Aftersales Service Manual Voith Retarder 115 E Table of Content Table of Content Page 2 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 1. Preface.................................................................................. 4 2. General ................................................................................. 9 2.1 Assembly Overview ....................................................................................10 2.2 Retarder Data Plate ....................................................................................12 2.3 Data Plate of Retarder-Control Unit ............................................................13 2.4 Function- and Operation Scheme...............................................................15 3. Maintenance ....................................................................... 19 3.1 Maintenance Work / Oil Change Intervals ..................................................20 3.2 Inspection of Oil Level.................................................................................23 3.3 Oil Change..................................................................................................26 4. Diagnosis / Troubleshooting ............................................... 32 4.1 Electrical Connections Diagram..................................................................33 4.2 Overview of Control Parts...........................................................................37 4.3 Troubleshooting Diagram............................................................................38 4.4 Troubleshooting and Remedies..................................................................41 4.5 Checking Supply-Air Pressure (p v ) .............................................................77 4.6 Checking Constant-Air Pressure (p y ) and Pump Pressure (p dyn ) ...............78 4.7 Checking Control Current of Proportional Valve.........................................86 4.8 Checking Pressure Sensor .........................................................................88 4.9 Checking Temperature Adaption ................................................................90 4.10 Table of Measurements ..............................................................................93 Table of Content Table of Content Page 3 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 5. Removing, Installing Retarder............................................. 99 6. Repair Retarder ................................................................ 110 6.1 Overall Illustration of Main Components ...................................................111 6.2 Removing, Checking and Installing Casing Ventlation .............................112 6.3 Removing, Cleaning and Installing Silencer .............................................122 6.4 Removing and Installing Water Neck........................................................123 6.5 Removing, Checking, Installing Heat Exchanger......................................124 6.6 Removing, Installing Oil Tank Cover.........................................................133 6.7 Removing, Installing Non-Return Valve Outlet .........................................136 7. Control Parts..................................................................... 139 7.1 Removing, Installing Proportional Valve and Damping Plate....................140 7.2 Removing, Installing Temperature Sensor Cooling Water........................141 7.3 Removing, Installing Temperature Sensor Oil ..........................................142 7.4 Removing, Installing Pressure Sensor......................................................143 8. Appendix........................................................................... 144 8.1 Retarder Data Sheet .................................................................................145 8.2 Tightening Torques...................................................................................146 Preface Preface Page 4 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 03-01 1. Preface This Aftersales Service Manual provides information and instructions on maintenance and repair of the Voith Retarder 115 E. These instructions present the basis for performing appropriate and expert maintenance and repair. It is indispensable that you observe the safety instructions and warning notes in this manual. Nevertheless, the user is obliged to exercise pertinent and professional care when handling machines, aggregates and hot media such as for example oil or water.
Attention! ... points out safety instructions and warning notes where persons are endangered, quality of work- manship is reduced or property damage may occur. Notice ... points out information on improved handling of work at the retarder. Preface Preface Page 5 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 03-01 Attention! Maintenance and repair work may only be carried out by accordingly qualified personnel. Make sure that the retarder is fully functional during all vehicle manoeuvres! Non-observance may inflict damages to the retarder! When towing the vehicle, the following restrictions apply for the retarder: - tow distance: up to 100 km - towing speed: max 40 km/h. The activated retarded may not be used as parking brake! During failure of the retarder, or while temperature adaptation is active, use the service brake to slow down the vehicle and switch into the lowest possible gear (target: high engine speed). This vehicle state must be maintained until the retarder resumes full operation. Unauthorized changes to the retarder, the use of spare parts, accessories, attachments and spe- cial features not tested and released by Voith may negatively affect the security of the entire ve- hicle. Voith does not assume any liability for damages arising as a result. Preface Preface Page 6 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 03-01 Attention! The retarder is constructed according to the state of the art in technology and acknowledged safety regulations. Nevertheless, hazardous situations and property damages may occur during improper use, maintenance and repair. Therefore, Voith is not capable of warning the user in this Aftersales Service Manual about any situation conceivable in which he may suffer injuries and/or cause damage to the retarder. As a consequence, it is indispensable that any person engaged in operation, servicing, maintenance and repair of the retarder does not endanger his or her personal safety with the work and that the retarder is not affected adversely, particularly with regard to the safety regulations. Voith assumes no liability for personal and/or property damage caused by improper and unprofessional work. Absolute cleanliness is essential during all stages of the work process. The presence of dirt due to improper handling may cause considerable material damages or malfunctions. Be careful when handling hot media! Risk of burning and scalding! Preface Preface Seite 7 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 03-01 Notice The item numbers used in this documentation are the same as the item numbers in the spare parts lists. Exception: Items and components with one- or two-digit item numbers are no spare parts and therefore are not included in the spare parts lists. Also items and components with dash numbers are no spare parts and therefore not included in the spare parts lists. The relevant regulations for prevention of accidents, other generally acknowledged safety regulations and occupational health rules as well as the Motor Vehicle Regulations must be observed. Voith assumes no liability for damages resulting from non-observance of these regulations. When handling oil, grease and other chemical substances, the pertinent safety regulations for these products must be heeded! For the sake of environmental protection, drained fuels and fluids must be disposed of according to the relevant statutory regulations. Information on the safe, technically correct and economical operation of the Voith Retarder 115 E are given in the operating instructions. The valves and the pressure sensor of the retarder must be protected from the direct jet of a high- pressure cleaner (steam-jet device). When troubleshooting, do not replace parts on mere speculation. Warranty or goodwill service will only be rendered if there is proof that the parts in question are really defective. Preface Preface Seite 8 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 03-01 If you have any questions or if you are uncertain about work steps, which are not described in this documentation, please ask your contact person responsible for your country or contact:
Voith Turbo GmbH & Co. KG Department Retarder PO box 1555 D-74555 Crailsheim
Direct dials: Customer service line and spare parts: 32-401 32-422 32-1860 General General Page 9 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 2. General 2.1 Assembly Overview ....................................................................................10 2.2 Retarder Data Plate ....................................................................................12 2.3 Data Plate of Retarder-Control Unit ............................................................13 2.4 Function- and Operation Scheme...............................................................15 General Assembly Overview Page 10 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 General Assembly Overview
Illustration: Voith Retarder R115 E 2.1 Assembly Overview Basic Group with Heat Exchanger 4100 100 6400 3700 11001 100 Retarder housing 3700 Proportional valve 4100 Oil filler plug M 30 x 1,5 6400 Heat exchanger General Assembly Overview Page 11 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 General Assembly Overview Basic Group with Heat Exchanger
Illustration: Voith Retarder 115 E
11002 103 107 4200 3700 6400 3500 5500/1 103 Screw plug M 12 x 1,5 107 Oil drain plug M 24 x 1,5 3500 Screw plug with sieve M 30 x 1,5 3700 Proportional valve 4200 Oil drain plug M 24 x 1,5 5500/1 Ventilation 6400 Heat exchanger General Retarder Data Plate Page 12 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 General Retarder Data Plate
Illustration: Retarder Data Plate 2.2 Retarder Data Plate The data plate is mounted on the left below of the retarder housing in right direction of tra- velling. The following details are on the data plate:
a d e f b Voith-item-No c Type R 115 E 11003e Serial No Year of Man. Cust. item No Kd.-Sach-Nr. Voith-Sach-Nr. a) Type of Retarder b) Serial number 6-digit number c) Year of manufacturing d) Retarder ratio (i Ret ) e) Customer-item number f) Voith-item number 8-digit number Notice Please, always quote the retarder data when submitting queries or ordering spare parts. In this case a quick and working is possible. General Data Plate of Retarder-Control Page 13 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 General Data Plate of Retarder-Control
Illustration: Data Plate of Retarder Control Unit Digiprop 2.3 Data Plate of Retarder-Control Unit Digiprop The data plate of the Digiprop-control unit is mounted on the control unit and contains following information: B a s is -N r.: 5 3 .x x x x .1 2 C o d e -N r.: x x x S e rie n -N r.: x x x x / V O IT H Basic-No.: Code-No.: Serial-No.: VOITH 11004e 1. Basic-number 8-digit number The last t wo digits show the soft ware version. Example: .12 = version 1.2 2. Code-number 3-digit number (Adjusting of control unit) 3. Serial-number 5-digit number with date of coding 4. Voith precast unit number as well as customer number, if ne- cessary Notice Please, always quote the retarder data and retarder control unit data when submitting queries or ordering spare parts. In this case a quick and working is possible. General Data Plate of Retarder-Control General Data Plate of Retarder-Control Page 14 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Illustration: Data Plate of Retarder Control Unit VERA Data Plate of Retarder-Control Unit VERA The data plate of the VERA-control unit is moun- ted on the control unit and contains following information: Retarder Control Unit VE RA.STD Serial-No. XXXX / 2002-08-01 Part-No. 67.2763.20 OEM-No. V O I T H
T U R B O X1 X2 X3 e 1 * 7 2 / 2 4 5 * 9 5 / 5 4 * 2 0 8 4 * 0 0 R e ta r d e r
C o n tr o l U n it V E R A .S T D S e r ia l-N o . X X X X / 2 0 0 2 -0 8 -0 1 P a r t-N o . 6 7 .2 7 6 3 .2 0 O E M -N o . V O I T H T U R B O X 1 X 2 X 3 e 1 * 7 2 / 2 4 5 * 9 5 / 5 4 * 2 0 8 4 * 0 0 11005 1. Serial-number 4-digit number / date 2. Spare-part-number 8-digit number 3. OEM-number Notice Please, always quote the retarder data and retarder control unit data when submitting queries or ordering spare parts. In this case a quick and working is possible. General Function- and Operation Scheme General - Function- and Operation Scheme Page 15 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 2.4 Function- and Operation Scheme Illustration: Functional Drawing Retarder 115 E Digiprop
Notice Example of application hand control Digiprop. Further OEM-specific versions are possible. The given position numbers aren't identical with the position numbers of the spare part lists. 1 Heat exchanger complete 41 Filling duct 1/1 Retarder-oil cooling circuit 42 Oil tank 1/2 Gearbox-oil cooling circuit 43 Oil sump 19 Temperature sensor cooling water 44 Stator 20 Temperature sensor oil 46 Rotor 21 Proportional valve 55 Oil drain plugs 22 Ventilation 62 Pressure regulating valve 23 Casing ventilation 63 Non-return valve (inlet) 25 Air-pressure line A constant-air pressure (p y ) 64 Non-return valve (outlet) 26 Air-pressure line supply-air pressure (p v ) 72 Pressure sensor (OEM-specific) 36 Exhaust line R 25 26 23 36 1 19 63 20 43 46 22 44 62 55 64 A R 21 42 Oil sump Supply-air pressure p Constant-air pressure p y Coolant (water) 11006e Pump pressure p P 41 1/1 1/2 72 Vehicle electronic v General Function- and Operation Scheme General Function- and Operation Scheme Page 16 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Functional Description The Voith Retarder 115 E is a powerful, hydrodynamic continous brake of compact design. The retarder is driven and braking torque is transmitted by pinions in the gearbox. The transmission ratio enables the retarder to achieve high braking torques right down to low r.p.m. ranges with the compactest configuration (small rotor/stator). Retarder braking torque is sustained even when gear changes are made. Do not use the switched-on retarder as handbrake while vehicle is in still-stand! During a failure of the retarder, or while the temperature-adaptation is effective, the vehicle-speed must be settled by using the service-brake and the lowest possible gear. General Function- and Operation Scheme General Function- and Operation Scheme Page 17 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Temperature Sensor Cooling Water (19), Oil (20) The temperature sensors 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 adapted to protect the vehicle cooling system and the retarder. 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 adaption range, the consequence is an adap- tion of the retarder braking torque to protect the vehicle cooling system. If the temperature rises above the temperature adaption range, there is no more braking torque output. While the temperature adaption is effective or if there is a retarder failure, the service brake must be used to control the vehicle. Additionally the control unit cuts back braking torque if oil temperature rises too rapidly - irrespective of actual oil temperature. Pressure regulating valve (62) The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder. General Function- and Operation Scheme General Function- and Operation Scheme Page 18 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Pressure sensor (72) The pressure sensor (72) observes the pneumatic constant-air pressure. At deviation of the permissible pressure tolerance an error is stored from the control unit displayed in the vehicle display in dependence of the OEM equipment. 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. Non-return valve (63) inlet When the retarder is switched on, the oil sump is pressurized, causing the check valve (63) to open and the oil to enter the working space. Non-return valve (64) outlet The oil pressure in the working space opens the check valve (64), causing the oil to enter the heat exchanger (1), to be cooled and to be returned to the working circuit. Proportional valve (21) Depending on the size of the electrical input signal a pneumatic constant-air pressure gets controlled from the proportional valve to the oil tank of the retarder. Maintenance Maintenance Page 19 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 3. Maintenance 3.1 Maintenance Work / Oil Change Intervals ..................................................20 3.2 Inspection of Oil Level.................................................................................23 3.3 Oil Change..................................................................................................26 Maintenance Maintenance Work / Oil Change Intervals Maintenance Maintenance Work / Oil Change Intervals Page 20 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 3.1 Maintenance Work / Oil Change Intervals Maintenance work At each oil change: - Clean sieve of pressure regulating valve - Check fastening screws of the retarder heat exchanger - Check all screw plugs on leak and correct fitment - Carry out visual inspection on possible leak and existing damages Please note the following data into the service overview of the Operation Manual Gearbox-Retarder-System / GO170 - GO210 with R 115 E : - maintenance work been carried out - the oil grade used for the oil change Maintenance Maintenance Work / Oil Change Intervals Maintenance Maintenance Work / Oil Change Intervals Page 21 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Oil change intervals, operating specification 1) according operating specification 2) carry out change oil at the latest after 1 year, if fewer kilometres are travelled 3) carry out change oil at the latest after 2 year, if fewer kilometres are travelled Please take into account the oil recommendation list (Voith code number 67.2246.11). Single grade-mineral oil 1) Synth. / part synth. oil 1) Synthetic oil 1) Normal duty 135.000 km 2) 180.000 km 3) 300.000 km 3) Heavy duty 60.000 km 2) 90.000 km 3) 300.000 km 3) Classification let- ter to DIN 51502 HD HC HC Class of viscosity to DIN 51511 SAE 10W SAE 20W20 SAE 30 SAE 0W40 SAE 5W30 SAE 5W40 SAE 5W50 SAE 10W30 SAE 10W40 SAE 75W80 Performance category API - CC/SF and higher API - CC/SF and higher Emgard MTF,Henkel Maintenance Maintenance Work / Oil Change Intervals Maintenance Maintenance Work / Oil Change Intervals Page 22 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 1. Normal duty Example: Long distance traffic 2. Heavy duty Subject to more than normal stress. Examples: Use in regions with high ambient temperature (e.g. Saudi-Arabia) High max. permissible weight with low rated engine power (< 6 kW / metric ton) Streches with lots of hills and valleys Extreme short-distance traffic with lots of gradients The given maximum specified figures can be lowered, if overall maintenance cycles for the vehicle are improved. With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as other factors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervals between oil changes in individual cases. For use in extremely cold zones, oils in an appropriately lower viscosity class must be used. In doubts please contact our customer service. Maintenance Inspection of Oil Level Maintenance Inspection of Oil Level Page 23 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 3.2 Inspection of Oil Level Notice For satisfactory retarder operation it is important to adhere to the specified service filling of 7,0 litres and to use only oils specified in the operating specifications for operating the retarder in the relevant applica- tion. The oil level check must be carried out with the vehicle in a horizontal position. For the inspection of oil level, temperature of retarder oil must have reached the operating temperature. Caution! Two version of the screw plugs (107, 4100, 4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the inspection of oil level; replace completely if necessary. B) Version with loose inserted copper-sealing ring. In this Aftersales Workshop Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings have to be renewed in general. Maintenance Inspection of Oil Level Maintenance Inspection of Oil Level Page 24 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Work scope 1. Push a clean vessel under retarder.
