turbo transmission t 211 r.3 operating instructions 120.00402821...

Turbo TransmissionT 211 r.3

Version 1

Operating Instructions120.00402821_EN

Op

era

tin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

2

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]

http://www.voithturbo.com

Voith Turbo | Turbo Transmission T 211 r.3 ContentsO

pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

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

Voith Turbo | Turbo Transmission T 211 r.3O

pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Contents

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Contents

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

6

Op

era

tin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

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.

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 major

overhauls) is permitted on the turbo transmission without prior approval from Voith.

Maintenance Instructions, register 3

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

7


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

User Information

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

8


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

User Information

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Safety

2 Safety

2.1 Transport

2.2 Operation

2.3 Working on the Turbo Transmission

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.

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.

Any modifications, attachments oder conversions of the turbo transmission must not

be implemented without approval from Voith.

10


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Safety

2.4 Handling Power Transmission Oil

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.

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

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

1

12


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Product Description

3.2 Technical Data

Figure 3-2: Output end

2 Output drive

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-

stalled and ready for operation

85 °C

Minimum permissible ambient temperature Power transmission oils for

Voith turbo transmission,

register 4

1. Observe notes on towing ( Chapter 7.2, page 33).

2

13


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Product Description

For details on the dimensions and centre of gravity of the turbo transmission, see

Outline Drawing, register 2.

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:

3.3 Design and Function

3.3.1 Components of the Turbo Transmission

The turbo transmission contains the following mechanical and hydrodynamic compo-

nents:

Table 3-2: Maximum Deflection Angle of the Universal Joint Shafts

Maximum deflection angle of the universal joint shafts

(static, installed)

Value

Secondary end 4°

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

transmission

108 °C

Flow rate of the power transmission oil 3 l/s

Maximum permitted pressure loss in the heat exchanger and pipe-

lines

1.3 bar

Maximum permitted return flow quantity of oil from the heat ex-

changer to the main oil sump when turbo transmission not operating

30 l

14


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Product Description

Mechanical Components

Step-up gearThe step-up gear is a single-ratio gear wheel for adjusting the input speed to the re-

quired primary shaft speed.

Torsional vibration

damper

The torsional vibration damper deflects critical resonances and reduces vibrations in

the drive train. The torsional vibration damper is located at the input end of the turbo

transmission in the form of a connection to the diesel engine.

Reversing unitThe reversing unit changes the direction of rotation in the turbo transmission.

section „Functioning principle of the reversing unit“, page 18

Mechanical unitThe mechanical unit on the turbo transmission contains single-ratio gear wheels for

adjusting the output speed.

Hydrodynamic Components

Hydrodynamic

circuits

This turbo transmission has the following hydrodynamic circuits:

• Torque converter

section „Functioning principle of the torque converter“, page 17

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

15


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Product Description

• Hydrodynamic coupling

section „Functioning principle of the hydrodynamic coupling“, page 18

Changing over the

hydrodynamic

circuits

The transmission control switches automatically from one hydrodynamic circuit to an-

other, depending on the vehicle speed and engine load stage. The torque converter is

filled in the lower speed range and the hydrodynamic coupling is filled in the upper

speed range. There is no interruption in traction during the changeover process.

Power transferPower in the turbo transmission is transmitted in the filled circuit by the mass forces of

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.

Power transmission

oil

Apart from transferring power, the oil in the turbo transmission is also used for lubri-

cating, cooling and controlling the turbo transmission. Because the power transmis-

sion oil in the turbo transmission has to meet very stringent requirements, only power

transmission oils approved by Voith may be used.

Waste heatWaste heat is generated in traction mode. This heat is dissipated by the coolant circuit

on the diesel engine.

Pumps

Primary endThe following pumps are connected to the 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.

Secondary endThe following pumps are connected to the 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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Product Description

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

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.

Figure 3-4: Torque Converter

1 Pump impeller

2 Turbine wheel

3 Guide wheel

2

1

3

17


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Product Description

Functioning principle of the hydrodynamic coupling

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.

