Operating Manual-Voith

Turbo Transmission
T 211 r.3
Operating Instructions
120.00402821_EN
Version 1
Voith Turbo | Turbo Transmission T 211 r.3 Imprint
Contact:
Voith Turbo GmbH & Co. KG

Diesel Driveline Rail
Alexanderstr. 2
89522 Heidenheim, Germany
Phone +49 7321 37-4059
Fax +49 7321 37-4155
service-diesel-driveline@voith.com
www.voithturbo.com
Please specify serial number and design pat-

tern number (see name and rating plate).
This document describes the state of design

of the product at the time of the editorial dead-
line on 2012-01-12.
Copyright 2012 by
Voith Turbo GmbH & Co. KG
This document is protected by copyright. It

must not be translated and reproduced (by
mechanical or electronic means) in whole or
Operating Instructions 120.00402821_EN, Version 1
in part or transmitted to third parties without

the written authorisation of the publisher.
Editorial deadline: 2012-01-12
2
Voith Turbo | Turbo Transmission T 211 r.3 Contents
Contents
Changes 6
1 User Information 7
1.1 Designation of Text Types 7
1.2 Designation of Safety Instructions 8
1.3 Page Layout 9
2 Safety 10
2.1 Transport 10
2.2 Operation 10
2.3 Working on the Turbo Transmission 10
2.4 Handling Power Transmission Oil 11
3 Product Description 12
3.1 View of Transmission 12
3.2 Technical Data 13
3.3 Design and Function 14
3.3.1 Components of the Turbo Transmission 14
3.3.2 Functioning Principle of the Main Components 17

3.4 Flow of Power in the Turbo Transmission 19

4 Packaging, Transport and Storage 20
4.1 Corrosion Prevention 20
3
4.2 Packaging and Storage 20
4.2.1 Packaging for Transportation over Land 20
4.2.2 Packaging for Transportation by Air 20
4.2.3 Packaging for Transportation by Sea 21
4.2.4 Checking the Delivery Condition 21
4.2.5 Returning the Shipment 21
4.3 Storage 21
4.4 Instructions for Lifting the Transmission 22
4.4.1 Suspension Devices 22
4.4.2 Setting Down the Transmission 23
5 Installation 24
5.1 Unpacking 24
5.2 Preparing the Mounting Surfaces 24
5.3 Installing the Turbo Transmission 24
5.3.1 Transmission Suspension 24
5.3.2 Removal Dimensions 25
5.3.3 Instructions for Installing the Turbo Transmission 25
5.3.4 Connecting the Turbo Transmission and the Diesel Engine 26
5.3.5 Heat Exchanger Connector 28
5.3.6 Connecting the Compressed Air Lines 28
5.3.7 Electrical Connections 28
6 Taking into Servce 29

6.1 Filling the Turbo Transmission with Power Transmission Oil 30

4
7 Operation 32
7.1 Operation 32
7.1.1 Starting and Moving Off 32
7.1.2 Changing the Direction of Travel 32
7.1.3 Traction Mode 32
7.2 Towing Operations 33
7.3 Engine Operation without Transmission Function 34
8 Malfunctions 35
9 Taking out of Service and Disposal 44
9.1 Taking out of Service 44
9.2 Removing the Turbo Transmission 44
9.2.1 Draining the Power Transmission Oil 44
9.2.2 Removal 45
9.3 Disposal 45
5
Voith Turbo | Turbo Transmission T 211 r.3 Changes
Changes
The version of this document is marked on each page. When the document is revised,
the version number increases. Modifications are documented in the following table.
Version Changes
6
Voith Turbo | Turbo Transmission T 211 r.3 User Information
1 User Information
These operating instructions contain important information concerning the proper

handling of the Voith turbo transmission and are a part of the product.
Read and observe carefully before installing the turbo transmission and prior to taking
the vehicle into service. Retain until the turbo transmission is no longer operative.
Observe all applicable local regulations in addition to these operating instructions.
Validity of these operating instructions
These operating instructions are valid for the state of construction of the turbo trans-
mission on the publishing date. The manufacturer reserves the right to alter the de-
sign.
Authorised personnel
Work on the turbo transmission should only be performed by competent personnel.

Trainees must not work on the turbo transmission unless they are supervised by ex-
perienced personnel.
Warranty
Statutory and contractual conditions apply.
During the warranty period, only preventative maintenance work (except for major
overhauls) is permitted on the turbo transmission without prior approval from Voith.
Maintenance Instructions, register 3
1.1 Designation of Text Types
Text is identified according to its function as follows:
Table 1-1: Identification of Text
Text type Mark-up Function
Handling instructions, 1st 1., 2. etc. Asks you to perform an ac-

level tion
Handling instructions, 2nd a), b) etc. Designates a partial stage in

level a handling sequence
List Identifies individual ele-

ments of the list
7
Table 1-1: Identification of Text (continued)
Text type Mark-up Function
Highlight Identifies important com-

