax. reached Gear range selector flashes Repair or replace the transmission.
Disk slip detected Read out the ALADIN event mem-
ory.
DK solenoid coil Gear range selector flashes Check and, if required, replace the
Read out the ALADIN event mem- coil and its cabling.
ory. Î Page 4-26, Chapter 4.6.7 and
4.5.8 Engine is reduced considerably in reverse gear

WP solenoid Gear range selector flashes Check and, if required, replace the
ory.
WP solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.

Tubing to the WP solenoid valve Test drive Replace the WP tubing.
broken Engine is reduced considerably in
Check the WP tubing. reverse gear
Strong retarder effect
Check the WP tubing.

2011-02-02 4-16
Repair Manual
4.5.9 No retarder operation
RBK/RBG solenoid coil Gear range selector flashes Check and, if required, replace the
coil and its cabling.
ory.
Solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.
No brake request from vehicle Read out the ALADIN event mem- Contact OEM.
ory.
Vehicle diagnostic systems

4.5.10 Hard activation of the retarder
Speed sensor N3 Read out the ALADIN event mem- Replace the speed sensor.
ory.
Perform the ALADIN function test.
Solenoid coil Gear range selector flashes Check and, if required, replace the
ory.
WP, RGB or RBK solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.

Tubing to the WP broken Test drive Replace the WP tubing.
Engine is reduced considerably in
reverse gear



2011-02-02 4-17
Repair Manual
4.5.11 Braking force in 2nd, 3rd and 4th gear too high

The converter outlet valve is slug- Check the converter outlet valve. Repair or, if required, replace the
gish or jammed valve.
4.5.12 Braking force too low

WR solenoid coil Read out the ALADIN event mem- Check and, if required, replace the
ory. coil and its cabling.
WR solenoid valve Perform the ALADIN actuator test. Make the valve run smoothly (e.g.

Tubing to the WR solenoid valve Test drive Check, clean or, if required, replace
broken Engine is reduced considerably in the tubing.
reverse gear
Check the oil pressure at the mea-
suring cover connection, pAtarget
≥ 3.5 bar.
Converter inlet or outlet valve is Check the valve. Repair or replace the valve.
sluggish or jammed
Converter pressure too low Measure the converter pressure. Repair or replace the transmission.
2011-02-02 4-18
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Disassembling the transmission into assemblies
4.6 Disassembling the transmission into assemblies
4.6.1 Dismounting the heat exchanger
WARNING
There might be hot oil left in the heat exchanger. This oil
might flow out when removing the heat exchanger. This can
cause burns.
Ö Wear personal protection gear when removing and working

on the heat exchanger.
Environmental hazard due to escaping oil!
The oil from the heat exchanger must not leak out to the environment.
Any oil must be disposed of in compliance with the respective local and state regulations.
6
7
6
5
1
4
3
2
2BAnn160
Fig. 4-5 Dismounting the heat exchanger

1. Loosen and remove the 4 hex head nuts (1).

2. Loosen and remove the 4 hex head screws (2).
3. Remove the 8 washers (3).

4. Remove the heat exchanger with fastener (4).
5. Pull out the 2 plug-in tubes (7) with 2 gaskets (6) each.
2011-02-02 4-19
Repair Manual
6. Remove the two gaskets (5).
4.6.2 Dismounting the control block cover
2BAnn165
Fig. 4-6 Dismounting the control block cover
1. Loosen 20 screws (1) and remove them with their washers (2).
2. Remove the cover (3).
3. Remove the gasket (4).
2011-02-02 4-20
Repair Manual
4.6.3 Speed sensors
Position of the speed sensors
2BAnn170
Fig. 4-7 Speed sensor N1

2BAnn171
Fig. 4-8 Speed sensors N2 and N3

2011-02-02 4-21
Repair Manual
Dismounting the speed sensors
CAUTION
Never use an impact screwdriver to dismount the speed sensors!
The speed sensors might get damaged.
Ö Carefully dismount the speed sensors manually with suitable tools.
1. Disconnect the plug connectors of the speed sensors from the cable harness.
2. Unscrew the screws at the speed sensors.
4.6.4 TIM - Transmission Identification Module
Position of the TIM
2BAnn175
Fig. 4-9 Position of the TIM
Dismount the TIM
1. Pull the cable (1).

2. Loosen the hexagon socket screw (3).
3. Remove the TIM (2) from the transmission housing.

2011-02-02 4-22
Repair Manual
4.6.5 Converter temperature sensor
Position of the converter temperature sensor
2BAnn172
Fig. 4-10 Position of the converter temperature sensor
Dismounting the converter temperature sensor
1. Unplug the temperature / oil level sensor from the cable (1).
2. Unscrew the temperature sensor (2).
2011-02-02 4-23
Repair Manual
4.6.6 Dismounting the control blocks
2BAnn180
Fig. 4-11 Dismounting the control blocks
Ö Remove the protective cover for cables (1).
CAUTION
The connection between the plug and cable might get damaged.
When removing the cable plug (1), the connection between the cable (2) and cable
plug (1) might get damaged.
1. Use the special tool (3) to remove the cable plug (1) from the solenoid coils.
2. Never tug at the cables (2).
2011-02-02 4-24
Repair Manual
2BAnn181
Ö Pull off cable plug (1) from the solenoid coils.

Use special tool (Î Page 3-5, Fig. 3-5).
2BAnn182
1. Loosen and remove the 12 socket head screws M8 x 50 (2).

2. Remove the spring washers 8 (12x) beneath.
3. Take off the control blocks (1) and (4).
4. Pull out the connecting tube (3).
2011-02-02 4-25
Repair Manual
4.6.7 Dismounting the cable harness
2BAnn190
Fig. 4-14 Dismounting the cable harness
1. Unplug the plug connection between the cable harness and oil sump temperature
sensor (6) with the special tool (5) (Î Page 3-3, Fig. 3-3).
2. Unplug the connection between the cable harness and converter oil temperature sen-
sor (7).
3. Loosen the hex head screw (2).
4. Loosen the hex head screw (3).
5. Take out the cable duct (4).
6. Dismount the pipe for oil level check with fastener (1).
2011-02-02 4-26
Repair Manual
Cable harness with flexible cable feedthrough
2BAnn192
Fig. 4-15 Cable harness with flexible cable feedthrough
1. Loosen the 4 socket head screws (1).

2. Pull the cable harness (2) carefully out of the housing.
Cable harness with cable plug attached to housing

2BAnn193
Fig. 4-16 Cable harness with cable plug attached to housing

1. Loosen cable 1 from the cable harness (1).

2. Loosen the 4 socket head screws (2).
3. Pull the cable harness (3) carefully out of the housing.
2011-02-02 4-27
Repair Manual
Dismounting the plug-in tubes and tubing
2BAnn195
Fig. 4-17 Dismounting the plug-in tubes and tubing
1. Unscrew the converter oil temperature sensor (3).

2. Use a screw M12 to pull the plug-in tubes (1) out of the housing.
3. Dismount the WR pipe (2).
4. Use a screw M10 to pull the plug-in tube (4) out of the housing.
Dismounting the pressure relief valve
2BAnn196
Fig. 4-18 Dismounting the pressure relief valve
1. Loosen and remove the screw plug (1).

2. Remove the washer (2) and insert (3).

3. Loosen the screw (4).

2011-02-02 4-28
Repair Manual
4.6.8 Dismounting the oil pan
WARNING
The transmission might overturn.
Risk of injury and risk of damages to the transmission.
1. Wear personal protection gear when removing and working

on the transmission.
2. Secure the transmission against overturning.
Environmental hazard due to oil!
Oil might flow out when removing the oil pan.

The oil must not leak out to the environment and has to be disposed of in compliance
with the respective local and state regulations.
2BAnn200
Fig. 4-19 Dismounting the oil pan

1. Set up the transmission with the main drive pinion facing upwards.
2. Loosen and remove the oil drain plug (1).

3. Remove the sealing ring (2).
4. Unscrew the oil filter cover (3).

6. Remove the oil filter (5).
2011-02-02 4-29
Repair Manual
Housing with 28 stud bolts
2BAnn201
Fig. 4-20 Oil pans with 28 stud bolts

3. Carefully remove the oil pan (3) from the housing (5) by means of the stud bolts.
2BAnn202
Fig. 4-21 Oil pan with 4 stud bolts




4. Carefully remove the oil pan (3) from the housing (5) by means of the stud bolts.
2011-02-02 4-30
Repair Manual
4.6.9 Dismounting the temperature sensor / oil level sensor
Position of the oil sump temperature sensor / oil level sensor
2BAnn173
Fig. 4-22 Position of the oil sump temperature sensor / oil level sensor
1 Oil sump temperature sensor / oil level sensor

2011-02-02 4-31
Repair Manual
Dismounting the oil sump temperature sensor / oil level sensor
2BAnn174
Fig. 4-23 Dismounting the oil sump temperature sensor / oil level sensor
To remove the oil sump temperature sensor / oil level sensor, you must first dismount the
oil pan (Î Page 4-29, 4.6.8).
1. Unplug the temperature sensor / oil level sensor from the cable (1).
2. Loosen the screw (2).
3. Dismount the temperature sensor / oil level sensor.
2011-02-02 4-32
Repair Manual
4.6.10 Dismounting the output assembly
Transmission with angle drive
Ö Dismount the angle drive (see repair instructions for angle drive).
Transmission without angle drive
2BAnn210
Fig. 4-24 Dismounting the output flange

2. Remove the output flange (2) with washer, shim rings and O-ring.
2BAnn211
Fig. 4-25 Dismounting the output cover

4. Use an appropriate lifting device (1) to lift off the output cover (2) at two eyebolts M10
(3) with the help of a crane.

5. Remove the gasket under the output cover.

2011-02-02 4-33
Repair Manual
2BAnn212
Fig. 4-26 Dismounting the output assembly
6. Take out the R external and internal disks (1).

7. Dismount the parallel key (2).
2BAnn213
8. Unscrew the screw-in socket (2).
The hose line (1) is loose.

2011-02-02 4-34
Repair Manual
2BAnn214
9. Let the hose line hang loosely.

10.Pull out the RG planet carrier (1) with special tools (Î Page 3-8, Fig. 3-10).
11.Dismount the R external crown (2).
12.Dismount the RG-TB disk carrier (3).
2011-02-02 4-35
Repair Manual
4.6.11 Dismounting the turbine transmission
CAUTION
The turbine transmission might get jammed at the planet carrier shaft!
The toothing of the planet carrier shaft might get damaged.
1. Carefully pull out the turbine transmission.
2. If the turbine transmission is jammed, loosen it by carefully shaking it.
CAUTION
The tubing might get damaged!
Do not put up the transmission without the oil pan.
Ö Fasten the oil pan provisionally to the housing with 2 nuts when dismounting the
turbine transmission.
2BAnn220
Fig. 4-29 Dismounting the turbine transmission
1. Pull out the turbine transmission (1) with the special tool (2) (Î Page 3-8, Fig. 3-10).
2011-02-02 4-36
Repair Manual
2BAnn221
2. Take out the TB disks (1).

