Retardador 120 (Of 1721)

Training
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Aftersales Service Manual

VOITH Retarder 120 with Digiprop Control
Content
Table of Contents
1.
Preface ....................................................................................................1/1
2.
General....................................................................................................2/1
2.1 Assembly Overview ..........................................................................2.1/1
2.2 Function and Operation Scheme .........................................................2.2/1
2.3 Retarder Data ..................................................................................2.3/1
3.
Maintenance............................................................................................3/1
3.1 Maintenance Work .............................................................................3.1/1
3.2 Oil Change .......................................................................................3.2/1
With Stainless-Steel Heat Exchanger ....................................................3.2/1
With Aluminium Heat Exchanger ..........................................................3.2/5
3.3 Checking Oil Level .............................................................................3.3/1
3.4 Cleaning Line Filter (Optional extra) ......................................................3.4/1
4.
Diagnosis/Troubleshooting......................................................................4/1
4.1 Troubleshooting Diagram ....................................................................4.1/1
Elektrical Connections Diagram ...........................................................4.1/2
4.2 Troubleshooting and Remedies ............................................................4.2/1
4.3 Checking Pump Pressure ...................................................................4.3/1
4.4 Checking Control System ....................................................................4.4/1
4.5 Operational Check .............................................................................4.5/1
5.
Removing, Installing Retarder .................................................................5/1

5.1 Removing, Installing Retarder (Free Mount Installation)............................5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment) ...............................5.2/1
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Page IHV/1
Content
6.
Table of Contents
(Continue)
Retarder Basic Group Repair (Gearbox Attachment)..............................6/1

6.1 Assembly Overview ...........................................................................6.1/1
6.2 Removing, Checking and Installing Casing Ventilation .............................6.2/1
6.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......6.3/1
6.4 Removing, Checking and Installing Non-Return Valve
(Stainless-Steel Heat Exchanger) .........................................................6.4/1
6.5 Removing, Cleaning and Installing Silencer ............................................6.5/1
6.6 Removing and Installing Bottom Cover ..................................................6.6/1
6.7 Checking, Removing and Installing Closing Cover of Retarder Housing ......6.7/1
6.8 Removing and Installing Labyrinth Ring (Output Side),
Renewing Radial Shaft Sealing Ring .....................................................6.8/1
6.9 Removing and Installing Centering Cover (Input Side),
7.
Retarder Basic Group Repair (Free Mount Installation) ..........................7/1

7.1 Assembly Overview ...........................................................................7.1/1
7.2 Removing, Checking and Installing Casing Ventilation .............................7.2/1
7.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......7.3/1
7.4 Removing, Checking and Installing Non-Return Valve
(Stainless-Steel Heat Exchanger) .........................................................7.4/1
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Content
Table of Contents
(Continue)
Removing, Cleaning and Installing Silencer ............................................7.5/1

Removing and Installing Bottom Cover ..................................................7.6/1
Removing and Installing Prop Shaft Flanges ..........................................7.7/1
Checking, Removing and Installing Closing Cover of Retarder Housing ......7.8/1
Removing and Installing Labyrinth Ring (Output Side),
7.10 Removing and Installing Centering Cover (Input Side),
Renewing Radial Shaft Sealing Ring ...................................................7.10/1
7.5
7.6
7.7
7.8
7.9
8.
Removing, Checking and Installing Heat Exchanger ..............................8/1

8.1 Stainless-steel Heat Exchanger ...........................................................8.1/1
8.2 Aluminium Heat Exchanger .................................................................8.2/1
9.
Control Parts ...........................................................................................9/1
10.
Annex ....................................................................................................10/1
Data Sheet
Miscellaneous Conversions
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Page IHV/3
Preface
Preface
The present service manual serves as training material of the basics course.
The information and instructions which is given to you furthermore provide the basis for
appropriate and professional maintenance and repair at the VOITH Retarder 120 with Digiprop control.
We ask you firmly to notice the safety and warning notes which you will find in these instructions.
Caution!
is associated for safety instructions and for warning notes at dangerous situations for persons,
at reduction of quality of workmanship and the possibility of damage to property.
Notice
is associated for general notices for a better handling during maintenance of the retarder.
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Preface
Preface
(Continue)
Caution!
The switched-on retarder will not secure the parked vehicle.
At a failure of the retarder, or while the temperature limitation is effective the vehicle speed must be
settled with the service brake.
Notice
Only genuine spare parts may be used for repairs. For inquiries and orders, please provide the following
information (see also Section 2.3):
Serial-Number
Code-Number
Notice
The used three- or four-digit item numbers in these instructions are corresponding to the item numbers
in the spare part lists in the annex. Items or components shown with an oblique-number are not
available. Items or components with two-digit item numbers are no spare parts and therefore not
available in the spare part lists.
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Preface
Preface
(Continue)
Caution!
Pay attention to absolute cleanliness in maintenance work. Dirt on bearing and sealing surfaces and
electrical contacts may cause considerable damage or operational malfunctions.
Notice
To observe environmental protection you should dispose of drained fuels, coolants and lubricants
professionally.
Notice
Shield retarder proportional valve from direct jet of high-pressure cleaner (steam jet cleaner)!
Notice
In troubleshooting you must not replace parts on suspicion. Warranty work or goodwill work can only be
offered, if the parts involved are demonstrably defective.
To exclude injuries and to avoid impairment of the operational reliability of the retarder or damage to the
retarder as a result of inexpert workmanship, the information and instructions must be read carefully and
complied with in their entirety.
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Preface
Preface
(Continue)
Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situations
which might entail the risk of injury for the person carrying out the work. It is therefore imperative that
any person carrying out repair work on VOITH retarders uses his professional knowledge to make sure
that his own safety is not endangered and that the retarder suffers no negative effects, in particular
safety-wise, through the chosen working procedure. For these reasons, no liability can be assumed for
damage incurred.
It is therefore expressly pointed out that all working procedures described must be carried out only in
compliance with the valid general directions and regulations of the locally responsible authorities, of the
health protection, accident prevention and environmental protection organisations.
The technical status of the present instructions can be seen from the updating index. There may be
discrepancies between the actual technical status of the retarders and the descriptions owing to
continuous development and improvement of the retarders.
VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and without
prior notification.
Should you have queries about the descriptions, please contact the responsible person in the
appropriate organisation of the country involved or:
VOITH TURBO GmbH & Co. KG
D-74564 Crailsheim
Department cb; Voithstrae 1
Telephone (07951) 32-0
Telefax (07951) 32-756
Extensions:
Customer telephone and Spare Parts Service
32-401 / 32-422
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General
General
2.1
Assembly Overview ....................................................................................2.1/1

With Stainless-Steel Heat Exchanger .................................................................2.1/1
With Aluminium Heat Exchanger .......................................................................2.1/3
2.2
Function and Operation Scheme................................................................2.2/1
2.3
Retarder Data.............................................................................................2.3/1
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General
2.1
Assembly Overview
Illustration VOITH Retarder R 120

with Digiprop control system
basic group with stainless-steel
heat exchanger
100/1
100/2
100/3
1000
1900
100/3
Retarder data
Constant-air pressure
connection p y A
Ventilation connection R
Heat exchanger
Oil filler/check plug (M 30 x 1,5)
100/2
100/1
1900
1000
16001
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General
2.1
Assembly Overview
(Continue)

basic group with stainless-steel
heat exchanger
(Continue)
1000
1000/1
1000/5
1700
Heat exchanger
Leakage oil drain plug
(M 14 x 1,5)
Cooling water drain plug
(M 18 x 1,5)
Retarder oil drain plug
(M 22 x 1,5)
1700
1000/1
1000/5
1000
16002
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General
2.1
Assembly Overview
(Continue)

basic group with aluminium heat exchanger
100/1
100/2
100/3
1000
1000/5
1900
100/3
Retarder data
Constant-air pressure
connection p y A
Ventilation connection R
Heat exchanger
(M 12 x 1,5)
100/2
1900
100/1
1000
1000/5
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16003
General
2.1
Assembly Overview
(Continue)

basic group with aluminium heat exchanger
(Continue)
1000
1000/1
1000/3
1000/5
1700
Heat exchanger
(M 10 x 1)
Heat exchanger oil drain plug
(M 12 x 1,5)
(M 12 x 1,5)
(M 22 x 1,5)
1700
1000/3
1000/1
1000/5
1000
16004
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2.2
General
Function and Operation Scheme
Illustration of VOITH Retarder 120 with Digiprop control system
25
21
44
12
50
A R
67
46
16
26
37
69
23
52
20
2
19
45
18
53
43
56
66
17
15
47
70
1
Oil sump
Coolant (water)
Supply-air pressure p V
Constant-air pressure p y
Pump pressure p P
16005e
Notice
The reference numbers indicated in Section 2.2 are not identical with the reference numbers of the spare parts lists.
1
2
4
5
7
8
12
15
16
17
18
19
20
21
23
25
26
37
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Heat exchanger
Control unit
Connection terminal 15
Connection terminal 30
Fuses (5A)
Connection ground
Pump pressure test connection
ABS-Signal
Retarder stage switch
Retarder pilot light
Stop light relay
Temperature pick-up cooling water
Oil temperature pick-up
Proportional valve
Casing ventilation
Constant-air pressure line p y A
Supply-air pressure line p v P
Ventilation line R
43
44
45
46
47
50
52
53
56
66
67
69
70
Oil sump
Stator
Stator pin
Rotor
Speedometer signal
Output restrictor D1
Filling restrictor D2
Filling duct
Leakage oil return line
Check valve
(stainless-steel heat exchanger)
Check valve
(casing ventilation cover)
ISO interface plug
Extra operations plug

Page 2.2/1
General
2.2
Function and Control System

(Continue)
Description of the function

The VOITH Retarder 120 is a powerful hydrodynamic continous brake of compact design for buses and
commercial vehicles of the medium range. The VOITH Retarder 120 is mounted between the gearbox
and the rear axle of the vehicle.
The retarder braking torque is sustained even when gear changes are made.
The switched-on retarder will not secure a parked vehicle.
In the event of a retarder failure or when the temperature limit is effective, the service brake must be
used to regulate the vehicle speed.
A retarder stage switch (16) with a maximum of 5 switching stages is used to control the
VOITH Retarders 120. A special version combines the retarder stage switch (16) with ABS,
a 3-stage pedal-operated brake valve or a service-brake pressure switch.
The following variaties in operation are available:
Operation with function ,,Constant speed"
The retarder is operated by a 5-stage retarder stage switch.
When the retarder stage switch (16) is shifted to position 1, the Constant Speed function is activated.
The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit
of the maximum braking torque.
If the retarder is switched off (0 position), or switched to braking stage (position 2 to 5), the memorized
constant speed is deleted. If the constant speed function is re-activated, the new present speed
is memorized.
When the retarder stage switch is shifted to position 2 to 5, braking stage 1 to 4 is energized.
Maximum braking torque is obtained when the retarder stage switch is in the maximum position.
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General
2.2

(Continue)
Description of operation of retarder R 120 with digiprop control system

As a special version, the control system is available with push button operation for constant speed.
The retarder is operated in this case by a 4-stage retarder stage switch.
When the push button is pushed in any position of the retarder stage switch, the momentary speed is
transferred to memory. In the 0 braking stage, this transfer to memory takes effect and the retarder holds
the vehicle speed downhill constant within the limits of the maximum braking torque. Another push on
the push button in any switch position will delete the speed data.
On a downhill run with constant speed operation, the vehicle can be slowed down within the limits of
the maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting to
braking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle accelerates
to the speed previously transferred to memory.
The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank for
auxiliary equipment on the vehicle.
When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2).
From this input signal, the control unit (2) provides a control current which flows to the
proportional valve (21).
The proportional valve (21), depending on the magnitude of the control current, provides a
constant-air pressure p y on the oil sump (43).
16006
The hydrodynamic principle

a Rotor (46)
b Stator (44)
c
Oil flow
The constant-air pressure p y in the oil sump (43), depending on the operating conditions
(prop shaft speed), forces a certain quantity of oil into the working chamber between rotor (46)
and stator (44).
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General
2.2

(Continue)
The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarder
housing.
The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between
the rotor (46) and stator (44).
The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking of
the rotor (46) and consequently to braking of the vehicle.
During braking, the kinetic energy of a deceleration is transformed into heat. To dissipate this heat, part
of the circulating oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and via
filling ducts to join the circulating flow again.
In the heat exchanger (3300), the heat energy of the oil is transferred to the cooling water of the vehicle
and dissipated via the vehicle radiator to the ambient air.
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General
2.2

(Continue)
Temperatur pick-ups, water (19), oil (20)

The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from the
retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and
oil temperature to the control unit (2).
To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarder
braking torque is limited to protect the vehicle cooling system and the retarder.
The constant-air pressure p y is limited.
The braking torque and consequently the heat generated are reduced until a balance is obtained
between the braking energy of the retarder and the amount of heat which can be dissipated by
the vehicle cooling system.
If the cooling water temperature rises into the temperature limit range, the consequence is a limitation of
the retarder braking torque to protect the vehicle cooling system. If the temperature rises above the
temperature limit range, there is no more braking torque output.
While the temperature limit is effective or if there is a retarder failure, the service brake must be used to
control the vehicle.
The control unit (2) also cuts back braking torque if oil temperature rises too rapidly, irrespective of actual
oil temperature.
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General
2.2

(Continue)
Casing ventilation (23)

During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) and
the ventilation system (22) out of the retarder.
Once the working circuit is free of air, a float rises and closes the casing ventilation.
Stator pins (45)
When the working chamber is empty, the rotor (46) sets up in it an air flow, which is retarded by the stator
(44). To minimize this loss, automatically operating stator pins have been installed in the outer zone of
the stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent the
build-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back on
their seats against the force of the spring and the full space between the blades is available.
Check valve (66) stainless-steel heat exchanger
The check valve (66) prevents the airflow emptying the heat exchanger insert of oil when idling.
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General
2.3
Retarder Data
The retarder data (arrow) are punched on the left side on the retarder housing.
The retarder data plate (2) provides the following information:
1.
Serial number:
Six-digit number
2.
Code number:
Eight-digit number
Notice
Please, always quote the retarder serial-No. and code-No. when submitting queries
or ordering spare parts.
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16007
Maintenance
Maintenance
3.1
Maintenance Work .....................................................................................3.1/1
3.2
Oil Change .................................................................................................3.2/1

Stainless-steel Heat Exchanger ........................................................................3.2/1
Aluminium Heat Exchanger ..............................................................................3.2/5
3.3
Checking Oil Level .....................................................................................3.3/1
3.4
Cleaning Line Filter (Optional Extra) ..........................................................3.4/1
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Maintenance
3.1
Maintenance Work
Overview of maintenance work

Carry out the following maintenance work at each oil change:
l
Clean the cleaning line filter (optional extra)
Carry out visual inspection on leaks at the complete retarder
Check hex.-head screws of prop shaft on correct fitment, or tighten.