ments
Reference Makes reference to other

chapters or documents
Note Important information on

correct handling of the prod-
uct
1.2 Designation of Safety Instructions
Safety instructions are categorised as follows:
DANGER
... indicates a definite danger of serious or fatal injury.
Failure to comply with these instructions will lead to severe or fatal injuries.
WARNING
... indicates a possible danger of injury or death.
Ignoring this instruction may lead to serious or fatal injuries.
CAUTION
... indicates a possible danger for the health of persons.
Failure to comply with this note can result in light or moderate injury.
NOTICE
...indicates a possible danger of damage to property.
Ignoring this note may lead to damage to the product or to other items of
property.
8
1.3 Page Layout
The product name, product type and chapter title appear in the header. The document
designation, document number and version as well as the publishing date can be
found in the bottom left corner.
9
Voith Turbo | Turbo Transmission T 211 r.3 Safety
2 Safety
2.1 Transport
WARNING
Suspended loads may fall on personnel and cause serious or fatal injury.
Never step under suspended loads.
Use the attachment points on the turbo transmission.
Only lift the turbo transmission using suitable lifting gear. The lifting gear must
correspond to safety regulations and must be approved to withstand the total
weight of the turbo transmission including attachments.
2.2 Operation
NOTICE
Operation without power transmission oil leads to immediate damage to
the turbo transmission.
Ensure that the turbo transmission is filled with power transmission oil before
the diesel engine is started or the vehicle moved.
NOTICE
Unauthorised oil grades, oil mixtures or impure oil may damage the turbo
transmission.
Only use oil grades approved by Voith.
2.3 Working on the Turbo Transmission

Any modifications, attachments oder conversions of the turbo transmission must not
be implemented without approval from Voith.
10
Voith Turbo | Turbo Transmission T 211 r.3 Safety
WARNING
If the vehicle starts to move while you are working on the installed turbo
transmission, you or other people may be run over.
Secure the vehicle to prevent it from rolling away accidentally. Read the
instructions provided by the vehicle manufacturer.
WARNING
People or items of clothing may be caught by rotating parts and dragged

in. This may result in serious injury or death.
Switch off the vehicle engine before working on the turbo transmission.
Wait for rotating parts to come to a complete stop.
WARNING
The turbo transmission may reach up to 130C during use. Contact with
hot transmission sections may result in serious burns.
Allow the turbo transmission to cool before performing any work on it.
2.4 Handling Power Transmission Oil
NOTICE
Serious damage to the environment can be caused if oil seeps into the
ground, or flows into a body of water or drainage system.
Make sure that the oil does not seep into the ground, or flow into a body of water
or drainage system.
Dispose of used oil in accordance with existing regulations.

11
Voith Turbo | Turbo Transmission T 211 r.3 Product Description
3 Product Description
Intended use
The turbo transmission T 211 r.3 is designed for installation in rail vehicles. Consult
Voith regarding all general technical conditions and interfaces to the rail vehicle and
other components.
3.1 View of Transmission
Figure 3-1: Input end

1 Input drive
12
Figure 3-2: Output end

2 Output drive
3.2 Technical Data
Table 3-1: Technical Data of the turbo transmission
Characteristic Value
Maximum input power P 320 kW
Maximum input speed n1 1,884 rpm
Maximum output speed n2 2,683 rpm
Mass (without oil filling) approx. 840 kg
Oil filling (without heat exchanger and tubing) approx. 75 l
Maximum towing speed1 120 km/h
Minimum permissible idling speed 700 rpm

Maximum permissible ambient temperature when in- 85 C

stalled and ready for operation
Minimum permissible ambient temperature Power transmission oils for

Voith turbo transmission,
register 4
1. Observe notes on towing ( Chapter 7.2, page 33).
13
For details on the dimensions and centre of gravity of the turbo transmission, see
Outline Drawing, register 2.
Table 3-2: Maximum Deflection Angle of the Universal Joint Shafts
Maximum deflection angle of the universal joint shafts Value

(static, installed)
Secondary end 4
The maximum deflection angle of the universal joint shafts must not be 0. The
flanges of the universal joint shafts must be arranged in a parallel position.
Minimum requirements for the heat exchanger and pipelines
The following minimum requirements for the heat exchanger and pipelines must be
met in traction mode to ensure correct function of the turbo transmission under normal
operating conditions:
Table 3-3: Construction Data of the Heat Exchanger and Pipelines for Traction
Mode
Parameter Value
Required cooling output from the heat exchanger 89 kW
Outlet temperature of the power transmission oil from the turbo 108 C
transmission
Flow rate of the power transmission oil 3 l/s
Maximum permitted pressure loss in the heat exchanger and pipe- 1.3 bar
lines
Maximum permitted return flow quantity of oil from the heat ex- 30 l
changer to the main oil sump when turbo transmission not operating
3.3 Design and Function
3.3.1 Components of the Turbo Transmission

The turbo transmission contains the following mechanical and hydrodynamic compo-
nents:
14
Figure 3-3: Hauptkomponenten

1 Output drive 5 Torque converter
2 Step-up gear 6 Mechanical section
3 Input drive 7 Shifting shaft of the reversing unit
4 Hydrodynamic coupling
Mechanical Components
The step-up gear is a single-ratio gear wheel for adjusting the input speed to the re- Step-up gear
quired primary shaft speed.
The torsional vibration damper deflects critical resonances and reduces vibrations in Torsional vibration
the drive train. The torsional vibration damper is located at the input end of the turbo damper
transmission in the form of a connection to the diesel engine.
The reversing unit changes the direction of rotation in the turbo transmission. Reversing unit
section Functioning principle of the reversing unit, page 18
The mechanical unit on the turbo transmission contains single-ratio gear wheels for Mechanical unit
adjusting the output speed.
Hydrodynamic Components
This turbo transmission has the following hydrodynamic circuits: Hydrodynamic

