turbo transmission t 211 r.3 maintenance instructions 120 ... · voith turbo | turbo transmission t...

Turbo TransmissionT 211 r.3

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Maintenance Instructions120.00402841_EN

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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

[email protected]

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

in part or transmitted to third parties without

the written authorisation of the publisher.

mailto:[email protected]://www.voithturbo.com

Voith Turbo | Turbo Transmission T 211 r.3 ContentsM

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Contents

Changes 4

1 User Information 5

1.1 Designation of Text Types 5

1.2 Designation of Safety Instructions 6

1.3 Page Layout 7

2 Safety 8

2.1 Working on the Turbo Transmission 8

2.2 Handling Power Transmission Oil 9

2.3 Cleaning 9

3 Maintenance Schedule 10

4 Maintenance Levels 11

4.1 Maintenance Level W1 11

4.2 Maintenance Level W2 12

4.2.1 Oil and Filter Change 12

4.2.1.1 Draining the Power Transmission Oil 12

4.2.1.2 Flush with New Oil Type 12

4.2.1.3 Filter Change 13

4.2.1.4 Filling the Turbo Transmission with Power Transmission Oil 13

4.2.2 Visual Inspection of the Turbo Transmission 15

4.3 Maintenance Level H1, H2, H3 15

Voith Turbo | Turbo Transmission T 211 r.3

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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

Voith Turbo | Turbo Transmission T 211 r.3M

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1 User Information

These maintenance instructions contain important information concerning proper useof the Voith turbo transmission.

Read carefully before performing any work on the turbo transmission. Retain until theturbo transmission is no longer operative.

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

Validity of these maintenance instructions

These maintenance instructions are valid for the state of construction of the turbotransmission on the publishing date. The manufacturer reserves the right to alter thedesign.

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.

1.1 Designation of Text Types

Text is identified according to its function as follows:

During the warranty period, only preventative maintenance work (except for majoroverhauls) is permitted on the turbo transmission without prior approval from Voith.

Table 1-1: Identification of Text

Text type Mark-up Function

Handling instructions, 1st level

1., 2. etc. Asks you to perform an ac-tion

Handling instructions, 2nd level

a), b) etc. Designates a partial stage in a handling sequence

List • Identifies individual ele-ments of the list

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1.2 Designation of Safety Instructions

Safety instructions are categorised as follows:

Highlight Identifies important com-ments

Reference Makes reference to other chapters or documents

Note Important information on correct handling of the prod-uct

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.

Table 1-1: Identification of Text (continued)

Text type Mark-up Function

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1.3 Page Layout

The product name, product type and chapter title appear in the header. The documentdesignation, document number and version as well as the publishing date can befound in the bottom left corner.

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2 Safety

2.1 Working on the Turbo Transmission

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 130°C during use. Contact with hot transmission sections may result in serious burns.

Allow the turbo transmission to cool before performing any work on it.

CAUTION

The power transmission oil in the lines may be pressurised. Transmission sections may jump out and injure persons when removed.

Switch off the vehicle engine before working on the turbo transmission.

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2Safety

2.2 Handling Power Transmission Oil

2.3 Cleaning

WARNING

The power transmission oil may reach up to 130°C during use. Contact with hot power transmission oil may result in serious burns.

Wear heat-resistant gloves.

Drain the power transmission oil carefully.

NOTICE

Unauthorised oil grades, oil mixtures or impure oil may damage the turbo transmission.

Only use oil grades approved by Voith.

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.

NOTICE

When using a high pressure or steam jet to clean the turbo transmission and water or dirt enters it as a result, the turbo transmission or its components may be damaged.

When cleaning, never direct the high pressure or steam jet directly at the transmission control, sensors or seals on the turbo transmission inlets or outlets.

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Maintenance Schedule

3 Maintenance Schedule

Have the specified maintenance work performed by competent personnel in accord-ance with the deadlines given. Use only original Voith spare parts. Spare Parts Catalogue, wearing part set A

All the details for scheduled maintenance work listed below are recommended. De-pending on the load and configuration of the vehicle, maintenance tasks may have tobe performed earlier than the time specified.

chapter 4.2.1.4, page 13

Table 3-1: Maintenance Schedule

Maintenance level

Interval1 ActivityRequired spare parts and flu-ids / lubricants

W1 25 000 km or 500 hours of driv-

ing2 after

• initial start-up

• Maintenance levels H1, H2, H3

1. Change fine filter element • Fine filter element (included in scope of supply)

W2 Every 300,000 km or 5,000 hours of driving, and no later than every 2.5 years

1. Oil change and filter change

2. Visual inspection of the turbo transmission

• Wearing part set A

• Power transmission oil

H1, H2, H3 Every 1,200,000 km or

20,000 hours of driving3Major Overhaul

1. Depending on which is reached first.2. Driving hours are the sum of all operating hours with a vehicle speed greater than 1 km/h.3. We recommend to check the seals, rubber elements and wiring for aging and wear after not more than 7 years

and, if necessary, to arrange for an inspection of the turbo transmission carried out by Voith.

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 upthe power transmission oil with the same oil grade.