Observe guidelines and instructions!
Tighten all screw plugs of the retarder basic groups and the heat exchanger with the appropriate
torque (see Annex) except all fastening nuts of the heat exchanger (see Annex).
Caution!
Tighten fastening nuts of heat exchanger only in case of leakage. Tightening torque: 23 Nm
The oil change intervals and operating specifications have to be taken from the annex!
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Maintenance
3.2
Oil Change
Illustration oil change R 120

with stainless-steel heat exchanger
1000/1
1000/2
1000/5
1000/6
1600
1700
1800
1900

(M 10 x 1), 13 Nm
Sealing ring (A 10 x 13,5), renew
(M12 x 1,5), 25 Nm
Sealing ring (A12 x 18), renew
Sealing ring (A 22 x 29), renew
(M 22 x 1,5), 66 Nm
Oil filler/check plug
(M 30 x 1,5), 150 Nm
1900
1800
1000/6 1000/5
1000/2
1000/1
1600
1700
16008
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Maintenance
3.2
Oil Change
(Continue)
Notice
For satisfactory retarder operation, it is important to adhere to the specified service filling
(see table below) and to use only oils specified in the operating specifications (see Annex) for
operating the retarder in the relevant application.
Heat exchanger
Service filling
Stainless-steel
heat exchanger
(L+R)
4,5 l
After complete
After exchange of
taking apart and cle- heat exchanger
aning, as well as
emptied heat
exchanger
5,8 l
6,5 l
The retarder oil temperature must be higher than 60 o C (operating temperature) for the oil
to be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressure is acting in the retarder.
The retarder and the ignition must have been switched off!
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Maintenance
3.2
Oil Change
(Continue)
Job scope
1.
Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and
switch it off after approx. 5 sec.
Repeat this procedure twice.
Switch off the retarder and ignition and wait 5 minutes (control function).
Caution! Risk of injury!
The oil filler/check plug is heated up (oil temperature)!

2.
Push an oil collecting pan under retarder.
3.
Screw out the oil check plug (1900) and remove sealing ring (1800).
The retarder oil drain plug is heated up (oil temperature)!

4.
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Screw out the retarder oil drain plug (1700) and remove sealing ring (1600) and drain oil.

Page 3.2/3
Maintenance
5.
3.2
Oil Change
(Continue)
Screw out the leakage oil drain plug (1000/1) and remove sealing ring (1000/2) and drain the
accumulated oil.
Notice
If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening the
leakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with the
vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two
radial shaft sealing rings at the Retarder and renew those, if necessary
(see Section 6.8, 6.9, 7.9, 7.10).
If it is necessary to drain the cooling water during the service, remove and empty the retarder on oil side
completely (see Section 8.1, 8.2).
This process also must be enforced with strongly spent oil.
6.
Screw the oil drain plugs (1700 and 1000/1) tight with new sealing rings (1600 and 1000/2).
Retarder oil drain plug (1700):
Leakage oil drain plug (1000/1):
Tightening torque 66 Nm
7.
Fill in slowly, in the hole of the oil filler/check plug (1900), the quantity of oil specified
(see page 3.2/2) in accordance with the operating specifications (see Annex).
8.
Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm
9.
Check the oil level (see Section 3.3).
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Maintenance
3.2
Oil Change
(Continue)
Illustration oil change R 120

with aluminium heat exchanger
1000/1
1000/2
1000/3
1000/4
1600
1700
1800
1900

(M 10 x 1), 13 Nm
Heat exchanger oil drain plug
(M 12 x 1,5), 25 Nm
(M 22 x 1,5), 66 Nm
Oil filler/check plug
(M 30 x 1,5), 150 Nm
1900
1000/4
1000/3
1800
1000/2
1000/1
1600
1700
16009
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Maintenance
3.2
Oil Change
(Continue)
Notice
For satisfactory retarder operation, it is important to adhere to the specified service filling
(see table below) and to use only oils specified in the operating specifications (see Annex) for
operating the retarder in the relevant application.
Heat exchanger
Service filling
New filling
Aluminium heat exchanger (AKG)
5,5 l
6,0 l
The retarder oil temperature must be higher than 60 o C (operating temperature) for the oil
to be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressure is acting in the retarder.
The retarder and the ignition must have been switched off!
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Maintenance
3.2
Oil Change
(Continue)
Job scope
1.
Switch off the retarder and ignition and wait 5 minutes (control function).
The oil filler/check plug is heated up (oil temperature)!

2.
3.
Screw out the oil filler/check plug (1900) and remove sealing ring (1800).
The retarder oil drain plug is heated up (oil temperature)!

4.
Screw out the retarder oil drain plug (1700) and the heat exchanger oil drain plug (1000/3) and
remove the sealing rings (1600 and 1000/4) and drain oil.
5.
Screw out the leakage oil drain plug (1000/1) and drain the accumulated oil.
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Maintenance
3.2
Oil Change
(Continue)
Notice
If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening the
leakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with the
vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two
radial shaft sealing rings at the Retarder and renew those, if necessary
(see Section 6.8, 6.9, 7.9, 7.10).
6.
Screw the oil drain plugs (1700, 1000/3 and 1000/1) tight with new sealing rings (1600, 1000/2
and 1000/4).
Retarder oil drain plug (1700):
Heat exchanger oil drain plug (1000/3):
Leakage oil drain plug (1000/1):
7.
Fill in slowly, in the hole of the oil filler/check plug (1900), the quantity of oil specified
(see page 3.2/2) in accordance with the operating specifications (see Annex).
8.
Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm
9.
Check the oil level (see Section 3.3).
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Page 3.2/8
Maintenance
3.3
Checking Oil Level
Illustration checking oil level
1900
Notice
The oil change intervals and operating
specifications have to be taken from the annex.
1800
1900
1800

Oil filler/check plug (M 30 x 1,5),
150 Nm
Notice
The illustration shows a retarder 120 with
stainless-steel heat exchanger. A version with
aluminium heat exchanger is possible.
16010
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Maintenance
3.3
Checking Oil Level

(Continue)
Notice
For satisfactory retarder operation, it is important to use only oils specified in the operating specifications
(see Annex) for operating the retarder in the relevant application.
Service filling
The service filling for the complete retarder system depends on the version of the
mounted heat exchanger.
For relevant application approved oils
Use only approved oils specified in the operating specifications (see Annex).
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Page 3.3/2
Maintenance
3.3
Checking Oil Level

(Continue)
Notice
For the oil level check, the temperature of the retarder oil must be higher
than 60C (operating temperature).
The oil level check must be carried out with the vehicle in a horizontal position.
Difference between min. and max. mark on oil filler/check plug is approx. 0,5 l.
Job scope
1.
Caution!
While the oil level is being checked, make sure that retarder and ignition system must have
been switched off!
Risk of injury exists at nonobservance, by hot leaving oil when screw out oil filler/check plug!
2.
Switch off the retarder and wait 5 minutes (control function).

The oil filler/check plug (1900) is heated up (oil temperature)!

3.
cbtd 98-01
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53.2659.10
53.2640.10
Screw out the oil filler/check plug (1900) and remove sealing ring (1800).
Wipe off oil of the oil filler/check plug.

Page 3.3/3
Maintenance
3.3
Checking Oil Level

(Continue)
4.
Position oil filler/check plug (1900) plane at the thread.

Do not screw in the oil filler/check plug!
5.
Pull out again the oil filler/check plug (1900).

Oil level is correct bewteen min. and max. mark of the oil filler/check plug.
6.
Top up slowly any lacking oil through the hole for the oil filler/check plug.
7.
Screw the oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm
1900
Max
Min
16011
cbtd 98-01
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Page 3.3/4
Maintenance
3.4
Cleaning Line Filter

(Optional Extra)
Illustration line filter

Complete line filter
Pressure spring
Intermediate plate
Cover
Holding plate
Pressure spring
Filter housing
Filter insert
O-ring (36,2 x 3), renew,
coat with silicone-free and
non-corossive grease
for installation
12000/1
12000/6
12111
12000/2
12000
12000
12000/1
12000/2
12000/3
12000/4
12000/5
12000/6
12111
12112
12000/5
Lubricants
O-ring
12112
Silicone-free and
12000/3
12000/4
16012
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Page 3.4/1
Maintenance
3.4

(Continue)
Notice
Vehicle specific can be installed a line filter within the constant-air pressure line between air tank
for auxiliary equipment and the proportional valve of the retarder control system.
The line filter is designed and in the way installed, to ensure an optimum air flow to the proportional valve
also when filter insert is badly soiled. In this case the compressed air will not be cleaned anymore.
Job scope

Observe fall in pressure in the compressed air circuit for auxiliary equipment (e.g. air springs)!
1.
Disconnect constant-air pressure line at the line filter for air tank of auxiliary equipment .
2.
Press in the cover (12000/3) and pull out the holding plate (12000/4).
3.
Pull out of the filter housing (12000/6) the cover (12000/3) with O-ring (12112),
the pressure spring (12000/5), the intermediate plate (12000/2), the filter insert (12111)
and the pressure spring (12000/1) .
4.
Blow out the filter insert (12111) with compressed air from inside out. Check filter insert for
damages and renew if necessary.
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Page 3.4/2
Maintenance
3.4

(Continue)
5.
Insert the pressure spring (12000/1), the filter insert (12111), the intermediate plate (12000/2) and
the pressure spring (12000/5) in filter housing (12000/6).
6.
Coat new O-ring (12112) with silicone-free and non-corossive grease. Pull the new O-ring on to
the cover (12000/3).
7.
Press in the cover (12000/3) into the filter housing (12000/6) and put in the
holding plate (12000/4).
Notice
If complete filter (12000) has to be removed, observe the correct installing position.
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Page 3.4/3
Diagnosis /
Troubleshooting
Diagnosis / Troubleshooting
4.1
Troubleshooting Diagram ...........................................................................4.1/1

Electrical Connections Diagram ........................................................................4.1/2
4.2
Troubleshooting and Remedies .................................................................4.2/1
4.3
Checking Pump Pressure...........................................................................4.3/1
4.4
Checking Control System...........................................................................4.4/1
4.5
Operational Check......................................................................................4.5/1
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Page 4/1
4.1
Diagnosis /
Troubleshooting Diagram
Troubleshooting
Illustration troubleshooting diagram
Notice
Before starting troubleshooting the oil level of the retarder must be checked and corrected
(see chapter 3.3 Checking oil level).
It is important that the specific service filling is kept for a trouble-free operation of the retarder
(see chapter 3.2 Oil change and annex).
Renew non-return
valve
NOK
Contact
VOITH
OK
Check non-return
valve in cover of
casing ventilation
(Chapter
6.3)
Renew casing
ventilation
NOK
OK
Correct oil level of
retarder (*)
see chapter6.4
Check casing
ventilation
(Chapter6.2)
Check cooling system:

Check heat
exchanger
NO
YES
YES
OK
Water in the oil?

(emulsion)
NOK
-coolant level
-thermostat
-coolant pump
-radiator fan
-radiator grill for
dirtiness
NO
Water in the oil?

(emulsion)
Check oil level of

retarder
Retarder:
Check Temp.-Sens.
(oil/water)
Driver instruction!
Oil leak by
ventilation
OK
flashes
If the retarder is
still leaking, or the
chamber of
leakage oil is filled
again with oil after
1000 km,
renew radial shaft
seal
Empty chamber of
return of leakage oil
(at heat exchanger)
(Chapter3.3)
Check operation
(by braking with
retarder nominal
engine speed,
if possible
Complaint
Oil leak input side
or output side
NOK
Temperature limit!
Retarder pilot
light
R 120
Digiprop
Permanent
lighting
No respectively
too insufficient
retarder braking
effect
Activate flash code

and read out
trouble code
(Chapter4.2)
Clear faults and

delete fault memory
(Chapter4.2)
Check oil level of

retarder
Water in the oil?
(emulsion)
NO
OK
YES
YES
NO
Check heat
exchanger
Check yp(static)
(Chapterl 4.4
)
OK
Water in the oil?