3. Take out the planet carrier shaft (2).
2BAnn222
4. Loosen and remove the 4 socket head screws (1).

5. Take out the supporting ring (2).
6. Take out the washer (3).
7. Take out the disk spring (4).
8. Take out the disk spring (5).
9. Take out the brake piston (6).
2011-02-02 4-37
Repair Manual
2BAnn223
10.Loosen the 12 socket head screws (1) and remove them together with the washers
(2).
11.Press off the stator with turbine wheel and turbine shaft (3) with the special tool
(Î Page 3-8, Fig. 3-10).
12.Place the transmission on its output side.
2011-02-02 4-38
Repair Manual
4.6.12 Dismounting the drive unit
2BAnn230
Fig. 4-33 Dismounting the drive unit
1. Loosen and remove the 13 hex head screws M10.

2. Pull out the cover with the special tool (Î Page 3-8, Fig. 3-10).
3. Lift off the cover with the input differential using an appropriate lifting device.
4. Dismount the gasket under the drive cover.
4.6.13 Dismounting the suction screen

2BAnn230
Fig. 4-34 Dismounting the suction screen

2011-02-02 4-39
Repair Manual
2. Take out the suction screen (1).
4.6.14 Dismounting the gear pump
2BAnn235
Fig. 4-35 Dismounting the gear pump
1. Loosen and remove the 4 hex head screws M10 (1).

2. Take out the plug-in tube (2).
3. Take out the gear pump (3).
2011-02-02 4-40
Repair Manual
4.6.15 Dismounting the converter outlet valve
2BAnn240
Fig. 4-36 Dismounting the converter outlet valve
1 Hollow screw 9 Pipe

2 Screw connection 10 Screw connection
3 Pipe 11 Pipe
4 Pipe 12 Hex head nut
6 Hollow screw 14 Hollow screw
17 Screw connection
1. Loosen the hollow screws (1) and (6).

2. Remove the pipe (4).
3. Loosen the screw connection (2) and hollow screw (5).

5. Loosen the hollow screw (7), hex head screw (12) and screw connection (17).

7. Loosen the screw connection (10) and hollow screw (16).
2011-02-02 4-41
Repair Manual
9. Loosen the hollow screws (8) and (15).

10.Remove the pipe (9).
11.Loosen the hollow screw (14).
2BAnn241
Fig. 4-37 Dismounting the converter outlet valve
12.Loosen and remove the 5 socket head screws (2).

13.Take out the converter outlet valve (1).
2011-02-02 4-42
Repair Manual
4.6.16 Dismounting the operating pressure valve
2BAnn245
Fig. 4-38 Dismounting the operating pressure valve

3. Take out the valve shim (1).
2BAnn246
4. Loosen and remove the hollow screw (1).

5. Pull out the plug-in tubes (2) (3).

6. Take out the operating pressure valve (4).
7. Dismount the oil sump temperature sensor (5).
2011-02-02 4-43
Repair Manual
2BAnn247
8. Dismount the pipes (1) (2) (4) (5) (6).

9. Take out the pipe for the oil sump temperature sensor line (3).
2011-02-02 4-44
Repair Manual
4.6.17 Dismounting the pump brake
2BAnn250
Fig. 4-41 Dismounting the pump brake
1. Loosen and remove the socket head screw M10 (1).

2. Remove the gear wheel (2).
3. Dismount all pipes.
2BAnn251
Fig. 4-42 Dismounting the pump brake

5. Press off and remove the pump brake (3) with the special tool (Î Page 3-8, Fig. 3-10),
2 forcing screws M10).
Positions for screwing in the forcing screws (2).

2011-02-02 4-45
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Dismounting and mounting assemblies
4.7 Dismounting and mounting assemblies
4.7.1 Dismounting the input differential
Pulling off the drive cover
2BAnn260
Fig. 4-43 Pulling off the drive cover
1. Remove the locking ring (3).

2. Pull off the input cover with the special tool (1) (Î Page 3-8, Fig. 3-10) and
(2) (Î Page 3-8, Fig. 3-9).
Dismounting the input shaft

2BAnn261
Fig. 4-44 Dismounting the input shaft

2. Dismount the input shaft (3).
2011-02-02 4-46
Repair Manual
Dismounting the EK disk carrier
2BAnn262
Fig. 4-45 Dismounting the EK disk carrier

2. Press off the EK disk carrier (4) evenly using 2 screws M12 (1).
3. Take out the ring (3).
4. Take out the EK disks.
Dismounting the EK/DK piston carrier

2BAnn263
Fig. 4-46 Dismounting the EK/DK piston carrier

1. Pull off the external crown (5) using the auxiliary tool (3) (Î Page 3-12, Fig. 3-17)
and the special tool (2) (Î Page 3-8, Fig. 3-9) and 2 screws M 10 (1).
Doing so, the spacer ring (4) is also pulled off.
2011-02-02 4-47
Repair Manual
2. Lift off the entire EK/DK piston carrier (6).

2011-02-02 4-48
Repair Manual
Dismounting the DK planet carrier
2BAnn264
Fig. 4-47 Dismounting the DK planet carrier
Ö Take out the entire planet carrier (1) including the DK disk unit (2).
Dismounting the cover disk
2BAnn265
Fig. 4-48 Dismounting the cover disk
Ö Take out the cover disk (1).

2011-02-02 4-49
Repair Manual
Dismounting the SK disk carrier
CAUTION
The disk carrier is under spring tension!
Risk of injury and risk of damage due to disk carrier or springs

that jump out.
Ö Hold the SK disk carrier with your hand when loosening

the screws.
2BAnn266
Fig. 4-49 Dismounting the SK disk carrier
1. Evenly unscrew the hex head screws M10 (1) crosswise.

2. Carefully remove the SK disk carrier (2).
2011-02-02 4-50
Repair Manual
Dismounting the SK disks
2BAnn267
Fig. 4-50 Dismounting the SK disks
1. Take out all SK disks (1).

2. Take out the springs (2) and spring sleeves (3).
Dismounting the piston
2BAnn268
Fig. 4-51 Dismounting the piston
1. Take the pistons (1) out of the piston carrier (3).

2. Take off the piston rings.

3. Remove the 6 O-rings (2).
2011-02-02 4-51
Repair Manual
Dismounting the SK planet carrier
2BAnn270
Fig. 4-52 Dismounting the SK planet carrier
1. Press off the SK planet carrier (4) from the disk carrier (5).
2. Use auxiliary and special tools for this.
Tool
• Auxiliary tool (3) (Î Page 3-12, Fig. 3-16)
• Special tool (2) (Î Page 3-8, Fig. 3-10)
• Special tool (1) (Î Page 3-8, Fig. 3-9)

2011-02-02 4-52
Repair Manual
Disassembling the SK planet carrier
2BAnn269
Fig. 4-53 Disassembling the SK planet carrier
1. Take the circlip (1) out of the groove of the SK planet carrier.
2. Check whether the seal bushing has shrunk.
2011-02-02 4-53
Repair Manual
Dismounting the guide disk
CAUTION
Springs under tension might jump out!
Risk of injury due to springs under tension.
Ö Remove spring cap carefully.
2BAnn271
Fig. 4-54 Dismounting the guide disk
1. Attach special tools (2 and 4) (Î Page 3-9, Fig. 3-11 and Î Page 3-9, Fig. 3-122).
2. Loosen 2 toothed plate rings simultaneously by turning the special tool (1)
(Î Page 3-8, Fig. 3-10).
2BAnn272
Fig. 4-55 Dismounting the guide disk
3. Carefully remove the toothed plate rings (2) using the special tool (1).
2011-02-02 4-54
Repair Manual
4. Take out the springs, spring sleeves, rods and guide disk.
Dismounting the EK/DK pistons
2BAnn273
Fig. 4-56 Dismounting the EK/DK pistons
1. Dismount the pistons (1) and (6) from the EK/DK piston carrier (3).
2. Remove the piston rings (2) and (5).
3. Take out the 4 O-rings (4).
Dismounting the cylindrical sieve

2BAnn274
Fig. 4-57 Dismounting the cylindrical sieve
1. Check the cylindrical sieves (1) on the EK/DK side for soiling.
2. Replace the cylindrical sieves, if necessary.
2011-02-02 4-55
Repair Manual
Dismounting the grooved ball bearing
2BAnn275
Fig. 4-58 Dismounting the grooved ball bearing
1. Dismount the locking ring (1).

2. Dismount the grooved ball bearing (2) from the supporting washer (3).
Disassembling the external crown
2BAnn276
Fig. 4-59 Disassembling the external crown

Ö Dismount the circlip (2) and supporting washer with driving pin (1) from the external
crown (3).
2011-02-02 4-56
Repair Manual
4.7.2 Dismounting the planet carrier
The following instruction applies accordingly to all planet carriers in the DIWA.5 trans-
mission.
2BAnn280
Fig. 4-60 Dismounting the planet carrier
1. Dismount the roll pin (1).

2. Dismount the axle (2).
3. Dismount the planet wheel (5).
4. Dismount the lateral washers (3).
5. Dismount the needle collars (4) from the planet wheel.
Check all parts for wear and replace them, if necessary.

2011-02-02 4-57
Repair Manual
4.7.3 Mounting the planet carrier
2BAnn280
Fig. 4-61 Mounting the planet carrier
1. Insert the new oiled needle collars (4) into the planet wheel (5).
2. Mount the planet wheel (5) with the new lateral washers (3).
3. Press the axle (2) into the right position and secure it with the new roll pin (1).
2011-02-02 4-58
Repair Manual
4.7.4 Mounting the input differential
CAUTION
Piston bearing surfaces and piston rings can get jammed when you insert them so
that they will not sit properly then!
Risk of transmission failure.
1. Slightly stretch the inner piston rings before inserting them.
2. Look for damages of the piston bearing surface and retouch, if necessary.
The following instruction applies accordingly to the insertion of all piston rings in the
DIWA.5 transmission.
Inserting the piston rings
2BAnn300
Fig. 4-62 Inserting the piston rings
1. Insert the new piston rings (4) into the SK piston (1) of the SK piston carrier (3) with
the groove facing the oil pressure side.
2. Grease the bearing surfaces in the piston carrier.
3. Mount the pistons.
4. Insert 6 greased O-rings 9 x 2 (2) into the piston carrier.

2011-02-02 4-59
Repair Manual
Mounting the grooved ball bearing
2BAnn301
Fig. 4-63 Mounting the grooved ball bearing
1. Place the circlip (1) on the SK disk carrier (3).

2. Check and mount the grooved ball bearing (2).
Mounting the SK planet carrier
CAUTION
When turning over the assembly, the planet carrier can drop
out of the grooved ball bearing.
Risk of injury and risk of damages to the transmission.
1. Wear personal protection gear when working on the planet

carrier.
2. Secure parts against dropping out when turning the
assembly over.
CAUTION
The circlip might get jammed!