2. Screw out oil drain plugs and drain oil in clean vessel. 3. Check sealing rings of oil drain plugs for damages, renew oil drain plugs if necessary. 4. Screw in oil drain plugs and screw them tight. Tightening torque oil drain plugs (107, 4200): 47 Nm (80 Nm) 5. Measure drained oil. 6. Top up any lacking oil according to the operating specifications, page 29. 4200 107 11007 107 Oil drain plug M 24 x 1,5 Inhex-head w.a.f. 12, 47 Nm (80 Nm) 4200 Oil drain plug M 24 x 1,5 Inhex.head w.a.f. 12, 47 Nm (80 Nm) Caution! Risk of injury! The oil drain plugs (107, 4200) and oil filler plug (4100) are hot (oil temperature)! The retarder must be switched-off during the inspection of oil level! If the retarder is switched-on during working step 2 and screwed out oil drain plugs and/or oil filler plug, high risk of injury exist by hot leaving oil (increased pressure)! Maintenance Inspection of Oil Level Maintenance Inspection of Oil Level Page 25 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 7. Fill in slowly over a time period longer than 3 minutes the quantity of oil specified, in the bore of the oil filler plug (4100).
8. Check sealing ring of oil filler plug for possible damages, renew oil filler plug if necessary. 9. Screw in oil filler plug and screw it tight. Tightening torque oil filler plug (4100): 100 Nm (100 Nm)
10. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 times for respectively approx. 5 seconds in position 2 at the retarder stage switch or brake stage 1. Take the OEM specific using variants into account to this. The vehicle must not go slower than 20 km/h at this. Caution! The retarder must only be filled with oil via the bore of the oil filler plug (4100)! Notice With determined lacking oil quantity check retarder for possible outer leak. Hinweis The following work step is required to the correct ventilation of the retarder system. Nonobservance can cause oil leak via the ventilation. If available, the foot control of the retarder must be switched off and switched on first after the described work process again. Maintenance Oil Change Maintenance Oil Change Page 26 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 3.3 Oil Change Notice The gearbox- and retarder oil tanks are seperated from each other at the gearbox-retarder-system. Both oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder - without limited compromizes. For satisfacory retarder operation, it is important to adhere to the specified service filling (see table page 29) and to use only oils specified in the operating specifications page 21 for operating the retarder in the relevant application. For draining the oil the temperature of the retarder oil must have reached the operating temperature. Ensure that during the entire oil change no constant-air pressure acts on the retarder, that means the retarder must be switched off! Maintenance Oil Change Maintenance Oil Change Page 27 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Attention! Two versions of screw plugs (107, 3500, 4100, 4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the inspection of oil level; replace completely if necessary. B) Version with loose inserted copper-sealing ring. In this Aftersales Workshop Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings have to be renewed in general. Maintenance Oil Change Page 28 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Maintenance Oil Change
Illustration: Oil change Retarder R 115 E
Lubricants and cleaning agents 3500 4100 4200 4200 107 11008 Kd.-Sach-Nr. Voith-Sach-Nr. 107 Oil drain plug M 24 x 1,5 Inhex-head w.a.f. 12 47 Nm (80 Nm) 3500 Screw plug with sieve M 30 x 1,5 Inhex-head w.a.f. 17 100 Nm (100 Nm) Clean sieve with appropriate cleaning agent and blow out with compressed-air 4100 Oil filler plug M 30 x 1,5 Inhex-head w.a.f. 17 100 Nm (100 Nm) 4200 Oil drain plug oil tank M24x1,5 Inhex-head w.a.f. 12 47 Nm (80 Nm) Sieve in screw plug Benzine Maintenance Oil Change Maintenance Oil Change Page 29 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Work scope 1. Push an oil collecting pan under the retarder.
2. Screw out the oil drain plugs (107 and 4200) and drain the oil. 3. Check integrated sealing rings of oil drain plugs on possible damages, renew oil drain plugs if necessary. 4. Screw in the oil drain plugs tight. Tightening torque oil drain plugs (107, 4200): 47 Nm (80 Nm) Oil filling with heat exchanger Service filling (oil change, inspection of oil level) 7,0 l After exchange of heat exchanger 7,5 l Attention! Risk of injury! The oil drain plugs (107, 4200) are hot! Oil temperature! 4200 107 4200 11009 Maintenance Oil Change Maintenance Oil Change Page 30 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 5. Screw screw plug with sieve (3500) out of the retarder. 6. Clean sieve in screw plug with appropriate cleaning agent (Benzine) and blow it out with compressed-air. 7. Check integrated sealing ring of screw plug with sieve on possible damages, renew screw plug if necessary. 8. Screw in screw plug with sieve hand-tight then tighten it. Tightening torque screw plug (3500): 100 Nm (100 Nm) 9. Screw out oil filler plug (4100).
10. Fill in slowly over a time period longer than 3 minutes the quantity of oil, via the bore of the oil filler plug, specified in accordance to the service filling (see table page 29). This work step is required to the correct ventilation of the retarder system. 3500 11010 Kd.-Sach-Nr. Voith-Sach-Nr. 4100 11011 Attention! The retarder must only be filled with oil via the bore of the oil filler plug (4100)! Maintenance Oil Change Maintenance Oil Change Page 31 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 11. Check integrated sealing ring of oil filler plug on possible damages, renew oil filler plug if necessary. 12. Fit oil filler plug and screw it tight. Tightening torque oil filler plug (4100): 100 Nm (100 Nm) 13. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 times for respectively approx. 5 seconds in position 2 at the retarder stage switch or brake stage 1. Take the OEM specific using variants into account to this. The vehicle must not go slower than 20 km/h at this. Achtung! The following work step is required to the correct ventilation of the retarder system. Nonobservance can cause oil leak via the ventilation. If available, the foot control of the retarder must be switched off and switched on first after the described work process again. Diagnosis / Troubleshooting Diagnosis / Troubleshooting Page 32 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4. Diagnosis / Troubleshooting 4.1 Electrical Connections Diagram..................................................................33 4.2 Overview of Control Parts...........................................................................37 4.3 Troubleshooting Diagram............................................................................38 4.4 Troubleshooting and Remedies..................................................................41 4.5 Checking Supply-Air Pressure (p v ) .............................................................77 4.6 Checking Constant-Air Pressure (p y ) and Pump Pressure (p dyn ) ...............78 4.7 Checking Control Current of Proportional Valve.........................................86 4.8 Checking Pressure Sensor .........................................................................88 4.9 Checking Temperature Adaption ................................................................90 4.10 Table of Measurements ..............................................................................93 Diagnosis / Troubleshooting Elektrical Connections Diagram Page 33 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Diagnosis / Troubleshooting Elektrical Connections Diagram 4.1 Elektrical Connections Diagram (Voith-Wiringharness Digiprop without CAN) 18 70 47 15 21 - - + + + - 19 20 17 4 16 69 4 2 X1 X2 X3 8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8 14 8 7 8 7 a 3 0 13 11 12 10 1 9 5 8 4 3 2 7 6 18 17 16 6 5 4 8 9 10 11 12 13 14 15 7 4 3 2 1 4 8 3 2 5 6 7 3 1 2 7 11012 1 2 4 . . . . P U 72 2 Control unit 4 Connection terminal 15 15 ABS-signal 16 Retarder stage switch 17 Retarder pilot light 18 Brake light relay 19 Temperature sensor cooling water 20 Temperature sensor oil 21 Proportional valve 47 Speedometer signal 69 Plug ISO-interface 70 Plug optional function 72 Pressure sensor (OEM-specific) Diagnosis / Troubleshooting Elektrical Connections Diagram Page 34 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Diagnosis / Troubleshooting Elektrical Connections Diagram Digiprop with CAN 21 - - + + + - 19 20 17 4 16 4 2 X1 X2 X3 8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8 18 17 16 6 5 4 8 9 10 11 12 13 14 15 7 3 1 2 7 1 2 4 . P U 72 CAN 11013 2 Control unit 4 Connection terminal 15 16 Retarder stage switch 17 Retarder pilot light 19 Temperature sensor cooling water 20 Temperature sensor oil 21 Proportional valve 72 Pressure sensor (OEM-specific) Diagnosis / Troubleshooting Elektrical Connections Diagram Page 35 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Diagnosis / Troubleshooting Elektrical Connections Diagram VERA general 11014 47 4 2 X1 X2 X3 8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8 18 8 7 8 7 a 3 0 21 18 17 16 6 5 4 8 9 10 11 12 13 14 15 7 3 1 2 7 - + 19 + - 20 1 2 4 P U 72 17 4 . CAN 80 - + - + 16 15 83 82 81 2 Control unit 4 Connection terminal 15 15 ABS-signal 16 Retarder stage switch 17 Retarder pilot light 18 Brake light relais 19 Temperature sensor cooling water 20 Temperature sensor oil 21 Proportional valve 47 Speedometer signal 72 Pressure sensor (OEM-specific) 80 On/off valve 81 Input (3 times) 82 Output (3 times) 83 ISO-diagnosis Diagnosis / Troubleshooting Elektrical Connections Diagram Page 36 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Diagnosis / Troubleshooting Elektrical Connections Diagram VERA DAFBUS 11015 4 2 X1 X2 X3 8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8 18 8 7 8 7 a 3 0 21 18 17 16 6 5 4 8 9 10 11 12 13 14 15 7 3 1 2 7 - + 19 + - 20 1 2 4 P U 72 93 CAN - + 90 94 16 92 91 4 . 96 95 2 Control unit 4 Connection terminal 15 16 Retarder stage switch 18 Brake light relais 19 Temperature sensor cooling water 20 Temperature sensor oil 21 Proportional valve 72 Pressure sensor (OEM-specific) 90 Fan relais 91 Brake valve 92 Diagnosis K-Lead 93 Fault light 94 Operating light 95 Foot Off/On 96 Indication light Diagnosis / Troubleshooting Overview of Control Parts Page 37 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Diagnosis / Troubleshooting Overview of Control Parts 4.2 Overview of Control Parts 71 32 33 31 34 35 40 61 11016 39 19 1 20 2 21 26 72 P 36 11 25 A R Notice The given position-numbers are not identical with position-numbers of spare parts lists. 