Direction of rotation

A or B

The reversing cylinder meshes the corresponding gear wheels for the selected direc-

tion of rotation. The mechanical energy can be transferred to the output shaft.

Figure 3-5: Hydrodynamic coupling

1 Pump impeller

2 Turbine wheel

12

Figure 3-6: Reversing unit (direction of

rotation A)

1 Gear wheels meshed

2 Reversing cylinder with sliding shaft

3 Gear wheel on output shaft

4 Flow of power

Figure 3-7: Reversing unit (direction of

rotation B)

1 Gear wheels meshed

2 Reversing cylinder with sliding shaft

3 Gear wheel on output shaft

4 Flow of power

12

34

12

3

4

18


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Product Description

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

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.

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.

NOTICE

Exposure to humidity may corrode the turbo transmission.

Protect the turbo transmission from humidity during transport and storage.

Protect the packaging from damage.

20


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12


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

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

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

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.

The packaging material required for returning the turbo transmission can be ordered

from Voith.

21


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12


• Protection from direct UV rays

• No permanent vibrations

Long-term conservation

4.4 Instructions for Lifting the Transmission

4.4.1 Suspension Devices

Table 4-1: Storage Period

Test run with power

transmission oil

Test run with con-

servation oil

Packed in foil and a

wooden box

Transportation

over land

6 months 1 year 2 years

Transportation by

air

- - 1 year

Sea transport - - 1 year

If the turbo transmission is not taken into service within the specified storage dura-

tion, it must be conserved again in coordination with Voith.

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12


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

1. Set the turbo transmission down on a pallet.

Figure 4-1: Suspending the turbo trans-

mission

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.

min

. 1

00

0m

m

23


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Installation

5 Installation

5.1 Unpacking

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.

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.

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.

24


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Installation

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.

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

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.

On request, Voith can provide assistance in calculating the transmission suspension

points on provision of the dimension and weight specifications of the transmission

suspension.

Always follow the installation instructions in the Voith publication G 1334.

25


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Installation

5.3.4 Connecting the Turbo Transmission and the Diesel Engine

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 5-1: 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

2

3

4

5

6

7

1

Hexagon bolts (with washers) and hexagon bolts are not included in the Voith scope

of delivery.

Figure 5-2: Using a spirit level to align the

diesel engine

26


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Installation

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

6. Apply molybdenum disulphide to the multitooth profile on the drive shaft and the

torsional vibration damper.

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.

Figure 5-3: Using a spirit level to align the

turbo transmission

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.

27


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Installation

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

Figure 5-4: Joining the turbo transmission and the diesel engine

Figure 5-5: Assembly opening

8 Assembly opening

8

28


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Taking into Servce

6 Taking into Servce

table 3-1, page 13

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.

29


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Taking into Servce

6.1 Filling the Turbo Transmission with Power Transmission

Oil

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 μm(c) (purity class 17)



Filling the turbo transmission

NOTICE

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

transmission.

Only use oil grades approved by Voith.

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Taking into Servce

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 .

Figure 6-1: Oil filler neck and oil level sight-

glass

1 Oil filler neck

2 Oil level sightglass

2

1

31


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Operation

7 Operation

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.

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.

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Operation

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

register 4

NOTICE

Towing at low temperatures may damage the turbo transmission.

Check whether the power transmission oil is suitable for use at low

temperatures.

33


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Operation

table 3-1, page 13

7.3 Engine Operation without Transmission Function

Examples

• Engine test

• Fill main air reservoir

• Operate auxiliary assemblies

Requirement

• Vehicle standstill

• No traction command

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.

The turbo transmission must be fully functional.

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

8 Malfunctions

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.

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.

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

line 618 to sensor valve 44.

1. Correct the malfunction on the vehicle.

Piston 441/442 in sensor valve 44 blocked in

idle position and/or sensor fingers 443

blocked in disengaged position.