(emulsion)
NOK
see chapter
Correct oil level of

retarder
6.4
NOK
Check p (dynamic)
(Kapitel4.3)
OK
NOK
Check voltage of
proportional valve
(Chapter4.4)
OK
Contact
VOITH
NOK
Contact
VOITH
Check control unit
(Chapter4.4)
OK
Contact
VOITH
Check compressed-air supply

(Chapter 4.4)
OK
NOK
Contact
VOITH
NOK
Check vehicle
compressed-air
supply
Mechanical fault of
proportional valve
OK
Contact
VOITH
* If you get oil leakage after a trail run again:

continue at Checking casing ventilation
NOK
Contact vehicle
manufacturer
FD 1601
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Page 4.1/1
4.1
Diagnosis /
Troubleshooting
Troubleshooting Diagram
(Continue)
Electrical Diagram Version 1
Connecting plug 4 pins

"ISO Interface"
3 1 2 4
Digiprop
X1.
18pins
X2.
9pins
X3.
12pins
3
2
1
6
5
4
9
8
7
CAN-high
CAN-Ground
CAN-low
Position 1
Position 2
Position 3
Position 4
Position 5
T 15 (Ignition lock)
Lead E-Box
T 30 (Battery)
Output / high side 1 `HS 1`
Output / low side 1 `LS 1`
Output / high side `HS 2`
pink
blue
orange
white
wei
grey
red
red
blue/white
orange/white
purple
purple
brown
brown
black
beige
yellow/green
black/white
Prop valve `+`

Prop valve `-`
Changeover valve `+`
Changeover valve `-`
Water temp.`+`
Water temp.`-`
Oil temp.`+`
Oil temp.`-`
pink
grey
orange
beige
yellow/green
blue
purple
white
12
11
10
ISO K
ISO L
Retarder Stage Switch`+`
15
14
13
18
17
16
T 31 (Ground)
3
2
1
6
5
4
9
8
7

"Retarder Stage Switch"
3
2
1
6
5
4
9
8
7
12
ABS
Speedometer signal
Input / pull-up `DIU 1`
Input / pull-down `DID 1`
Input / pull-down `DID 3 `
Input / (m 0...5V ) ÌNA-U `
Input / p.-down / PWM-in `DID 4 `
11
10
Stop light relay

Input / (0...20mA ) ÌNA-I
7
6
5
3
2
8
4
Position 1
Position 2
Position 3
Position 4
Position 5
T 31 (Ground)
T 30 (Battery)
+
+
Lead Retarder
Pin 1
2
3
4
Prop valve `+`

Prop valve `-`
Water temp.`+`
Water temp.`-`
Oil temp.`+`
Oil temp.`-`
black/white
blue
white
pink
blue/white
brown/white
orange/white
yellow/green
grey/black
grey
grey
orange
red/white
ABS
Speedometer signal
Stop light relay
1 9 5 8 4 3 2 7 6 1112101314
Connecting plug 14 ins
"Additional Functions"
16014e
Electrical Diagram Version 2
"ISO Interface"
3 1 2 4
Digiprop
X1.
18pins
X2.
9pins
X3.
12pins
3
2
1
6
5
4
9
8
7
CAN-high
CAN-Ground
CAN-low
Position 1
Position 2
Position 3
Position 4
Position 5
Lead E-Box
T 30 (Battery)
Output / high side 1 `HS 1`
Output / low side 1 `LS 1`
Output / high side `HS 2`
pink
blue
orange
white
wei
grey
red
red
blue/white
orange/white
purple
purple
brown
brown
black
beige
yellow/green
black/white
Prop valve `+`

Prop valve `-`
Water temp.`+`
Water temp.`-`
Oil temp.`+`
Oil temp.`-`
pink
grey
orange
beige
yellow/green
blue
purple
white
12
11
10
ISO K
ISO L
15
14
13
18
17
16
T 31 (Ground)
3
2
1
6
5
4
9
8
7

"Retarder Stage Switch"
3
2
1
6
5
4
9
8
7
12
ABS
Speedometer signal
Input / pull-down `DID 3 `
Input / (m 0...5V ) ÌNA-U `
Input / p.-down / PWM-in `DID 4 `
11
10
Stop light relay

Input / (0...20mA ) ÌNA-I
7
6
5
3
2
8
4
Position 1
Position 2
Position 3
Position 4
Position 5
T 31 (Ground)
T 30 (Battery)
+
+
Lead Retarder
Pin 1
2
3
4
Pin 1
2
3
4
black/white
blue
white
pink
blue/white
brown/white
orange/white
yellow/green
grey/black
grey
grey
orange
red/white
Prop valve `+`

Prop valve `-`
Water temp.`+`
Water temp.`-`
Oil temp.`+`
Oil temp.`-`
ABS
Speedometer signal
Stop light relay
1 9 5 8 4 3 2 7 6 1112101314
"Additional Functions"
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Page 4.1/2
16015e
Diagnosis /
Troubleshooting
4.2
Troubleshooting and Remedies
Troubleshooting and remedies

Check requirements
Battery voltage 18 - 32 V
Vehicle electrical system checked in accordance with the Owners Manual for the vehicle
and found satisfactory.
Fuse for retarder control unit checked and found satisfactory.
Compressed-air pressure 6 - 11 bar
For check with the multimeter, pin 15 (plug X1) on the control unit (2)
must be connected to pin 15 ground (terminal 31),
at pin 7 (plug X1) must be connected terminal 15 and
at pin 13 (terminal X1) terminal 30.
Notice
Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary
(see Section 3.3 Checking Oil Level).
For trouble-free retarder operation, it is important that the filling quantity specified is adhered to
(see table, Section 3.2, page 3.2/2).
cbtd 98-01
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Page 4.2/1
Diagnosis /
Troubleshooting
4.2

(Continue)
Notice
The retarder pilot light (arrow) has additionally the function of a fault code:
- slight fault
Permanent lighting in position 0 - 5 of retarder stage switch, braking is still possible to limited extent.
- serious fault
Permanent lighting in position 0 - 5 of retarder stage switch, braking no longer possible
- retarder is switched off.
16016
Notice
If the ignition is switched off and on, the retarder is in operation again and the retarder pilot light
goes off. If a serious fault remains present or reoccurs, the retarder switches off again and the retarder
pilot light comes on permanently in position 0 to 5 of the retarder stage switch.
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Page 4.2/2
Diagnosis /
Troubleshooting
4.2

(Continue)
Connector arrangement and pin assignment
Notice: All plugs illustrated from plug-in side (i.e. leads at back).
Plug X1 Control unit

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
cbtd 98-01
53.2659.10
Not in use
Not in use
Not in use
Retarder stage switch, position 3 -(or)
Retarder stage switch, position 2 -(bl)
Retarder stage switch, position 1 -(pi)
Terminal 15 (rd)
Retarder stage switch, position 5 -(gr)
Retarder stage switch, position 4 -(wh)
Retarder stage switch + (vi)
ISO-interface, L-lead (or/wh)
ISO-interface, K-lead (bl/wh)
Terminal 30 (bl)
Not in use
Terminal 31 (br)
Output / high side 2 HS2 (bl/wh)
Output / low side 1 LS1 (ye/gr)
Output / high side 1 HS1 (be)
16
13
10
17
14
11
18
15
12
16017

Page 4.2/3
Diagnosis /
Troubleshooting
4.2

(Continue)

1
2
3
4
5
6
7
8
9
Not operational/usable for applications (or)

Proportional valve - (gr)
Proportional valve + (pi)
Cooling water temperature pick-up - (bl)
Cooling water temperature pick-up + (ye/gr)
Not operational/ground (be)
Not in use
Oil temperature pick-up - (wh)
Oil temperature pick-up + (vi)
16018

1
2
3
4
5
6
7
8
9
10
11
12
cbtd 98-01
53.2659.10
Input / pull up DIU 1 (wh)

Speedometer signal (bl)
ABS-Signal (bl/wh)
Input / pull down DID 2 (br/wh)
Input / pull down DID 1 (bl/wh)
Input / pull up DIU 2 (pi)
Input / (0...5V) INA-U (gr/bl)
Retarder pilot light (ye/gr)
Input / pull down DID 3 (or/wh)
Input / (0...20 mA) INA-I (rd/wh)
Stop light relay (or)
Input / pull down / PWM-in DID4 (gr) / engine-speed signal

Page 4.2/4
10
11
12
16019
Diagnosis /
Troubleshooting
4.2

(Continue)
Extra operations plug

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Input / pull down DID 1 (bl/wh)
Input / pull down DID 2 (br/wh)
Input / pull down DID 3 (or/wh)
Input / pull down / PWM -in DID 4 (gr)
Input / pull up DIU 1 (wh)
Input / pull up DIU 2 (pi)
Input / (0...5V) INA-U (gr/bl)
Input / (0...20 mA) INA-I (rd/wh)
Output / high side 1 HS1 (be)
Output / high side 2 HS2 (bl/wh)
Output / low side 1 LS1 (ye/gr)
Terminal 15 (rd)
Terminal 31 (br)
10
12
14
11
13
16020
ISO-Interface plug
1
2
3
4
K-lead (bl/wh)
K-lead (or/wh)
Terminal 15 (rd)
Terminal 31 (br)
16021
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Page 4.2/5
Diagnosis /
Troubleshooting
4.2

(Continue)
Cooling water temperature pick-up plug

Oil temperature pick-up plug
16022
Proportional valve plug

1
2
3
4
Proportional valve + (pi)

Proportional valve + (gr)
Not operational (or)
Not operational (be)
4
1
2
3
16023
cbtd 98-01
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Page 4.2/6
Diagnosis /
Troubleshooting
4.2

(Continue)
Retarder stage switch plug

1
2
3
4
5
6
7
8
Not in use
Position 5 - (gr)
Position 4 - (wh)
Position 3 - (or)
Position 2 - (bl)
Position 1 - (pi)
Bridge to pin 4
16024
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Page 4.2/7
Diagnosis /
Troubleshooting
4.2

(Continue)
A. With fault code

Special tool
53.8224.10
Commercially available tool

Multimeter
recommended: Fluke 87
Notice
The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-out
from the fault memory.
Furthermore a diagnosis with the PC DigiDia software is possible. In this case please contact
VOITH TURBO or a responsible contracting party.
cbtd 98-01
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Page 4.2/8
Diagnosis /
Troubleshooting
4.2

(Continue)
Fault memory read-out via retarder pilot light blinking code
R
Notice
If several faults have been stored in the memory, they are indicated in the sequence of their occurance,
but always only one fault per triggering.
Exception:
The fault Coding fault is not held in the memory but is indicated via the blinking code.
The blinking code can be read-out of the control unit with service cable or retarder stage switch.
16016
Fault memory read-out with service cable

(Digiprop-Version 0.2)
Requirements
-
1.
Retarder stage switch in position 0

Vehicle in parking position, Ignition ON
Service interface L-lead connected to ground for 2 s. For this purpose, press push-button of
service cable switch.
2.
First fault as blinking code output.
3.
Repeat from step 2 and 3 for more blinking code outputs.
Meaning
-
cbtd 98-01
53.2659.10
long blinking signals (2 sec.) tens unit.

short blinking signals (0,5 sec.) single unit.

Page 4.2/9
Diagnosis /
Troubleshooting
4.2

(Continue)
Digiprop-Version 1.0
The blinking code can be triggered analogous to V 0.2, the conditions are the same. Additionally the
blinking code can be triggered with the help of the retarder stage switch during the service function:
1.
2.
3.
4.
5.
Shift RSS-Position 0
Shift RSS-Position 1 ( 2 Seconds)
Shift RSS-Position 0
Blinking code of first fault is indicated
Repeat from step 2 to 3 for more blinking code outputs
Addition for versions as of V 1.1

There is a break of 3 seconds before and after each blinking code output, during this time the retarder
pilot light is switched off.
16025
Display example: Fault code 23
Display example for fault code 23:

The number of tens will be indicated first as long ON-time:
The number of singles afterwards will be indicated as short ON-time:
Breaks between each ON-time:
each 2 seconds
each 0,5 seconds
each 1 second
E
A
t
If a relevant fault is indicated, the retarder pilot light is ON before triggering of the blinking code, the
retarder pilot light switches to permanent lighting again after the blinking code.
If there is only one fault in the memory, the retarder pilot light stays OFF after the output.
cbtd 98-01
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Page 4.2/10
Retarder stage switch on

Retarder stage switch off
Time
Diagnosis /
Troubleshooting
4.2

(Continue)
Delete fault memory

No marginal conditions in accordance with read-out of fault memory.
1.
Ignition: OFF
2.
Service interface L-lead connected to ground. For this purpose, press push-button of
service cable switch.
3.
Ignition: ON
4.
Disconnect after 2 seconds the L-lead of ground.
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Page 4.2/11
Diagnosis /
Troubleshooting
4.2

(Continue)
Notice
Meaning of entries in Measurement/test connection column: X 1/15 W X 3/11
Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3
Table 1:
Fault
Code
01
Fault text
Fault
class
Trigger time
Requirement /
Operation
Measurement/
test
connection1 )
Result/
Set point
Cause/
Remedy 2)
Stop light relay/
slight
1s
- Ignition: OFF
- Pull plug X3 out of
control unit
X 3/11 W X 1/15
Relay is
installed:
250 - 350 W
Check lead, plugs

and relay
or consumers
slight
400 ms
- Ignition: OFF
control unit
- Disconnect plug
for extra operation
(e.g. lamp or
relay)
- Ignition: ON
X 1/17 V X 1/15
0V
Check lead, plugs

and relay
or consumers
(Check)
Short circuit to
ground
02
LS 1 output
Short circuit to
battery
1)
2)
cbtd 98-01
53.2659.10
X 1/15 = ground control unit

Only, if no fault is recognizable after a complete check of the periphery: change control unit.