circuits
Torque converter
section Functioning principle of the torque converter, page 17
15
Hydrodynamic coupling
section Functioning principle of the hydrodynamic coupling, page 18
The transmission control switches automatically from one hydrodynamic circuit to an- Changing over the
other, depending on the vehicle speed and engine load stage. The torque converter is hydrodynamic
filled in the lower speed range and the hydrodynamic coupling is filled in the upper circuits
speed range. There is no interruption in traction during the changeover process.
Power in the turbo transmission is transmitted in the filled circuit by the mass forces of Power transfer
the operating fluids (power transmission oil). The projected traction is only achieved
once the power transmission oil reaches operating temperature.
Once the traction command is issued, it may take a second before the hydrodynamic
circuits on the turbo transmission are filled.
Apart from transferring power, the oil in the turbo transmission is also used for lubri- Power transmission
cating, cooling and controlling the turbo transmission. Because the power transmis- oil
sion oil in the turbo transmission has to meet very stringent requirements, only power
transmission oils approved by Voith may be used.
Waste heat is generated in traction mode. This heat is dissipated by the coolant circuit Waste heat
on the diesel engine.
Pumps
The following pumps are connected to the primary end: Primary end
Filler pump for the hydrodynamic circuits

The filler pump supplies power transmission oil to all hydrodynamic circuits and lu-
brication points.
Control oil pump

The control oil pump supplies power transmission oil to the control lines.
The following pumps are connected to the secondary end: Secondary end
Lubricating pump
The lubricating pump supplies power transmission oil to the lubrication points.
Electrical components
The following electrical components are used:
Sensors
Actuators
Wiring
Plug connections
16
The sensors, actuators and plug connections satisfy protection class IP 67. For infor-
mation on the protection class of other electrical components, refer to the description
for the relevant component.
3.3.2 Functioning Principle of the Main Components
Functioning principle of the torque converter
Figure 3-4: Torque Converter

1 Pump impeller
2 Turbine wheel
3 Guide wheel
The diesel engine drives pump impeller 1 via the step-up gear. The mechanical en-
ergy generated by the diesel engine is converted into hydrodynamic energy in the
power transmission oil.
Adjacent turbine wheel 2 harnesses the hydrodynamic energy by decelerating and re-
directing the power transmission oil and converts it back into mechanical energy.
The torque produced in the turbine wheel depends on the volumetric flow, degree of
redirection and speed of the power transmission oil. The turbine torque reaches its
peak when the turbine is not running and decreases with increasing turbine speed.
The power consumption of the pump impeller is only slightly influenced by the respec-
tive turbine speed.
Guide wheel 3 has the task of optimising and maintaining a constant supply direction
to the pump impeller regardless of the output flow direction at the turbine wheel. The
guide wheel absorbs the torque differential between the pump impeller and the turbine
wheel and thereby achieves the torque conversion.
17
Functioning principle of the hydrodynamic coupling
Figure 3-5: Hydrodynamic coupling

1 Pump impeller
2 Turbine wheel
1
2
The diesel engine drives pump impeller 1 via the step-up gear. The mechanical en-
ergy generated by the diesel engine is converted into hydrodynamic energy in the
power transmission oil.
Adjacent turbine wheel 2 harnesses the hydrodynamic energy by decelerating and re-
directing the power transmission oil and converts it back into mechanical energy.
The pump torque and turbine torque for a hydrodynamic coupling are identical.
Functioning principle of the reversing unit
The reversing unit consists of a hydraulically actuated reversing cylinder and accom-
panying sliding shaft.
The reversing cylinder meshes the corresponding gear wheels for the selected direc- Direction of rotation
tion of rotation. The mechanical energy can be transferred to the output shaft. A or B
Figure 3-6: Reversing unit (direction of

1 rotation A)
2
1 Gear wheels meshed
2 Reversing cylinder with sliding shaft
3 Gear wheel on output shaft
4 Flow of power
4 3
Figure 3-7: Reversing unit (direction of

1 rotation B)
2
1 Gear wheels meshed
2 Reversing cylinder with sliding shaft
3 Gear wheel on output shaft
4 Flow of power
4
3
18
The reversing unit is electronically activated and monitored by the transmission con-
trol. The various operating conditions that arise during the reversing process are mon-
itored by different sensors.
3.4 Flow of Power in the Turbo Transmission
The fully automatic turbo transmission measures the input speed of the diesel engine
and transfers the corresponding output speed to the transmission output drive de-
pending on the operating conditions.
The torque of the diesel engine is transferred to the drive shaft on the turbo transmis-
sion via a torsional vibration damper.
The gear wheel on the drive shaft transfers the torque to the toothed primary shaft on
the turbo transmission via the step-up gear.
The following are fastened to the primary shaft:
Torque converter pump impeller
Hydrodynamic coupling pump impeller
The torque resulting at the turbine wheel when the torque converter or hydrodynamic
coupling is filled is transferred to the output drive via the secondary shaft.
The following are fastened to the secondary shaft:
Torque converter turbine wheel
Hydrodynamic coupling turbine wheel
Hydrodynamic brake rotor
When the hydrodynamic brake is filled, the adjustable braking torque acts on output
drive via the rotor.
The direction of rotation of the output flange depends on the position of the sliding
shaft in the reversing unit.
Direction of rotation A:
Output direction of rotation identical to input direction of rotation
Direction of rotation B:
Output direction of rotation opposite to input direction of rotation
19
Voith Turbo | Turbo Transmission T 211 r.3 Packaging, Transport and Storage
4 Packaging, Transport and Storage
4.1 Corrosion Prevention
Each turbo transmission is subjected to a test run prior to delivery. Either power trans-
mission oil or conservation oil (for special corrosion protection requirements) is used
here. The oil is drained after the test run. The turbo transmission is supplied without
an oil fill.
Test run with power transmission oil
After the test run, the inside of the turbo transmission remains coated with power
transmission oil. This inner coating provides corrosion prevention for six months.
Test run with conservation oil
After the test run, the inside of the turbo transmission remains coated with conserva-
tion oil. This inner coating provides corrosion prevention for a year.
4.2 Packaging and Storage
Packaging of the turbo transmission depends on the mode of transport and on the
storage time before installation and commissioning.
The turbo transmission is supplied on a pallet.
NOTICE
Exposure to humidity may corrode the turbo transmission.
Protect the turbo transmission from humidity during transport and storage.
Protect the packaging from damage.
4.2.1 Packaging for Transportation over Land