2. Remove sensor valve 44 and enable pis-

ton 441/442 to run freely.

figure 8-4, page 41

Tripping piston 404 in reversing unit 40

blocked or seal rings leaking.

1. Remove reversing unit 40.

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


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

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

is not vented.

1. Correct the malfunction on the vehicle.

Main control piston 411 or pilot control piston

413 blocked.

1. Remove main control piston 411 and pilot

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

Projected traction will be reached once the oil

has heated up to above 70 °C.

1. Brake vehicle and move master controller

several times between driving and idling

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

Filter clogged with oil emulsion.

1. Check heat exchanger for leaks, seal if

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

Malfunction 1: Reversing Shift Fault (continued)

Cause Remedy

36


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

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.

Intake filter 53 or pressure filter 54 choked.

1. Measure the control pressure at measur-

ing point 1x.

figure 8-2, page 40

2. Remove and clean intake filter 53 and

pressure filter 54 .

figure 8-8, page 43


413 blocked.



figure 8-1, page 39

Malfunction 3: Malfunctions during Shifting of Gears

Cause Remedy

Governor 42 does not switch to 2nd gear.

Control pin 422 in governor 42 blocked.

1. Remove governor 42 and enable control

pin 422 to run freely .

figure 8-2, page 40


413 blocked.



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

piston 411 does not switch to position for 2nd

gear.

1. Check control pressure at measuring

point 1x at maximum input speed.

figure 8-2, page 40

2. If the pressure is too low, remove pres-


figure 8-3, page 40

Malfunction 2: No Traction or Insufficient Traction (continued)

Cause Remedy

37


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

Control pump 51 defective 1. Check control pressure at measuring


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

blocked. Switching point occurs too soon.

1. Check engine regulating unit, readjust if

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-

nated.

1. Clean cooling elements.

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.

Control pin 422 in governor 42 blocked.

1. Remove governor 42 and enable control

pin 422 to run freely .

figure 8-1, page 39

Malfunction 3: Malfunctions during Shifting of Gears (continued)

Cause Remedy

38


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

Figures


413 blocked.



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

piston 411 does not switch to position for 2nd

gear.

1. Check control pressure at measuring


figure 8-1, page 39

2. If the pressure is too low, remove pres-


figure 8-3, page 40

Figure 8-1: Primary shaft, main control valve, governor

10 Drive shaft

41 Main control valve

42 Governor

Malfunction 4: Oil too Hot (continued)

Cause Remedy

10

41 42

4x5x

39


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

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

Figure 8-3: Pressure relief valve

46 Pressure relief valve

40

30

44

55

43

50/51

1x

46

40


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

Figure 8-4: Output shaft, control components

30 Output shaft

40 Reversing unit

44 Sensor valve

71 Internal limit switch

807 Plug screw

Figure 8-5: Heat exchanger connection

70 Temperature switch

804 Oil drain valve

805 Connection to heat exchanger

806 Connection from heat exchanger

30

40

44

71

807

805

806

70

804

41


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

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

Figure 8-7: Governor

42 Governor

807 Plug screw

41

411

412

413

414

807

42

42


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Malfunctions

Figure 8-8: Draining oil

53 Intake filter

54 Pressure filter

804 Oil drain valve

Figure 8-9: Check Oil Level

801 Oil-level glass

803 Oil filler neck

10

54

53

804

10

801

803

43


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

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

9.2 Removing the Turbo Transmission

9.2.1 Draining the Power Transmission Oil

Contact Voith if it is likely that the transmission will remain out of service for more

than 6 months.

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.

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.

44


pe

ratin

g I

nstr

uctio

ns 1

20

.00

40

28

21

_E

N,

Ve

rsio

n 1

Ed

ito

ria

l d

ea

dlin

e:

20

12

-01

-12

Taking out of Service and Disposal

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.

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

45

turbo transmission t 211 r.3 operating instructions 120.00402821...

Documents