Page 4.2/12
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 2:
Fault text
Fault
Code
03
Fault
class
Trigger time
slight
1s
Measurement/
test connection
Result/
Set point
Cause/
Remedy
- Ignition: OFF
control unit
X 1/18
W X 1/
15
With relay
installed:
250 - 350 W
Check lead, plugs

and relay
or consumers
slight
1s
- Ignition: OFF
control unit
X 1/16 W X 1/15
With relay
installed:
250 - 350 W
Check lead, plugs

and relay
or consumers
serious
60 s
- Ignition: OFF
control unit
- Ignition: ON
X 1/7
V X 1/15
17,5 V
Check lead, plugs

and fuses
serious
10 s
- Ignition: OFF
control unit
- Ignition: ON
- Start engine
(idle speed)
X 1/7
V X 1/15
32,5 V
Checking electrical
installation of vehicle
(see manufacturer
instructions)
Operation
(Check)
HS 1 output
Short circuit
04
HS 2 output
Short circuit
05
Terminal 15
Undervoltage
06
Terminal 15
Overvoltage
cbtd 98-01
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Requirement /

Page 4.2/13
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 3:
Fault text
Fault
Code
08
09
Fault
class
Trigger time
Requirement /
Operation
Measurement/
test connection
Result/
Set point
(Check)
1s
Water temperature sensor

Discontinuity /
Short circuit to
battery
serious/
slight *
- Ignition: OFF
control unit
X 2/5 W X 2/4 20C 10 C =

1039 - 1117W
60C 10 C =
1099 - 1271W
80C 10 C =
1271 - 1347W
Notice:
The measuring in
one temperature
range
normally is
sufficient.
cbtd 98-01
53.2659.10
Cause/
Remedy
Fault is in serious class, if temperature sensor for oil and water are defective at the same time.

Page 4.2/14
Check lead and

sensor
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 4:
Fault text
Fault
Code
11
12
Fault
class
Trigger time
Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
X 2/9 W X 2/8
20C 10 C =
1039 - 1117W
Check lead and

sensor
(Check)
Oil temperature
sensor
1s
serious/
slight *
- Ignition: OFF
control unit
60C 10 C =
1099 - 1271W
Discontinuity /
Short circuit to
battery
80C 10 C =
1271 - 1347W
Notice:
The measuring in
one temperature
range
normally is
sufficient.
*
cbtd 98-01
53.2659.10
Fault is in serious class, if temperature sensor for oil and water are defective at the same time.

Page 4.2/15
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 5:
Fault text
Fault
Code
(Check)
13
13
13
Retarder stage
switch
Undefined
switch state
Fault
class
Trigger time
serious
100 ms
Requirement /
Measurement/
test connection
Result/
Set point
Cause/
Remedy
- Ignition: ON
- Retarder stage
switch:
Position 0
X 1/10 V X 1/15
17,5 V
Check lead, plug and

retarder stage switch
- Ignition: ON
- Retarder stage
switch:
Position 1
X 1/10 V X 1/15
X 1/6 V X 1/15
Operation
- Ignition: ON
- Retarder stage
switch:
Position 2
X 1/6
X 1/5
X 1/4
X 1/9
X 1/8
X 1/5
X 1/4
X 1/9
X 1/8
V
V
V
V
X 1/15
X 1/15
X 1/15
X 1/15
X 1/15
X 1/15
X 1/15
X 1/15
X 1/15
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4
X 1/9
X 1/8
cbtd 98-01
53.2659.10
V
V
V
V
V
V X 1/15
V X 1/15
V X 1/15

Page 4.2/16
0V
0V
0V
0V
0V
17,5 V
17,5 V

0V
0V
0V
0V
17,5 V
17,5 V
17,5 V
0V
0V
0V

Diagnosis /
Troubleshooting
4.2

(Continue)
Table 6:
Fault text
Fault
Code
(Check)
13
Fault
class
Trigger time
Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
- Ignition: ON
- Retarder stage
switch:
Position 3
X 1/10 V
X 1/6 V
X 1/5 V
X 1/4 V

X 1/15
X 1/15
X 1/15
X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
13
- Ignition: ON
- Retarder stage
switch:
Position 4
X
X
X
X
X
1/10 V
1/6 V
1/5 V
1/4 V
1/9 V
X
X
X
X
X
1/15
1/15
1/15
1/15
1/15
X 1/8 V X 1/15
13
cbtd 98-01
53.2659.10
- Ignition: ON
- Retarder stage
switch:
Position 5
X 1/10
X 1/6
X 1/5
X 1/4
X 1/9
X 1/8
V
V
V
V
V
V
X
X
X
X
X
X
1/15
1/15
1/15
1/15
1/15
1/15

Page 4.2/17
17,5 V
17,5 V
17,5 V
17,5 V
0V
0V
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V

0V
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V

Diagnosis /
Troubleshooting
4.2

(Continue)
Table 7:
Fault text
Fault
Code
Fault
class
Trigger time
Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
(Check)
14
Retarder stage
switch
Short circuit to
battery
serious
10 s
- Ignition: OFF
control unit
- Ignition: ON
- Retarder stage
switch:
Position 0
X 1/10 V X 1/15
0V
Check lead and plug
15
Retarder stage
switch
Short circuit to
battery
serious
1s
- Ignition: OFF
control unit
- Retarder stage
switch:
Position 5
X 1/10 W X 1/15
Resistor
infinite
Single check of
stages for
short circuit
cbtd 98-01
53.2659.10

Page 4.2/18
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 8:
Fault text
Fault
Code
16
Fault
class
Trigger time
serious
Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
2s
- Ignition: ON
X 3/2 V X 1/15
==1 V
Check lead and

speedometer
serious
2s
- Ignition: OFF
control unit
- Ignition: ON
X 3/2 V X 1/15
==9 V
Check lead and

speedometer
serious
60 s
- Ignition: ON
X 3/3 V X 1/15
3,5 V
Check lead,
relay and ABS-control unit
(Check)
Speedometer
signal
Discontinuity
18
Speedometer signal
Short circuit to
battery
19
cbtd 98-01
53.2659.10
ABS
Short circuit to
ground

Page 4.2/19
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 9:
Fault text
Fault
Code
Fault
class
Trigger time
Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
X 3/3 V X 1/15
16,5 V
Check lead,
relay and ABScontrol unit
Replace control
unit
==10 V
Check lead
(Check)
21
ABS-Signal undefined
serious
60 s
- Ignition: ON
22
Internal fault
ABS-current path
serious
1s
23
Proportional valve
Fault No. 1:
Short circuit to battery
serious
1s
- Ignition: OFF
control unit
- Ignition: ON
cbtd 98-01
53.2659.10
X 2/3 V X 1/15

Page 4.2/20
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 10:
Fault text
Fault
Code
(Check)
24
24
cbtd 98-01
53.2659.10
Proportional valve
Fault No. 2:
- Short circuit proportional
valve magnetic
- Short circuit connection
lead proportional valve
- Discontinuity proportional valve magnetic
Valve magnetic
- Discontinuity connection lead proportional
valve
- Short circuit to ground at
proportional valve
- Prop.- and shift valve
interchanged
Fault
class
Trigger time
serious
1s
Requirement /
Measurement/
test connection
Result/
Set point
Cause/
Remedy
- Ignition: ON
- Pull plug X2 out
of control unit
X 2/2 W X 2/3
18-25 W
Check lead and

proportional
valve (valve
block)
- Ignition: OFF
- Pull plug X2 out
of control unit
X 2/3 W X 1/15
Resistor
infinite
Check lead and

proportional
valve (valve
block)
Operation

Page 4.2/21
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 11:
Fault text
Fault
Code
(Check)
24
Fault
class
Trigger time
Requirement /
Operation
- Ignition: OFF
control unit
Measurement/
test connection
Result/
Set point
Cause/
Remedy
X 2/2 W X 1/15
Resistor
infinite
Check lead and

proportional
valve (valve
block)
25
Proportional valve
Fault No. 3:
defective control unit
serious
10 s
Replace
control unit
27
Proportional valve
Fault No. 5:
defective control unit
serious
2s
Replace
control unit
28
Terminal 30
serious
60 s
Undervoltage
cbtd 98-01
53.2659.10
- Ignition: OFF
control unit
- Ignition: ON
X 1/13 V X 1/15

Page 4.2/22
17,5 V
Check lead,
plug and fuse
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 12:
Fault text
Fault
Code
Fault
class
Trigger time
Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
(Check)
29
Fault control unit
serious
180 ms
Replace
control unit
31
Control unit:
Coding fault
serious
100 ms
Provide new
parameters for
control unit
32
Retarder pilot light:

Discontinuity /
Short circuit to ground
serious
3s
- Ignition: OFF
control unit
- Ignition: ON
X 3/8 V X 1/15
17,5 V
Check lead,
retarder pilot
light and fuse
33
Retarder pilot light:

Short circuit to battery
serious
3s
- Ignition: ON
- Retarder stage
switch:
Position 1
X 3/8 V X 1/15
==2 V
Check lead and

retarder pilot
light
cbtd 98-01
53.2659.10

Page 4.2/23
Diagnosis /
Troubleshooting
4.2

(Continue)
Table 13:
Fault text
Fault
Code
Fault
class
Trigger time
Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
(Check)
35
Fault control unit
serious
500 ms / 123 s
Replace
control unit
37
Fault pedal operation
slight
100 ms / 1 s
Check installation relating to

OEMrespectively
VOITHinstructions
cbtd 98-01
53.2659.10

Page 4.2/24
Diagnosis /
Troubleshooting
4.2

(Continue)
B. Without fault code

Notice
Retarder faults without fault code are not recognized electronically.
cbtd 98-01
53.2659.10

Page 4.2/25
Diagnosis /
Troubleshooting
4.3
Checking Pump Pressure
Illustration checking pump pressure

Preconditions for checking
Ignition OFF
101 Hex.-head screw (M 12 x 1,5),
(Pump pressure measuring point)
25 Nm
102 Sealing ring (A 12 x 15,5), renew
101
102
Notice
The pump-pressure check provides information
on the mechanical condition of rotating parts,
on internal leaks and on the operation
of the retarder.
Special tool
53.4788.10
16026
Pressure gauge
0 - 25 bar
cbtd 98-01
53.2659.10

Page 4.3/1
Diagnosis /
Troubleshooting
4.3

(Continue)
99/1

The screw plug is heated up!
Job scope
1.
Screw out screw plug (101) with sealing ring (102) at the retarder housing.
2.
Connect up pressure gauge (99/1) to retarder housing.
3.
Shift retarder stage switch (16) to the highest braking stage with the vehicle in parking position and
read-off after 30 sec. the pump pressure from the pressure gauge (99/1).
4.
Compare read-off pump pressure with the setpoint of the static pump pressure
(see following table page 4.3/3).
16027
99/1 Pressure gauge 53.4788.10
Caution!
If the measurement of the static pump pressure falls short of the setpoint, either the retarder is leaking or
the control system is defective (see troubleshooting diagram).
cbtd 98-01
53.2659.10

Page 4.3/2
Diagnosis /
Troubleshooting
Setting [Nm]
4.3
Code Number
3)

(Continue)
Pump pressure static

Setpoint [bar]
Pump pressure dynamic 1 )

v p s = 1000 r.p.m.
Minimum value [bar]
1)
2)
3)
1000
027
1,15 1,45
1250
028
1,45 1,75
1500
029
1,75 2,05
12
1750
030
2,05 2,35
14
2000
031
2,35 2,65
16
Retarder stage switch in highest position

Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure)
The code number is to be found at the control unit
Notice
The data represent the state of the art at the time of going to print.
Control units with different values are still in circulation. The manufacturer reserves the right to make
further modifications.
cbtd 98-01
53.2659.10

Page 4.3/3
Diagnosis /
Troubleshooting
4.3

(Continue)
Job scope dynamic

1.
Drive the vehicle with a prop-shaft speed of v p s = 1000 r.p.m.
2.
Shift the retarder stage switch (16) to position 5 while on the move at vps = 1000 r.p.m. and
read-off pump pressure at pressure gauge (99/1).
3.
Compare read-off pump pressure with the value of dynamic pump pressure
(see table page 4.3/3).
Caution!
If the setpoint is obtained in the check at parking position but the minimum value is not reached in the
dynamic check, please contact VOITH TURBO!

The screw of the pressure gauge and the retarder are heated up!
4.
cbtd 98-01
53.2659.10
Disconnect the pressure gauge (99/1). Screw in screw plug (101) with new sealing ring.