1 Heat exchanger 2 Control unit (e.g. Digiprop/ VERA) 11 Connection control current of proportional valve 19 Temperature sensor cooling water 20 Temperature sensor oil 21 Proportional valve 25 Compressed-air pressure line constant-air pressure (p y ) 26 Compressed-air pressure line suppla-air pressure (p v ) 31 Compressed-air pressure line (pressure regulator - four- circuit protection valve) 32 Compressed-air pressure line (four-circuit protection valve - air tank for auxiliary equip- ment) with with test connec- tion 33 Compressed-air pressure line (brake circuit 1) 34 Compressed-air pressure line (brake circuit 2) 35 Compressed-air pressure line (parking brake) 36 Ventilation line connection R 39 Electrical lead (temperature sensor cooling water) to control unit, 2 wires) 40 Electrical lead (temperature sensor oil) to control unit, 2 wires) 61 Four-circuit protection valve 71 Air tank for auxiliary equipment 72 Pressure sensor (OEM-specific) Diagnosis / Troubleshooting Troubleshooting Diagram Diagnosis / Troubleshooting Troubleshooting Diagram Seite 38 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4.3 Troubleshooting Diagram Complaint Retarder R 115 E A Retarder Pilot Light (Standard version) B Oil leak via ventilation and / or non or too low braking efficiency * * Notice: OEM-specific is an on-board-diagnosis possible (display). Notice the information from the vehicle manufacturer to it. 11017e Diagnosis / Troubleshooting Troubleshooting Diagram Diagnosis / Troubleshooting Troubleshooting Diagram Page 39 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Illustration: Complaint main group A Activate flash code and read out fault code * * Retarder Pilot L ight (Standard version) A Permanent light in position 0 after lamp test? Clear fault and erase fault memory * no function? Check pilot light and renew, if necessary flashes? Temperature adaption OK NOK Check operation (during Retarder braking most possible engine nominal speed) Instruct driver! OK NOK Check temp.-sensors (oil / water) (page 90 ff) Replace temp.-sensos (page 141, 142) Check vehicle cooling system: - coolant level - Thermostat - Coolant pump - Radiator fan - Radiator on pollution 11018e Check fuse ABS or idle switch active? * OE M-specific is an on-board-diagnosis possible (display). Notice the information from the vehicle manufacturer to it. * Notice the information of the vehicle manufacturer Diagnosis / Troubleshooting Troubleshooting Diagram Diagnosis / Troubleshooting Troubleshooting Diagram Seite 40 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Prior work Check retarder system on outer leaks (apart from ventilation) Check whether running in instruction was carried out after oil change, carry out if necessary
Illustration: Complaint main group B 11019e Check retarder oil level (page 23 ff) OK NOK Yes No Water in oil (emulsion) (page 124 ff) Check heat exchanger Correct retarder oil level OK NOK NOK OK Check p (dynam.) and py (statisch) (page 78 ff) For examination the retarder oil level must be correct! NOK OK Check temperature adaption or temp.-sensors (oil/water) and pressure sensor or leads (page 88 ff) OK NOK Check gearbox oil level check p (static) (page 78 ff) y Replace temperature sensors or leads (page 141, 142) Consultation Voith B Check retarder oil level too low too high NOK OK Check gear box oil level Check gear box oil level too high too low Correct retarder- and gearbox oil level Check gearbox oil level too high too low Correct retarder- and gearbox oil level Yes No Outer Leak (apart ventilation) Repair Retarder Correct retarder- and gearbox oil level If problem occours again: Consultation Voith OK NOK Check gearbox ventilation Correct retarder- and gearbox oil level If problem occours again: Consultation Voith For examination the retarder oil level must be correct! At complaint "non or too low braking efficiency": Consultation Voith At complaint "Oil leak via ventilation": continue with checking casing ventilation NOK OK Check vehicle compressed-air system NOK OK Check supply- air pressure (page 77) Proportional valve or damping plate mechanically defect NOK OK Check casing ventilation (page 112 ff) OK NOK Replace casing ventilation (page 112 ff) p (dynamic) NOK p (static) NOK y Check proportional valve (page 86 ff) NOK OK Replace proportinal valve (page 140) If problem occours again: Consultation Voith No Yes Outlet valve .11 and higher? Replace outlet valve (page 136 ff) If problem occours again: Replace proportional valve. Contact vehicle manufacturer Compressed-air pressure line to prop. valve interrupted or leaking Oil leak via ventilation and / or non or too low brake efficiency Check control current of prop. valve as well as leads und plug connections (page 86 ff) Repair gearbox ventilation; correct retarder- and gearbox oil level Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 41 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4.4 Troubleshooting and remedies Requirements for check 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 Version Digiprop with and without CAN: for check with multimeter must be at the control unit pin 15 (plug X1) Ground (terminal 31), at pin 7 and pin 13 (plug X1) must be connected terminal 15 Version VERA: for check with multimeter must be at the control unit pin 14 (plug X1) Ground (terminal 31), at pin 7 (plug X1) must be connected terminal 15 Note Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary (see page 29). Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 42 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Note The retarder pilot light additionally has the function of a fault code. An on-board-diagnosis (display) is OEM-specific possible. Heed herefore the statements of the vehicle manufacturer: slight fault Permanent light in position 0 - 5 of retarder stage switch, braking is still possible to limited extent. serious fault Permanent light in position 0 - 5 of retarder stage switch,, braking is no longer possible - the retarder is switched off. Note If 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. Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 43 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Connector arrangement and pin assignment
Plug X1 control unit (Digiprop) Note All plugs illustrated from plug-in side (i.e. leads at back). 11020 1 4 7 10 13 16 2 5 8 11 14 17 3 6 9 12 15 18 1 Not in use or CAN-LOW 2 Not in use or CAN-GROUND 3 Not in use or CAN-HIGH 4 Retarder stage switch, Position 3 5 Retarder stage switch, Position 2 6 Retarder stage switch, Position 1 7 Terminal 15 8 Retarder stage switch, Position 5 9 Retarder stage switch, Position 4 10 Retarder stage switch + 11 ISO-interface, L-lead 12 ISO-interface, K-lead 13 Connected with terminal 15 14 Not in use 15 Terminal 31 16 Output / high side 2 HS2 17 Not in use 18 Output / high side 1 HS1 Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 44 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Plug X2 control unit (Digiprop) Plug X3 control unit (Digiprop) 11021 1 4 7 2 5 8 3 6 9 1 Not operational 2 Proportional valve - 3 Proportional valve + 4 Cooling-water temperature-sensor - 5 Cooling-water temperature-sensor + 6 Not operational 7 Not in use 8 Oil-temperature sensor - 9 Oil-temperature sensor + 11022 1 4 7 10 2 5 8 11 3 6 9 12 1 Input / pull up DIU 1 2 Speedometer signal 3 ABS-signal 4 Input / pull down DID 2 5 Input / pull down DID 1 6 Pressure-sensor ground 7 Pressure-sensor signal voltage 8 Retarder pilot light 9 Input / pull down DID 3 10 Pressure-sensor supply voltage 11 Stop light relais 12 Input / pull down / PWM-in DID4 Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 45 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Plug optional functions (cable Digiprop) Plug ISO-interface (cable Digiprop) 2 1 4 3 6 5 8 7 10 9 12 11 14 13 11023 1 Retarder stage switch + 2 Input / pull down DID 1 3 Input / pull down DID 2 4 Input / pull down DID 3 5 Input / pull down / PWM -in DID 4 6 Input / pull up DIU 1 7 Pressure-sensor Ground 8 Pressure-sensor signal voltage 9 Pressure-sensor supply voltage 10 Output / high side HS1 11 Output / high side 2 HS2 12 Not operational 13 Terminal 15 14 Terminal 31 2 1 4 3 11024 1 K-lead 2 L-lead 3 Terminal 15 4 Terminal 31 Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 46 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Connector arrangement and pin assignment
Plug X1 control unit (VERA) Note All plugs illustrated from plug-in side (i.e. leads at back). 11025 1 4 7 10 13 16 2 5 8 11 14 17 3 6 9 12 15 18 1 CAN-LOW 2 CAN-GROUND 3 CAN-HIGH 4 Retarder stage switch, Position 0 5 Retarder stage switch, Position 1 6 Retarder stage switch, Position 2 7 Terminal 15 = battery voltage 8 Retarder stage switch, Position 3 9 Retarder stage switch, Position 4 10 Retarder stage switch + 11 Speedometer signal 12 ISO-interface, K-lead 13 ABS-signal 14 Terminal 31 = Ground 15 Retarder pilot light 16 Brake light relais 17 Engine speed 18 Retarder stage switch, Position 5 Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 47 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Plug X2 control unit (VERA) Plug X3 control unit (VERA) 11026 1 4 7 2 5 8 3 6 9 1 Output / highside OUT 1 2 Output / highside OUT 2 3 Output / highside OUT 3 4 Input / analog IN 3 5 Input / analog IN 1 6 Not in use (boot 1) 7 Not in use (boot 2) 8 Not in use (boot 3) 9 Input / digital IN 2 11027 1 4 7 10 2 5 8 11 3 6 9 12 1 Cooling-water temperature-sensor - 2 Cooling-water temperature-sensor + 3 Proportional valve + 4 Proportional valve - 5 Oil-temperature sensor + 6 Oil-temperature sensor - 7 Pressure-sensor signal voltage 8 Pressure-sensor Ground 9 Pressure-sensor supply voltage 10 Not in use (switch valve +) 11 Not in use (switch valve -) 12 Not in use Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 48 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Plug cooling-water temperature pick-up Plug oil temperature pick-up Plug proportional valve 11028 1 2 3 4 11029 1 Proportional valve + 2 Proportional valve 3 Not in use 4 Not in use Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 49 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Plug retarder stage switch 11030 1 2 3 4 5 6 7 8 1 Not in use 2 Position 5 3 Position 4 4 Retarder stage switch + 5 Position 3 6 Position 2 7 Position 1 8 Bridge to pin 4 Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 50 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 A. With fault code, e.g. retarder control unit reports fault Special tool Service cable (only Digiprop) Commercially available tool Multimeter recommended: Fluke 87 Note The fault memory can be read-out from blinking code of retarder pilot light via service-cable (53.8224.10 only Digiprop), if this function is realised. An on-board-diagnosis (display) is OEM-specific possible. Heed herefore the statements of the vehicle manufacturer. 53.8224.10 Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 51 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault memory readout via retarder pilot light blinking code Fault memory readout with service cable (only Digiprop) Requirements Retarder stage switch in position O. Vehicle at standstill, ignition ON 1. L-lead of service interface connected to ground 2s. For this pupose, press L - pushbutton on service cable 2. First fault as blinking code output. 3. Item 2 and 3 repeated for more blinking code outputs. Meaning Long blinking signals (2 sec.) tens unit. Short blinking signals (0,5 sec.) single unit. Note If sveral faults have been stored in the memory, they are output in the sequence of their occurence, but always only one fault per triggering. Exception: The fault Coding Fault is not held in the memory but is output via the blinking code. The blinking code can be read-out of control unit by using the service cable (only Digiprop) or retarder stage switch. Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 52 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault memory read out with retarder stage switch The blinking code can be triggered with the retarder stage switch during the service function (vehicle ignition system ON and v = 0): 1. Retarder stage switch in position 0 2. Retarder stage switch in position 1 3. Retarder stage switch in position 0 4. First fault as blinking code 5. Items from ...3 for more blinking code outputs There is a break of 3 seconds before and after each blinking code output, during this time the retarder pilot light is switched off.