For transport over land, the turbo transmission is packed onto pallets and sealed with
foil to protect against moisture and contamination. Bare uncoated surfaces are pre-
served and sealed in packing foil. Smaller components are packed into boxes.
4.2.2 Packaging for Transportation by Air

For transportation by air, the turbo transmission is packed in a wooden box. Bare un-
coated surfaces are preserved and sealed in packing foil. Smaller components are
packed into boxes.
20
4.2.3 Packaging for Transportation by Sea

For transportation by sea, the turbo transmission is treated for long-term conservation
and sealed in foil. Desiccant pouches inside the sealed transmission will absorb any
moisture. The sealed turbo transmission is also packed in a wooden box. Smaller
components are packed into boxes.
4.2.4 Checking the Delivery Condition
NOTICE
The turbo transmission may be damaged if dirt enters the turbo
transmission or moisture condenses on the mounting surfaces.
Only unpack the turbo transmission directly before installation in the vehicle.
Only remove the plastic caps and adhesive tape directly before connecting
pipelines.
On receiving a delivery:
1. Check the delivery for transport damage.
2. Contact the transport company if there is any evidence of transport damage.
3. Check that the delivery is complete.
4. Contact Voith if the delivery is incomplete.
4.2.5 Returning the Shipment
The packaging material required for returning the turbo transmission can be ordered
from Voith.
Voith can accept no responsibility for damage caused by improper packaging.
4.3 Storage
Storage room
The turbo transmission should be stored only in a dry closed room and protected from
dust. The storage room must satisfy the following conditions:
Storage temperature +5 to +35 C
Maximum temperature fluctuations +/- 5 C
Maximum relative air humidity of 70 %

No escaped aggressive chemicals in the storage room
No ozone emission in the storage room
21
Protection from direct UV rays
No permanent vibrations
Table 4-1: Storage Period
Test run with power Test run with con- Packed in foil and a
transmission oil servation oil wooden box
Transportation 6 months 1 year 2 years

over land
Transportation by - - 1 year
air
Sea transport - - 1 year
Long-term conservation
If the turbo transmission is not taken into service within the specified storage dura-
tion, it must be conserved again in coordination with Voith.
4.4 Instructions for Lifting the Transmission
4.4.1 Suspension Devices
WARNING
Suspended loads may fall on personnel and cause serious or fatal injury.
Never step under suspended loads.
Use the attachment points on the turbo transmission.
Only lift the turbo transmission using suitable lifting gear. The lifting gear must
correspond to safety regulations and must be approved to withstand the total
weight of the turbo transmission including attachments.
The lifting eye bolts on the turbo transmission are only designed to bear the total
weight of the turbo transmission without attached parts. If the total weight of the turbo
transmission increases as a result of attached parts, these lifting eye bolts can only
be used after consulting Voith.
22
Figure 4-1: Suspending the turbo trans-

mission
min. 1 000 mm
1. Secure the lifting gear to the attachment points on the turbo transmission.
figure 4-1, page 23
2. Lift the turbo transmission.
4.4.2 Setting Down the Transmission
WARNING
The turbo transmission may tip over or slip if set down incorrectly. This
may result in serious injuries. It may also damage the turbo transmission.
Always make sure the turbo transmission is stable when set down.
1. Set the turbo transmission down on a pallet.

23
Voith Turbo | Turbo Transmission T 211 r.3 Installation
5 Installation
The turbo transmission must be installed by competent personnel from the vehicle
manufacturing company in accordance with the manufacturer's instructions.
Observe the following in addition to the existing operating instructions:

Outline drawing, register 2
Any modifications, attachments oder conversions of the turbo transmission must not
be implemented without approval from Voith.
5.1 Unpacking
NOTICE
The turbo transmission may be damaged if dirt enters the turbo
transmission or moisture condenses on the mounting surfaces.
Only unpack the turbo transmission directly before installation in the vehicle.
Only remove the plastic caps and adhesive tape directly before connecting
pipelines.
1. Remove the outside packaging (wooden box, foil).
2. Remove the desiccant pouch.
5.2 Preparing the Mounting Surfaces
1. Remove the packaging foil.
2. Clean all mounting surfaces with cleaning benzene or kerosene.
3. Apply fitting grease to the mounting surfaces.
5.3 Installing the Turbo Transmission