The transmission function cannot be ensured.
Ö Make sure that the circlip does not get jammed.

2011-02-02 4-60
Repair Manual
2BAnn302
Fig. 4-64 Mounting the SK planet carrier
Ö Mount the SK planet carrier (1) on the grooved ball bearing.
Inserting the circlip
2BAnn303
Fig. 4-65 Inserting the circlip
Ö Insert the circlip (1) into the groove of the SK planet carrier.
2011-02-02 4-61
Repair Manual
Mounting the SK disks
2BAnn304
Fig. 4-66 Mounting the SK disks
1. Insert the 8 new SK disks in the following order:
• External disk 2 mm thick
• Internal disk
• External disk 3.5 mm thick
• Internal disk
• Internal disk
• Internal disk
2. Align the disks.
2011-02-02 4-62
Repair Manual
Mounting the SK disk carrier
2BAnn305
Fig. 4-67 Mounting the SK disk carrier
Ö Mount the 4 rods (1) with the cylindrical pressure springs (3), spring retainers (2) and
guide disk (4) at 2 opposite sides.
Mounting the SK guide disk
2BAnn306
Fig. 4-68 Mounting the SK guide disk
1. Place the SK piston carrier (1) on the guide disk.

Mind the position of the guide pin.
2. Secure the SK piston carrier with 2 screws M10 x 30 – 8.8 (2).

Do not tighten the screws.

2011-02-02 4-63
Repair Manual
Mounting the springs
CAUTION
Springs under tension might jump out!
Risk of injury due to springs under tension.
Ö Wear personal protection gear when working on the

springs.
CAUTION
Make sure that the pistons, disks, springs, spring sleeves and lock washers do not
get jammed when you mount them!
The transmission function is no longer ensured.
1. Make sure that the disks run smoothly.
2. Make sure that the SK piston fits correctly.
2BAnn307
Fig. 4-69 Mounting the springs
1. Mount the 12 spring sleeves (1) and 12 springs (2).

2. Screw the disk carrier together with the SK piston carrier with 12 hex head screws
M10 x 30 – 8.8, with B10.5 washers placed underneath.

2011-02-02 4-64
Repair Manual
Mounting the planet carrier
2BAnn308
Fig. 4-70 Mounting the planet carrier
1. Mount the external crown (2).

2. Place the planet carrier (1).
Mounting the DK disks
2BAnn309
Fig. 4-71 Mounting the DK disks
1. Insert the 8 new DK disks in the following order:

• External disk 2 mm thick

• Internal disk
• Inside disk
2011-02-02 4-65
Repair Manual
• Internal disk
• Internal disk
2. Place the EK/DK planet carrier with mounted external crown (1) on the assembly.
Mounting the EK/DK pistons
2BAnn310
Fig. 4-72 Mounting the EK/DK pistons
1. Insert the new piston rings (2) and (5) into the EK piston (1) and the DK piston (6)
with the groove facing the oil pressure side.
2. Grease the bearing surfaces in the EK/DK piston carrier (3).
3. Mount both pistons (1) and (6) into the piston carrier.
2011-02-02 4-66
Repair Manual
2BAnn311
Fig. 4-73 Position of the DK pistons
2BAnn312
Fig. 4-74 Position of the EK pistons
4. Mind the correct position of the pistons.

2011-02-02 4-67
Repair Manual
Assembling the piston carrier
2BAnn313
Fig. 4-75 Assembling the piston carrier
1. Insert the 4 new greased O-rings 9 x 2 (1) into the piston carrier.
2BAnn314
2. Put on the external disk (5) and mount it as follows:

• Mount the rods (6), tapering on the O-ring side.
• Mount the spring sleeves (5).
2011-02-02 4-68
Repair Manual
• Mount the cylinder pressure springs (3).
• Mount the toothed plate rings (2) with lock washers (1).
3. Hold tight the rods and guide disk.
4. Turn over the piston carrier.
2BAnn271
5. Put on the external disk (3).

6. Mount the spring sleeves, cylinder pressure springs and toothed plate rings with lock
washers on the already mounted rods.
7. Attach special tools (1) (Î Page 3-8, Fig. 3-10), (2) and (4) (Î Page 3-9, Fig. 3-11)
and (Î Page 3-9, Fig. 3-12) on the rods which have already been mounted.
8. Use special tools (2) and (4) to press down the cylinder pressure springs and mount
the toothed plate rings with lock washers.
9. Mount the remaining rods, spring sleeves, cylinder pressure springs and toothed plate
rings with the special tools (1, 2, 4).
2011-02-02 4-69
Repair Manual
Assembling the DK/EK/SK piston carrier
2BAnn316
Fig. 4-78 Assembling the DK/EK/SK piston carrier
1. Place the EK/DK piston carrier (1) on the SK piston carrier (2).
2. Mind the position of the guide pin.
Mounting the EK disks
2BAnn317
Fig. 4-79 Mounting the EK disks

1. Mount the external crown (1).

2. Insert the 8 new EK disks in the following order:
• Internal disk

2011-02-02 4-70
Repair Manual
• Internal disk
• Internal disk
• Internal disk

3. Align the disks.
Assembling the EK disk carrier
2BAnn318
Fig. 4-80 Assembling the EK disk carrier
1. Mount the EK disk carrier (2).

2. The spacer ring (1) is to be glued in with Loctite 270.
3. Screw the disk carrier (2) to the EK/DK piston carrier (4) using 12 screws
M10 x 150 - 10.9 (3).

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Repair Manual
Tilting the input differential
CAUTION
When overturned, the input differential can start to roll.
Risk of injury and risk of damages to the input differential.
1. Wear personal protection gear when working on the input

differential.
2. Secure the differential against rolling.
2BAnn319
Fig. 4-81 Tilting the input differential
1. Tilt the input differential by 90°.

2. Press on the bearing until the planet carrier sits close.
Use auxiliary tools (Î Page 3-11, Fig. 3-15) for this.
3. Insert the new locking ring 62 x 3 (1).
4. Set up the input differential.
2011-02-02 4-72
Repair Manual
Measuring the input shaft
2BAnn320
Fig. 4-82 Measuring the input shaft
Ö Measure the tooth profile of the shaft at the wear points using balls or rollers ø 4 mm.
If the measure is below 53.85 mm, replace the input shaft.
Mounting the input shaft
1. Place the input shaft on the input differential and screw it tight using 12 hex head
screws
M12 x 30 – 10.9, with B12 spring washers placed underneath.
2. Insert the new O-ring.
Mounting the drive cover
Spare parts
• Ball bearing 6210C3
• Locking ring 90 x 3
• Shaft seal A60 x 78 x 10

Tool
• Auxiliary tools (Î Page 3-11, Fig. 3-14)
Procedure
Ö Mount the input cover on the input shaft completely with new spare parts.
2011-02-02 4-73
Repair Manual
Mounting the bushing
2BAnn321
Fig. 4-83 Mounting the bushing
Ö Mount the bushing (1) greased on the inside and outside and the new locking ring 50
x 2 (2).
Mind the mounting position of the bushing.

2011-02-02 4-74
Repair Manual
4.7.5 Dismounting the pump brake
Dismounting the pump wheel
2BAnn330
Fig. 4-84 Dismounting the pump wheel

2. Dismount the guide ring (2).
3. Lift off the pump wheel (3).
4. Take off the washer (4).
5. Loosen and remove evenly the 3 socket head screws M8 (5).
2011-02-02 4-75
Repair Manual
Disassembling the PB disk carrier
CAUTION
The disk carrier is under spring tension!
Risk of injury when dismounting the tensioned springs.
Ö Wear personal protection gear when working on the

springs.
2BAnn331
Fig. 4-85 Disassembling the PB disk carrier
1. Lift off the pressure plate (2) from the piston carrier.
2. Lift off the PB disks (3) from the piston carrier.
3. Dismount the springs (5).
4. Dismount the spring sleeves (6).
5. Lift off the guide disk (7).
6. Remove the sealing ring (1).
7. Lift off the internal PB disk carrier (4) from the piston carrier.
2011-02-02 4-76
Repair Manual
Disassembling the PB piston carrier
2BAnn332
Fig. 4-86 Disassembling the PB piston carrier
1. Pull the PB piston (2) out of the piston carrier using 2 screws M8 (1).
3. Dismount the piston carrier with a plastic hammer or press.
Dismounting the cylindrical roller bearing

2BAnn333
Fig. 4-87 Dismounting the cylindrical roller bearing

2. Lift off the piston ring carrier (2) from the pump shaft (4).
2011-02-02 4-77
Repair Manual
3. Remove the rectangular rings (3).

To remove the rectangular rings, press one end inwards and unhook.
4. Dismount the cylindrical roller bearing.

There are 2 holes provided for dismounting the cylindrical roller bearing (not depicted in
the figure).
5. Clean all parts carefully, check them for wear and replace them, if necessary.
Disassembling the pump shaft
2BAnn334
Fig. 4-88 Disassembling the pump shaft
1. Dismount the double ring (5) out of the pump shaft (2).
2. Dismount the bushing (4) out of the pump shaft.
3. Dismount the 2 rectangular rings (3) out of the pump shaft.
Dismount the Teflon bushing (1) if it is damaged, worn or scratched.
2011-02-02 4-78
Repair Manual
4.7.6 Mounting the pump brake
Assembling the pump brake
CAUTION
Do not reuse the dismounted Teflon bushing!
The transmission function is no longer ensured.
1. If the Teflon bushing (1) has been removed, press a new Teflon bushing flush into
the pump shaft.
2. The Teflon bushing has to be dry when installed.
2BAnn340
Fig. 4-89 Assembling the pump brake
1. Mount 2 new rectangular rings (3).

2. Install the bushing (4).
Mind the mounting position of the bushing (4).
3. Mount the double ring (5).

2011-02-02 4-79
Repair Manual
Mounting the piston ring carrier
2BAnn333
Fig. 4-90 Mounting the piston ring carrier
1. Install 2 new rectangular rings (3) into the piston ring carrier (2).
2. Slide the piston ring carrier over the pump shaft (4) and, in doing so, press the rect-
angular rings slightly together.
3. Insert the new locking ring (1).
2011-02-02 4-80
Repair Manual
Mounting the PB piston carrier
2BAnn342
Fig. 4-91 Mounting the PB piston carrier
1. Check the grooved ball bearing (4); replace it, if necessary.

2. Place the new gasket (1) on the piston ring carrier (2).
3. Mount the PB piston carrier (3) on the piston ring carrier.
The bores (5) must face in the same direction.
2011-02-02 4-81
Repair Manual
Mounting the PB pistons
CAUTION
Dry piston rings can shrink and seize!
Never install dry piston rings.
Ö Grease the bearing surface of the piston rings before you mount them.
2BAnn343
Fig. 4-92 Mounting the PB pistons
1. Tighten the 6 socket head screws M8 x 20 – 10.9 with washers B8 (1) crosswise.
2. Grease the bearing surfaces of the new piston rings.