Page 4.3/4
4.4
Diagnosis /
Checking Control System
Troubleshooting
Illustration checking control system
25
Notice
The reference numbers indicated in Section 4.4
are not identical with the reference numbers of
the spare parts lists.
33
71
32
21
61
A R
P
37
1
2
11
19
20
21
25
26
31
32
33
34
35
37
39
40
61
71
cbtd 98-01
53.2659.10
Heat exchanger
Control unit
Proportional valve
current connection
Temperatur pick-up cooling water
alternative: positions 19 and 20
joining in the central-plug (see electrical diagram Version 2)
Temperature pick-up oil
Proportional valve
Constant-air pressure line p y
(Connection A)
Supply-air pressure line p v
(Connection P)
Compressed air line
(pressure regulator - four-circuit
protection valve)
Compressed-air pressure line
(four-circuit protection valve air tank for auxiliary equipment
with test connection
Compressed-air line
(brake circuit No. 1)
Compressed-air line
(brake circuit No. 2)
Compressed-air line
(parking brake)
Ventilation line R
Electrical lead (cooling-water
temperature pick-up to control unit,
2 wires)
Electrical lead (oil temperature
pick-up to control unit, 2 wires)
Four-circuit protection valve
Air tank for auxiliary equipment
31
1
35
26
34
40
2

Page 4.4/1
20
39
19
16028
4.4
Diagnosis /
Troubleshooting

(Continue)
Check requirements
Electrical system checked in accordance with the Owners Manual for the vehicle
Fuse for retarder control unit checked and found satisfactory.
Retarder stage switch in Position 0
Ignition OFF
Special tools
Wasser
53.4788.10
53.8207.10
53.8279.10
53.8198.10
Pressure gauge
0 -25 bar
The adapter lead 53.8279.10 (98/5) has to be used only to connect the temperature simulator
53.8207.10 (99/2), if the temperature sensor for oil and water are using one central plug.
Commercially available tool
Multimeter
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10
recommended: Fluke 87

Page 4.4/2
Diagnosis /
Troubleshooting
4.4

(Continue)
Checking supply-air pressure pv

1.
Connect pressure gauge to test connection of compressed-air line (32) (four-circuit protection
valve - air tank for auxiliary equipment) and check supply-air pressure pv .
Minimum pressure:
6 bar
Maximum pressure:
11 bar
Notice
If the pressure is not within the specified range, the service brake must be checked
to the manufacturers data.
32
16029
Pressure gauge 53.1403.10
Test set-up job scope

1.
57
98/5
Connect temperature simulator (99/2) with the adapter lead (98/5) at the temperature pick-up (57).
99/2
Notice
Pay attention to the correct connection of the plugs for cooling water and oil.
16030
99/2 Temperature simulator 53.8207.10
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 4.4/3
Diagnosis /
Troubleshooting
2.
4.4

(Continue)
Screw out oil filler/check plug (1900) with sealing ring (1800).
1900
1800
16031
3.
Connect pressure gauge (99/7) to retarder housing.
99/7
16032
99/7 Pressure gauge 53.1403.10
cbtd 98-01
53.2659.10

Page 4.4/4
Diagnosis /
Troubleshooting
4.4

(Continue)
4.
Connect up Propstrom measuring adapter (99/3).
Disconnect plug from proportional valve (21) and connect it up

to Propstrom measuring adapter (99/3).
21
Connect plug of Propstrom measuring adapter (99/3) to proportional valve (21).
Connect up multimeter (98/8) to measure mA.
Set switch Propvalve on Propstrom measuring adapter (99/3) to position I.
98/8
99/3
16033
99/3 Propstrom measuring adapter 53.8198.10

99/8 Multimeter
cbtd 98-01
53.2659.10

Page 4.4/5
Diagnosis /
Troubleshooting
4.4

(Continue)
Job scope test
57
98/5
Preconditions for checking

Ignition ON
1.
Set the rotary switch of the temperature simulator (99/2) to 95C cooling water temperature and
165C oil temperature operate the retarder at the highest stage.
The constant-air pressure p y and the control current must reach the values given in table on the
next page (page 4.4/7).
2.
Set the rotary switch of the temperature simulator (99/2) to 105 oC cooling water temperature. The
constant-air pressure p y must drop to at approx. 7% bar below the set maximum pressure. Set
rotary switch of the temperature simulator (99/2) to 125 oC cooling water temperature. There must
be no more output of constant-air pressure p y .
Set rotary switch of temperature simulator (99/2) again to 95o C cooling water temperature.
16030
99/2 Temperature simulator 53.8207.10
3.
Set the rotary switch of the temperature simulator (99/2) to 185 C oil temperature.
The constant-air pressure must drop to at approx. 4% below the set maximum pressure. Set the
rotary switch of the temperature simulator (99/2) to 225 oC oil temperature. There must be no more
output of constant-air pressure p y .
4.
Carry out measurements for current and constant-air pressure regarding the following table
(see page 4.4/7).
5.
Screw oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm
6.
Reconnect electrical lead (57) for cooling water and oil to temperature pick-ups for
cooling water and oil.
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10
99/2

Page 4.4/6
Diagnosis /
Troubleshooting
4.4

(Continue)
Notice
If the control current is reached but the constant-air pressure is not, either the retarder is leaking or the
proportional valve is defective and must be renewed.
If both values are not reached, please see Section 4.2 Troubleshooting and Remedies.
Setting [Nm]
1)
2)
3)
cbtd 98-01
53.2659.10
Code Number1 )
Control current
[mA] 2 )
Constant-air pressure p y
[bar] 3 )
1000
027
429 441
1,15 1,45
1250
028
449 461
1,45 1,75
1500
029
470 482
1,75 2,05
1750
030
490 502
2,05 2,35
2000
031
510 522
2,35 2,65
The Code Number is to be found on the control unit.

If a commercially available multimeter is used for measurements (without real effective measuring)
exact readings cannot be made (indication jumps!).
Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).

Page 4.4/7
Diagnosis /
Troubleshooting
4.5
Operational Check
Requirements for check
Electrical system checked in accordance with the Owners Manual for the vehicle
Constant-air pressure 6 -11 bar
Retarder oil level satisfactory
The following operational states are indicated by the retarder pilot light (arrow):
16016
Retarder pilot light without indication

The retarder is switched off. There is no fault in the memory.
Retarder pilot light permanently on
The retarder is switched on, i.e., one of the four possible retarder braking stages or
Constant Speed operation has been selected with the retarder stage switch.
The retarder pilot light additionally has the function of a fault indicator.
-
slight fault
The retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch, braking
operations are possible (the retarder operates with limited braking torque).
serious fault
The retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch.
There are no more braking operations possible - the retarder is switched off.
cbtd 98-01
53.2659.10

Page 4.5/1
Diagnosis /
Troubleshooting
4.5
Operational Check
(Continue)
Notice
If the ignition is switched off and on again, the retarder is in operation and the retarder pilot light
is going off.
If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on in
position 0 to 5 of the retarder stage switch.
Retarder pilot light flashes
-
cbtd 98-01
53.2659.10
while the retarder is braking

The temperature limitation is functioning, the retarder cuts back its braking torque.
This flashing function only is realized at defined control variants!

Page 4.5/2
Diagnosis /
Troubleshooting
4.5
Operational Check
(Continue)
Troubleshooting
Test step
1
cbtd 98-01
53.2659.10
Scope of check
Retarder
Requirement /
Operation
Ignition: ON
Vehicle on move
- Shift retarder stage
switch
to stage 1 to 5.
Result / Set point
Note, Cause / Remedy
Retarder pilot light comes on and

goes off after approx. 5 sec.
Retarder pilot light trouble-free
Retarder pilot light does not come

on, or does not go off.
Troubleshooting as on page 4.1/1
Retarder pilot light comes on,

retarder brakes in stages 1 to 5.
Retarder operates trouble-free.
Retarder pilot light does not come

on, or retarder does not brake
properly.
Troubleshooting as on page 4.1/1

Page 4.5/3
Retarder Removing, Installing
Removing, Installing Retarder
5.1
Removing, Installing Retarder (Free Mount Installation) ............................5.1/1
5.2
Removing, Installing Retarder (Gearbox Attachment)................................5.2/1
cbtd 98-01
53.2659.10

Page 5/1
5.1

(Free Mount Installation)
Illustration Retarder (Free mount installation)
1300
1300
1400
1400
1200
1200
94
92
95
36
92
25
1100
96
93
97
1000
96
57
1000/6
1200
1000-5
1200/1
1500
16034
Preconditions for job
Drain oil from retarder (see Section 3.2)

Drain oil from heat exchanger (see Section 8.1 and 8.2)
Drain cooling water
Retarder stage switch in switch position 0
Ignition OFF
Notice
When stainless-steel heat exchanger is installed, oil can not be drained from the heat exchanger.
25
36
57
92
93
94
95
96
97
1000
Constant-air pressure line p y A

Ventilation line R
Plug temperature pick-up
Prop-shaft
Hex.-head screw
Spring washer
Hex.-head screw
Hose clamp
Hose connection
Heat exchanger
1000/5
1000/6
1100
1200
1200/1
1300
1400
1500
Drain plug cooling water (M 18 x 1,5), 50 Nm

Suspension complete
Megi-pads, check, renew if necessary
Spacer tube
Hex.-head screw (M 16 x 90)
Washer (B 16)
Hex.-head nut (M 16) self-locking, renew, 110 Nm
Note for installation

The universal joints for both prop-shafts must be installed aligned with one another.
Max. permissible offset 5 .
Tightening torques, see manufacturers data.
Renew spring washer.
Caution!
Observe VOITH-Installation instructions. These have to be requested from VOITH TURBO.
Should these installation instructions be disregarded, the retarder may be completely wrecked!
cbtd 98-01
53.2659.10

Page 5.1/1
5.2

(Gearbox Attachment)
To install the retarder 120 according to regulations to the gearbox or to remove from the gearbox,
specific working steps requiring special tools have to be carried out.
Caution!
Observe VOITH-Installation instructions and gear-box specific installation instructions.
These have to be requested from VOITH TURBO.
Should these installation instructions be disregarded, the retarder may be completely wrecked!
cbtd 98-01
53.2659.10

Page 5.2/1
Repair Gearbox
Attachment
Repair (Gearbox Attachment)
6.1
6.2
Removing, Checking and Installing Casing Ventilation ..............................6.2/1
6.3
Removing, Installing Non-Return Valve (Casing Ventilation) .....................6.3/1
6.4
Removing, Checking and Installing Non-Return Valve

(Stainless-Steel Heat Exchanger) ..............................................................6.4/1
6.5
Removing, Checking and Installing Silencer ..............................................6.5/1
6.6
Removing and Installing Bottom Cover ......................................................6.6/1
6.7
Checking, Removing and Installing Closing Cover of Retarder Housing ...6.7.1
6.8
Removing and Installing Labyrinth Cover (output side)

Renewing Radial Shaft Sealing Ring .........................................................6.8/1
6.9
Removing and Installing Centering Cover (input side)

cbtd 98-01
53.2659.10

Page 6/1
6.1
Repair Gearbox
Assembly Overview
Attachment
Illustration assembly overview (retarder basic group)
3200
3100
2800
2700
2900
2500
2902
2901
2903
4600
4400
4500
2600
2300/1
3000
2301
4300
101
2300
2300/2
102
2300/3
2400
1900
1800
700
850
800
900
104
103
103
104
1200
1300
1100
1400
1600
1500
1000
1700
16035
101
102
103
104
700
800
850
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2300
2300/1
2300/2
2300/3
cbtd 98-01
53.2659.10
Hex.-head screw (M 12 x 1,5)

Sealing ring (A 12 x 15,5)
Silencer-ventilation (30 x 4)
Circlip (JL 30 x 1,2)
Raduial shaft sealing ring (80 x 100 x 10)
Labyrinth cover
O-ring (125 x 2,5)
Cover
O-ring (82 x 4)
Gasket
Bottom cover
Washer (B 8,4)
Cap screw (M 6 x 20)
Sealing ring (A 22 x 29)
Screw plug (M 22 x 1,5)
Casing ventilation (D 30 x 38)
contents Position 2301
Valve insert
Float
Float cage
2301
2400
2500
2600
2700
2800
2900
2901
2902
2903
3000
3100
3200
4300
4400
4500
4600
O-ring (55 x 3)
Sieve (D 60 x 23)
Cover sheet metal
Spacer (D 50/42 x 15,5)
Washer (B 6,4)
Top cover
with 7 threads for M 6
Valve internal part
Spring
Connector
Gasket
for 7 fixing screws M 6
Washer (B 6,4)
Radial shaft sealing ring (85 x 105 x 13)
Centering cover (D 180 x 70)
O-ring (130 x 4)

Page 6.1/1
Repair Gearbox
Attachment
6.2
Removing, Checking and Installing

Casing Ventilation
Illustration casing ventilation

Retarder removed (see Section 5.1).