5.3.1 Transmission Suspension

Rubber elements are used for statically determinate suspension of the turbo transmis-
sion in the main frame of the rail vehicle.
This type of transmission suspension with rubber elements reduces the transfer of
structure-borne sound and vibrations from the turbo transmission to the main frame.
24
The constructive layout of the suspended component located in the main frame of the
rail vehicle is adapted to spacial dimensions and is the responsibility of the vehicle
manufacturer.
On request, Voith can provide assistance in calculating the transmission suspension

points on provision of the dimension and weight specifications of the transmission
suspension.
Refer to Voith publication G 1334 for further information on the structural layout of
the transmission suspension.
5.3.2 Removal Dimensions

The clearance gauge of the turbo transmission is not determined by the external
housing but by accessibility and the ability to remove different transmission assem-
blies and measuring points.
Specific removal dimensions must be taken into consideration in order to guarantee

accessibility and the possibility of removing different transmission assemblies. These
removal dimensions (RD) are specified in the accompanying outline drawing.
5.3.3 Instructions for Installing the Turbo Transmission
Always follow the installation instructions in the Voith publication G 1334.
1. Check the transmission suspension for damage.
2. Connect the turbo transmission and the diesel engine.

chapter 5.3.4, page 26
3. Install the turbo transmission together with the diesel engine into the rail vehicle.
Read the instructions provided by the vehicle manufacturer.
25
5.3.4 Connecting the Turbo Transmission and the Diesel Engine
1 5
6
2
4
7
Figure 5-1: Connecting the turbo transmission and the diesel engine
1 Flywheel housing 5 Hexagon bolts
2 Hexagon bolts (with washers) 6 Adaptor housing (turbo transmission)
3 Engine flywheel 7 Drive shaft
4 Torsional vibration damper
Hexagon bolts (with washers) and hexagon bolts are not included in the Voith scope
of delivery.
1. Clean all mounting surfaces on the following parts with cleaning benzene or kero-
sene.
Engine flywheel and diesel engine flywheel housing
Multitooth profile of torsional vibration damper
Multitooth profile of drive shaft
Adaptor housing (turbo transmission)
2. Set down the diesel engine in a horizontal position at working height and on a sta-
ble base.
3. Align the diesel engine horizontally using a spirit level.

figure 5-2, page 26
Figure 5-2: Using a spirit level to align the

diesel engine
26
4. Secure torsional vibration damper on engine flywheel using hexagon bolts.

5. Suspend the turbo transmission from an adjustable suspension bracing and align
horizontally using a spirit level
figure 5-3, page 27
Figure 5-3: Using a spirit level to align the

turbo transmission
6. Apply molybdenum disulphide to the multitooth profile on the drive shaft and the
torsional vibration damper.
NOTICE
The torsional vibration damper may be damaged and begin to lose oil if
the drive shaft in the torsional vibration damper is twisted.
Align the diesel engine and the turbo transmission accurately, while preventing
the drive shaft in the torsional vibration damper from twisting.
Less than 30 ml of leaked oil from the torsional vibration damper is normal.
NOTICE
The turbo transmission and the diesel engine may be damaged if they are
joined together using excessive force.
Align the diesel engine and the turbo transmission accurately and join together
without using excessive force.
7. Join the diesel engine and the turbo transmission without using excessive force
figure 5-4, page 28
If the multitooth profile is in a tooth-on-tooth position, reach into the assembly

opening 8 and turn the drive shaft 7 until the profile is no longer in this position.
27
Figure 5-4: Joining the turbo transmission and the diesel engine
Figure 5-5: Assembly opening

8 Assembly opening
8. Join flywheel housing with the adaptor housing (turbo transmission) using hexagon
bolts.
5.3.5 Heat Exchanger Connector

1. Remove the plastic caps and adhesive covers from the heat exchanger connector.
2. Clean the heat exchanger and pipelines using a suitable filtering unit.
3. Install the heat exchanger and pipelines.

5.3.6 Connecting the Compressed Air Lines

1. Connect the compressed air lines.
Outline Drawing, register 2
5.3.7 Electrical Connections

1. Establish the electrical connections according to outline drawing.
register 2
28
Voith Turbo | Turbo Transmission T 211 r.3 Taking into Servce
6 Taking into Servce
Voith personnel are always responsible for initial start-up of the first turbo transmis-
sion in a vehicle series.
NOTICE
If exposed to moisture, corrosion may form in the turbo transmission.
Commission the turbo transmission immediately following installation in the

vehicle.
NOTICE
Operation without power transmission oil leads to immediate damage to
the turbo transmission.
Ensure that the turbo transmission is filled with power transmission oil before
the diesel engine is started or the vehicle moved.
NOTICE
The turbo transmission may be damaged if operated when the complete
drive train is not yet ready for operation.
Make sure that the complete drive train is ready for operation before taking the
turbo transmission into service.
NOTICE
Excessive rotational speeds may damage the turbo transmission.
Note maximum permissible rotational speeds. Do not exceed the maximum

permissible speed of the vehicle.
table 3-1, page 13

29
6.1 Filling the Turbo Transmission with Power Transmission

Oil
NOTICE
Unauthorised oil grades, oil mixtures or impure oil may damage the turbo
transmission.
Only use oil grades approved by Voith.
Power Transmission Oils for Voith Turbo Transmissions, register 4
Filtering the power transmission oil
Before the turbo transmission is filled, the power transmission oil must be filtered to
purity class 17/15/11 according to ISO 4406:1999. Suitable filtering units are available
from commercial retail outlets.
The maximum number of foreign particles in 100 ml power transmission oil stipulated
in ISO 4406:1999 is:
130,000 with particle size > 4 m(c) (purity class 17)
Filling the turbo transmission
When changing the oil grade or returning the vehicle to service after repairs:
Flush the complete system (turbo transmission, heat exchanger and related pipe-
lines) with filtered power transmission oil before refilling the turbo transmission.
NOTICE
Serious malfunction of the turbo transmission may be the consequence if
the turbo transmission does not contain the specified amount of power
transmission oil.
Measure the oil level on level track (no sloping in any direction).
Do not measure the oil level immediately after long periods of inoperation of the
diesel engine, while the diesel engine is running or while the vehicle is moving.
Always measure the oil level according to the relevant procedure.
30
Figure 6-1: Oil filler neck and oil level sight-