3. Insert the new piston rings (4) into the PB piston (2) with the groove facing the oil
pressure side.
4. Mount the PB piston (2) into the PB piston carrier (3).
2011-02-02 4-82
Repair Manual
Mounting the PB disks
2BAnn344
Fig. 4-93 Mounting the PB disks
1. Insert the inside PB disk carrier (2) into the piston carrier (3).
2. Grease, centre and mount the new sealing ring (1).
3. Insert the new guide disk (7) into the piston carrier.
4. Insert 10 spring sleeves (5) and 10 cylinder pressure springs (4).
5. Align the external disks with the guide disk.
6. Insert the disks (6) in the following order:
• 1 new internal disk
• 2 new external disks, 3.5 mm thick
• 1 new internal disk

7. Install the pressure plate (3).
2011-02-02 4-83
Repair Manual
Assembling the disk carrier
2BAnn345
Fig. 4-94 Assembling the disk carrier
1. Place the PB disk carrier (1) on the piston carrier.

2. Mind the position of the bore for the dowel pin (2) and the correct fit of the spring
seats.
3. Screw the disk carrier tight using 3 socket head screws M8 x 20 – 10.9 (2).
4. When tightening the screws, make sure that the disks do not get jammed when in-
serting them into the guide brackets.
2011-02-02 4-84
Repair Manual
Mounting the pump wheel
2BAnn346
Fig. 4-95 Mounting the pump wheel
1. Mount the washer (4).

2. Mount the pump wheel (3).
3. Mount the guide ring (2).
4. Mount the new locking ring (1).
Do not overstretch the locking ring when you mount it.
2011-02-02 4-85
Repair Manual
4.7.7 Dismounting the stator - turbine wheel
Dismounting the turbine wheel
2BAnn350
Fig. 4-96 Dismounting the turbine wheel
1. Take the 2 circlips and the locking ring (1) out of the turbine wheel (2).
2. Take off the turbine wheel (2) and the stator (3) from the turbine shaft.
Replacing the stator
CAUTION
Do not open the screws (2) on the core ring of the stator (1)!
Ö If the stator is damaged, replace it as a whole.
2BAnn351
Fig. 4-97 Replacing the stator
2011-02-02 4-86
Repair Manual
Dismounting the turbine shafts
2BAnn352
Fig. 4-98 Dismounting the turbine shaft
1. Press the turbine shaft (2) out of the grooved ball bearing (4) and inner ring (3).
2. Take the double ring (7), ring (6) and seal bushing (5) out of the shaft.
2011-02-02 4-87
Repair Manual
4.7.8 Mounting the stator - turbine wheel
Checking the stator bushing
2BAnn360
Fig. 4-99 Checking the stator bushing
Ö Check that stator bushing (2) and roll pin (1) sit tightly.
The inside diameter of the stator bushing must not exceed 68.200 mm.
Assembling the turbine shaft
2BAnn361
Fig. 4-100 Assembling the turbine shaft
1. Mount the new seal bushing (2) into the turbine shaft (1).
2. Mount the ring (3).

3. Mount the double ring (4).
2011-02-02 4-88
Repair Manual
Mounting the grooved ball bearing
2BAnn362
Fig. 4-101 Mounting the grooved ball bearing
1. Press the new grooved ball bearing (2) with inserted double ring (1) and inner ring
(5) on the turbine shaft (4) using the auxiliary tool (Î Page 3-13, Fig. 3-18).
2. Place the spacing ring (3) on the grooved ball bearing.
2011-02-02 4-89
Repair Manual
Assembling the stator
2BAnn350
Fig. 4-102 Assembling the stator
1. Place the stator (3) and turbine wheel (2) on the turbine shaft.
2. Secure it with a locking ring A58 x 2 and 2 circlips B73 (1).
Assembly instructions for the locking ring for turbine wheel on the turbine shaft
These instructions only apply to the installation

of the locking ring of the new 150.00085811 series,
on the turbine shaft of the new 150.00101811 series,
together with the turbine wheel H64.154310, without any bores for shim rings. The device
151.00198410 is required for that.
CAUTION
The locking ring must not be mounted with pliers!
Danger of overexpansion.
Ö Mount the locking ring only with the special tool (pin and sleeve) provided for this
purpose.
2011-02-02 4-90
Repair Manual
2BAnn364
Fig. 4-103 Device 151.00198410
1 Short side of pin 3 Sleeve

2 Long side of pin 4 Locking ring on mandrel
2BAnn365
Fig. 4-104 Device 151.00198410
1. Slip the locking ring (4) onto the mandrel.

2. Press pin with the long side (2) onto the sleeve (3) by hand.
3. Move the locking ring to shortly before edge A.

2011-02-02 4-91
Repair Manual
2BAnn366
Fig. 4-105 Assembly of the locking ring for the turbine wheel on the turbine shaft
4. Mount the turbine wheel with turbine shaft 150.00101811 in the stator.
5. Place the mandrel with locking ring and sleeve on the turbine shaft.
2BAnn367
6. Insert the pin into the sleeve with the short end (1) and press the locking ring into the
groove by pressing on the pin.
2011-02-02 4-92
Repair Manual
2BAnn368
7. Install the 2 locking rings 150.00086010 (1) in such a way that the openings of the
locking rings are not positioned on top of each other.
2011-02-02 4-93
Repair Manual
4.7.9 Dismounting the turbine transmission
Dismounting the sun gear
2BAnn370
Fig. 4-108 Dismounting the sun gear

2. Dismount the double ring (2).
Disassembling the sun gear
2BAnn371
Fig. 4-109 Disassembling the sun gear
1. Press off the sun gear (2) with special tool (Î Page 3-8, Fig. 3-10) from the planet
carrier.
2. Take off the T-external crown (3).

2011-02-02 4-94
Repair Manual
Disassembling the planet carrier
2BAnn372
Fig. 4-110 Disassembling the planet carrier
1. Remove the spacer plate (1).

3. Take out the ring (2).
2BAnn373
4. Press off the retainer washer (3) and ball bearing (2) evenly from the planet carrier
(4) using 2 forcing screws M8 (1).

The forcing screws must not press on an axle.

2011-02-02 4-95
Repair Manual
Dismounting the grooved ball bearing
2BAnn374
Fig. 4-112 Dismounting the grooved ball bearing
1. Check the grooved ball bearing (1); replace it, if necessary.
If the grooved ball bearing has to be replaced:

2. apply Loctite 270.
2011-02-02 4-96
Repair Manual
4.7.10 Mounting the turbine transmission
Assembling the planet carrier
2BAnn380
Fig. 4-113 Assembling the planet carrier
1. Place the retaining washer (2) with turned groove facing upwards on the planet carrier
(1).
2. Mount the grooved ball bearing (4) with locking ring (3) with the auxiliary tool
(Î Page 3-13, Fig. 3-18) on the planet carrier (1).
3. Mount the spacer ring (6), locking ring A80 x 2.5 (7) and spacer plate (5).
Assembling the sun gear

2BAnn381
Fig. 4-114 Assembling the sun gear

1. Place the sun gear (1) on the external crown (2).

2. Mount the double ring (3); replace it, if necessary.
2011-02-02 4-97
Repair Manual
Mounting the sun gear
2BAnn382
Fig. 4-115 Mounting the sun gear
Ö Screw the sun gear with mounted external crown on the planet carrier using 6 hex
head screws M8 x 16 – 8.8 (1), with spring washers placed underneath.

2011-02-02 4-98
Repair Manual
4.7.11 Dismounting the output and reverse gear
Dismounting the output and reverse gear
2BAnn385
Fig. 4-116 Dismounting the output and reverse gear
Ö Loosen and remove the 6 socket head screws M8.
Dismounting the reverse gear
2BAnn386
Fig. 4-117 Dismounting the reverse gear

1. Press off the supporting ring (1) using two forcing screws M8 (2).
2. Take off the disk spring (3), brake piston (4) and shim ring behind.
2011-02-02 4-99
Repair Manual
4.7.12 Dismounting the TB-RB disk carrier
Disassembling the TB/RB disk carrier
2BAnn390
Fig. 4-118 Disassembling the TB/RB disk carrier

2. Dismount the counter ring (2).
Dismounting the R planet carrier
2BAnn391
Fig. 4-119 Dismounting the R planet carrier

Ö Dismount the R planet carrier with external crown (1) from the TB-RB disk carrier (2).
2011-02-02 4-100
Repair Manual
Disassembling the planet carrier
2BAnn392
Fig. 4-120 Disassemble the planet gears
1. Take the external crown (1) off the planet carrier (2).
2BAnn393
2. Disassemble the planet carrier (1) (Î Page 4-57, 4.7.2).

3. Mount the new rectangular rings (2).
2011-02-02 4-101
Repair Manual
Disassembling the disk carrier
2BAnn394
Fig. 4-122 Disassembling the disk carrier

2. Dismount the thrust ring (2).
Checking the thrust ring
2BAnn395
Fig. 4-123 Checking the thrust ring

Ö Make sure that the thrust ring (1) sits tightly.

If the thrust ring is loose:

1. Fasten the thrust ring with the new rivets; replace the thrust ring, if necessary.
2. Take out and clean the springs (2).
2011-02-02 4-102
Repair Manual
4.7.13 Assembling the TB-RB disk carrier
Mounting the thrust ring
2BAnn400
Fig. 4-124 Mounting the thrust ring
1. Mount the springs (2).

2. Insert the thrust ring (1).
3. Set up the disk carrier.
4. Insert the 3 sleeves (3).
5. Screw it tight with 3 screws M8 x 25 – 10.9 (5), with washers (4) placed underneath.
Assembling the planet carrier

2BAnn393
Fig. 4-125 Assembling the planet carrier
1. Assemble the planet carrier (1) (Î Page 4-58, 4.7.3).

2. Mount the new rectangular rings (2).
2011-02-02 4-103
Repair Manual
Mounting the external crown
2BAnn402
Fig. 4-126 Mounting the external crown
Ö Place the external crown (1) on the planet carrier (2).
Mounting the planet carrier into the disk carrier
2BAnn391
Fig. 4-127 Mounting the planet carrier into the disk carrier
Ö Mount the R planet carrier with external crown (1) into the TB-RB disk carrier (2).
2011-02-02 4-104
Repair Manual
Mounting the counter ring
2BAnn390
Fig. 4-128 Mounting the counter ring
Ö Screw the counter ring (2) tight using 4 socket head screws M6 x 15 – 10.9 (1).