Display example for fault code 23 (Digiprop) E Retarder pilot light ON A Retarder pilot light OFF t Time Display example for fault code 23 (Digiprop): The number of tens units first indicated as long ON time: each 2 seconds The number of single unit then is indicated as short ON time: each 0,5 seconds Breaks between each ON time: each 1 second If an actual fault occours (before triggering blinking code of retarder pilot light is switched ON) the retarder pilot light switches to permanent light again after the blinking code. Is there only one stored fault, the retarder pilot light is OFF after the output (only for Digiprop). 2
s e c 1
s e c 0 , 5
s e c 1
s e c 1
s e c 1
s e c 0 , 5
s e c 0 , 5
s e c 2
s e c 11031 Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 53 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Display example for fault code 23 (VERA) E Retarder pilot light ON A Retarder pilot light OFF t Time Display example for fault code 20 (only for VERA): The number of tens units first indicated as long ON time: each 2 seconds Then blinking code goes off, no single unit in this method Breaks between each ON time: each 1 second 2
s e c 1
s e c 2
s e c 11032 Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 54 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Delete fault memory (only for Digiprop) No marginal notes in accordance with fault memory read out. 1. Vehicle ignition system: OFF 2. Servcie interface L-lead connected to ground. For this purpose, press L-pushbutton of service cable. 3. Vehicle ignition system: ON 4. Release L-lead from ground after 2 sec. Delete fault memory (only for VERA) It is only possible to delete fault memory via WinDia. Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 55 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Version Digiprop 1) X 1/15 = ground control unit 2) Only, if no fault is recognizable after a complete check of the periphery: change control unit. Note Meaning of entries in Measurement/test connection column: X 1/15 X3/11 Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection 1) Result/ Set point Cause/ Remedy 2) Code Test step 01 Stop light relay/ Short circuit to ground slight 1 s - Ignition: OFF - Pull plug X3 out of control unit X 3/11 X 1/15 Relay is installed: 250-350 Check lead, plugs and relay or consumers Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 56 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 03 HS 1 output Short circuit slight 1 s - Ignition: OFF - Pull plug X1 out of control unit X 1/18 X 1/15 Relay is installed: 250-350 Check lead, plugs and relay or consumers 04 HS 2 output Short circuit slight 1 s - Ignition: OFF - Pull plug X1 out of control unit X 1/16 X 1/15 Relay is installed: 250-350 Check lead, plugs and relay or consumers 05 Terminal 15 Undervoltage serious 60 s - Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON X 1/7 V X 1/15 17,5 V Check lead, plugs and fuses 06 Terminal 15 Overvoltage serious 10 s - Ignition: OFF - Pull plug X1 out of 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) Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 57 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 * Fault is in serious class, if temperature sensor for oil and water are defect at the same time. Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 08 09 Cooling-water temperature sensor Discontinuity / Short circuit to battery
serious/ slight * 1 s - Ignition: OFF - Pull plug X2 out of control unit X 2/5 X 2/4 20C 10C = 1039 - 1117
60C 10C = 1194 - 1271
80C 10C = 1271 - 1347
Notice: The measuring in one tempera- ture range normally is sufficient. Check lead and sensor Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 58 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 * Fault is in serious class, if temperature pick-up for oil and water are defect at the same time. Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 11 12 Oil temperature sensor Discontinuity / Short circuit to battery
serious/ slight * 1 s - Ignition: OFF - Pull plug X2 out of control unit X 2/9 X 2/8 20C 10C = 1039 - 1117
60C 10C = 1194 - 1271
80C 10C = 1271 - 1347
Notice: The measuring in one tempera- ture range normally is sufficient. Check lead and sensor Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 59 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 13 1 Retarder stage switch Undefined switch state serious 1s - Ignition: ON - Retarder stage switch: Position 0 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 17,5 V
0 V 0 V 0 V 0 V 0 V Check lead, plug and retarder stage switch 13 2 - Ignition: ON - Retarder stage switch: Position 1 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 17,5 V 17,5 V
0 V 0 V 0 V 0 V Check lead, plug and retarder stage switch 13 3 - Ignition: ON - Retarder stage switch: Position 2 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 17,5 V 17,5 V 17,5 V
0 V 0 V 0 V Check lead, plug and retarder stage switch Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 60 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 13 4 - Ignition: ON - Retarder stage switch: Position 3 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 17,5 V 17,5 V 17,5 V 17,5 V
0 V 0 V Check lead, plug and retarder stage switch 13 5 - Ignition: ON - Retarder stage switch: Position 4 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V
0 V Check lead, plug and retarder stage switch 13 6 - Ignition: ON - Retarder stage switch: Position 5 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V Check lead, plug and retarder stage switch Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 61 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operati- on Measurement/ Test connec- tion Result/ Set point Cause/ Remedy Code Test step 14 Retarder stage switch Short circuit to battery serious 10 s - Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Retarder stage switch: Position 0 X 1/10 V X 1/15 0 V Check lead and plug 15 Retarder stage switch Short circuit to battery serious 1 s - Ignition: OFF - Pull plug X1 out of control unit - Retarder stage switch: Position 5 X 1/10 X 1/15 Resistor endless Single check of stages for short circuit 16 Speedometer signal Discontinuity serious 2 s - Ignition: ON X 3/2 V X 1/15 1 V Check lead and speedometer Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 62 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 18 Speedometer signal Short circuit to battery undefined signal serious 2 s - Ignition: OFF - Pull plug X3 out of control unit - Ignition: ON X 3/2 V X 1/15 9 V Check lead and speedometer 19 ABS Short circuit to ground serious 60 s - Ignition: ON X 3/3 V X 1/15 3,5 V Check lead, relay and ABS-control unit 21 ABS-Signal undefined serious 1 s - Ignition: ON X 3/3 V X 1/15 16,5 V Check lead, relay and ABS-control unit 22 Internal fault ABS-current path serious 1 s - - - Replace control unit 23 Proportional valve Fault No. 1: Short circuit to battery serious 1 s - Ignition: OFF - Pull plug X2 out of control unit - Ignition: ON X 2/3 V X 1/15 10 V Check lead Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 63 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 24 1 Proportional valve Fault No. 2: - Short circuit proportional valve magnetic - Short circuit connection lead proportional valve - Discontinuity proportio- nal valve magnetic Valve magnetic - Discontinuity connec- tion lead proportional valve - Short circuit to ground at proportional valve - Prop.- and shift valve interchanged serious 1 s - Ignition: ON - Pull plug X2 out of control unit X 2/2 X 2/3 18-25 Check lead and proportional valve (valve block) 2 - Ignition: OFF - Pull plug X2 out of control unit X 2/3 X 1/15 Resistor endless Check lead and proportional valve (valve block) 3 - Ignition: OFF - Pull plug X2 out of control unit X 2/2 X 1/15 Resistor endless Check lead and valve block Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 64 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 25 Valve block Fault No. 3: defective control unit serious 10 s Replace control unit 27 Valve block Fault No. 5: defective control unit serious 2 s Replace control unit 28 Terminal 30 Undervoltage serious 60 s - Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON X 1/13 V X 1/15 17,5 V Check lead, plug and fuse 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 3 s - Ignition: OFF - Pull plug X3 out of control unit - Ignition: ON X 3/8 V X 1/15 17,5 V Check lead, retarder pilot light and fuse Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 65 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step 33 Retarder pilot light: Short circuit to battery serious 3 s - Ignition: ON - Retarder stage switch: Position 1 X 3/8 V X 1/15 2 V Check lead and retarder pilot light 35 Fault control unit serious 500 ms / 123 s Replace control unit 37 Fault foot operation slight 100 ms / 1 s Check installation in accordance with OEM - as well as Voith requirements 38 1 Fault constant-air pressure slight 1 s to 10 s Ignition: ON Position 0 X 3/7 V X 1/15 and X 3/10 V X 1/15 0,3-0,7 V 4,75-5,25 V Pressure sensor wiring harness If deviation: step 2 2 Troubleshooting in wiring harness, pressure sensor, proportional valve, supply-air pressure, ECU (Contact Voith) Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 66 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Version VERA Note - X1 / 14 = Ground control unit - replace control unit first, if complete check of periphery did not yield any faults - Project specifically is normally only a part of the listed pins used (e.g.: ABS not via pin X1/13, but via CAN) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 1 1 Data set fault heavy immediately af- ter ignition ON Parameter setting fault, new parameter setting 2 1 EEprom fault heavy immediately af- ter ignition ON Replace control unit 3 1 ROM fault heavy approx. 10s after ignition ON Replace control unit 4 1 SIBA fault heavy 60 ms Replace control unit 5 1 Proportional- valve chasssis ground end, interruption, short circuit, connecting lead heavy 1s - Ignition: OFF - disconnect plug X3 X 3/3 X 3/4 18 ... 25 Check electrical lead and proportional valve Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 67 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 5 2 X 3/3 X 1/14 Resistor endless Check electrical lead and proportional val- ve 5 3 X 3/3 X 1/14 Resistor endless Check electrical lead and proportional val- ve 6 1 Proportional- valve battery short cir- cuit heavy 1s - Ignition: OFF - Pull off plug X1, X3 - Ignition: ON X 3/3 V X 1/14 10 V Check electrical lead and plug 8 1 Proportional- valve-control, int. fault at con- trol unit heavy 3s Replace control unit 9 1 Terminal 15 undervoltage heavy 60s - Ignition: OFF - Pull off plug X1 - Ignition: ON X 1/7 V X 1/14 17,5 V Check electrical lead, fuse and plug 10 1 Terminal 15 overvoltage heavy 10s - Ignition: OFF - Pull off plug X1, X3 - Ignition: ON X 1/7 V X 1/14 32,5 V Check electrical unit of vehicle (see manu- facturers instruc- tions) Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 68 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 11 1 Retarder stage switch undefined con- dition heavy 2s - Ignition: ON - Retarder stage switch: position 0 X 1/10 V X 1/14 X 1/5 V X 1/14 X 1/6 V X 1/14 X 1/8 V X 1/14 X 1/9 V X 1/14 X 1/18 V X 1/14 17,5 V 0 V 0 V 0 V 0 V 0 V Check electrical lead, plug and retarder sta- ge switch 2 - Ignition: ON - Retarder stage switch: position 1 X 1/10 V X 1/14 X 1/5 V X 1/14 X 1/6 V X 1/14 X 1/8 V X 1/14 X 1/9 V X 1/14 X 1/18 V X 1/14 17,5 V 17,5 V 0 V 0 V 0 V 0 V Check electrical lead, plug and retarder sta- ge switch 3 - Ignition: ON - Retarder stage switch: position 2 X 1/10 V X 1/14 X 1/5 V X 1/14 X 1/6 V X 1/14 X 1/8 V X 1/14 X 1/9 V X 1/14 X 1/18 V X 1/14 17,5 V 17,5 V 17,5 V 0 V 0 V 0 V Check electrical lead, plug and retarder sta- ge switch 4 - Ignition: ON - Retarder stage switch: position 3 X 1/10 V X 1/14 X 1/5 V X 1/14 X 1/6 V X 1/14 X 1/8 V X 1/14 X 1/9 V X 1/14 X 1/18 V X 1/14 17,5 V 17,5 V 17,5 V 17,5 V 0 V 0 V Check electrical lead, plug and retarder sta- ge switch Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 69 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 11 5 - Ignition: ON - Retarder stage switch: position 4 X 1/10 V X 1/14 X 1/5 V X 1/14 X 1/6 V X 1/14 X 1/8 V X 1/14 X 1/9 V X 1/14 X 1/18 V X 1/14 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V 0 V Check electrical lead, plug and retarder sta- ge switch 6 - Ignition: ON - Retarder stage switch: position 5 X 1/10 V X 1/14 X 1/5 V X 1/14 X 1/6 V X 1/14 X 1/8 V X 1/14 X 1/9 V X 1/14 X 1/18 V X 1/14 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V Check electrical lead, plug and retarder sta- ge switch 12 1 Retarder stage switch chasssis ground end heavy 1s - Ignition: OFF - Pull off plug X1 - Retarder stage switch: position 5 X 1/10 X 1/14 Resistor endless Check each stage on chsssis ground end 13 1 Retarder stage switch battery shortcir- cuit heavy 10s - Ignition: OFF - Pull off plug X1 - Retarder stage switch: position 0 X 1/10 V X 1/14 0 V Check electrical lead and plug Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 70 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 16 1 Temperature- sensors (both sensors defect) heavy 1s See blinking code 17 to 20 17 1 Cooling-water temperature sensor interruption light 1s - Ignition: OFF - Pull off plug X3 X 3/1 X 3/2 20C 10 C = 1039 - 1117 60C 10 C = 1194 - 1271