glass
1 Oil filler neck
1
2 Oil level sightglass
1. Open the seal cover on the oil filler neck.
2. Fill filtered power transmission oil at the oil filler neck up to the maximum mark on
the oil level sightglass.
The total oil volume, not including the volume of pipelines and the heat exchanger,
is approx. 75 l.
3. Close the seal cover on oil filler neck.
4. Start the diesel engine and let it run at idle speed for about three minutes.
The lines and the heat exchanger fill with power transmission oil.
5. Stop the diesel engine.
6. Check the oil level at oil level sightglass within two minutes of stopping the engine.
7. If necessary, top up power transmission oil at oil filler neck until it reaches the max-
imum mark on oil level sightglass .
31
Voith Turbo | Turbo Transmission T 211 r.3 Operation
7 Operation
At regular intervals, ideally on a daily basis, check to ensure that the turbo transmis-
sion contains the specified amount of power transmission fluid. If necessary, top up
the power transmission oil with the same oil grade.
chapter 6.1, page 30
7.1 Operation
7.1.1 Starting and Moving Off
Requirements
Vehicle at standstill
No traction or braking commands
Procedure
1. Start the diesel engine.
2. Issue a command for the direction of motion required.
3. Issue a traction command.
The turbo transmission is in traction mode.
7.1.2 Changing the Direction of Travel

1. Withdraw the traction command.
2. Brake the vehicle to a standstill.
3. Issue a command for the direction of motion required.
7.1.3 Traction Mode

The turbo transmission operates automatically in traction mode.
NOTICE
Excessive rotational speeds may damage the turbo transmission.
Note maximum permissible rotational speeds. Do not exceed the maximum

permissible speed of the vehicle.
32
Changing from traction to rolling mode
1. Withdraw the traction command.
The turbo transmission circuits are drained and the diesel engine slows to idling
speed.
Changing from rolling to traction mode
The corresponding circuit fills automatically, depending on the vehicle speed.
Automatic rapid transmission engagement in the event of wheelslip
Rapid transmission engagement quickly reduces the tractive force should wheelslip
occur.
The shift up lock becomes active when the rapid transmission engagement function is
activated. This prevents the turbo transmission from upshifting.
7.2 Towing Operations
NOTICE
Towing at low temperatures may damage the turbo transmission.
Check whether the power transmission oil is suitable for use at low
temperatures.
register 4
33
NOTICE
Excessive towing speeds or towing in the direction opposite to the
engaged direction of travel may result in serious damage to the turbo
transmission or the complete drive system.
Do not exceed the maximum permissible towing speed.
Note maximum permissible rotational speeds.
Remove cardan shafts between the turbo transmission and the axle gearboxes
if adherence to the maximum permissible towing speed cannot be guaranteed.
When towing with diesel engine running:

Make sure, using operational measures and the vehicle control, that the
direction of rotation of the turbo transmission corresponds to the engaged
direction of travel.
table 3-1, page 13
The turbo transmission must be fully functional.
7.3 Engine Operation without Transmission Function
Examples
Engine test
Fill main air reservoir
Operate auxiliary assemblies
Requirement
Vehicle standstill
No traction command
NOTICE
The turbo transmission may be damaged if the turbo transmission is not

in driving mode and the speed of the diesel engine is increased to greater
than 1,500 rpm.
Only increase the speed of the diesel engine outside of driving mode to greater
than 1,500 rpm for max. 2 minutes.
34
Voith Turbo | Turbo Transmission T 211 r.3 Malfunctions
8 Malfunctions
During the warranty period, only preventive maintenance work (except for major
overhauls) is permitted on the turbo transmission.
Should faults occur during the warranty period, contact Voith.
This chapter contains descriptions of possible malfunctions. The tables below list
these malfunctions together with the possible cause and information about rectifying
the fault. Contact Voith, if malfunctions can not be resolved.
No oil pressures are specified in this chapter, since this information changes with the
application. Contact Voith if you suspect that the oil pressure values are incorrect,
specifying the transmission number.
Table 8-1: Possible Malfunctions
No. Malfunction Cause and remedy

1 Malfunction of the reversing gear Table Malfunction 1, page 35
2 No or insufficient traction Table Malfunction 2, page 36
3 Malfunctions during shifting of gears Table Malfunction 3, page 37
4 Oil too hot Table Malfunction 4, page 38
Malfunction 1: Reversing Shift Fault

Cause Remedy
No control air from vehicle control system in 1. Correct the malfunction on the vehicle.
line 618 to sensor valve 44.
Piston 441/442 in sensor valve 44 blocked in 2. Remove sensor valve 44 and enable pis-
idle position and/or sensor fingers 443 ton 441/442 to run freely.
blocked in disengaged position.
figure 8-4, page 41
Tripping piston 404 in reversing unit 40 1. Remove reversing unit 40.
blocked or seal rings leaking.
2. Inspect tripping piston 404 and seal rings.
figure 8-4, page 41
Rotary actuator 43 defective. 1. Remove rotary actuator 43 and check .
figure 8-2, page 40
35
Malfunction 1: Reversing Shift Fault (continued)