2011-02-02 4-105
Repair Manual
4.7.14 Mounting and dismounting the operating pressure valve
Disassembling the operating pressure valve
Do not dismount the threaded pin and thread insert (6) for setting the operating pressure.
CAUTION
Risk of injury due to springs under compression!
The housing (1) and cover (12) are under spring tension in
their assembled condition. When you loosen the screws (13)
the housing and cover might unintentionally jump apart.
Ö Hold the housing and cover when you disassemble them.
2BAnn410
Fig. 4-129 Disassembling the operating pressure valve


3. Dismount the piston with the locking ring (11).

4. Dismount the piston (10).

5. Dismount the piston actuator (9).
6. Dismount the pressure spring 2.0 x 15.5 x 76.5 (8).
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Repair Manual
7. Loosen and remove the 3 socket head screws CV84 M6 x 20 (5).

8. Dismount the console (4).
10.Dismount the cylindrical pressure spring 3.2 x 21.0 x 101 (7).
11.Dismount the washer (2).
12.Check the pistons and bores for damage and replace them, if necessary.
Make sure that the pistons are mounted in the correct position and run smoothly.
2BAnn411
Fig. 4-130 Disassembling the operating pressure valve
13.Loosen and remove the 2 socket head screws CV84 M6 x 20 (7).

14.Remove the cover (6).
15.Dismount the pressure spring 3.0 x 20.0 x 31.6 (5).
16.Dismount the piston (4).
17.Loosen and remove the 2 socket head screws CV84 M6 x 20 (3).
18.Remove the cover (2).

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Repair Manual
Assembling the operating pressure valve
2BAnn412
Fig. 4-131 Assembling the operating pressure valve
1. Check the piston and bores for damage and replace them, if necessary.
2BAnn410
2. Mount the washer (2).

3. Screw the console (4) tight using 3 socket head screws CV84 M6 x 20 (5).
4. Mount the cylindrical pressure spring 3.2 x 21.0 x 101 (7).

5. Mount the cylindrical pressure spring 2.0 x 15.5 x 76.5 (8).

6. Mount the piston actuator (9).
7. Mount the piston (10).
2011-02-02 4-108
Repair Manual
8. Mount the piston with locking ring (11).

9. Screw the cover (12) tight with 4 hex head screws M6 x 45 - 8.8 (13), with 4 spring
washers B6 placed underneath.
2BAnn411
10.Screw the cover (2) tight using 2 socket head screws CV84 M6 x 20 (3).
11.Mount the piston (4).

12.Mount the pressure spring 3.0 x 20.0 x 31.6 (5).
13.Screw the cover (6) tight using 2 socket head screws CV84 M6 x 20 (7).

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Repair Manual
4.7.15 Mounting and dismounting the converter outlet valve
Disassembling the converter outlet valve
2BAnn415
Fig. 4-134 Disassembling the converter outlet valve
1. Loosen and remove the 4 socket head screws M6 x 30 – 8.8 (15).

6. Dismount the pressure spring 0.9 x 10.5 x 31 (8).
7. Dismount one piston (17).
11.Dismount the 2 pressure springs 0.9 x 10.5 x 31 (8).
12.Dismount 2 pistons (7).
13.Loosen and remove the 3 socket head screws M6 x 16 – M8.8 (11).
14.Dismount the cover (4).


16.Loosen and remove the 2 socket head screws M6 x 50 – 8.8 (13).

17.Remove the plate (2).
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Assembling the converter outlet valve
2BAnn416
Fig. 4-135 Assembling the converter outlet valve
1. Check the pistons for wear and replace them, if necessary.
2BAnn415
Fig. 4-136 Assembling the converter outlet valve
2. Check the bores for pistons in the housing (1) for wear and replace the housing, if
necessary.
3. Screw the plate (2) tight using 2 socket head screws M6 x 50 – 8.8 (13).


5. Mount 2 pistons (7).
6. Mount 2 pressure springs 0.9 x 10.5 x 31 (8).
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7. Screw the cover (4) tight using 3 socket head screws M6 x 16 – 8.8 (11).
8. Tightening torque 9 Nm.
10.Screw the cover (6) tight using 4 socket head screws M6 x 30 – 8.8 (15).

13.Mount the pressure spring 0.9 x 10 x 5 x 31 (8).
14.Screw the cover (10) tight using 3 socket head screws M6 x 55 – 8.8 (12).
15.Screw the cover (16) tight using 3 socket head screws M6 x 55 (12).

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Repair Manual
4.7.16 Dismounting the control blocks
Dismounting the input-side control block
2BAnn420
Fig. 4-137 Dismounting the input-side control block
1. Loosen the 5 hex head screws (1) and dismount the cover (2).
2. Loosen all screw plugs M10 (12) and remove them with the sealing rings (11).
If not, the pistons cannot be dismounted.
3. Dismount the following parts from the housing (8):
• 4 pistons (5)
• 4 control pins (4)
• 4 pressure springs (3)
• Piston (7)
• Pressure spring (6)
4. Loosen 10 socket head screws M 5 x 20 – CV84 (13) and dismount 5 solenoid coils
(14).
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Dismounting the output-side control block
2BAnn421
Fig. 4-138 Dismounting the output-side control block
1. Loosen the 4 hex head screws (1) and dismount the cover (2).
2. Loosen all screw plugs M10 (15) and remove them with the sealing rings (16).
If not, the pistons cannot be dismounted.
3. Dismount the following parts from the housing (17):
• Piston (3, 18)
• Control pin (4, 19)
• 2 pistons (6)
4. Dismount the insert (9), 2 O-rings (8), ball (10), valve body (11) and locking ring (12).
5. Loosen the 8 socket head screws M 5 x 20 (13) and dismount 4 solenoid coils (14).
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4.7.17 Mounting the control blocks
CAUTION
Risk of mounting the pistons incorrectly!
If the pistons are mounted incorrectly, transmission malfunctions may occur during
operation.
Ö Make sure that the pistons are mounted in the correct position and run smoothly.
Mounting the input-side control block
2BAnn420
Fig. 4-139 Mounting the input-side control block
1. Use 10 socket head screws M 5 x 12 – CV84 (13) to screw the 5 solenoid coils (14)
tight.

The connections must be on top.

2. Mount the following parts into the housing (8) again:
• 4 pistons (5)
• 4 control pins (4)
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Repair Manual
• Piston (7)
• Pressure spring (6)

3. Screw the cover (2) tight using 5 hex head screws (1) M6 x 12 – 8.8.
4. Screw in 5 screw plugs WP M10 x 1 (12) with sealing rings (11).
Mounting the output-side control block
2BAnn421
Fig. 4-140 Mounting the output-side control block
1. Use 8 socket head screws M 4 x 12 – CV84 (13) to screw the 5 solenoid coils (14)
tight.
The connections must be on top.

2. Mount the following parts into the housing (18) again:

• Piston (3, 18)

• Control pin (4, 19)
2011-02-02 4-116
Repair Manual
• 2 pistons (6)

3. Mount the insert (9), 2 O-rings (8), ball (10), valve body (11) and locking ring (12).
4. Screw the cover (2) tight using 4 hex head screws M6 x 12 – 8.8 (1).
5. Screw in 5 screw plugs WP M10 x 1 (15) with sealing rings (16).

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Voith Turbo GmbH & Co. KG Maintenance / Assembling the transmission
4.8 Assembling the transmission
4.8.1 General information
Prerequisite
The following work has to be carried out on all piston rings, O-rings, shaft sealing rings
and locking rings before mounting them.
Procedure
1. Check the bearing surfaces of the piston rings for grooves and polish slight grooves,
if necessary.
2. Stretch the inner piston rings before inserting them.
3. Insert piston rings generally with the groove facing the oil pressure side.
4. Grease all piston rings and O-rings before mounting them.
5. Grease bearing surfaces of radial sealing rings.
6. Do not open locking rings more than necessary during mounting.
4.8.2 Checking and replacing parts
Prerequisite
The following work has to be carried out on all parts before the transmission is assem-
bled.
1. Check ball bearings, roller bearings and needle bearings and replace them, if neces-
sary.
2. Replace all sealing elements, hose lines and internal disks.
3. Before installation, immerse internal disks in oil.
4. Check TB internal disks and external disks for wear. Replace disks if you detect any
signs of overheating or deformation.
Install all flat gaskets without using grease.
If flat gaskets are installed with grease, they can slip out during the assembly and will
not have a sealing effect anymore.
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4.8.3 Mounting the screw plug
2BAnn430
Fig. 4-141 Mounting the screw plug
1. Mount the insert (3).

2. Insert the washer (2).
3. Mount the screw plug (1) into transmission housing.
4. Screw in the screw plug until it is at least flush with the housing.

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4.8.4 Mounting the pump brake
Mounting the O-ring
2BAnn435
Fig. 4-142 Mounting the O-ring
1. Place the transmission housing on its output side.

2. Insert the new O-ring 275 x 2.65 (1) into the housing groove.
Stretch (do not overstretch!) and grease the O-ring before mounting.
Mounting the pump brake assembly

2BAnn436
Fig. 4-143 Mounting the assembly
1. Mount the pump brake assembly (1) with the special tool (Î Page 3-8, Fig. 3-10).
2. Align the pump brake with the centring pin (3).

3. Screw the pump brake tight with the 9 hex head screws M10 x 65 – 8.8 (2), with the
9 B1 spring washers placed underneath.
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The positions 4 and 5 remain empty.
Installing oil lines
2BAnn437
Fig. 4-144 Screwing on oil lines
1. Screw the line (1) tight with the hex head screw (2) M10 x 65.
2. Insert and fasten the line (3).
3. Insert and fasten the pipe with the cable (4).
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Fastening the temperature sensor
2BAnn438
Fig. 4-145 Fastening the temperature sensor
1. Screw the plate (6) with the temperature sensor (4) to the housing using a hex head
screw M 10 x 20 – 8.8 (7).
2. Screw the pipe with the cable (3) and oil line (2) to the housing using a hex head
screw M10 x 20 – 8.8 (1).
3. Insert the cable (5) at the temperature sensor (4).
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Plug-in tubes and lines
2BAnn439
Fig. 4-146 Plug-in tubes and lines
Put new greased O-rings on all plug-in tubes before mounting.
1. Mount the plug-in tubes (1) (2) (3) with the thread facing upwards – O-rings 12 x 2.
2. Mount the pipe (4) – O-rings 12 x 2.
3. Screw the pipe (4) tight using a hex head screw M 10 x 65 – 8.8 (6) and a spring
washer placed underneath.
4. Screw the pipe (5) tight using a hollow screw M16 x 1.5 x 28 (7).

5. Fasten the pipe H68.0766xx (8).

6. Screw the pipe H68.3153xx (10) and pipe H68.3158xx (11) tight using a hollow screw
M10x1 (9).
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4.8.5 Mounting the operating pressure valve
CAUTION
When the operating pressure valve is re-installed, it is not

secured by screws at first!
Risk of injury from dropping operating pressure valve
Ö Wear appropriate protection gear.
2BAnn440
Fig. 4-147 Mounting the operating pressure valve
1. Insert the operating pressure valve (2).