Ignition OFF
2800
2700
3200
2500
3100
2600
2300
2300/1
2300/2
2300/3
2301
2400
2500
2600
2700
2800
2900
3000
3100
3200
Casing ventilation
Valve insert
Float checking, renew if necessary
Float cage
O-ring (55 x 3), renew,
coat of silicone-free and noncorrosive grease for installation
Mesh strainer clean with benzine
Cover plate
Spacer
Washer (B 6,4)
Hex.-head screw (M 6 x 12), 10 Nm
Cover
Gasket, renew
Washer (B 6,4)
Cap screw (M 6 x 30), 10 Nm
2900
2300/1
2300
3000
2301
2300/2
2300/3
2400
16036
cbtd 98-01
53.2659.10

Page 6.2/1
6.2
Repair Gearbox
Attachment

Casing Ventilation (Continue)
Lubricants and cleaning agents

Mesh strainer
Benzine
O-ring
Silicone-free and
non-corrosive grease
Float
Methylated Spirit
Special tools
53.7712.10
53.9428.10
To remove
1.
Screw out hex.-head screws (3200).
2.
Remove washer (3100).
cbtd 98-01
53.2659.10

Page 6.2/2
Repair Gearbox
Attachment
6.2

3.
Remove the cover (2900) from the retarder housing.
4.
Remove gasket (3000) and clean the sealing surface.
5.
Screw out hex.-head screws (2800) and remove Washer (2700).
98/7
6.
Remove cover plate (2500).
2300
7.
Remove spacer (2600).
8.
Use the impact tool (99/5) and adapter (98/9) to extract the casing ventilation (2300).
99/5
16037
98/7 Adapter 53.9428.10

99/5 Impact tool 53.7712.10
9.
Extract the valve insert (2300/1) from float cage (2300/3).
10.
Lever O-ring (2301) out of the groove of the valve insert (2300/1).
11.
Remove the mesh strainer (2400), check and wash with benzine, if necessary.
2300/1
2301
2300/3
16038
cbtd 98-01
53.2659.10

Page 6.2/3
Repair Gearbox
Attachment
6.2

To check
1.
Check the float (2300/2) for damage to the surface and to the sealing surfaces (arrow).
2.
Weight the float (2300/2).

Specified weight 11g 1 Gramm. If the weight is more than the specified weight, renew the
complete casing ventilation.
2300/2
Notice
Oil has penetrated into the float, the retarder is impaired in its operation.
16039
3.
Check sealing edge of shaft sealing ring (arrow) in valve insert (2300/1).
Set the valve insert (2300/1) down on the float (2300/2) and fill up the cavity between float (2300/2)
and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not
damaged, the fluid level must not change within 1 minute. If necessary, renew the
2300/2
2300/1
16040
cbtd 98-01
53.2659.10

Page 6.2/4
Repair Gearbox
Attachment
6.2

To install
1.
Install the mesh strainer (2400).
2.
Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on
to the valve insert (2300/1).
3.
Fit the float (2300/2) into float cage (2300/3).
2300/1
2301
Notice
If the float only has one polished surface fit float with this surface on top.
16041
4.
Fit the float cage (2300/3) into the valve insert (2300/1).
5.
Fit the casing ventilation (2300) into the retarder housing.
6.
Use the impact tool (99/5) and adapter (98/9) to knock in carefully the casing ventilation (2300).
cbtd 98-01
53.2659.10

Page 6.2/5
Repair Gearbox
Attachment
6.2

7.
Place the spacer (2600) on the casing ventilation (2300)
8.
Position cover plate (2500).
9.
Screw new hex.-head screws (2800) with washer (2700) tight. Tightening torque 10 Nm
10.
Position new gasket (3000) and the cover (2900) at the retarder housing.
Caution!
Make sure the gasket (3000) is properly located.
11.
cbtd 98-01
53.2659.10
Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm

Page 6.2/6
Repair Gearbox
Attachment
6.3
Removing and Installing Non-Return Valve

(Casing Ventilation)
Illustration non-return valve

(casing ventilation)
2901
2902
2903
2902
Valve internal components,

check for damage, renew complete
non-return valve, if necessary
Spring,
Connector,
install with Loctite 270 locking
agent, 100 Nm
check valve seat, renew complete
2901
2903
Locking agent
Connector
Loctite 270
16042
cbtd 98-01
53.2659.10

Page 6.3/1
Repair Gearbox
Attachment
6.4
Removing, Checking and Installing Non-Return

Valve (Stainless-Steel Heat Exchanger

1400
1200
1200/1
1200/2
1200/3
1200/4
1200/5
1300
1400
Non-return valve (stainless-steel

heat exchanger)
Valve cover
Valve housing
O-ring , renew,
Spring, check for fatigue, renew
complete non-return valve (1200),
if necessary
Valve piston, check valve seat in
heat exchanger and vulcanization,
renew complete non-return valve
(1200), if necessary.
Spring washer, renew
1300
1200/1
1200/2
1200/3
1200
1200/4
1200/5
Lubricants
O-ring
Silicone-free and
16043
cbtd 98-01
53.2659.10

Page 6.4/1
6.5
Repair Gearbox
Attachment
Removing, Checking and Installing Silencer
Illustration Silencer

Ignition OFF
Notice
This step can be performed with the retarder

removed or installed.
103
104
Silencer (30 x 4)
clean with Benzine and blow out
with compresse-air
Circlip (JL 30 x 1,2),
concave side must face silencer
104
103
Cleaning agents
Silencer
Benzine
103
104
16044
cbtd 98-01
53.2659.10

Page 6.5/1
Repair Gearbox
Attachment
6.6
Removing and Installing Bottom Cover
Illustration bottom cover

Oil drained from retarder (see Section 3.2)

Ignition OFF
1200
1300
1400
1500
Gasket, renew
Bottom cover
Washer (B 6,4)
1200
1300
1400
1500
16045
cbtd 98-01
53.2659.10

Page 6.6/1
Repair Gearbox
Attachment
6.7
Checking, Removing and Installing Closing

Cover of Retarder Housing
Special tool
1000
53.7712.10
99/5
To check
1.
1100 1000
Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.
99/5 Impact tool 53.7712.10
To remove
1.
Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).
To install
1.
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10
Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease
and install together with closing covers (1000).

Page 6.7/1
16046
Repair Gearbox
Attachment
6.8
Removing and Installing Labyrinth Cover (Output

Side), Renewing Radial Shaft Sealing Ring
Illustration labyrinth cover (output side)

Prior jobs
Prop shaft removed from flange

(see vehicle manufacturer instructions)
Prop shaft flange removed
(see VOITH-installation schemes)
Ignition OFF
700
850
800
Notice
900
This job can be performed with the retarder

700
800
850
900
cbtd 98-01
53.2659.10
Radial shaft sealing ring

(80 x 100 x 10), renew,
for installation
Labyrinth cover, coat with Hylomar
sealant around leakage oil return
bore
O-ring (125 x 2,5), renew,
for installation
self-locking, renew, 23 Nm
16047

Page 6.8/1
Repair Gearbox
Attachment
6.8

Side), Renewing Radial Shaft Sealing Ring (Cont.)
Sealants and locking agents

Housing sealing surfaces
O-ring
Hylomar
Silicone-free and
Special tool
53.0742.10
Job scope
1.
Screw out hex.-head screw (900).
2.
Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the
rotor housing.
800
16048
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 6.8/2
Repair Gearbox
Attachment
6.8

3.
Place the labyrinth cover (800) on a piece of pipe.
4.
Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes
(arrows) out of the labyrinth cover (800).
Notice
Check race of radial shaft sealing ring for scores and uneven surface. If a sealing function is no longer
guaranteed, please contact VOITH TURBO.
5.
800
700
Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (700).
16049
6.
Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into
the labyrinth cover (800).
Position for installation: Sealing lip at top.
94/4
700
800
16050
94/4 Press-in equipment 53.0742.10

cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 6.8/3
Repair Gearbox
Attachment
6.8

7.
Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in
the labyrinth cover.
8.
Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800).
Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow)
are in alignment.
9.
Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
850
800
16051
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 6.8/4
Repair Gearbox
Attachment
6.9
Removing and Installing Centering Cover (Input

Illustration centering cover (input side)

Prior job
Retarder removed (see Section 5)

4300
4400
4500
4600

(85 x 105 x 13), renew,
for installation
Centering cover
for installation
Hex.-head screw (M 8 x 20),
4600
Lubricants
O-ring
Silicone-free and
4500
4300
4400
16052
cbtd 98-01
53.2659.10

Page 6.9/1
Repair Gearbox
Attachment
6.9

Special tool
53.0742.10
Job scope
1.
2.
Use two hex.-head screws (M 8 x 30) (arrows) to press centering cover (4400) off
retarder housing.
3.
Remove O-ring (4500) of centering cover (4400).
4.
Use an appropriate punch to knock the radial shaft sealing ring (4300) out of
the centering cover (4400).
Notice
4400
4400
Check race of radial shaft sealing ring for scores and uneven surface. If a sealing function is no longer
guaranteed, please contact VOITH TURBO.
cbtd 98-01
53.2659.10
4500

Page 6.9/2
16053
Repair Gearbox
Attachment
5.
6.9

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (4300).
94/4
6.
the centering cover (4400).
4300
4400
16054
7.
the centering cover.
8.
Apply thin coat of Hylomar sealant around leakage-oil return bore in centering cover (4400).
Install so that the leakage-oil return bores in the rotor housing and in the centering cover (arrow)
are in alignment.
9.
4600
4500
4400
16055
cbtd 98-01
53.2659.10

Page 6.9/3
Repair Free Mount

Installation
Repair (Free Mount Installation)
7.1
7.2
Removing, Checking and Installation Casing Ventilation ...........................7.2/1
7.3
Removing, Installing Non-Return Valve (Casing Ventilation) .....................7.3/1
7.4
Removing, Checking and Installing Non-Return Valve

(Stainless-Steel Heat Exchanger) ..............................................................7.4/1
7.5
Removing, Checking and Installing Silencer ..............................................7.5/1
7.6
Removing and Installing Bottom Cover ......................................................7.6/1
7.7
Removing and Installing Prop Shaft Flanges ............................................7.7/1
7.8
Checking, Removing and Installing Closing Cover of Retarder Housing ...7.8/1
7.9
Removing and Installing Labyrinth Cover (output side)

7.10
Removing and Installing Labyrinth Cover (input side)

cbtd 98-01
53.2659.10

Page 7/1
Repair Free Mount

Installation
7.1
Assembly Overview
Illustration assembly overview (retarder basic group)

3200
2800
2700
2900
3100
2500
4700
2902
2901
2903
800
3000
850
700
2600
2300/1
2301
2300
101
102
2300/2
2300/3
5400
5500
2400
1900
1800
5500
5400
700
850
800
104
900
103
103
104
1200
1300
1400
1500
1100
1600
1000
1700
16056
101
102
103
104
700
800
850
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2300
2300/1
2300/2
2300/3
cbtd 98-01
53.2659.10
Hex.-head screw (M 12 x 1,5)

Sealing ring (A 12 x 15,5)
Silencer-ventilation (30 x 4)
Circlip (JL 30 x 1,2)
Raduial shaft sealing ring (80 x 100 x 10)
Labyrinth cover
O-ring (125 x 2,5)
Cover
O-ring (82 x 4)
Gasket
Bottom cover
Washer (B 8,4)
Screw plug (M 22 x 1,5)
Casing ventilation (D 30 x 38)
contents Position 2301
Valve insert
Float
Float cage
2301
2400
2500
2600
2700
2800
2900
2901
2902
2903
3000
3100
3200
4300
4700
5400
5500
5600
O-ring (55 x 3)
Sieve (D 60 x 23)
Cover sheet metal
Spacer (D 50/42 x 15,5)
Washer (B 6,4)
Top cover
with 7 threads for M 6
Valve internal part
Spring
Connector
Gasket
for 7 fixing screws M 6
Washer (B 6,4)
(95 x 115 x 10)
Hex.-head screw (M 8 x 30),
self-locking
Race
O-ring (80 x 3)
O-ring (125 x 2,5)

Page 7.1/1
Repair Free Mount7.2

Installation

Casing Ventilation
Illustration casing ventilation
2800
3200
2700

The job in this section can be performed with
the retarder removed or installed.
Ignition OFF
2300
2300/1
2300/2
2300/3
2301
2400
2500
2600
2700
2800
2900
3000
3100
3200
Casing ventilation
Valve insert
Float checking, renew if necessary
Float cage
Mesh strainer clean with benzine
Cover plate
Spacer
Washer (B 6,4)
Cover
Gasket, renew
Washer (B 6,4)
3100
2500
2600
2900
2300/1
2300
3000
2301
2300/2
2300/3
2400
16057
cbtd 98-01
53.2659.10

Page 7.2/1
Repair Free Mount 7.2

Installation

Lubricants and cleaning agents

Mesh strainer
Benzine
O-ring
Silicone-free and
Float
Methylated Spirit
Special tools
53.7712.10
53.9428.10
To remove
1.
2.
Remove washer (3100).
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.2/2

Installation

3.
Remove the cover (2900) from the retarder housing.
4.
Remove gasket (3000) and clean the sealing surface.
5.
Screw out hex.-head screws (2800) and remove Washer (2700).
99/5
99/9
6.
Remove cover plate (2500).
7.
Remove spacer (2600).
8.
Use the impact tool (99/5) and adapter (98/9) to extract the casing ventilation (2300).
16058
99/9 Adapter 53.9428.10

99/5 Impact tool 53.7712.10
9.
Extract the valve insert (2300/1) from float cage (2300/3).
10.
Lever O-ring (2301) out of the groove of the valve insert (2300/1).
11.
Remove the mesh strainer (2400), check and wash with benzine, if necessary.
2300/1
2301
2300/3
16038
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.2/3

Installation

To check
1.
Check the float (2300/2) for damage to the surface and to the sealing surfaces (arrow).
2.
Weight the float (2300/2).