Cause Remedy
Limit switch 71 defective. 1. Remove cover of reversing unit 40.
2. Check limit switch 71 .
figure 8-4, page 41
Control air line 643 for main control valve 41 1. Correct the malfunction on the vehicle.
is not vented.
Main control piston 411 or pilot control piston 1. Remove main control piston 411 and pilot
413 blocked. control piston 413 and check .
figure 8-1, page 39
Malfunction 2: No Traction or Insufficient Traction

Cause Remedy
Not enough oil in transmission. 1. Check oil level .
figure 8-9, page 43
Oil too cold 1. Brake vehicle and move master controller
Projected traction will be reached once the oil several times between driving and idling
has heated up to above 70 C. settings until oil reaches operating tem-
perature. Shift to idling several times to
empty the converter and prevent it from
overheating.
Incorrect oil grade or exhausted oil 1. Change oil.

Water in the oil 1. Check heat exchanger for leaks, seal if
Filter clogged with oil emulsion. necessary. Change oil.
2. Change filter.
figure 8-9, page 43
No control pressure in line 621. 1. Correct the malfunction on the vehicle.
Engine does not reach full load speed. 1. Correct the fault on the engine.
Limit switch 71 defective 1. Remove cover of reversing unit 40. Check

limit switch 71 .
figure 8-4, page 41
36
Malfunction 2: No Traction or Insufficient Traction (continued)

Cause Remedy
No or too low filler pump pressure. 1. Measure filler pump pressure at maximum
input speed and with filled converter 21 at
measuring point 4x and measuring point
5x.
figure 8-1, page 39
2. If the pressure is too low, dismantle pres-
sure relief valve 45 and check.
figure 8-3, page 40
No or too low control pressure. 1. Measure the control pressure at measur-
Intake filter 53 or pressure filter 54 choked. ing point 1x.
figure 8-2, page 40
2. Remove and clean intake filter 53 and
pressure filter 54 .
figure 8-8, page 43
figure 8-1, page 39
Malfunction 3: Malfunctions during Shifting of Gears

Cause Remedy
Governor 42 does not switch to 2nd gear. 1. Remove governor 42 and enable control
Control pin 422 in governor 42 blocked. pin 422 to run freely .
figure 8-2, page 40
figure 8-1, page 39
Engine does not reach full load speed. 1. Correct the fault on the engine.
No or too low control pressure, main control 1. Check control pressure at measuring
piston 411 does not switch to position for 2nd point 1x at maximum input speed.
gear.
figure 8-2, page 40
2. If the pressure is too low, remove pres-
figure 8-3, page 40
37
Malfunction 3: Malfunctions during Shifting of Gears (continued)

Cause Remedy
Control pump 51 defective 1. Check control pressure at measuring
point 1x at maximum input speed.
figure 8-2, page 40
2. If there is no pressure, remove pumps
50/51 and check.
figure 8-2, page 40
Switching point misadjusted at governor 42 1. Unscrew screw plug 807 .
2. Push an adjusting pin through the bore
hole on the plug screw using a screw-
driver and close the anti-turn lock.
3. Adjust the shift point by turning with a
screwdriver:
Clockwise: lower shift point
Anticlockwise: higher shift point
4. Insert plug screw 807 again and tighten.
figure 8-7, page 42
Air pressure in line 622 too low or piston 425 1. Check engine regulating unit, readjust if
blocked. Switching point occurs too soon. necessary. Make sure that piston 425 in
governor 42 can move freely.
figure 8-1, page 39
Malfunction 4: Oil too Hot

Cause Remedy
Residues in heat exchanger. 1. Clean interior of heat exchanger.
Too low fan speed. 1. Check hydrostatic system.
Cooling elements of cooling system contami- 1. Clean cooling elements.

nated.
Intake filter 53 or pressure filter 54 choked. 1. Measure the control pressure at measur-
ing point 1x
figure 8-2, page 40
pressure filter 54
figure 8-8, page 43
Governor 42 does not switch to 2nd gear. 1. Remove governor 42 and enable control
Control pin 422 in governor 42 blocked. pin 422 to run freely .
figure 8-1, page 39
38
Malfunction 4: Oil too Hot (continued)

Cause Remedy
figure 8-1, page 39
No or too low control pressure. 1. Measure the control pressure at measur-
ing point 1x.
figure 8-2, page 40
pressure filter 54 .
figure 8-8, page 43
No or too low control pressure, main control 1. Check control pressure at measuring
piston 411 does not switch to position for 2nd point 1x at maximum input speed.
gear.
figure 8-1, page 39
2. If the pressure is too low, remove pres-
figure 8-3, page 40
Figures
41 42
10
4x
5x
Figure 8-1: Primary shaft, main control valve, governor

10 Drive shaft
41 Main control valve
42 Governor
39
50/51
44
40 1x
43
30
55
Figure 8-2: Primary shaft, control components, pumps, filter

30 Primary shaft 50 Filler pump
40 Reversing unit 51 Primary control and lubricating pump
43 Rotary actuator 55 Fine filter
44 Sensor valve
46
Figure 8-3: Pressure relief valve

