Voith Turbo

Engineered reliability.

DIWA®.3

DIWA.3 users know:

the standard
Voith sets against which the performance of

modern automatic transmissions is measured

 Voith DIWA® Transmissions –
Economy and comfort through convincing technology
A good idea is never obsolete. This is why Voith Turbo is consistently
pursuing the development of its pioneering DIWA® transmissions.
Today, nearly all midi, city and long-distance buses can be fitted with
Voith automatics – a technology for the entire range of modern combustion
engines. What has remained is the unique principle of the DIWA® trans-
mission: the differential converter.

Starting characteristics
Voith DIWA® transmission
Engine output

Hydraulic Gear-shifting
share 1–2

Mechanical
share

0
Starting range
DIWA®-range

“State-of-the-art”
automatic transmission

Shifting into 1st gear Gear-shifting This principle allows stepless driving in the DIWA®
hydr./mech. 1 – 2 mech.
range even over longer periods – comparable con-
verter transmission need up to 50 % more gear-
shifts
Engine output

Not having to shift gears during starting ist not

1st gear 1st gear 2nd gear
hydr. mech. hydr./mech. just more comfortable but also safer

0
Starting range
Converter transmission

Less gear-shifting also means less wear on the
clutch plates and hence longer service life.

The DIWA® principle has proven itself – and has

stayed young. Others have to shift gears in order
to achieve what Voith automatics manage easily
without gear-shifts.
Superior technology – demonstrated in practical application

DIWA® transmissions are an ideal match for the technological developments

in the commercial vehicle sector. The transmissions and their gear-shifting
programs are adapted to the environmentally friendly, low-emission
EURO-3 combustion engines. Their electronic-hydraulic control systems
increase the gear-shifting quality of the transmission in such a way, that
gear-shifts are hardly perceptible, even under extreme conditions.

The acceleration-dependent gear-shifting program Further advantages: the filter which is integrated
takes the acceleration and the load conditions into the housing, the more compact stainless
of the bus into account and puts the gear-shifting steel heat exchanger in modular design for longer
points automatically in the optimum fuel con- service life and the advanced torsional vibration
sumption range. damper for low engine speeds and less fuel con-
One single gear-shifting program is sufficient for sumption. This is added by the particularly fine
all operating conditions. The unique PC diagnosis adjustment of the braking behaviour of the retar-
system is able to record the transmission func- der: smooth activation, strong braking perfor-
tions while the bus is at a halt or on the move. The mance, fast switch-on/switch-off response. This
control system also provides the possibility of is achieved via a controlled partial draining of
operating data storage. The evaluation of the oper- the converter.
ating data allows detailed analyses of traffic situa-
tions and helps with the selection of a driveline
that matches the prevailing operating conditions.

Performance data DIWA® transmission

Types D 823.3E* D 851.3E D 854.3E D 863.3E D 864.3E

Input power P1max [kW] 180 220 220 290 290

Input torque M1max [Nm] 650 1 100 1 100 1 600** 1 600**
Input speed n1max [rpm] 2 800 2 800 2 500 2 800 2 500
Retarder braking torque MBR*** [Nm] 2 000 2 000 2 000 2 000 2 000
No. of speeds**** 3 3 4 3 4
Transmission mass (dry)
inc. retarder [kg] 270 275 310 280 315
Max. vehicle weight [t] 15 28 28 28 28

Major areas of application Midibuses Standard single deckers Buses with high transmission put torque
and articulated buses Also suitable for long-distance/intercity applications

* The letter E denotes the consistent further development of the proven DIWA®.3 transmission
** For engines exceeding 1 300 Nm with torque reduction during gear-shifting
*** Maximum value, depending on retarder configuration
**** 1st gear with hydrodynamic/mechanical power-split (DIWA® range)
Design and operation of the DIWA® transmission

The mature design of Voith automatic transmissions is up-to-date

with the latest technological developments. It is simple, logical
and clear. Every transport operator is able to maintain and over-
haul the transmission at his own premises – with standard equip-
ment and no need for costly special tools.