2. Fasten the line (1).
3. Mount the plug-in tubes (3) and (4).
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2BAnn441
Fig. 4-148 Mounting the operating pressure valve
1 Pipe 68.3153XX 2 Pipe 68.0766XX

3 Pipe 68.3034XX
4. Fasten the pipe (1) to the operating pressure valve using a hollow screw.
7. Mount the valve shim. Only fix the valve shim, do not tighten it.
Tighten the screws only when all pipes have been fastened.
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4.8.6 Mounting the converter drain valve
2BAnn445
Fig. 4-149 Mounting the converter drain valve
1 Pipe H68.0763XX 11 Pipe

3 Pipe H68.0761XX 13 socket head screw M6x40
4 Operating pressure valve 14 Converter outlet valve
5 Hex head screw 15 Hollow screw
7 Pipe 17 Hollow screw
8 Hex head screw M8 x 10 18 Hollow screw
9 Pipe 19 Pipe H68.3152XX
10 Union nut 20 Hollow screw
1. Fasten the converter drain valve (14) using 5 socket head screws M6 x 40 – 10.9 (13).
Do not tighten the socket head screws.
2. Fasten the pipe (12) to the converter drain valve (14) with the hollow screw (18) and
to the operating pressure valve with the union nut (10).
3. Fasten the pipe H68.3152XX (19) to the converter drain valve (14) with a hollow screw
(20) and to the operating pressure valve (4) with a hollow screw (6).
4. Fasten the pipes (1) H68.0763XX and (11) to the converter drain valve (14) with a
hollow screw (17).

5. Fasten the pipe (1) H68.0763XX to the operating pressure valve (4) with a hollow
screw (2).
6. Fasten the pipe (3) H68.0761XX to the converter drain valve (14) with a hollow screw
(15).
7. Fasten the pipe (9) to the converter drain valve (14) with a hollow screw (16) and to
the pipe 68.3153XX (Î Page 4-125, Fig. 4-148, 1) with a hollow screw.
2011-02-02 4-126
Repair Manual
8. Screw the pipe (7) to the housing with a hex head screw M8 x 10 – 8.8 (8).
9. Tighten all screws.
Tightening torques (Î Page 5-1, Chapter 5.1).

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4.8.7 Mounting the gear pump
2BAnn446
Fig. 4-150 Mounting the gear pump
1. Fasten the gear pump (2) to the housing with 3 hex head screws M10 x 45 – 8.8 (4),
with B10 spring washers placed underneath.
2. Fasten the pipe (1) to the housing with a new O-ring using a hex head screw
M10 x 45 – 8.8 (3).
3. Tighten the hex head screws (3) and (4).

2BAnn447
Fig. 4-151 Mounting the gear pump
4. Screw the gear wheel (1) tight using a socket head screw M10 x 30 – 10.9 (3), with
the spring washer B10 x 18 (2) placed underneath.
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4.8.8 Mounting the drive unit
2BAnn448
Fig. 4-152 Mounting the drive unit
1. Place the new gasket (4) on the transmission housing.

2. Lower the input differential (2) by continuously turning the shaft (1) and align it with
the roll pin (3).
The gears of the drive section must mesh.
3. Screw the input cover tight using 13 hex head screws M10 x 50 – 8.8 and 13 B10
spring washers placed underneath.

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4.8.9 Mounting the stator - turbine wheel
2BAnn450
Fig. 4-153 Mounting the stator - turbine wheel
1. Install the stator with the turbine wheel and turbine shaft (1) in the transmission hous-
ing using the special tool (2) (Î Page 3-8, Chapter Fig. 3-10).
2BAnn451
The guide at the stator (1) and the groove at the housing (2) must be aligned to each
other.
2.
2011-02-02 4-131
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2BAnn452
3. Insert the throttle (1) with the new O-ring 12 x 2 (2) in the bore of the transmission
housing (control block side).
2BAnn453
4. Mount the piston rings (4) and (5) with the groove facing the pressure side into the
T-piston (3).
6. Screw the stator (2) tight using 12 socket head screws M10 x 35 (1) and washers
B10.5.

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2BAnn454
7. Insert the disk spring (6).

8. Insert the supporting ring (1).
9. Insert the 4 socket head screws M8 x 30 – 10.9 (2) with Loctite 242 and tighten them.
10.Insert the two disk springs (3) and (4).
Insert the disk springs in X-shape.
11.Insert the brass washer (5) into the supporting ring.

2BAnn456

12.Insert the planet carrier shaft (1) with the double ring (2).
13.Bring the planet carrier shaft into toothing by turning it.
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4.8.10 Mounting the turbine transmission
TB disks
2BAnn460
Fig. 4-159 Mounting the turbine transmission - TB disks
The external disks (3) of the turbine transmission bear a special marking (5) that allows
them to be distinguished from the external disks of the reverse-gear transmission.
Observe the marking to distinguish from reverse-gear disks.
1. Place 4 external disks with marking (3) and 3 internal disks (4) on the turbine trans-
mission on top of each other.
Begin with an external disk.
2. Align the disks.

3. Press the disks and the turbine transmission together with the special tool (2)
(Î Page 3-8, Fig. 3-10).
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Repair Manual
2BAnn461
4. Insert the turbine transmission (2) into the housing using the special tool (1).
5. Remove the special tool (1).
2BAnn462
6. Insert the RG-TB disk carrier (1) completely with the external crown with thrust ring
(2) facing upwards and the groove facing the parallel key groove.
The disk carrier must not get jammed.

The disk carrier must sit on the stator.

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Repair Manual
Reverse gear
2BAnn463
Fig. 4-162 Mounting the turbine transmission - reverse gear
1. Screw in the screw-in socket (1) with the hose line (2).
2. Screw the hose line to the converter drain valve using the hollow screw (3) and sealing
rings A10 x 16.
2BAnn464
3. Insert 2 new O-rings 12 x 3 (1).

4. Insert the parallel key (2).

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Repair Manual
2BAnn465
5. Mount 6 external and 5 internal disks (1) alternately.
Begin with an external disk.

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Repair Manual
4.8.11 Mounting the reverse gear into the output unit
2BAnn470
Fig. 4-165 Mounting the reverse gear into the output unit
1. Press the new shaft sealing ring (1) into the output cover (2).
The shaft sealing ring must lie 2 mm below the upper edge of the input cover.
2BAnn471
Fig. 4-166 Mounting the reverse gear into the output unit
2. Turn the input cover.

3. Mount the ring (2).
4. Insert the brake piston (1).
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Repair Manual
4.8.12 Measure and adjust the disk clearance of the reverse gear.
2BAnn472
Fig. 4-167 Measure and adjust the disk clearance of the reverse gear.
Insert the brake piston without the piston rings into the output cover.
Disks and piston must be flush during measurement.
Do not press the disks together.
1. Take measure A.
2. Take measure B.
A minus B provides the measured disk clearance.
• Example:
Measure A = 5.5 mm
Measure B = 1.0 mm
5.5 mm - 1.0 mm = 4.5 mm disk clearance.
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Repair Manual
Defining the shim rings:
Shim rings are available in 0.5 mm, 1.0 mm and 1.5 mm thickness.
The disk clearance must lie between 2.7 and 3.2 mm.
• Example:
4.5 mm measured disk clearance
minus 1.5 mm shim ring
yields a clearance of 3.0 mm.
1. Take the brake piston out of the output cover.

2. Insert the new piston rings with the groove facing the pressure side.
3. Insert the new piston ring without groove into the brake piston.
4. Insert the brake piston into the output cover.
2011-02-02 4-140
Repair Manual
4.8.13 Mounting the output unit
Grooved ball bearing
2BAnn475
Fig. 4-168 Mounting the output unit - grooved ball bearing
Ö Check the grooved ball bearing 6215 (1) and replace it, if necessary.
Spring washer
2BAnn476
Fig. 4-169 Mounting the output unit - spring washer
1. Insert the new spring washer (2) and ring (1) into the output cover.
2. Screw the output cover tight using 6 socket head screws M8 x 30 – 10.9 (3) and 6
spring washers A8.

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Repair Manual
Gasket
2BAnn477
Fig. 4-170 Mounting the output unit - gasket
1. Slightly roughen the bearing surface of the gasket on the housing.

2. Place the new gasket (1) on the transmission housing.
Output cover
2BAnn478
Fig. 4-171 Mounting the output unit - output cover
1. Mount the output cover (2) with the special tool (1) (Î Page 3-8, Fig. 3-10).
When lowering the output cover, make sure that the ring gear does not get jammed
and the radial sealing ring is not damaged.
2011-02-02 4-142
Repair Manual
2BAnn479
Fig. 4-172 Mounting the output unit - output cover
2. Fasten the output cover and the gasket with the special tool (2) (Î Page 3-8, Fig. 3-
10).
3. Insert the output flange (1).

4. Use a plastic hammer to knock on the output flange until the cover sits tight on the
transmission housing.
5. Screw the output cover tight using 12 hex head screws M10 x 65 – 8.8 and 12 B10
spring washers.

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Repair Manual
Adjusting the clearance
2
3
X
30
A
2BAnn480
Fig. 4-173 Adjusting the output clearance
1. Place the measuring device (2) on the shaft.

2. Screw the measuring device tight to the shaft using 3 hex head screws M10 x 70 –
10.9 (1).
3. Tighten the screws one after the other with a tightening torque of 50 Nm.
4. Repeat this process three times.
5. Measure the distance between the planet carrier shaft (4) and the upper edge of the
measuring device (2) using a depth gauge.
Clearance: X = A - 30 mm.
6. Set the clearance to 0.2 + 0.1 mm.
This clearance cannot be checked anymore once the transmission has been in oper-
ation. During operation the tightened parts settle so that the clearance changes.
7. Loosen and remove the hex head screws (1).

8. Remove the measuring device.

9. Use the shim rings (3) where necessary to adjust the clearance.
2011-02-02 4-144
Repair Manual
2BAnn510
Fig. 4-174 Mounting the output flange
10.Place the shim (1) on the output flange (3).

11.Screw the output flange (3) tight using 3 hex head screws M10x50-SBE-R, with spring
rings 10 placed underneath.
Tightening torque 66 Nm
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Repair Manual
4.8.14 Mounting the oil sump temperature sensor / oil level sensor
2BAnn174
Fig. 4-175 Mounting the oil sump temperature sensor / oil level sensor
1. Insert the sensor.

2. Tighten the screw (2).
3. Plug in the plug (1).

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Repair Manual
4.8.15 Mount the oil pan.
2BAnn201
Fig. 4-176 Mounting the oil pan
1. Put on the new gasket (4).
The gasket must be free of grease when installed.
2. Screw the oil pan (3) tight using 28 hex head nuts (1) and 28 washers (2) placed
underneath.

2011-02-02 4-147
Repair Manual
2BAnn202
Fig. 4-177 Mounting the oil pan
1. Put on the new gasket (4).
2. Screw the oil pan (3) tight using 4 hex head nuts (1) and 4 washers (2) placed under-
neath.
3. Screw the oil pan (3) tight using 24 hex head screws (6) and 24 washers (2) placed
underneath.