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4 Maintenance Levels

4.1 Maintenance Level W1

Changing the fine filter insert

1. Remove the retaining clamp.

2. Unfasten filter pot with screw wrench (size 27).

3. Replace the filter insert.

4. Tighten filter pot with screw wrench until firmly home.

5. Unscrew the filter pot again 45° using the wrench.

6. Slide the retaining clamp back onto the filter cup.

Figure 4-1: Fine filter

1 Retaining clamp

2 Filter cup

3 Screw surface

2

1

3

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4.2 Maintenance Level W2

4.2.1 Oil and Filter Change

4.2.1.1 Draining the Power Transmission Oil

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. Read the instructions provided by the vehicle manufacturer.

3. Close the oil drain valve.

If the same oil grade is used, continue the maintenance work with a filter change.

chapter 4.2.1.3, page 13

4.2.1.2 Flush with New Oil Type

1. Filter the new grade of power transmission oil. section „Filtering the power transmission oil“, page 13

2. Fill the transmission with power transmission oil. figure 4-4, page 14

a) Open the cap on the oil filler neck.

b) Fill filtered power transmission oil at the oil filler neck until it reaches the maxi-mum mark on the oil level sightglass.

The total oil volume, not including the volume of pipelines and the heat ex-changer, is approx. 75 l.

Figure 4-2: Draining power transmission oil

1 Oil drain valve

1

When changing the oil grade, the turbo transmission, heat exchanger and pipelinesbetween the heat exchanger and turbo transmission must be flushed through.

Use half the quantity of the new oil grade (based on the capacity of the turbo trans-mission including the pipelines and heat exchanger) to flush through the compo-nents. Refer to the document "Power Transmission Oils for the Voith Turbo Transmission"

in register 7 for a list of approved oil grades.

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c) Close the cap on oil filler neck.

3. Start the diesel engine and allow to idle for approx. three minutes.

4. Stop the diesel engine.

5. Drain the power transmission oil again. chapter 4.2.1.1, page 12 Do not reuse drained power transmission oil.

4.2.1.3 Filter Change

1. Change the filter cartridge in intake filter.

a) Loosen the hexagon bolts with screw wrench (size 13) and remove the cover.

b) Pull out the filter cartridge.

c) Replace the seal.

d) Insert a new filter cartridge.

e) Replace the cover and tighten hexagon bolts with screw wrench.

2. Change the filter cartridge in pressure filter.

a) Loosen the hexagon boltswith screw wrench (size 13) and remove the cover.

b) Pull out the filter cartridge.

c) Replace the seal.

d) Insert a new filter cartridge.

e) Replace the cover and tighten hexagon bolts with screw wrench.

3. Replace the filter insert in fine filter. section „Changing the fine filter insert“, page 11

4.2.1.4 Filling the Turbo Transmission with Power Transmission Oil

Filtering the power transmission oil

Before the turbo transmission is filled, the power transmission oil must be filtered topurity class 17/15/11 according to ISO 4406:1999. Suitable filtering units are availablefrom commercial retail outlets.

Figure 4-3: Intake filter, pressure filter

1 Intake filter

2 Pressure filter

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The maximum number of foreign particles in 100 ml power transmission oil stipulatedin ISO 4406:1999 is:

• 130,000 with particle size > 4 μm(c) (purity class 17)



Filling the turbo transmission

1. Open the cap on oil filler neck.

2. Fill filtered power transmission oil at oil filler neck until it reaches the maximummark on oil level sightglass.

The total oil volume, not including the volume of pipelines and the heat exchanger,is approx. 75 l.

3. Close the cap 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.

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.

Figure 4-4: Oil filler neck and oil level sight-glass

1 Oil filler neck

2 Oil level sightglass

2

1

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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 .

4.2.2 Visual Inspection of the Turbo Transmission

1. Visual inspection of the turbo transmission for:

• Dirt

• External damage

• Loose parts (wiring, connections, protective caps, etc.)

4.3 Maintenance Level H1, H2, H3

The major overhaul can prevent damage caused by wear or the ageing of compo-nents. During a major overhaul, Voith gives you the opportunity to upgrade your turbotransmission to state-of-the-art technology. Publication G1347 "Major Overhaul of Voith Turbo Transmissions and Modernisa-

tion Options - Recommendations of the Transmission Manufacturer"

The major overhaul is carried out by qualified service personnel on Voith's premises.

In special cases, the major overhaul can also be performed on the operator'spremises. The preconditions for this are:

• a workshop suitably equipped to perform the necessary work

• spare parts on hand

• Voith special tools on hand

Contact Voith. There, you will receive an offer for a complete major overhaul based onthe specific requirements of your turbo transmission.

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Changes1 User Information1.1 Designation of Text Types1.2 Designation of Safety Instructions1.3 Page Layout

2 Safety2.1 Working on the Turbo Transmission2.2 Handling Power Transmission Oil2.3 Cleaning

3 Maintenance Schedule4 Maintenance Levels4.1 Maintenance Level W14.2 Maintenance Level W24.2.1 Oil and Filter Change4.2.1.1 Draining the Power Transmission Oil4.2.1.2 Flush with New Oil Type4.2.1.3 Filter Change4.2.1.4 Filling the Turbo Transmission with Power Transmission Oil

4.2.2 Visual Inspection of the Turbo Transmission

4.3 Maintenance Level H1, H2, H3

turbo transmission t 211 r.3 maintenance instructions 120 ... · voith turbo | turbo transmission t...

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