80C 10 C = 1271 - 1347
Note: The measuring in one temperature range normally is sufficient. Check electrical lead, sensor and plug 18 1 Cooling-water temperature sensor chasssis ground end light 1s - Ignition: OFF - Pull off plug X1, X3 X 3/2 X 1/14 Resistor endless Check electrical lead Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 71 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 19 1 Oil-temperature sensor interruption light 1s - Ignition: OFF - Pull off plug X3 X 3/5 X 3/6 20C 10 C = 1039 - 1117 60C 10 C = 1194 - 1271
80C 10 C = 1271 - 1347
Note: The measuring in one temperature range normally is sufficient. Check electrical lead and plug 20 1 Oil-temperature sensor chasssis ground end light 1s - Ignition: OFF - Pull off plug X1, X3 X 3/5 X 1/14 Resistor endless Check electrical lead and plug 21 1 Speedometer signal interruption heavy 2s - Ignition: ON X 1/11 V X 1/14 1 V Check electrical lead and speedometer 22 1 Speedometer signal battery shortcir- cuit heavy 2s - Ignition: OFF - Pull off plug X1 - Ignition: ON X 1/11 V X 1/14 9 V Check electrical lead and speedometer Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 72 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 23 1 Retarder pilot light interruption, chasssis ground end heavy 1s - Ignition: OFF - Pull off plug X1 - Ignition: ON X 1/15 V X 1/14 17,5 V Check electrical lead and fuse 24 1 Retarder pilot light interruption, battery shortcir- cuit heavy 3s - Ignition: ON - Retarder stage switch: position 1 X 1/15 V X 1/14 2 V Check electrical lead and retarder pilot light 25 1 Pressure sensor fault (supply) light 0,5s - Ignition: ON X 3/8 V X 3/9 4,75 ... 5,25 V Check electrical lead 26 1 Pressure sensor interruption, chasssis ground end light 1s - Ignition: OFF - Pull off plug X1, X3 X 3/7 X 1/14 Resistor endless Check electrical lead and pressure-sensor 27 1 Pressure sensor battery shortcir- cuit light 1s - Ignition: ON X 3/9 V X 3/8 4,75 ... 5,25 V Check electrical lead and pressure-sensor 28 1 Pressure sensor unplausible signal light 10s - Ignition: ON - Retarder stage switch: position 0 X 3/7 V X 3/8 0,3 ... 0,7 V Check electrical lead and pressure-sensor Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 73 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 29 1 ABS chasssis ground end heavy 60s - Ignition: ON X 1/13 V X 1/14 3,5 V Check electrical lead, relay and ABS-con- trol unit 30 1 ABS undefined con- dition heavy 5s - Ignition: ON X 1/13 V X 1/14 16,5 V Check electrical lead, relay and ABS-con- trol unit 31 1 ABS int. fault at con- trol unit heavy 1s Replace control unit 33 1 Brake light relay chasssis ground end light 1s - Ignition: OFF - Pull off plug X1 X 1/16 X 1/14 At installed relay 250-350 Check electrical lead plug and relay or con- sumer 34 1 Brake light relay interruption, battery shortcir- cuit light 1s - Ignition: OFF - Pull off plug X1 X 1/16 X 1/14 < 1,5k Check electrical lead plug and relay or con- sumer 2 - Ignition: OFF - Pull off plug X1 - Ignition: ON X 1/16 V X 1/14 0 V Check electrical lead plug and relay or con- sumer 35 1 Output 1 (OUT-1) chasssis ground end light 1s - Ignition: OFF - Pull off plug X2 X 2/1 X 1/14 At installed con- sumer > 150 Check electrical lead plug and relay or con- sumer Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 74 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 36 1 Output 1 (OUT-1) interruption, battery short cir- cuit light 1s - Ignition: OFF - Pull off plug X2 X 2/1 X 1/14 < 3k Check electrical lead plug and relay or con- sumer 2 - Ignition: OFF - Pull off plug X2 - Ignition: ON X 2/1 V X 1/14 0 V Check electrical lead plug and relay or con- sumer 37 1 Output 2 (OUT-2) chasssis ground end light 1s - Ignition: OFF - Pull off plug X2 X 2/2 X 1/14 At installed con- sumer > 150 Check electrical lead plug and relay or con- sumer 38 1 Output 2 (OUT-2) interruption, battery shortcir- cuit light 1s - Ignition: OFF - Pull off plug X2 X 2/2 X 1/14 < 3k Check electrical lead plug and relay or con- sumer 2 - Ignition: OFF - Pull off plug X2 - Ignition: ON X 2/2 V X 1/14 0 V Check electrical lead plug and relay or con- sumer 39 1 Output 3 (OUT-3) chasssis ground end light 1s - Ignition: OFF - Pull off plug X2 X 2/3 X 1/14 At installed con- sumer > 150 Check electrical lead plug and relay or con- sumer Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 75 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Blink- Code Test step 40 1 Output 3 (OUT-3) interruption, battery shortcir- cuit light 1s - Ignition: OFF - Pull off plug X2 X 2/3 X 1/14 < 3k Check electrical lead plug and relay or con- sumer 2 - Ignition: OFF - Pull off plug X2 - Ignition: ON X 2/3 V X 1/14 0 V Check electrical lead plug and relay or con- sumer 41 1 CAN-fault mes- sages failing to appear, inter- ruption heavy 1s Check electrical con- nections and leads of vehicle CAN-Bus 42 1 CAN BusOff heavy 200ms Check electrical con- nections and leads of vehicle CAN-Bus 46 1 Retarder foot- switch chasssis ground end (IN-3) light 500ms - Ignition: ON X 2/4 V X 1/14 > 0,4 V Check analoge foot- pedal, electrical lead and plug Diagnosis / Troubleshooting Troubleshooting and remedies Diagnosis / Troubleshooting Troubleshooting and remedies Page 76 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 B. Without fault code Hinweis Retarder faults without fault code are not recognized electronically. Diagnosis / Troubleshooting Checking Supply-Air Pressure (pv) Diagnosis / Troubleshooting Checking Supply-Air Pressure (pv) Page 77 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4.5 Checking Supply-Air Pressure (p v ) Work scope test 1. Connect appropriate test pressure gauge to test connection of compressed-air line (32) at four-circuit protection valve - air tank for auxiliary equipment and check supply-air pressure (p v ). Minimum pressure: 6 bar Maximum pressure: 11 bar
11033 32 Notice If pressure is not within the specified range, the compressed-air system must be checked according to the manufacturers data. Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 78 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) 4.6 Checking Constant-Air Pressure (p y ) and Pump Pressure (p dyn ) Requirements for check Retarder stage switch in position 0 Vehicle ignition OFF
11034 103 4100 Kd.-Sach-Nr. Voith-Sach-Nr. 103 Screw plug (test connection pump pressure) M12x1,5 Inhex-head w.a.f. 6 13 Nm (20 Nm) 4100 Oil filler plug M30x1,5 Inhex-head, w.a.f. 17 100 Nm (100 Nm) Notice The pump pressure check provides e.g. information on internal leaks and on the correct operation of the retarder. Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 79 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Requirements for check Retarder stage switch in position 0 Vehicle ignition OFF Vehicle electrical system (e.g. battery voltage, fuse etc.) checked in accordance with the Owners Manual for the vehicle and found satisfactory Compressed-air pressure 6 - 11 bar Special tools: Compressed-air Oil-pressure gauge pressure gauge 0 - 6 bar 0 - 25 bar 99/7 99/1 H53.478810 Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 80 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Attention! Two version of the screw plugs (107, 3500, 4100, 4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the inspection of oil level; replace completely if necessary. B) Version with loose inserted copper-sealing ring. In this Aftersales Workshop Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings have to be renewed in general. Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 81 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Work scope check 1. Screw out oil filler plug (4100).
99/7 Air-pressure gauge 53.1403.10 2. Connect air-pressure gauge (99/7) to bore of oil filler plug (4100). 4100 11035 Attention! Risk of injury! The oil filler plug (4100) and the retarder are hot! oil temperature! 99/7 11036 Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 82 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 3. Screw out screw plug (103).
99/1 Oil-pressure gauge 53.4788.10
4. Connect oil-pressure gauge (99/1) to bore of screw plug (103). Attention! Risk of injury! The screw plug (103) and the oil are hot! Oil temperature! 103 11037 11038 99/1 Attention! Easy oil-exit is caused constructively, but has no effect on function of retarder, however. Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 83 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 5. Drive the vehicle with a prop shaft speed of v ps = 1000 r.p.m. 6. Shift the retarder stage switch to position 5 while on move at prop shaft speed v ps = 1000 r.p.m. and read-off pump pressure (p dyn ) of oil-pressure gauge (99/1). 7. Compare read-off pump pressure with the minimum value of dynamic pump pressure (p dyn ) according to the table see pages 93 ff. 8. Compare read-off constant-air pressure (p y ) with determined value of constant-air pressure (p y ) according tables on pages 93 ff.
Notice Shift into direct gear (ratio 1:1). The engine speed 1000 r.p.m.
corresponds to prop shaft speed of 1000 r.p.m.. Attention! If the nominal value of the constant-air pressure (p y ) is obtained, however the pump pressure is below, the retarder is inside defect. If the respectively required set point is fallen at the measuring of the constant-air pressure (p y ), either a leak of the retarder or a defect is due to the control (see troubleshooting diagram). The constant-air pressure (p y ) must not change during the drive. Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 84 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
99/1 Oil-pressure gauge 53.4788.10 9. Disconnect oil-pressure gauge (99/1). 10. Screw tight screw plug (103). Tightening torque screw plug (103): 13 Nm (20 Nm) Attention! Risk of injury! Screwing of oil-pressure gauge and retarder are hot! When screwing out oil-pressure gauge (99/1) hot oil can flow out! 11039 99/1 103 11040 Notice Check sealing ring of screw plug (103) for a possible damage, replace screw plug (103) if necessary. Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 85 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
99/7 Air-pressure gauge 53.1403.10 11. Disconnect air-pressure gauge (99/7). 12. Screw tight oil filler plug (4100). Tightening torque oil filler plug (4100): 100 Nm (100 Nm) Attention! Risk of injury! The screwing of the air-pressure gauge and the retarder are hot! 99/7 11041 4100 11042 Notice Check sealing ring of oil filler plug (4100) for a possible damage, replace oil filler plug (4100), if necessary. Diagnosis / Troubleshooting Checking Control Current of Proportional Valve Diagnosis / Troubleshooting Checking Control Current of Proportional Valve Page 86 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4.7 Checking Control Current of Proportional Valve Requirements for check Battery voltag 24 - 28 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 Plug at proportional valve and socket checked for damage as well as wear (notch scratches) Electrical lead and plug-in connection checked (visual examination) and found satisfactory Special tool: Measuring adapter 99/3 Commercially available tool Multimeter Fluke 87 or 79 (otherwise possible differing in measurements!) Diagnosis / Troubleshooting Checking Control Current of Proportional Valve Diagnosis / Troubleshooting Checking Control Current of Proportional Valve Page 87 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Work scop check
98/8 Multimeter 99/3 Measuring adapter 53.8198.10 1. Disconnect plug at proportional valve (21) and connect with measuring adapter (99/3). 2. Connect plug of measuring adapter (99/3) with the proportional valve (21). 3. Connect the Multimeter (98/8). Switch position: mA. 4. Turn switch Propvalve at measuring adapter (99/3) in position I . 5. Shift the retarder stage switch in position 5 and compare the read-off value with the given values of the control current of the proportional valve in accordance with the tables see page 93 ff. 6. Disconnect plug of measuring adapter (99/3) and connect to the proportional valve (21) again. 11043 98/8 99/3 21 Diagnosis / Troubleshooting Checking Pressure Sensor Diagnosis / Troubleshooting Checking Pressure Sensor Page 88 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4.8 Checking Pressure Sensor Requirements for check Vehicle ignition OFF Connected pressure gauge constant-air pressure Retarder stage switch in position 0 Electrical lead and plug-in connection checked (visual examination) and found satisfactory Special tool: Measuring adapter 99/3 Commercially available tool Multimeter recommended: Fluke 87 Diagnosis / Troubleshooting Checking Pressure Sensor Diagnosis / Troubleshooting Checking Pressure Sensor Page 89 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Work scope check
98/8 Multimeter 99/3 Measuring adapter 53.8198.10 1. Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3). 2. Connect plug of measuring adapter (99/3) to pressure sensor (38). 3. Connect electrical lead ground of multimeter (98/8) to measuring socket 4 (ground) of adapter. 4. Turn switch Propvalve at measuring adapter (99/3) in position Propventil . 5. Now, switch on vehicle ignition! 6. Connect electrical lead positive of Multimeter (98/8) to measuring socket 1 (positive). 7. The measured voltage must be between 4,75 and 5,25 V.