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Repair Manual
Inserting the oil filter
2BAnn200
Fig. 4-178 Mounting the oil pan - inserting the oil filter
1. Insert the oil filter (5).

2. Screw in the oil filter cover (3) with the new gasket (4).
3. Screw in the oil drain plug (1) with a new sealing ring A26 x 34 (2).

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Repair Manual
4.8.16 Mounting the speed sensors
CAUTION
Incorrect distance between speed sensors and pulse-generator wheel!
Risk of destruction of the speed sensors.
1. Set the distance with spacing washers.
The distance must be between 0.8 and 2.5 mm.

or
2. Reuse the previously installed spacing washers.
CAUTION
Mount the speed sensors only with suitable tools!
The speed sensors might get damaged.
Ö Never use an impact screwdriver to mount the speed sensors.
1. Insert the new speed sensors.
Position of the speed sensors (Î Page 4-21, Chapter 4.6.3)
2. Set the distance between the speed sensors and pulse-generator wheel.
For N1 and N2, spacing washers are available for setting the distance between the
speed sensor and the rotary sensor. The distance must be between 0.8 and 2.5 mm.
3. Tighten the screws at the speed sensors.

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Repair Manual
4.8.17 Mounting the converter temperature sensor
2BAnn172
Fig. 4-179 Mounting the oil sump temperature sensor / oil level sensor
1. Insert the temperature sensor (2).

2. Tighten the screw.

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Repair Manual
4.8.18 Mounting the cable harness
2BAnn485
Fig. 4-180 Mounting the cable harness - preparation
1. Screw the fastener tight with the hex head screw M8 x 16 – 8.8 (1).
2. Screw the pipe tight with the hollow screw M10 x 1 (2).
Cable harness with flexible cable feedthrough

2BAnn486
Fig. 4-181 Cable harness with flexible cable feedthrough
1. Insert the cable harness (1).

2. Tighten the 4 hex head screws M6 x 40 – A4-70 (2).
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Repair Manual
Cable harness with plug attached to housing
2BAnn193
Fig. 4-182 Cable harness with plug attached to housing
1 Cable 1 3 Cable harness

2 socket head screws
1. Insert the cable harness (3) in the transmission housing.

2. Tighten the 4 hex head screws M6 x 35 – A4-70 (2).

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Repair Manual
Mounting the cable harness
2BAnn487
Fig. 4-183 Cable harness
1. Mount the protective cable cover (2).

2. Screw the protective cable cover tight with a hex head screw M8 x 16 – 8.8 (1).
2BAnn488
Fig. 4-184 Cable harness
3. Plug in the plug to the oil sump temperature / oil level sensor (2) with the special tool
(1) (Î Page 3-5, Fig. 3-6).
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Repair Manual
2BAnn489
Fig. 4-185 Mounting the cable harness
4. Plug in the connector to the converter temperature sensor (1).

5. Lay the cable and plug in the protective cable cover as shown in the picture.
2BAnn490
6. Plug in the connector to the speed sensor N1 (1).

2BAnn491
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Repair Manual
7. Plug in the plugs to the speed sensors N2(1) and N3 (2).

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Repair Manual
4.8.19 Mounting the control blocks
2BAnn495
Fig. 4-188 Mounting the control blocks
1. Fasten the control block (2) with 6 socket head screws M8 x 50 (1).
2. Plug the 5 cable plugs (4) into the solenoid coils with the special tool (Î Page 3-4,
Fig. 3-4).
2BAnn496
Fig. 4-189 Mounting the control blocks
3. Plug the cable plugs (3) into the solenoid coils with the special tool (1) (Î Page 3-4,
Fig. 3-4).
4. Mount the connecting tube (2) with new O-rings 12 x 2.

5. Fasten the control block (4) with 6 socket head screws M8 x 50 (5).
6. Tighten 12 socket head screws M8 x 50.
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Repair Manual
4.8.20 Mounting the control block cover
2BAnn165
Fig. 4-190 Mounting the control block cover
1. Insert the new gasket (4).
2. Screw the control block cover (3) tight using 20 hex head screws M8 x 30 – 8.8 (1)
and washers B 8.4 (2).

2011-02-02 4-159
Repair Manual
4.8.21 Mounting the heat exchanger
6
7
6
5
1
4
3
2
2BAnn160
Fig. 4-191 Mounting the heat exchanger
1. Mount 2 plug-in tubes (7) with gaskets (6).

2. Put on 2 new gaskets (5).
The gaskets must be free of grease when installed.
3. Attach the heat exchanger with fastener (4) to the transmission using 4 hex head
screws M12 x 40 – 8.8 (2), with 4 washers (3) placed underneath.
4. Attach the heat exchanger with fastener (4) to the transmission using 4 hex head
screws M12 (1), with 4 washers (3) placed underneath.

2011-02-02 4-160
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Mounting the hydrodamp
4.9 Mounting the hydrodamp
2BAnn500
Fig. 4-192 Mounting the hydrodamp
1. Apply gleitmo® 805 to the V-profile of the hydrodamp.

2. Fasten the hydrodamp to the external pitch circle on the engine flywheel in the posi-
tions 2 and 10 o'clock with 2 assembly pins.
or
3. The hydrodamp can also be fastened in the positions a and b on the engine flywheel
with 2 dowel pins.
4. Push the hydrodamp into the centring.
5. Screw the hydrodamp to the engine flywheel with 2 screws.
6. Unscrew the assembly pins.
7. Insert the remaining screws.
8. Tighten the 12 screws M10 - 8.8 evenly crosswise.

2011-02-02 4-161
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Installing the transmission
4.10 Installing the transmission
4.10.1 Transmission
CAUTION
The hydrodamp can be damaged if the transmission input shaft is improperly inserted
into the hydrodamp!
Damage to hydrodamp!
Ö When inserting the shaft, make sure that the shaft does not get jammed.
1. Apply gleitmo® 805 to the gear teeth of the transmission input shaft.
2. Move the transmission up to the engine.
The flywheel housing must be parallel to the transmission flange on the input side.
3. If the transmission input shaft and hydrodamp hub are aligned tooth-on-tooth, turn
the transmission input shaft until the gear teeth are engaged properly.
4. Move the transmission input shaft into the hydrodamp.
5. Move the transmission up to the hydrodamp until the transmission flange on the input
side rests against the flywheel housing.
6. Screw the input-side transmission flange to the flywheel housing.
4.10.2 Drive shaft
CAUTION
Damage to the transmission due to improperly mounted drive shaft!
If the two parts of the drive shaft are installed incorrectly, irregular rotations can occur
as a result, causing critical torsional vibrations especially at high speeds.
Ö When installing the two parts of the drive shaft, make sure that they are aligned
correctly with each other and observe the markings.
Ö Install the drive shaft and screw it tight.
The installation instructions and safety notes of the manufacturer of the vehicle or the
drive shaft must be observed.
2011-02-02 4-162
Repair Manual
4.10.3 Ports
Prerequisite
The heat exchanger bears markings that indicate how to make the connections:
• water out
• oil in
• oil out
• water in
Procedure
2BAnn505
Fig. 4-193 Heat exchanger connections
1. Mount the water pipes of the heat exchanger (2).

2. Make the electrical connections such as:
• Speedometer
• Oscillator
• Cable 1
2011-02-02 4-163
Repair Manual
CAUTION
The cable harness and cable 1 come with either gold-plated or tin-plated contacts
(see customer service letter 173a)!
Contacts may only be connected if they are plated alike (gold - gold, tin-plated - tin-
plated).
Ö Plug only gold-plated contacts on gold-plated contacts.
Plug only tin-plated contacts on tin-plated contacts.
The contacts will be destroyed when linking contacts of different material.
All cable connections must be latched properly and fastened tightly.
1. Fill in cooling water up to the maximum level. Please observe the manufacturer's
instructions.
2. Fill the transmission with oil.
2011-02-02 4-164
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Filling the transmission with oil
4.11 Filling the transmission with oil
CAUTION
Damage to the transmission due to incorrect oil level!
Insufficient oil can lead to transmission malfunctions and cause damage (disk dam-
age).
Excess oil can cause increased fuel consumption and may result in oil leakage at the
air breather filter.
Ö It is imperative to check the transmission oil level before starting the engine for
the first time after the transmission has been installed.
Ö Fill ATF oil into the transmission.
The oil filler can be located laterally or on top of the transmission.
Oil quantity
• For an oil change: 24 - 25 l.
• For a complete refill, e.g. after repair of the transmission: approx. 31 l.
• If oil was filled at the manufacturing plant, no additional oil filling is required.
• After short operation of the transmission, the oil level must be checked again and
corrected, if necessary.
The oil level must range between the "min" and "max" markings of the oil dipstick.
Oil quality
The transmission may only be filled with oil types that are specified in the current version
of the Voith lubricant lists H55.6335.. and H55.6336..
Ö Check the oil level after having filled in the oil and examine the transmission for leaks.
2011-02-02 4-165
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Test drive
4.12 Test drive
Preparation
Vehicle configuration!
Depending on the vehicle configuration, different components are installed or different
transmission functions are implemented.
1. For this purpose, please read the vehicle's circuit diagram.

2. Connect the computer running the ALADIN diagnostic software to the transmission
control unit.
3. Read out the identification data of the control unit:
• current software version,
• current dataset
Test the safety functions against inadvertent driving.
1. Press one of the forward buttons "D", "1", "2" or "3".

2. Start the engine.
The engine must not start.
3. Apply the reverse gear button "R".
The engine must not start.
5. Press the neutral button "N".
6. Step on the brake pedal.
The engine starts.
8. Press one of the gear buttons.
The vehicle starts to drive.
2011-02-02 4-166
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Test drive
During the test drive
1. Check the transmission functions, e.g.:
• all upshifts and downshifts
• function of the converter brake (using the vehicle or transmission diagnostics)
• driving in reverse
• ANS function
• shifting quality of the transmission at partial and full load
• the safety functions implemented in the vehicle according to its configuration, e.g.:
– gear acceptance when the vehicle is stationary and only the brake pedal is applied
– gear acceptance only up to the engine limit speed
2. Read out the event memory.

3. Clear the event memory after the faults have been eliminated.
After the test drive
1. Check the transmission for leaks.

2. Check the cooling water connections for leaks.
3. Check the oil level.
2011-02-02 4-167
Repair Manual
Voith Turbo GmbH & Co. KG Maintenance / Measuring and testing
4.13 Measuring and testing
4.13.1 Measuring the stall point
CAUTION
Operation at stall point!
If the vehicle is operated at the stall point for more than 20 seconds, the transmission
might be destroyed.
Ö Never operate the vehicle at the stall point for more than 20 seconds.
From the control unit software D5.3.0.0 on, a recovery time of 10 min. is required.
CAUTION
Engine run-up time!
Satisfactory engine run-up times are between 5 and 8 s. A run-up time of more than
10 s
implies bad engine run-up.
Ö In such cases, consult the vehicle or engine manufacturer.
1. Apply the parking brake.