Specified weight 11g 1 Gramm. If the weight is more than the specified weight, renew the
2300/2
Notice
Oil has penetrated into the float, the retarder is impaired in its operation.
16039
3.
Check sealing edge of shaft sealing ring (arrow) in valve insert (2300/1).
Set the valve insert (2300/1) down on the float (2300/2) and fill up the cavity between float (2300/2)
and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not
damaged, the fluid level must not change within 1 minute. If necessary, renew the
2300/2
2300/1
16040
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.2/4

Installation

To install
1.
Install the mesh strainer (2400).
2.
Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on
to the valve insert (2300/1).
3.
Fit the float (2300/2) into float cage (2300/3).
2300/1
2301
Notice
If the float only has one polished surface fit float with this surface on top.
16041
4.
Fit the float cage (2300/3) into the valve insert (2300/1).
5.
Fit the casing ventilation (2300) into the retarder housing.
6.
Use the impact tool (99/5) and adapter (98/9) to knock in carefully the casing ventilation (2300).
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.2/5

Installation

7.
Place the spacer (2600) on the casing ventilation (2300)
8.
Position cover plate (2500).
9.
Screw new hex.-head screws (2800) with washer (2700) tight. Tightening torque 10 Nm
10.
Position new gasket (3000) and the cover (2900) at the retarder housing.
Caution!
Make sure the gasket (3000) is properly located.
11.
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10
Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm

Page 7.2/6

Installation
Removing and Installing Non-Return Valve

(Casing Ventilation)

(casing ventilation)
2901
2902
2903
2902
Valve internal components,

non-return valve if necessary
Spring,
Connector,
install with Loctite 270 locking
agent, 100 Nm
check valve seat, renew complete
2901
2903
Locking agent
Connector
Loctite 270
16059
cbtd 98-01
53.2659.10

Page 7.3/1

Installation
Removing, Checking and Installing Non-Return

Valve (Stainless-Steel Heat Exchanger

1400
1200
1200/1
1200/2
1200/3
1200/4
1200/5
1300
1400
Non-return valve
Valve cover
Valve housing
O-ring , renew,
Spring, check for fatigue, renew
complete non-return valve (1200),
if necessary
Valve piston, check valve seat in
heat exchanger and vulcanization,
renew complete non-return valve
(1200), if necessary.
Spring washer, renew
1300
1200/1
1200/2
1200/3
1200
1200/4
1200/5
Lubricants
O-ring
Silicone-free and
16043
cbtd 98-01
53.2659.10

Page 7.4/1
Removing, Checking and Installing Silencer
Installation
Illustration Silencer

Ignition OFF
Notice
This step can be performed with the retarder

103
104
Silencer (30 x 4)
clean with Benzine and blow out
with compressed-air
Circlip (JL 30 x 1,2),
concave side must face silencer
104
103
Cleaning agents
Silencer
Benzine
103
104
16044
cbtd 98-01
53.2659.10

Page 7.5/1
Removing and Installing Bottom Cover
Installation
Illustration bottom cover
Oil drained from retarder (see Section 3.2)

Ignition OFF
1200
1300
1400
1500
Gasket, renew
Bottom cover
Washer (B 6,4)
1200
1300
1400
1500
16045
cbtd 98-01
53.2659.10

Page 7.6/1
Removing and Installing Prop Shafts Flanges
Installation
Illustration prop shafts flanges
Prior jobs
Prop shafts flanges removed

Notice
93/1
97/6
97/8
The jobs in this section can be performed with

the retarder removed or installed.
93/1
95/2
97/6
97/7
97/8
97/9
98
98
97/9

Hex.-head nut (M 20), 375 Nm
Prop shaft flange
(output side)
Prop shaft screw, renew
Guard ring (output side)
Guard ring (input side)
Prop shaft flange
(input side)
95/2
97/7
16060
cbtd 98-01
53.2659.10

Page 7.7/1

Installation
Removing and Installing Prop Shafts Flanges

(Continue)
Removing and installing

1.
Screw out hex.-head screw (95/2).

Screw hex.-head nut (95/2) tight. Tightening torque 375 Nm
2.
Pull out hex.-head screw (93/1) on output side.
3.
Pull both prop shaft flanges (97/6, 98) out of the retarder housing.
4.
Remove guard rings (97/8, 97/9).
97/7
97/8
97/9

Renew prop shaft screws (97/7).
Align hole patterns of both prop shaft flanges prior to installation.
Maximum permissible offset 5.
5.
Install the prop shafts in accordance to the vehicle manufacturer instructions.

16061
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.7/2

Installation
Checking, Removing and Installing Closing

Cover of Retarder Housing
Special tool
99/5 1000 1100
53.7712.10
1000
To check
1.
16062
Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.
To remove
1.
Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).
To install
1.
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10
Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease
and install together with closing covers (1000).

Page 7.8/1

Installation

Illustration labyrinth cover

Prior jobs

(see VOITH-installation schemes)
Ignition OFF
5500
5400
700
850
800
900
Notice
700
800
850
900
5400
5500
cbtd 98-01
53.2659.10

(80 x 100 x 10), renew, coat with
silicone-free and non-corossive
grease for installation
bore
O-ring (125 x 2,5), renew, coat with
Race
O-ring (80 x 3), renew, coat with
16063

Page 7.9/1

Installation


O-ring
900
Hylomar
Silicone-free and
Special tool
16064
53.0742.10
Job scope
1.
Screw out hex.-head screw (900).
2.
Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the
rotor housing.
800
16065
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.9/2

Installation

3.
4.
5.
Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft.
6.
Remove O-ring (5500) of hollow shaft.
7.
Check race for scores and radial shaft sealing ring for uneven surface and renew
race if necessary.
Notice
800
700
16049
If a sealing function is no longer guaranteed, please contact VOITH TURBO.

Recommendation:
Always change radial shaft sealing ring and race together.
8.
Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500)
and pull-on to the hollow shaft.
9.
Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it
will go.
10.
Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).
5400
16066
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.9/3

Installation
11.

94/4
700
800

12.
13.
are in alignment.
14.
850
800
16051
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.9/4

Installation
Removing and Installing Labyrinth Cover (Input

Illustration labyrinth cover

Prior jobs

(see Section 7.7)
5500
Notice
5400
700
850
800

700
800
850
4700
5400
5500
cbtd 98-01
53.2659.10

(95 x 115 x 10), renew, coat with
bore
O-ring (125 x 2,5), renew, coat with
Race
O-ring (80 x 3), renew, coat with silicone-free and non-corossive grease for installation
4700
16067

Page 7.10/1

Installation


Hylomar
O-ring
Silicone-free and
Special tool
53.0742.10
Job scope
1.
2.
Use two hex.-head screws (M 8 x 40) (arrows) to press labyrinth cover (4400) off
retarder housing.
3.
800
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.10/2
16068

Installation

4.
5.
Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft.
6.
Remove O-ring (5500) of hollow shaft.
7.
Check race for scores and radial shaft sealing ring for uneven surface and renew
race if necessary.
800
700
Notice
If a sealing function is no longer guaranteed, please contact VOITH TURBO.
16049
Recommendation:
Always change radial shaft sealing ring and race together.
8.
Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500)
and pull-on to the hollow shaft.
9.
Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it
will go.
10.
Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).
16069
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.10/3

Installation
11.

94/4
700
800
16050

12.
13.
are in alignment.
14.
850
800
16051
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 7.10/4
Repair
Heat Exchanger

Heat Exchanger
8.1
Removing, Checking and Installing Stainless-steel Heat Exchanger.........8.1/1
8.2
Removing, Checking and Installing Aluminium Heat Exchanger ...............8.2/1
cbtd 98-01
53.2659.10

Page 8/1
8.1
Repair
Heat Exchanger

Stainless-steel Heat Exchanger
Illustration stainless-steel heat exchanger
1000/6
1000/5
9500
3000
2000
1000/2
8000
1000/1
15000
9000
17000
1800
4000
7000
1700
4000
16000
4000
17000
5000
13000
14000
97
5000
96
1000
17000
16000
12000
14000
16070
Prior jobs
Retarder removed (Section 5.1)

This job sequence can also be performed with the retarder installed, if necesary.
Retarder stage switch on stage position 0
Ignition OFF
96
97
1000
1000/1
1000/2
1000/5
1000/6
1600
1700
2000
3000
4000
Hose clamp
Cooling water hose
Heat exchanger
Leaking oil drain plug (M 14 x 1,5), 32 Nm
Cooling water drain plug (M 18 x 1,5), 50 Nm
Retarder oil drain plug (M 22 x 1,5), 66 Nm
Throttle disc (outlet throttle)
O-ring (36 x 4), renew, coat with silicone-free and
Washer (B 8,4)
5000
7000
8000
9000
9500
12000
13000
14000
15000
16000
17000
Hex.-head nut M 8, self-locking, renew, 23 Nm

Pin screw (M 10 x 50)
O-ring (45 x 4) renew, coat with silicone-free and
O-ring (8 x 2) renew, coat with silicone-free and non-corrosive
grease
Connecting piece
Connecting piece
Sealing ring, renew
Washer (B 10,6)
Data
Pressure test (oil section) max.10 bar
Lubricants
O-ring
cbtd 98-01
53.2659.10
Silicone-free and

Page 8.1/1
Repair
8.1
Heat Exchanger

Stainless-steel Heat Exchanger (Continue)
Notice
If this job sequence will be performed with the retarder installed, the following prior jobs must be
performed prior to removal of the heat exchanger.
The coolant drain plug is heated up!
1.
Screw out coolant drain plug (1000/5) with sealing ring (1000/6) and drain the cooling water from
the heat exchanger. Remove the cooling water hoses (97) from the retarder.
2.

The oil drain plugs are heated up (oil temperature)!

3.
Screw out the oil drain plugs (1700, 1000/1) and remove the sealing rings (1600, 1000/2).
Drain the oil.
4.
Screw the coolant drain plug (1000/5) with new sealing ring (1000/6) and the oil drain plugs (1700,
1000/1) with new sealing rings (1600, 1000/2) tight.
cbtd 98-01
53.2659.10

Page 8.1/2
Repair
8.1
Heat Exchanger

To remove
1.
Screw out the four hex.-head nuts (5000) and remove the washers (4000).
2.
Screw out the two hex.-head screws (7000) remove the washers (4000)
and heat exchanger (1000).
3.
Remove the three O-rings (9000, 3000, 9500) and throttle disc (2000) from retarder housing.
Notice
Do not remove insert (93/8) with the throttle disc.

4.
Check closing cover (1000) for leaks, renew O-ring (1100), if necessary (see Section 6.7 and 7.8
Checking, removing and installing closing cover).
Caution!
Do not pressurize heat exchanger with pressure-test plate 53.4786.10.
An appropriate variant on the stainless-steel heat exchanger is in preperation.
Please, contact VOITH TURBO.
cbtd 98-01
53.2659.10

Page 8.1/3
Repair
Heat Exchanger
8.1

To install
Notice
New heat exchangers are wetted with preserving oil in the cooling water section and in the oil section.
Prior to installation of a new heat exchanger, drain any preserving oil which has collected and flush out
the cooling water section with hot water.
1.
Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (9000, 3000, 9500).
Fit them in the feed bores of the retarder housing.
2.
Apply thin coat of silicone-free and non-corrosive grease to the throttle disc (2000) and fit it in the
right bore.
3.
Install the heat exchanger (1000) to the retarder housing and use new
self-locking hex.-head nuts (5000) and washers (4000), hex.-head screws (7000) and
washers (4000) to screw it tight on the retarder housing. Tightening torque 23 Nm
4.
Install retarder, if necessary (see Section 5.1).
5.
Fill in cooling water and bleed coolant circuit according to the vehicle instructor manual.
Notice
Heed the statements of the vehicle-manufacturer respecting the cooling water-quality,

as well as the VOITH cooling water-list in the appendix.
cbtd 98-01
53.2659.10

Page 8.1/4
Repair
8.1
Heat Exchanger
6.

If the heat exchanger (1000) had been leaking in the oil section, splush the retarder:
While flushing, brake lightly several times to avoid the retarder oil overheating.
The oil drain plug is heated up (oil temperature)!

Fill retarder with 4,5 litres engine oil or flushing oil. Flush the retarder system by braking several
times and drain the oil through the oil drain plug (1700). Repeat the procedure two or three times
until no more oil is visible in the water.
Screw oil drain plug (1700) tight with new sealing ring.
7.
Fill in retarder oil in accordance with the operating specifications (see Section 3.2 Oil change
and annex).
Notice
If retarder oil has entered the cooling-water system, the vehicle-cooling system must be cleaned
in accordance with the instructions of the vehicle manufacturer.
8.
cbtd 98-01
53.2659.10
If heat exchanger (1000) had been leaking, deoil vehicle cooling and heating system in
accordance with vehicle manufacturers data.