Illustrated: 4-speed
DIWA® transmission
8 5 4 3 10 2 1 6 7 9

1 Counter-rotating
torque converter
2 Impeller brake
3 Coupling 3rd gear
4 Differential gear
5 Input clutch
6 Epicyclical gear
7 Epicyclical gear
for reverse gear
and retarder
8 Torsional vibration
damper
9 Heat exchanger
10 Coupling for
4th gear (D 854.3E/
D 864.3E only)

The heart of the DIWA® transmission The final set of epicyclical gears The heat exchanger of the Voith
is the hydrodynamic counter-rotating activates the reverse gear and, automatic transmission is integrated
torque converter. Situated in front of during braking, also the retarder. into the cooling circuit of the vehi-
it are the impeller, the lock-up clutch, A hydraulic torsional vibration dam- cle engine; generated heat is imme-
the differential transmission and per at the transmission input reduces diately dissipated.
the input clutch. With the 4-speed engine vibrations effectively. Gear- At the same time, the oil circuit of
transmission, the converter is addi- shifting occurs electro-hydraulically, the transmission is designed in such
tionally preceded by the clutch for with patented solenoid valves; the a way that the temperature stays
the 4th gear which is designed as gear-shifting commands are placed at a low level and that there is no
overdrive. Behind the converter, an by the control system. danger of an impaired performance,
epicyclical gear combines the hydro- if the initial temperature of the
dynamic and the mechanical forces. cooling agent is higher.
Power flow during gear-shifting and braking

The Voith principle: Idling/neutral position

Input clutch open
Driving and braking with
one hydraulic circuit 1st Gear
DIWA® range (stepless) Input clutch
and turbine brake are closing: smooth
start with high traction. Rapidly increa-
sing mechanical power transmission
via differential transmission (power-split
principle)

Driving: 2nd Gear

Power-split with differential Automatic gear-shifting is dependent
torque converter on acceleration and driving speed.
Impeller closes, turbine brake opens.
Power is now transmitted purely
mechanically

3rd Gear
At approximately 50 % (or 70 % with
D 851.3E/D 863.3E) of the maximum
speed, the input clutch opens automa-
tically and the lock-up clutch is closing
Braking:
Retarder function with 4th Gear (D 854.3E/D 864.3E only)
torque converter At approximately 70% of the maximum
speed, conversion occurs automati-
cally: clutch for the 4th gear closes and
1st Gear lock-up clutch opens
(DIWA® range)
Reversing (R)
Power is transmitted hydrodynamically/
mechanically like in 1st gear (DIWA®
range)
Traction

2nd Gear Braking (in 2nd – 4th Gear)

3rd Gear (Retarder function with converter)
4th Gear The turbine wheel acts as axial pump
which delivers oil against the stalled
impeller and the guide wheel. Heat
resulting from the conversion of kine-
0 Driving speed
tic energy is dissipated via the heat
exchanger

0 Driving speed

Active power flow ANS automatic disengagement of neutral.
Braking power

Braking stage I

Rotating components In order to save fuel, the power flow
II

Locked rotating components between engine and transmission, in-
III
Stationary components cluding the converter, is automatically

Clutch plates closed interrupted when the vehicle is at a halt.
DIWA®.3E, E 200, DIWAGNOSIS –
the combination for your economy

Transport companies and bus operators who

want to drive economically over long periods,
should always fully exploit their resources.
It is therefore vital to drive as efficiently as
possible and simultaneously minimise wear 7
and maintenance work. Here the unique
DIWA®.3 automatic transmission with E 200
control system and DIWAGNOSIS software
2
can help.
3 4