8. Connect electrical lead positive of Multimeter (98/8) to measuring socket 2 (output). 9. Compare measured voltage in conjunction of constant-air pressure with values on page 93 ff. For the purpose of comparison a manometer "p y " must be parallelly installed (unless for pressure = 0 / Re- tarder OFF) see page 78 ff. 10. Switch-off vehicle ignition after measurements! 11. Reconnect after removing measuring adapter (99/3) the electrical lead to the pressure sensor. 11044 98/8 99/3 38 Notice If there is an error (wire or sensor), the supply voltage is switched off by the control unit. Check the wire or the sensor and replace the defect part, if necessary. Diagnosis / Troubleshooting Checking Temperature Adaption Diagnosis / Troubleshooting Checking Temperature Adaption Page 90 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4.9 Checking Temperature Adaption Requirements for check Battery voltage 24 - 28 V Vehicle ignition OFF Pressure gauge constant-air pressure connected 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 Electrical lead and plug-in connection checked (visual examination) and found satisfactory Special tool: Temperature simulator 99/2 Diagnosis / Troubleshooting Checking Temperature Adaption Diagnosis / Troubleshooting Checking Temperature Adaption Page 91 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
99/2 Temperature simulator 53.8207.10 Work scope check 1. Disconnect electrical lead cooling water (39) and electrical lead oil (40) to cooling-water tempera- ture-sensors (19) and oil (20) and connect these to the temperature simulator (99/2).
2. Set rotary switch of temperature simulator (99/2) to 95C cooling water temperature and 165C oil temperature. 3. Switch-on vehicle ignition! 4. Operate retarder at highest braking stage. Constant-air pressure (p y ) control current must reach values given on table on pages 93 ff. 5. Set the rotary switch of the temperature simulator (99/2) to 105 o C cooling water temperature. The constant-air pressure p y must drop below the set maximum pressure. Set rotary switch of temperature simulator (99/2) to 125 o C cooling water temperature. There must be no more output of constant-air pressure p y . 6. Set rotary switch of temperature simulator (99/2) again to 95 o C cooling water temperature. Wasser l 99/2 39 40 11045 Notice Pay attention to the correct connection of the plugs for water and oil. If the two sensors are too far away from each other, then these have to be checked separated. Diagnosis / Troubleshooting Checking Temperature Adaption Diagnosis / Troubleshooting Checking Temperature Adaption Page 92 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 7. Set rotary switch of temperature simulator (99/2) to 185 o C oil temperature. The constant-air pressure must drop below the set maximum pressure. 8. Set rotary switch of temperature simulator (99/2) to 225 o C oil temperature. There must be no more output of constant-air pressure p y . 9. Take measurement for resistance on both temperature sensors according table on page 93 ff. 10. Switch-off vehicle ignition! 11. Reconnect electrical connection lead cooling water (39) and electrical connection lead oil (40) to temperature sensors cooling water (19) and oil (20). Diagnosis / Troubleshooting Table of Measurements Diagnosis / Troubleshooting Table of Measurements Page 93 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4.10 Table of Measurements Digiprop without CAN With pressure sensor 1) Retarder stage switch in highest shift position! 2) The code-number is on the control unit. 3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!) 4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure). 5) The values are not steadily because of continuous control in the closed loop (however within the stated range). . Code-Number 2) OLD NEW Amperage control current mA 1) 3) 5) Constant-air pressure (p y ) (static) 4) 1) nominal value [bar] Pump pressure (dynamic) 1) v ps = 1000 r.p.m.
(minimum value) [bar] 038 138 396 - 596 2,05 - 2,35 18 050 150 365 - 565 1,60 - 1,90 13,5 051 151 379 - 579 1,80 - 2,10 15 052 152 396 - 596 2,05 - 2,35 17 053 153 423 - 623 2,45 - 2,75 20 055 155 396 - 596 2,05 - 2,35 17 057 157 409 - 609 2,25 - 2,55 18,5 058 158 409 - 609 2,25 - 2,55 18,5 079 179 440 - 640 2,70 - 3,00 22 080 180 440 - 640 2,70 - 3,00 22 Notice These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications. Diagnosis / Troubleshooting Table of Measurements Diagnosis / Troubleshooting Table of Measurements Page 94 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Digiprop with CAN With pressure sensor 1) Retarder stage switch in highest shift position! 2) The code-number is on the control unit. 3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!) 4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure). 5) The values are not steadily because of continuous control in the closed loop (however within the stated range).
. Code-Number 2) Amperage control current mA 1) 3) 5) Constant-air pressure (p y ) (static) 4) 1) nominal value [bar] Pump pressure (dynamic) 1) v ps = 1000 r.p.m.
(minimum value) [bar] 502 440 - 640 2,70 - 3,00 22 504 440 - 640 2,70 - 3,00 22 508 440 - 640 2,70 - 3,00 22 510 430 - 630 2,55 - 2,85 21 512 440 - 640 2,70 - 3,00 22 Notice These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications. Diagnosis / Troubleshooting Table of Measurements Diagnosis / Troubleshooting Table of Measurements Page 95 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Without pressure sensor / without CAN 1) Retarder stage switch in highest shift position! 2) The code-number is on the control unit. 3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!) 4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure). 5) The values are not steadily because of continuous control in the closed loop (however within the stated range).
Code-Number 2) OLD NEW Amperage control current mA 1) 3) 5) Constant-air pressure (p y ) (static) 4) 1) nominal value [bar] Pump pressure (dynamic) 1) v ps = 1000 r.p.m. (minimum value) [bar] 059 159 534 - 546 2,60 - 3,10 22 Notice These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications. Diagnosis / Troubleshooting Table of Measurements Diagnosis / Troubleshooting Table of Measurements Page 96 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 VERA DAFBUS 1) Retarder stage switch in highest shift position! 2) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!) 3) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure). 4) The values are not steadily because of continuous control in the closed loop (however within the stated range).
Serial-Number Amperage control current mA 1) 2) 4) Constant-air pressure (p y ) (static) 3) 1) nominal value [bar] Pump pressure (dynamic) 1) v ps = 1000 r.p.m. (minimum value) [bar] H67.276320 440 - 640 2,70 - 3,00 22 Notice These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications. Diagnosis / Troubleshooting Table of Measurements Diagnosis / Troubleshooting Table of Measurements Page 97 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Voltage measurement at the pressure sensor
Notice These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications. 0 1 2 3 4 5 0,5 1,5 2,5 3,5 4,5 0 0,5 1 1,5 2 2,5 3 3,5 4 [ BAR ] [ V ] 11046 Diagnosis / Troubleshooting Table of Measurements Diagnosis / Troubleshooting Table of Measurements Page 98 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Resistance measuring at the temperature sensor
Temperature Resistor 20C 10 C 1039 - 1117 60C 10 C 1194 - 1271 80C 10 C 1271 - 1347 Notice The measuring in one temperature area normally is sufficient. These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications. Removing, Installing Retarder Removing, Installing Retarder Page 99 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 5. Removing, Installing Retarder Removing, Installing Retarder Page 100 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Removing, Installing Retarder
Illustration: Removing, installing retarder Prior work Cooling water drained * Oil drained of retarder (see page 26) Propeller shaft at the gearing flange removed * Oil drained of gearbox * Waterneck removed (see page 123) Speedometer sensor removed * Output shaft-flange removed * * Notice the information of the vehicle manufacturer
25100 25000 850 25300 25300 4100 25200 25200 850/1 11047 Notice The shim must always be determined newly, if: taper roller bearing (800) is renewed Retarder is installed at gearbox Retarder was repaired Gearbox was repaired 850/1 Taper roller bearing 850 Outer race Only removing, if the tapered roller bearing is replaced or a new shim enclosed 4100 Screw plug M 30 x 1,5 Inhex-head w.a.f. 17 100 Nm (100 Nm) 25000 Shim 25100 O-Ring, renewed coat with silicone-free and non-corrosive grease for installation 25200 Hex.-head screw M 10 x 70 Hex head w.a.f. 16 58 Nm 25300 Hex.-head screw M 10 x 60 Hex head w.a.f. 16 58 Nm Removing, Installing Retarder Removing, Installing Retarder Page 101 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Special tools: Tool for local fabrication Measuring device Drive in tool Puller Threaded bolt Bearing outer ring Bearing outer ring 98/1 98/3 98/4
Sealants and lubricants O-Ring Silicone-free and non-corrosive grease Retarder housing Omnifit FD 10-1042 67.3224.10 67.3319.10 FJ 6280 0 486 265 67.3320.10 15 80 M 1 0 28028e Material: St37-2, DIN 17100 (1.80) Removing, Installing Retarder Removing, Installing Retarder Page 102 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Removing 1. Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove with appropiate lifting device retarder from gearbox. Achtung! Two version of the screw plugs (4100) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the inspection of oil level; replace completely if necessary. B) Version with loose inserted copper-sealing ring. In this Aftersales Workshop Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings have to be renewed in general. 25300 11049 25200 25200 4100 Removing, Installing Retarder Removing, Installing Retarder Page 103 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
98/4 Puller bearing outer ring 67.3320.10 2. Remove O-Ring (25100) from gearbox.
3. Pull off outer ring (850) with puller bearing outer ring (98/4) and remove shim (25000). 11050 850 25000 98/4 25100 F J 6 2 8 0 0 4 8 6 2 6 5 Notice Carry out following working step, if: - taper roller bearing (800) is renewed - Retarder is installed at gearbox - Retarder was repaired - Gearbox was repaired Removing, Installing Retarder Removing, Installing Retarder Page 104 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Assembling 1. Determine thickness of shim as follows:
1.1 Measure the distance "B" between bearing surface on retarder side of the gearbox and the bearing surface of the shim and note value. Notice The shim must always be determined newly, if: taper roller bearing (800) is renewed Retarder is installed at gearbox Retarder was repaired Gearbox was repaired 11051 B Attention! The measurings described below may only carried out at ambient temperature and with the retarder in vertical position (see illustration)! Removing, Installing Retarder Removing, Installing Retarder Page 105 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 1.2 Put the bearing outer ring (850) on the taper roller bearing (850/1).
98/1 Measuring device 67.3224.10 1.3 Put measuring device (98/1) on gearbox and tighten hex.-head screws handtight (3 Nm). 1.4 Put the lever from position 1 in position 2 to pressurize the drive shaft with a defined preload of approx. 400 N. 1.5 Turn the pinion by hand 15 times clockwise and after that 15 times counterclockwise. 850 850/1 11052 98/1 Pos.1 Pos. 2 11053 Removing, Installing Retarder Removing, Installing Retarder Page 106 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 1.6 Set the vernier depth gauge on gearbox seperation area and zero vernier depth gauge. 1.7 Put vernier depth gauge on the measuring area of the measuring plate. 1.8 Measure distance of measuring area of the measuring plate to seperation area of the retarder housing and note value "A". 1.9 Determine thickness of shim as follows: Thickness of shim = dimension B minus dimension A minus 0,02mm 11054 11055 Removing, Installing Retarder Removing, Installing Retarder Page 107 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
98/3 Drive in tool 67.3319.10 2. Put shim (25000) into the gearbox housing (if removed).