46 Pressure relief valve
40
807
71
44
40
30
Figure 8-4: Output shaft, control components

30 Output shaft
40 Reversing unit
44 Sensor valve
71 Internal limit switch
807 Plug screw
70
805
806
804
Figure 8-5: Heat exchanger connection

70 Temperature switch
804 Oil drain valve

805 Connection to heat exchanger
806 Connection from heat exchanger
41
413 411
412
41
414
Figure 8-6: Main control valve

41 Main control valve removed
411 Main control piston
412 Compression spring
413 Pilot control piston
414 Compression spring
807
42
Figure 8-7: Governor

42 Governor
807 Plug screw
42
804
54
10
53
Figure 8-8: Draining oil

53 Intake filter
54 Pressure filter
804 Oil drain valve
803
801
10
Figure 8-9: Check Oil Level

801 Oil-level glass
803 Oil filler neck
43
Voith Turbo | Turbo Transmission T 211 r.3 Taking out of Service and Disposal
9 Taking out of Service and Disposal
9.1 Taking out of Service
When taking the transmission out of service for up to 6 months, observe the following
measures:
Store the vehicle in a dry, frost-free environment (maximum relative humidity 70 %)
Protect from aggressive chemicals
Protect from direct UV exposure
Contact Voith if it is likely that the transmission will remain out of service for more
than 6 months.
9.2 Removing the Turbo Transmission
9.2.1 Draining the Power Transmission Oil
WARNING
The turbo transmission may reach up to 130C during use. Contact with
hot transmission sections may result in serious burns.
Allow the turbo transmission to cool before performing any work on it.
WARNING
The power transmission oil may reach up to 130C during use. Contact
with hot power transmission oil may result in serious burns.
Wear heat-resistant gloves.
Drain the power transmission oil carefully.

44
Voith Turbo | Turbo Transmission T 211 r.3 Taking out of Service and Disposal
NOTICE
Serious damage to the environment can be caused if oil seeps into the
ground, or flows into a body of water or drainage system.
Make sure that the oil does not seep into the ground, or flow into a body of water
or drainage system.
Dispose of used oil in accordance with existing regulations.
Figure 9-1: Draining power transmission oil

1 Oil drain valve
1. Drain the power transmission oil from the oil drain valve as close to operating tem-
perature as possible.
2. Fully drain the heat exchanger and pipelines.

3. Close the oil drain valve.
9.2.2 Removal
1. Loosen all connections to the vehicle using a suitable tool.
2. Remove the turbo transmission using appropriate assembly and lifting gear.
3. Set down the turbo transmission correctly.

chapter 4.4.2, page 23
9.3 Disposal
1. Only arrange for the turbo transmission to be disposed of by a company licensed

for such tasks.
Observe all statutory regulations. If you have any further questions, please con-
tact Voith.
45

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Turbo Transmission

Voith Turbo GmbH & Co. KG

Please specify serial number and design pat-

This document describes the state of design

This document is protected by copyright. It

in part or transmitted to third parties without

1.1 Designation of Text Types 7

1.2 Designation of Safety Instructions 8

1.3 Page Layout 9

2.3 Working on the Turbo Transmission 10

2.4 Handling Power Transmission Oil 11

3.1 View of Transmission 12

3.2 Technical Data 13

3.3 Design and Function 14

3.3.1 Components of the Turbo Transmission 14

3.3.2 Functioning Principle of the Main Components 17

3.4 Flow of Power in the Turbo Transmission 19

4 Packaging, Transport and Storage 20

4.1 Corrosion Prevention 20

4.2 Packaging and Storage 20

4.2.1 Packaging for Transportation over Land 20

4.2.2 Packaging for Transportation by Air 20

4.2.3 Packaging for Transportation by Sea 21

4.2.4 Checking the Delivery Condition 21

4.2.5 Returning the Shipment 21

4.4 Instructions for Lifting the Transmission 22

4.4.1 Suspension Devices 22

4.4.2 Setting Down the Transmission 23

5.2 Preparing the Mounting Surfaces 24

5.3 Installing the Turbo Transmission 24

5.3.1 Transmission Suspension 24

5.3.2 Removal Dimensions 25

5.3.3 Instructions for Installing the Turbo Transmission 25

5.3.4 Connecting the Turbo Transmission and the Diesel Engine 26

5.3.5 Heat Exchanger Connector 28

5.3.6 Connecting the Compressed Air Lines 28

5.3.7 Electrical Connections 28

6 Taking into Servce 29

6.1 Filling the Turbo Transmission with Power Transmission Oil 30

7.1.1 Starting and Moving Off 32

7.1.2 Changing the Direction of Travel 32

7.1.3 Traction Mode 32

7.2 Towing Operations 33

7.3 Engine Operation without Transmission Function 34

9 Taking out of Service and Disposal 44

9.1 Taking out of Service 44

9.2 Removing the Turbo Transmission 44

9.2.1 Draining the Power Transmission Oil 44

These operating instructions contain important information concerning the proper

Observe all applicable local regulations in addition to these operating instructions.

Validity of these operating instructions

Work on the turbo transmission should only be performed by competent personnel.

Statutory and contractual conditions apply.

1.1 Designation of Text Types

Text is identified according to its function as follows:

Table 1-1: Identification of Text

Text type Mark-up Function

Handling instructions, 1st 1., 2. etc. Asks you to perform an ac-

Handling instructions, 2nd a), b) etc. Designates a partial stage in

List Identifies individual ele-

Table 1-1: Identification of Text (continued)

Text type Mark-up Function

Highlight Identifies important com-