CAN-Bus
EDC, FMR, E-Gas
The E 200 control system identifies 6

the vehicle acceleration and adjusts

5
itself to the topography and the
load conditions. As a result, gear-
shifting points can always be put in
the optimum range which reduces
1
fuel consumption. The driver keys in 1 Transmission
2 Push-button switch
the conditions, and the electronic
3 Pedal brake valve
system optimises in line with the pre- 4 Accelerator
selected program. The micro pro- 5 Electronic control unit
6 Level converter for diagnosis
cessor control processes the incom-
7 Diagnosis via PC
ing commands from the driver in
fractions of a second to ensure that
acceleration is always swift while The control concept: Hydraulic control
driving is always economical. Micro-processor control
Patented Voith control valves con-
The PC-based diagnosis system
Digital processing of electronic vert signals into hydraulic pressure
DIWAGNOSIS offers the user opti- engine signals such as EDC,
individually controlled gear-shifts
mum support with check-ups and E-Gas a. o. owing to controlled pressure in-
failure detection and elimination,
Adaptive control for independent crease
with minimal hardware requirements. adaptation to engine and vehicle
Reduced wear owing to minimised
It includes peripheral equipment, as a prerequisite for consistent stress
e. g. push-button switch or load gear-shifting quality throughout the
transmitters. entire service life Systems diagnosis
With DIWAGNOSIS, all required
Storage facility allows precise
Integration into other vehicle
information can be displayed on a diagnosis of transmission condition diagnosis possible
PC at any time. Preventative and
Easy data exchange allows adap-
Long-term planning of maintenance
routine maintenance are backed up tation to new conditions (vehicle, and overhauls
which contributes significantly to engine, driving conditions)
Oil change in connection with spe-
the reduction of standstill times.
CAN-compatible cial oils after every 120 000 km

Operating data storage
 Voith DIWA® –
Economy and comfort made to measure

On the basis of individual criteria such as wear, weight distribution, noise

levels, passenger compartment design, etc., bus manufacturers and
operators often select highly different drive solutions and overall concepts
for their vehicles.
Voith Turbo is flexible to these needs and, in addition to its standard pro-
duct range, also offers components for the adaptation to engine and axle.

Standard scope of supply Additional range*

Voith DIWA standard transmis-
®
Connecting flanges between en-
Push-button switch for gear
sion gine and transmission selection

Anti-corrosive heat exchanger
Suspension flanges
Braking stage manual switch

Torsional vibration camper
Input flanges
Load transmission

Electronic control
Input angle drives
*These parts are not included in the

Oil temperature pick-up
Output angle drives standard delivery package but can be

Set of cables supplied upon request

130 817 130 895 275 275

684-698 762-776
67 67

242
272

Performance data DIWA®.3 transmission

Types D 823.3E D 851.3E D 854.3E D 863.3E D 864.3E

Differential Torque ratio – Output/Input

1 Gear (DIWA range)

st ® 3 5.9 – 6.2 5.9 – 6.2 5.9 – 6.2 5.9 5.9
(Starting point) 4 – 5.1 – 6.4 5.1 – 5.4 5.1 – 5.4 5.1 – 5.4

Transmissions

2nd Gear 3 1.43 1.43 1.43 1.43 1.43

4 – 1.36 1.36 1.36 1.36
3rd Gear 3 1.0 1.0 1.0 1.0 1.0
4 – 1.0 1.0 1.0 1.0
4th Gear 3 – – 0.7 – 0.7
4 – – 0.73 – 0.73
Reverse Gear 3 4.7 – 5.2 4.7 – 5.2 4.7 – 5.2 4.7 4.7
4 – 3.8 – 4.3 3.8 – 4.3 3.8 – 4.3 3.8 – 4.3
Voith – The Company
World-wide, Voith is setting standards in paper Voith – Figures, Dates, Facts
technology, power transmission, power genera- Voith is one of Europe’s large family-owned
tion and industrial services. companies. The driving forces of our growth are
Quality, reliability, solidity – these are the key words innovative power and reliability.
of our corporate philosophy. This is reflected in:
Voith – Engineered Reliability. Holding: Voith AG
Head office: Heidenheim/Brenz, Germany
Turnover: EUR 3.3 billion
Employees: 23 500
Locations: over 180 world-wide

Voith Turbo – Competent Partner for Power Transmission

Voith Turbo is a Group Division of Voith AG.
We develop and produce state-of-the-art drive
and braking systems for industry, rail and road
applications.
Our products operate economically, efficiently
and fast. They save energy, reduce emissions

G 1748 e (RTS) 04/03 Print Run 2 000, Dimensions and illustrations without obligation. Subject to modifications.
and, at the same time, offer ultimate comfort.

Voith Turbo GmbH & Co. KG

Alexanderstraße 2
D-89522 Heidenheim
Tel.: +49 (0) 73 21 37-82 49
Fax: +49 (0) 73 21 37-75 04
[email protected]
www.voithturbo.com

Engineered reliability.