3. Insert bearing outer ring (850 if removed) into the gearbox housing and knock this with the drive in tool (98/3) in as far as possible. Notice The thicker shim must always be placed first in the gearbox housing. 11056 850 25000 98/3 Notice If taper roller bearing was replaced, also replace the bearing outer ring (850). Notice If necessary warm housing for the simpler assembly in the area of the bearing outer ring to approx. 80C. Removing, Installing Retarder Removing, Installing Retarder Page 108 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4. Clean sealing surface of retarder housing (1). 5. Turn gearbox till the sealing surface points up (gearing stands vertically). 6. Clean sealing surface of gearbox housing and coat with sealant Loctite 5203. 7. Coat O-Ring (25100) with silicon free and non-corrosive grease and place in gearbox. 8. Turn two threaded bolts M 10 x 80 (see arrows) into the gerarbox housing . The threaded bolts are needed so that the sealing surfaces (gearbox/retarder) can be assembled congruently. 11057 1 11058 25100 Removing, Installing Retarder Removing, Installing Retarder Page 109 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 9. Place retarder at gearbox and fix this with 5 hex.-head screws (25200). Tightening torque hex.-head screws (25200): 58 Nm 10. Screw out again the two threaded bolts M 10 x 80. 11. Insert the 17 hex.-head screws (25300) and tighten them. Tightening torque hex.-head screws (25300): 58 Nm 25200 25200 25200 25300 11059 Repair Retarder Repair Retarder Page 110 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 6. Repair Retarder 6.1 Overall Illustration of Main Components ...................................................111 6.2 Removing, Checking and Installing Casing Ventilation.............................112 6.3 Removing, Checking and Installing Silencer.............................................122 6.4 Removing and Installing Water Neck........................................................123 6.5 Removing, Checking and Installing Heat Exchanger................................124 6.6 Removing and Installing Oil Tank Cover...................................................133 6.7 Removing, Installing Non-Return Valve Outlet .........................................136 Repair Retarder Overall Illustration of Main Components Repair Retarder Overall Illustration of Main Components Page 111 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 6.1 Overall Illustration of Main Components Illustration: Components Retarder 115 E 4200 3100 2500 2600 107 7500 6101 6100 6101 9000 4100 3900 2900 5500 3700 4000 103 6600 5200 5300 3300 3300 2800 5400 5600 5300 5200 109 7300 7300 7600 7500 3100 2000 8000 6400 20100 20000 20200 6600 6600 20000 20200 20100 4100 2300/1 2301 2300 2300/2 2300/3 3500 3800 3850 3850 6700 6700 2100 2105 2106 1700 1600 3100 2810 20300 20400 6700 11060 100 20300 20400 100 Retarder housing 103 Screw plug M12 x 1,5, inhex-head, w.a.f. 6 107 Oil drain plug Retarder M 24 x 1,5, inhex.-head, w.a.f. 12 109 Screw plug M 24 x 1,5, inhex.-head, w.a.f. 12 1600 Valve cover 1700 O-Ring 60 x 3 2000 Top cover 2100 Non-return valve outlet, complete 2105 O-Ring, 34 x 3 2106 O-Ring, 54 x 3 2300 Casing ventilation 2300/1 Valve insert 2300/2 Float 2300/3 Float cage 2301 O-Ring 55 x 3 2500 Bottom cover 2600 Bottom gasket 2800 Cover for casing ventilation 2810 Vent and air filter M 12 x 1,5, hex.-head, w.a.f. 17 2900 Gasket 3100 Combined hex.-head screw M 8 x 30, hex.-head, w.a.f. 13 3300 Combined hex.-head screw M 8 x 80, hex.-head, w.a.f. 13 3500 Screw plug with sieve, M 30 x 1,5, inhex.-head, w.a.f. 17 3700 Proportional valve 3800 Damping plate 3850 O-Ring 16 x 3 3900 Combined hex.-head screw M 8 x 20, hex.-head, w.a.f. 13 4000 Hex.-head nut M8, hex.-head, w.a.f. 13 4100 Screw plug M 30 x 1,5, inhex.-head, w.a.f. 17 4200 Screw plug M 24 x 1,5, inhex.-head, w.a.f. 12 5200 Temperature sensor 5300 Sealing ring A 14 x 20 5400 Corrugated spring 5500 Disc (silencer) D 30 x 4 5600 Retaining ring JL 30 x 1,2 6100 Pipe 6101 O-Ring 15,3 x 2,4 6400 Heat exchanger 6600 Hex.-head screw M 14 x 45, hex.-head, w.a.f. 22 old: hex.-head screw with flange M 14 x 40, hex.-head, w.a.f. 19 6700 Washer A15 7300 O-Ring 15 x 4 7500 O-Ring 45 x 5 7600 O-Ring 25 x 4 8000 Intermdiate plate 196 x 144 x 2 9000 Pressure sensor 0 to 4 bar 20000 Water neck 20100 Gasket, renew 20200 Combined hex.-head screw M 8 x 80, hex.-head, w.a.f. 13 20300 Screw plug M 14 x 1,5, hex.-head, w.a.f. 13 20400 Sealing ring A 14 x20 Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 112 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 6.2 Removing, Checking and Installing Casing Ventilation
Prior jobs Vehicle ignition switched off Retarder switched off Proportional valve and damping plate removed (see page 140) Notice This working step can be performed with retarder removed or installed. Attention! Risk of injury! Retarder housing is hot! Repair Retarder Removing, Checking and Installing Casing Ventilation Page 113 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Repair Retarder Removing, Checking and Installing Casing Ventilation
Illustration: Casing ventilation
11061 2300/1 2900 2800 3300 2301 2300 2300/2 2300/3 6101 6100 6101 2300 Casing ventilation 2300/1 Valve insert 2300/2 Float desired weight 11g 1 g 2300/3 Float cage 2301 O-Ring 55 x 3, renew, coat with silicon-free and non- corrosive grease for installation 2800 Cover casing ventilation 2900 Gasket casing ventilation, renew 3300 Combined hex.-head screw M 8 x 80, renew hex.-head, w.a.f. 13, 30 Nm 6100 Air-pipe coat with silicon-free and non- corrosive grease for installation 6101 O-Ring 15,2 x 2,4, erneuern coat with silicon-free and non- corrosive grease for installation sealant and lubricant O-Ring silicon-free and non-corrosive grease Float Methylated spirit Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 114 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Special tools: Tool for local fabrication Impact puller Adapter Test ring 99/5 98/7 99/7
Notice The test ring also can be ordered with Voith item-number 67.2757.10 at Voith Turbo GmbH&Co. KG. 40,5 mm
7
m m 60 mm 28049e Material: St 37 Weight: 0,085 kg Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 115 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Removing 1. Screw out combined hex.-head screws (3300). 2. Remove cover (2800) with gasket (2900) from retarder housing. Clean sealing surface. 3300 11063 11064 2900 2800 Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 116 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 3. Remove air-pipe (6100) and O-Rings (6101).
99/5 Impact puller 53.7712.10 98/7 Adapter 53.9428.10 4. Use impact puller (99/5) and adapter (98/7) to extract valve insert of retarder housing (100). 11065 6101 6100 6101 11066 99/5 100 98/7 Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 117 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 5. Take float (2300/2) and float cage (2300/3) out of retarder housing (100). 6. Lever out O-Ring (2301) of groove of valve insert (2300/1) and remove this. 2300/2 2300/3 11067 100 11068 2300/1 2301 Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 118 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Checking 1. Check float (2300/2) on damages of surfaces and sealing surfaces (arrow). 2. Weigh float (2300/2). The desired weight is 11 g 1 g. If the weight is more than the desired weight renew complete casing ventilation.
99/7 Test ring 67.2757.10 3. Check sealing edge of radial shaft sealing ring (arrow) in valve insert (2300/1). Put down valve insert (2300/1) on float (2300/2) than weigh down valve insert with test ring (99/7). Fill up the hollow space between float and upper edge of valve insert with methylated spirit. If the sealing edge is not damaged, the fluid level must not alter in the course of 1 minute. If necessary, renew complete casing ventilation. 2300/2 11069 Notice Oil has penetrated into the float, the retarder is impaired in its operation. 2300/2 2300/1 99/7 11070 Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 119 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Installing 1. Coat new O-ring (2301) with silicon-free and non-corrosive grease and pull on valve insert (2300/1). 2. Insert float (2300/2) and float cage (2300/3) in valve insert (2300/1). 11071 2300/1 2301 2300/1 2300/2 2300/3 11072 Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 120 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
99/5 Impact puller 53.7712.10 98/7 Adapter 53.9428.10 3. Coat bore of casingventilation in retarder housing (100) with silicon-free and non-corrosive grease. 4. Insert casing ventilation in retarder housing (100). 5. Use the impact puller (99/5) and adapter (98/9) to knock in the casing ventilation. 6. Coat new O-rings (6101) with silicon-free and non-corrosive grease and pull over air-pipe (6100). 7. Coat bore for air-pipe (6100) in cover (2000) with silicon-free and non-corrosive grease. 8. Slip air-pipe (6100) in to the cover (2000). 11073 99/5 100 98/7 6100 2000 11074 6101 Repair Retarder Removing, Checking and Installing Casing Ventilation Repair Retarder Removing, Checking and Installing Casing Ventilation Page 121 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 9. Place new gasket (2900) on retarder housing. 10. Coat bore for air-pipe (6100) in cover (2800) with silicon-free and non-corrosive grease. 11. Slip cover (2800) in air-pipe (6100) and place this at retarder housing. 12. Screw in combined hex.-head screws (3300) and screw them tight. Tightening torque combined hex.-head screw (3300): 30 Nm. 11075 2900 2800 3300 6100 11076 Repair Retarder Removing, Cleaning and Installing Silencer Page 122 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Repair Retarder Removing, Cleaning and Installing Silencer
Illustration: Silencer 6.3 Removing, Cleaning and Installing Silencer
Cleaning agent Kd.-Sach-Nr. Voith-Sach-Nr. 5500 5400 5600 11077 Notice This work step can be performed with retarder installed or removed. 5400 Corrugated spring 5500 Disc (silencer) D 30 x 4, clean with appropriate cle- aning agent (Benzine) and blow out with compressed-air 5600 Circlip JL 30 x 1,2 dished side must face silencer Silencer Benzine Repair Retarder Removing and Installing Water Neck Page 123 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Repair Retarder Removing and Installing Water Neck
Illustration: Water neck 6.4 Removing and Installing Water Neck Prior jobs Vehicle ignition OFF Retarder switched off Cooling water drained
11078 20100 20000 20000 20200 20200 20100 Kd.-Sach-Nr. Voith-Sach-Nr. 20000 Water neck 20100 Gasket, renew 20200 Combined hex.-head screw M 8 x 80 hex.-head, w.a.f. 13, 30 Nm Repair Retarder Removing, Checking, Installing Heat Exchanger Repair Retarder Removing, Checking, Installing Heat Exchanger Page 124 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 6.5 Removing, Checking, Installing Heat Exchanger Prior jobs Vehicle ignition OFF Retarder removed (see page 99) With installed retarder: Oil drained from retarder (see page 26 ff) Cooling water drained Water neck removed (see page 123) Notice If necessary, the heat exchanger can be removed also with mounted retarder. Attention! The heat exchanger must be secured before removing with appropriate parts! Notice A throttle disk can be installed between heat exchanger and housing at retarder with ending number .10 in the type plate. This must be removed. In connection with this, the retarder control unit has to be progammed on the latest for this retarder valid code and the non-return valve (outlet) must be installed as of code number 67.2550.22. Repair Retarder Removing, Checking, Installing Heat Exchanger Page 125 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Repair Retarder Removing, Checking, Installing Heat Exchanger
Illustration: Removing heat exchanger
Lubricant 4200 11079 107 4200 7300 7300 7600 7500 7500 6400 6600 6600 6700 6700 107 Oil drain plug retarder M 24 x 1,5, inhex.-head, w.a.f. 12, 47 Nm (80 Nm) 4200 Oil drain plug oil tank M 24 x 1,5, inhex.-head, w.a.f. 12, 47 Nm (80 Nm) 6400 Heat exchanger 6600 Hex.-head screw M 14 x 45, renew hex.-head, w.a.f. 22, Pre-torque: 50 Nm Final torque: 30turning angle old version: hex.-head screw M14 x 40 with flange, hex.-head, w.a.f. 19 6700 Washer A15 7300 O-ring 15 x 4, renew coat with silicon-free and non- corrosive grease for installation 7500 O-ring 45 x 5, renew coat with silicon-free and non- corrosive grease for installation 7600 O-ring 25 x 4, renew coat with silicon-free and non- corrosive grease for installation O-rings silicon-free and non-corrosive grease Repair Retarder Removing, Checking, Installing Heat Exchanger Repair Retarder Removing, Checking, Installing Heat Exchanger Page 126 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Attention! Two versions of screw plugs (107, 4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the installation of the heat exchanger; replace complete screw plug if necessary. B) Version with loose inserted copper-sealing ring. In this Aftersales Service Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings are generally to be renew. Repair Retarder Removing, Checking, Installing Heat Exchanger Repair Retarder Removing, Checking, Installing Heat Exchanger Page 127 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Special tool Pressure test plate 99/6
Commercially available tool Turning angle measuring tool 3/4 e.g. Messrs Richard Abr. Herder Post box 10 08 67 D-42659 Solingen Tel. 0212/ 888-0 Ordering No. 8200-02 67.1948.10 Repair Retarder Removing, Checking, Installing Heat Exchanger Repair Retarder Removing, Checking, Installing Heat Exchanger Page 128 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 4200 107 4200 11080 Notice If this work sequence is performed with the retarder in situ, the following prior jobs must be performed: 1. Screw out oil-drain plugs (107 and 4200) as well as the oil filler plug (for quicker drain) and drain oil. 2. Shut, if available, the stopcocks in the cooling-water circuit of the vehicle. 3. Remove the cooling water hoses of the heat exchanger. Repair Retarder Removing, Checking, Installing Heat Exchanger Repair Retarder Removing, Checking, Installing Heat Exchanger Page 129 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Removing 1. Screw out hte four hex.-head screws (6600) and remove washers (6700). 2. Remove heat exchanger (6400). 3. Remove O-rings (7300, 7500 and 7600). 11081 6400 6600 6600 6600 6700 6700 6700 11082 7300 7500 7300 7600 7500 7300 Repair Retarder Removing, Checking, Installing Heat Exchanger Repair Retarder Removing, Checking, Installing Heat Exchanger Page 130 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Checking
99/6 Pressure test plate 67.1948.10 1. Install pressure test plate (99/6) with O-rings at heat exchanger (6400) and connect compressd-air pressure lines to bottom connection (arrow). 2. Fill heat exchanger (6400) on water side with hot water (approx. 70 o C). 3. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the heat exchanger).