Page 8.1/5
1700
16071
8.2
Repair
Heat Exchanger

Aluminium Heat Exchanger
Illustration aluminium heat exchanger
1000/4
9500
1000/3
1000/6
3000
1000/2
1000/5
2000
8000
1000/1
20
4000
93/9
4000
9000
7000
4000
1600
5000
1700
5000
1000
97
96
16072
Prior jobs
Retarder removed (Section 5.1)

This job sequence van also be performed with the retarder installed, if necessary.
Retarder stage switch in stage position 0
Ignition OFF
20
96
97
93/9
1000
1000/1
1000/2
1000/3
1000/4
1000/5
1000/6
1600
Oil temperature pick-up (M 14 x 1,5), 32 Nm

Hose clamp
Cooling water hose
Heat exchanger
Leaking oil drain plug (M 14 x 1,5), 32 Nm
Sealing ring (A14 x 18), renew
Oil drain plug heat exchanger (M 12 x 1,5), 25 Nm
Cooling water drain plug (M 18 x 1,5), 50 Nm
Sealing ring (A12 x 15,5), renew
1700
2000
3000
4000
5000
7000
8000
9000
9500
Heat exchanger oil drain plug (M 22 x 1,5), 66 Nm

Throttle disc (outlet throttle)
O-ring (36 x 4), renew, coat with silicone-free and non-corrosive
grease
Washer (B 8,4)
Hex.-head nut M 8, self-locking, renew, 23 Nm
Pin screw (M 10 x 50)
grease
grease
Data
Pressure test (oil section) max.10 bar
Special tool
Lubricants
O-ring
Silicone-free and
53.4786.10
cbtd 98-01
53.2659.10

Page 8.2/1
Repair
8.2
Heat Exchanger

Aluminium Heat Exchanger (Continue)
Notice
If this job sequence will be performed with the retarder installed, the following prior jobs must be
performed prior to removal of the heat exchanger.
The coolant drain plug is heated up!
1.
Screw out coolant drain plug (1000/5) with sealing ring (1000/6) and drain the cooling water from
the heat exchanger. Remove the cooling water hoses (97) from the retarder.
2.

The oil drain plugs are heated up (oil temperature)!

3.
Screw out the oil drain plugs (1700, 1000/1, 1000/3) and remove the sealing rings (1600, 1000/2,
1000/4).
Drain the oil.
4.
Screw the coolant drain plug (1000/5) with new sealing ring (1000/6) and the oil drain plugs (1700,
1000/1, 1000/3) with new sealing rings (1600, 1000/2, 1000/4) tight.
cbtd 98-01
53.2659.10

Page 8.2/2
Repair
8.2
Heat Exchanger

To remove
1.
Screw out the four hex.-head nuts (5000) and remove the washers (4000).
2.
Screw out the two hex.-head screws (7000) remove the washers (4000)
and heat exchanger (1000).
3.
Remove the three O-rings (9000, 3000, 9500) and throttle disc (2000) from retarder housing.
Notice
Do not remove insert (93/8) with the throttle disc.

4.
Check closing cover (1000) for leaks, renew O-ring (1100), if necessary (see Section 6.7 and 7.8
Checking, removing and installing closing cover).
To check
1.
Fit pressure-test plate (99/6) on heat exchanger (1000) and connect compressed-air line and
pressure minimizer.
2.
Fill the heat exchanger (1000) in water section with hot water (approx. 70C).
3.
Pressurize the heat exchanger (1000) slowly from 0 to max. 10 bar overpressure (oil section).
99/6
Notice
If air bubbles form in the hot water, the heat exchanger is leaking and must be renewed.
1000
16073
99/6 Pressure-test plate 53.4786.10

cbtd 98-01
53.2659.10

Page 8.2/3
Repair
8.2
Heat Exchanger
4.

Remove the pressure-test plate (99/6).
To install
Notice
New heat exchangers are wetted with preserving oil in the cooling water section and in the oil section.
Prior to installation of a new heat exchanger, drain any preserving oil which has collected and flush out
the cooling water section with hot water.
1.
Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (9000, 3000, 9500).
Fit them in the feed bores of the retarder housing.
2.
Apply thin coat of silicone-free and non-corrosive grease to the throttle disc (2000) and fit it in the
right bore.
3.
Install the heat exchanger (1000) to the retarder housing and use new
self-locking hex.-head nuts (5000) and washers (4000), hex.-head screws (7000) and
washers (4000) to screw it tight on the retarder housing. Tightening torque 23 Nm
4.
Install retarder, if necessary (see Section 5.1).
5.
Fill in cooling water and bleed coolant circuit according to the vehicle instructor manual.
Notice
Heed the statements of the vehicle-manufacturer respecting the cooling water-quality,

as well as the VOITH cooling water-list in the appendix.
cbtd 98-01
53.2659.10

Page 8.2/4
Repair
8.2
Heat Exchanger
6.

If the heat exchanger (1000) had been leaking in the oil section, splush the retarder:
While flushing, brake lightly several times to avoid the retarder oil overheating.
The oil drain plug is heated up (oil temperature)!

Fill retarder with 5,5 litres engine oil or flushing oil. Flush the retarder system by braking several
times and drain the oil through the oil drain plugs (1700, 1000/3). Repeat the procedure two or
three times until no more oil is visible in the water.
Screw oil drain plug (1700, 1000/3) tight with new sealing rings.
Oil drain plug retarder (1700)
66 Nm
Oil drain plug heat exchanger (1000/3)
25 Nm
7.
Screw out oil drain plug leakage oil (1000/1) and drain any leaking oil and water which has
collected.
8.
Fill in retarder oil in accordance with the operating specifications (see Section 3.2 Oil change
and annex).
cbtd 98-01
53.2659.10

Page 8.2/5
Control Parts
9.1
cbtd 98-01
53.2659.10
Control Parts
Proportional valve.................................................................. in preparation

Cooling Water Temperature Pick-up ..................................................................9.1/1
Oil Temperature Pick-up ..................................................................................9.1/2

Page 9/1
Control Parts
9.1
Control Parts
Removing and installing cooling water

temperature pick-up

The temperature pick-up is heated up
(cooling water temperature)!
Job scope
1.
2.
3.
Disconnect cooloing water temperature

pick-up (19). Tightening torque 28 Nm
The electrical lead of the temperature
pick-up is pured alternatively.
Screw out temperature pick-up (19) and
lock the opening immediately with one
stuffing.
38
19
Mount the temperature pick-up (19) in

reverse sequence.
16074
cbtd 98-01
53.2659.10

Page 9.1/1
Control Parts
9.1
Control Parts
(Continue)
Removing and installing oil temperature pick-up

The oil control plug is heated up (oil temperature)!
Job scope
1.
Disconnect oil temperature pick-up (20). Tightening torque 28 Nm

The electrical lead of the temperature pick-up is pured alternatively.
2.
Screw out temperature pick-up (20) and lock the opening immediately with one stuffing.
3.
Mount the temperature pick-up (20) in reverse sequence.
cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Page 9.1/2
Annex
10
Annex
Data Sheet
Miscellaneous Conversions
Operating Specifications
Spare Parts Lists
Other Information
cbtd 98-01
53.2659.10
Aftersales Service Manual VOITH Retarder R 120 Digiprop

Page 10/1
Data Sheet VOITH Retarder 120 Digiprop

Max. braking torque at prop shaft M (Br) ma x
2000 Nm *
Max. retarder speed (= max. prop shaft speed v(m ax. )
4870 r.p.m. at vps = 2400 r.p.m.
with stainless-steel heat exchanger
v(m ax. ) = 3000 r.p.m.
with aluminium heat exchanger
v(m ax. ) = 2800 r.p.m.
Working medium
Oil grade given in Operating Specification
Service filling:
With AKG heat exchanger
service filling (Oil change, checking oil level)
5,5 Litre
4,5 Litre
after complete taking apart and cleaning
5,8 Litre **
new filling
6,0 Litre
6,5 Litre
Overall weight (with flange and heat exchanger, without oil filling)
Overall weight will depend on the retarder version.
**
Emptied heat exchanger
cbtd 98-01
53.2659.10
With heat exchanger L+R
approx. 70 kg *
Service-Handbuch VOITH Retarder R 120 Digiprop

Seite 10/2
Miscellaneous Conversions Retarder 120 with Digiprop Control
cbtd 98-01
53.2659.10
GB
USA
GB
USA
10 oC
50 oF
50 o F
110 Nm
81 lbf-ft
81 lbf-ft
20 o C
68 oF
68 o F
150 Nm
111 lbf-ft
111 lbf-ft
60 o C
140 o F
140 oF
375 Nm
277 lbf-ft
277 lbf-ft
70 o C
158 o F
158 oF
1000 Nm
740 lbf-ft
740 lbf-ft
80 o C
176 o F
176 o F
1250 Nm
925 lbf-ft
925 lbf-ft
95 o C
203 oF
203 oF
1500 Nm
1110 lbf-ft
1110 lbf-ft
105 oC
221 o F
221 oF
1750 Nm
1295 lbf-ft
1295 lbf-ft
125 oC
257 oF
257 oF
2000 Nm
1480 lbf-ft
1480 lbf-ft
185 oC
365 oF
365 oF
1,15 - 1,45 bar
16,7 - 21,0 psi
16,7 - 21,0 psi
225 oC
437 oF
437 oF
1,45 - 1,75 bar
21,0 - 25,4 psi
21,0 - 25,4 psi
10 Nm
7 lbf-ft
7 lbf-ft
1,75 - 2,05 bar
25,4 - 29,7 psi
25,4 - 29,7 psi
13 Nm
10 lbf-ft
10 lbf-ft
2,05 - 2,35 bar
29,7 - 34,1 psi
29,7 - 34,1 psi
23 Nm
17 lbf-ft
17 lbf-ft
2,35 - 2,65 bar
34,1 - 38,4 psi
34,1 - 38,4 psi
25 Nm
18 lbf-ft
18 lbf-ft
7 bar
101,5 psi
101,5 psi
32 Nm
24 lbf-ft
24 lbf-ft
9 bar
130,5 psi
130,5 psi
50 Nm
37 lbf-ft
37 lbf-ft
12 bar
174 psi
174 psi
66 Nm
49 lbf-ft
49 lbf-ft
14 bar
203 psi
203 psi
100 Nm
74 lbf-ft
74 lbf-ft
16 bar
232 psi
232 psi

Seite 10/3
Miscellaneous Conversions Retarder 120 with Digiprop Control (Continue)
cbtd 98-01
53.2659.10
GB
USA
0 - 25 bar
0 - 362,5 psi
0 - 362,5 psi
0 - 10 bar
145 psi
145 psi
0,2 l
0,044 UK gal
0,053 US gal
0,5 l
0,110 UK gal
0,132 US gal
4,5 l
0,99 UK gal
1,188 US gal
5,5 l
1,210 UK gal
1,452 US gal
5,8 l
1,276 UK gal
1,531 US gal
6,0 l
1,320 UK gal
1,584 US gal
6,5 l
1,430 UK gal
1,716 US gal
1000 km
621,4 miles
621,4 miles

Seite 10/4

Retardador 120 (Of 1721)

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Retardador 120 (Of 1721)

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Training

Aftersales Service Manual

Removing, Installing Retarder .................................................................5/1

Aftersales Service Manual VOITH Retarder 120 Digiprop

Retarder Basic Group Repair (Gearbox Attachment)..............................6/1

Retarder Basic Group Repair (Free Mount Installation) ..........................7/1

Aftersales Service Manual VOITH Retarder 120 Digiprop

Removing, Cleaning and Installing Silencer ............................................7.5/1

Removing, Checking and Installing Heat Exchanger ..............................8/1

Control Parts ...........................................................................................9/1

Aftersales Service Manual VOITH Retarder 120 Digiprop

Aftersales Service Manual VOITH Retarder 120 Digiprop

Aftersales Service Manual VOITH Retarder 120 Digiprop

Aftersales Service Manual VOITH Retarder 120 Digiprop

Aftersales Service Manual VOITH Retarder 120 Digiprop

Assembly Overview ....................................................................................2.1/1

Function and Operation Scheme................................................................2.2/1

Aftersales Service Manual VOITH Retarder 120 Digiprop

Illustration VOITH Retarder R 120

Aftersales Service Manual VOITH Retarder 120 Digiprop

Illustration VOITH Retarder R 120

Aftersales Service Manual VOITH Retarder 120 Digiprop

Illustration VOITH Retarder R 120

Aftersales Service Manual VOITH Retarder 120 Digiprop

Illustration VOITH Retarder R 120

Aftersales Service Manual VOITH Retarder 120 Digiprop

Function and Operation Scheme

Illustration of VOITH Retarder 120 with Digiprop control system

Aftersales Service Manual VOITH Retarder 120 Digiprop

Function and Control System

Description of the function

Aftersales Service Manual VOITH Retarder 120 Digiprop

Function and Control System

Description of operation of retarder R 120 with digiprop control system

The hydrodynamic principle

Aftersales Service Manual VOITH Retarder 120 Digiprop

Function and Control System

Aftersales Service Manual VOITH Retarder 120 Digiprop

Function and Control System

Temperatur pick-ups, water (19), oil (20)

Aftersales Service Manual VOITH Retarder 120 Digiprop

Function and Control System

Casing ventilation (23)

Aftersales Service Manual VOITH Retarder 120 Digiprop

Aftersales Service Manual VOITH Retarder 120 Digiprop

Maintenance Work .....................................................................................3.1/1

Oil Change .................................................................................................3.2/1

Checking Oil Level .....................................................................................3.3/1

Cleaning Line Filter (Optional Extra) ..........................................................3.4/1

Aftersales Service Manual VOITH Retarder 120 Digiprop

Overview of maintenance work

Clean the cleaning line filter (optional extra)

Carry out visual inspection on leaks at the complete retarder

Check hex.-head screws of prop shaft on correct fitment, or tighten.

Aftersales Service Manual VOITH Retarder 120 Digiprop

Illustration oil change R 120

Leakage oil drain plug

Aftersales Service Manual VOITH Retarder 120 Digiprop

Aftersales Service Manual VOITH Retarder 120 Digiprop

The oil filler/check plug is heated up (oil temperature)!

Push an oil collecting pan under retarder.

The retarder oil drain plug is heated up (oil temperature)!

Aftersales Service Manual VOITH Retarder 120 Digiprop