The engine must have operating temperature.
3. Press one of the buttons "1", "2" "3" or "D".

A forward gear is engaged.
4. Floor the accelerator pedal and let engine run at full speed for 15 seconds maximum.
5. Determine the maximum achievable engine speed n1 (= stall speed) by means
of PC diagnosis.
2011-02-02 4-168
Repair Manual
4.13.2 Pump characteristic
CAUTION
Engine torque deviates with the vehicle being stationary and with the engine running!
The torque of the stationary vehicle can significantly deviate from the maximum en-
gine torque while driving since the electronic engine control may limit the engine
output to a certain value when being stationary.
Ö Consult the vehicle manufacturer.
1700
4H 4X
4V
1600
1500
1400
1300
3H
Motormoment M1 (Nm)
1200 3X
1100
1000
3V
900
800
700
3K
600
500
400
300
200
100
0
700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Motordrehzahl n1 (1/min)
Diff. 4H T2R2 Diff. 4X T2R2 Diff. 4V T0R2 / T0R0 Diff. 3H T2R2

Diff. 3X T2R2 Diff. 3V T2R2 Diff. 3K T0R2 / T0R0
2BAnn506
Fig. 4-194 Pump characteristic diagram:

(to the right: engine speed n1 [rpm]; upwards: engine torque M [Nm]).
1. Determine the input differential used in the transmission and the impeller model by
means of the rating plate.
The possible combinations of input differential and impeller range from 4H to 3K.
2. Check whether the determined engine torque complies with the specifications made
by the vehicle manufacturer.
3. Enter the measured maximum engine speed n1 in the pump characteristic diagram.
Read off the maximum possible engine torque at bus standstill from the pump char-
acteristic diagram.
If the determined engine torque is higher than the value indicated by the manufacturer:
Ö Check the converter pressure (Î Page 4-170, 4.13.3).

If the determined engine torque is lower than the value indicated by the manufacturer:
Ö Consult the vehicle or engine manufacturer.
2011-02-02 4-169
Repair Manual
4.13.3 Measuring pressures
WARNING
Improper behaviour may result in severe injuries or scalding.
1. Mount the measuring cover only when the engine is at

standstill.
2. Connect the pressure gauge only when the engine is at
standstill.
2BAnn130
Fig. 4-195 Measuring cover
1 WR 7 Operating pressure
2 Converter pressure 8 DK
3 TB 9 EK
4 RG 10 PB
5 RK 11 WP
6 SK
2011-02-02 4-170
Repair Manual
Operating pressure
Ö Measure the operating pressure at measuring point 7 (Î Page 4-170, Fig. 4-195).
• immediately after shifting into second gear,
• at an engine speed of approx. 1500 rpm,
• at an oil temperature of 80-90 °C.

The setpoint for the operating pressure is then pA =8.5, 9.5 or 10.5 bar (± 0.2 bar).
Please note the rating plate.
The setpoint for the operating pressure at engine idle speed (500 ± 50 rpm) is pA ≥ 3.5
bar.
If the operating pressure deviates from this value, it has to be re-adjusted. The operating
pressure may, for instance, deviate from the setpoint after disassembly and assembly of
the operating pressure valve.
In DIWA.5 transmissions produced as of the middle of 2010, the bore in the control block
for measuring the operating pressure is not manufactured any longer. Therefore, the
operating pressure cannot be measured at the measuring point
Î Page 4-170, Fig. 4-195/7 any longer. Then, the following applies: the operating pres-
sure is equal to the pressure at a connected solenoid valve.
The adjustment bore in the housing (Î Page 4-171, Chapter Fig. 4-196/1) allows the
threaded pin with hexagon socket at the operating pressure valve to be turned with a
hexagon socket wrench a/f 5. The threaded pin allows for adjusting the preload of the
spring in the operating pressure valve.
2BAnn507
Fig. 4-196 Operating pressure

1. Turn the threaded pin (1) until an operating pressure of 8.5 bar is reached.
If the operating pressure is below the setpoint and can no longer be set to 8.5 bar,
the gear pump could be defective.

2. Check the gear pump and replace it, if necessary (see repair manual).
2011-02-02 4-171
Repair Manual
Pressures at the solenoid valves
At the measuring points DK, EK, PB, WP and SK, the pressures must be the same as
the operating pressure.
CAUTION
WR pressure!
The WR oil pressure is cycled and therefore variable over time. Its height depends
on the operating status (braking or reversing).
Therefore, simple pressure measurements by means of a pressure gauge are not
suitable for more thorough troubleshooting at the WR valve.
1. The WR oil pressure is not measureable.
2. The cycle signal can be monitored with a digital measuring instrument.
CAUTION
RBK pressure!
The RBK pressure for braking in first gear is 1 bar.
In few cases the RBK pressure for braking in first gear is max. 2 bar.
Ö Check the RBK pressure.
The RBK pressure must not exceed the specified value.
Converter pressure
1. Measure the converter pressure at measuring point (2).

See the illustration for the measuring points (Î Page 4-170, Fig. 4-195).
• pC when the converter filling control (CFC) is active pC = 0 bar.
• pC ≥ 2 bar at
– oil temperature toil 80-90 °C,
– forward gear engaged,
– engine at idle speed (500 ± 50 rpm),
– parking brake applied.
2. If this value is not reached, the converter sealing must be improved.

Please contact the Voith customer service in this matter.
2011-02-02 4-172
Repair Manual
Voith Turbo GmbH & Co. KG Standard lists
5 Standard lists
5.1 DIWA.5 tightening torques
Tightening torques for hexagon head and cheese head screws
Dimension Property class Tightening torque [Nm] Tightening torque [lb-ft]

M5 8.8 5 4
M5 10.9 8 6
M6 8.8 9 7
M6 10.9 14 10
M8 8.8 23 17
M8 10.9 33 24
M10 8.8 46 34
M10 10.9 67 49
M10x1 8.8 51 38
M10x1 10.9 75 55
M12 8.8 78 57
M12 10.9 115 85
M14 10.9 184 136
M14x1,5 10.9 198 152
M14x1,5 12.9 232 171
M16 8.8 191 141
M16 10.9 281 208
M16x1,5 8.8 204 150
M16x1,5 10.9 300 221
2011-02-02 5-1
Repair Manual
Voith Turbo GmbH & Co. KG Standard lists / DIWA.5 tightening torques
Special cases
Designation Dimension Tightening torque [Nm] Tightening torque [lb-ft]

Drain plug converter oil M14 50 37
Control block M8x50-10.9 20 15

Input differential M10x135-10.9 55 41
M10x145-10.9
Stator M10x35-10.9 50 37
Output flange* M10x50-10.9 SBE-R 66 49
Intermediate wheel of M10x30-10.9 50 37

gear pump
Oil filter cover S110x3 25 18

Temperature sensor M14x1.5 20-25 15-19
Adapter screw connection 1.5/16-12 UNF 50 37
at the oil pan
Screw plug at the oil pan M26x1.5 100 74
*Installation of the screws at the output flange
1. Tighten the device with 3 screws to 50 Nm each.

2. Measure the clearance.
3. Set the clearance in the range of 0.2+0.1 mm.
4. Tighten the screws at the output flange rotationally in 3 complete tightening cycles
with an appropriate tightening torque (see table).
2011-02-02 5-2
Repair Manual
Voith Turbo GmbH & Co. KG Standard lists / DIWA.5 tightening torques
Tightening torques for screw plugs and hollow screws with Cu sealing rings
Dimension Sealing ring Torque [Nm] steel/Al Installation Designation

Nm lb-ft oiled dry
M10x1 10x13.5 13 10 x Hollow screw
M12x1.5 12x15.5 20 15 x Hollow screw
M16x1.5 16x20 42 31 x Hollow screw
M10x1 10x13.5 15 11 x Screw plug
M12x1.5 12x15.5 20 15 x Screw plug
M14x1.5 14x20 38 28 x Screw plug
M18x1.5 18x22 45 33 x Screw plug
M26x1.5* 26x34 100 74 x Screw plug
M30x1.5* 30x36 115 85 x Screw plug
M32x1.5* 32x38 130 96 x Screw plug
M38x1.5* 38x44 150 111 x Screw plug
M42x1.5* 42x49 190 141 x Screw plug
M48x1.5* 48x55 260 192 x Screw plug
Sealing rings and screws of dimensions marked with * have to be oiled slightly. All other
sealing rings and screws must be mounted dryly.
2011-02-02 5-3
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

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Voith Turbo

Translation of the original Operation Manual

Chapter 1 Preliminary Remarks on this Manual 1-1

1.1 Description of the warnings, symbols and signs 1-1

Chapter 2 Safety 2-1

2.1 Safety instructions for DIWA.5 2-1

Chapter 3 Preparation of installation 3-1

3.1 Tools 3-1

3.2 Service accessories 3-16

3.3 Dismounting the transmission 3-24

Chapter 4 Maintenance 4-1

4.1 Draining the transmission oil 4-1

4.2 Preparations for work on the transmission 4-5

4.3 Dismounting the transmission 4-6

4.4 Dismounting the hydrodamp 4-8

4.5 Faults 4-11

4.6 Disassembling the transmission into assemblies 4-19

4.7 Dismounting and mounting assemblies 4-46

4.7.8 Mounting the stator - turbine wheel 4-88

4.8 Assembling the transmission 4-118

4.9 Mounting the hydrodamp 4-161

4.10 Installing the transmission 4-162

4.11 Filling the transmission with oil 4-165

4.12 Test drive 4-166

4.13 Measuring and testing 4-168

Chapter 5 Standard lists 5-1

5.1 DIWA.5 tightening torques 5-1

1 Preliminary Remarks on this Manual

Pay special attention to the safety instructions in this manual.

1.1 Description of the warnings, symbols and signs

Probable imminent danger!

Tab. 1-1 Identiﬁcation of warnings

1.1.2 Symbols and signs

Note Indicates information on the proper handling

Environment Points out a potentially harmful

Tab. 1-2 Symbols in the right text column

Symbol Use Description

Ö Action instruction You are required to do something here.

2.1.1 General information

2.1.2 State of the art

• the transmission is used improperly,

• the transmission is operated, maintained or repaired by untrained staff,

• the transmission is modiﬁed or rebuilt improperly, and/or

• the safety instructions are not observed.

2.1.3 Intended use

2.1.4 Conditions for usage

• in technically ﬂawless condition,

• according to its prescribed use,

2.1.5 Staff qualiﬁcation

2.1.7 Unsafe instructions

2.1.8 Hoisting devices

2.1.9 Risk of burning

Improper handling may cause burns to the skin.

2.1.10 Risk of accidents caused by oil

2.1.11 Spare parts

2.1.12 Work on the transmission

2.1.13 Cleaning the transmission

2.1.14 Conversion or modiﬁcation of the transmission

Shift the transmission to idle position (N button).

• Max. permissible distance: 10 km

• Max. permissible speed: 30 km/h

3.1.1 Standard tools

Retainer for screwdriver bit