99/6 Pressure test plate 67.1948.10 4. Connect compressed-air line to top connection (arrow). 5. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the heat exchanger).
99/6 6400 11083 Notice If air bubbles form in the hot water the heat exchanger is leaking and must be exchanged. 99/6 6400 11084 Notice If air bubbles form in the hot water the heat exchanger is leaking and must be exchanged. New heat exchanger are wetted with corrosion-inhibiting oil in the water- and oil section of the heat exchanger. Prior to installing a new heat exchanger, drain any corrosion-inhibiting oil which may have collected and flush it out with hot water in the water section of the heat exchanger. Repair Retarder Removing, Checking, Installing Heat Exchanger Repair Retarder Removing, Checking, Installing Heat Exchanger Page 131 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Installing 1. Fit new O-rings (7300, 7500 and 7600) in the bores and coat them with silicon-free and non-corrosive grease. 2. Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) with washers (6700) tight. Initial torque: 50 Nm Final torque: 30turning angle 11085 7300 7300 7500 7500 7300 7600 11086 6400 6600 6600 6600 6700 6700 6700 Repair Retarder Removing, Checking, Installing Heat Exchanger Repair Retarder Removing, Checking, Installing Heat Exchanger Page 132 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 3. Install retarder, if necessary (see page 99 ff). 4. Fill in cooling-water and bleed cooling-water circuit. If available, open the check valves in the flow- and return pipe of the cooling-water section.
5. Flush the retarder, if the heat exchanger has leaked as follows: To flush the retarder, fill it with 7,0 litres of engine- or flushing oil. Apply the brakes gently several times to flush out the retarder system and drain the oil through the oil drain plugs (107 and 4200). Repeat the procedure 2 or 3 times. 6. Check integrated sealing rings of oil-drain plugs for possible damages; renew oil-drain plug if necessary. 7. Screw oil-drain plug (107, 4200) tight Tightening torque oil-drain plug (107, 4200): 47 Nm (80 Nm) 8. Fill in retarder oil (see page 29). 9. If heat exchanger were leaking, deoil cooling- and heatingsystem of vehicle according manufacturer instructions. Attention! If the heat exchanger leaks, there is water present in the retarder. If the retarder is filled up, a mixture of oil and water is created, causing the oil in the retarder to foam and escape through the casing ventilation system to the atmosphere. For this reason, it is indispensible to flush out the retarder after repair! While flushing, apply the brake gently several times to prevent the retarder oil warming up excessively. 4200 107 4200 11087 Repair Retarder Removing, Installing Oil Tank Cover Page 133 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Repair Retarder - Removing, Installing Oil Tank Cover
Illustration: Top Oil Tank Cover 6.6 Removing, Installing Oil Tank Cover A) Top Oil Tank Cover Prior jobs Vehicle ignition switched OFF Retarder switched off Lubricant 6101 6100 6101 8000 2000 9000 3300 3100 11088 Notice This working step can be performed with retarder removed or installed.. Attention! Risk of injury! The retarder housing is hot! 2000 Top cover 3100 Combined hex.-head screw M 8 x 30, renew hex.-head, w.a.f. 13 30 Nm 3300 Combined hex.-head screw M 8 x 80, renew inhex.-head, w.a.f. 13 30 Nm 6100 Air-pipe 6101 O-Ring 15,3 x 2,4, renew coat with silicon-free and non-corrosive grease for installation 8000 Intermediate plate, renew 9000 Pressure sensor O-ring Silicon-free and non-corrosive grease Repair Retarder Removing, Installing Oil Tank Cover Page 134 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Repair Retarder Removing, Installing Oil Tank Cover
Illustration: Bottom Oil Tank Cover B) Bottom Oil Tank Cover Prior jobs Vehicle ignition switched OFF Retarder switched off Retarder oil drained (see page 26 ff)
11089 4200 3100 2500 2600 2500 Bottom cover 2600 Bottom gasket, renew 3100 Combined hex.-head screw M 8 x 30, renew, hex.-head, w.a.f. 13, Heed tightening sequence! 30 Nm 4200 Oil drain plug oil tank M 24 x 1,5 inhex.-head, w.a.f. 12 47 Nm (80 Nm) Repair Retarder Removing, Installing Oil Tank Cover Repair Retarder Removing, Installing Oil Tank Cover Seite 135 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Installation note Pay attention to the mounting position of the gasket and the cover! Tighten all combined-hex.-head screws in specified sequence 1 to 17 first with 14 to 19 Nm. The combined-hex.-head screws are then tightened in the same sequence with 30 Nm. Attention! Two versions of screw plugs (4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the installation of the heat exchanger; replace complete screw plug if necessary. B) Version with loose inserted copper-sealing ring. In this Aftersales Service Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings are generally to be renew. 12 13 14 15 16 7 4 3 2 1 5 6 7 8 9 10 11 11090 Repair Retarder Removing, Installing Non-Return Valve (Outlet) Page 136 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Repair Retarder Removing, Installing Non-Return Valve (Outlet)
Illustration: Non-Return Valve (Outlet) 6.7 Removing, Installing Non-Return Valve (Outlet) Prior job Retarder oil drained (see page 26 ff) 11091 2105 2106 1700 1600 3100 2100 Kd.-Sach-Nr. Voith-Sach-Nr. 1600 Valve cover Heed mounting position! 1700 O-ring 60 x 3, renew, coat with silicon-free and non-corrosive grease for installation 2100 Non-return valve (outlet) Heed mounting position! coat bore with silicon-free and non-corrosive grease for installation 2105 O-ring 34 x 3, renew, coat with silicon-free and non-corrosive grease for installation 2106 O-ring 54 x 3, renew, coat with silicon-free and non-corrosive grease for installation 3100 Combined hex.-head screw M 8 x 30 hex.-head, w.a.f. 13 30 Nm Lubricant O-ring Silicon-free and non-corrosive grease Repair Retarder Removing, Installing Non-Return Valve (Outlet) Repair Retarder - Removing, Installing Non-Return Valve (Outlet) Page 137 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Special tool Puller non-return valve (outlet) 71/1 153.00005210 Repair Retarder Removing, Installing Non-Return Valve (Outlet) Repair Retarder Removing, Installing Non-Return Valve (Outlet) Page 138 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Removing 1. Screw out combined hex.-head screws (3100) of valve cover (1600). 2. Remove valve cover (1600).
71/1 Puller 3. Position puller (71/1) up to engaging to torque limiter valve and pull out non-return valve of its seat. 4. Remove O-rings (1700, 2106 and 2105). Installing 1. Install non-return valve in reverse sequence. 11092 71/1 Control Parts Control Parts Page 139 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 7. Control Parts 7.1 Removing, Installing Proportional Valve and Damping Plate....................140 7.2 Removing, Installing Temperature Sensor Cooling Water........................141 7.3 Removing, Installing Temperature Sensor Oil ..........................................142 7.4 Removing, Installing Pressure Sensor......................................................143 Control Parts Removing, Installing Proportional Valve and Damping Plate Page 140 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Control Parts Removing, Installing Proportional Valve and Damping Plate
Illustration: Proportional Valve and Damping Plate 7.1 Removing, Installing Proportional Valve and Damping Plate Prior jobs Vehicle ignition switched off Retarder switched off Supply-air pressure discharged Plug at the proportional valve as well as connector checked for damage or wear (notch- es). Lunbricant 11093 26 39 3900 4000 3800 3900 3700 4000 3850 3850 26 Compressed-air line p v 39 Electrical connection lead 3700 Proportional valve 3800 Damping plate, renew if necessary 3850 O-ring 16 x 3, renew coat with silicon-free and non-corrosive grease for installation 3900 Hex.-head screw M 8 x 20, renew, hex.-head, w.a.f. 13, 30 Nm 4000 Hex.-had nut M8, renew, 18 Nm Achtung If, during repair work the hex.-head nuts (4000) or the hex.-head screws (3900) have to be unscrewed the damping plate also has to be checked on mechanical and aging dama- ges and to be renewed, if necessary. O-ring Silicon-free and non-corrosive grease Control Parts Removing, Installing Temperature Sensor Cooling Water Page 141 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Control Parts Removing, Installing Temperature Sensor Cooling Water
Illustration: Temperature Sensor Cooling Water 7.2 Removing, Installing Temperature Sensor Cooling Water Prior jobs Vehicle ignition switched off Retarder switched off Cooling water drained
5300 5200 1109 5200 Temperature sensor cooling water, 28 Nm 5300 Sealing ring A14 x 20, renew Attention! Risk of injury! The cooling water is hot! Notice Please, bear in mind to the instructions regarding the quality of coolant given from the vehicle manufacturer or Voith Turbo cooling- water quality list (Voith Item-No. 67.2224.10). Control Parts Removing, Installing Temperature Sensor Oil Page 142 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Control Parts Removing, Installing Temperature Sensor Oil
Illustration: Temperature Sensor Oil 7.3 Removing, Installing Temperature Sensor Oil Prior jobs Vehicle ignition switched off Retarder switched off
5300 5200 11095 5200 Temperature sensor Oil, 28 Nm 5300 Sealing ring A14 x 20, renew Control Parts Removing, Installing Pressure Sensor Page 143 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 Control Parts Removing, Installing Pressure Sensor
Illustration: Pressure Sensor 7.4 Removing, Installing Pressure Sensor Prior jobs Vehicle ignition switched off Retarder switched off
9000 11096 9000 Pressure sensor, 30 Nm Appendix Appendix Page 144 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 8. Appendix 8.1 Retarder Data Sheet .................................................................................145 8.2 Tightening Torques...................................................................................146 Appendix Retarder Data Sheet Appendix Retarder Data Sheet Page 145 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 8.1 Retarder Data Sheet * dependent from the retarder and vehicle configuration Data Sheet Voith Retarder 115 E Max. possible braking torque at prop shaft M (Br) max at retarder ratio 1:2.03 * 3700 Nm Maximum Retarder Speed n max. = 4800 min -1 at v ps = 2365 min -1 Working Medium Oil according Operating Specification Control Medium Compressed-Air Supply-Air Pressure 7 to 10 bar Service filling:
- Service filling (Oil change, inspection of oil level)
- after exchange of heat exchanger
7,0 Litre
7,5 Litre Weight of unit (with het exchanger unit and service filling) approx. 73 kg Appendix Tightening Torques Appendix Tightening Torques Page 146 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11 8.2 Tightening Torques Pos.-No.: Title Dimensions Tightening torque 103 Screw plug M 12 x 1,5, Inhex.-head, w.a.f. 6 With integrated sealing ring: 13 Nm With a loose sealing ring: 20 Nm 105 Screw plug M 22 x 1,5, Inhex.-head, w.a.f. 10 With integrated sealing ring: 35 Nm With a loose sealing ring: 70 Nm 107 Oil drain plug M 24 x 1,5, Inhex.-head, w.a.f. 12 With integrated sealing ring: 47 Nm With a loose sealing ring: 80 Nm 1400 Dodecagonal nut M 38 x 1,5, w.a.f. 55 426 Nm 2810 Vent and air filter M 12 x 1,5, w.a.f. 17 10 Nm 3100 Combined hex.-head screw M 8 x 30, Hex.-head, w.a.f. 13 30 Nm 3300 Combined hex.-head screw M 8 x 80, Hex.-head, w.a.f. 13 30 Nm 3400 Dowel screw M 14 x 48, Hex.-head, w.a.f. 19 Initial torque: 50 Nm Final torque: 30turning angle 3500 Screw plug with sieve M 30 x 1,5, Inhex.-head, w.a.f. 17 With integrated sealing ring: 100 Nm With a loose sealing ring: 100 Nm 3900 Combined hex.-head screw M 8 x 20, Hex.-head, w.a.f. 13 30 Nm 4000 Hex.-head nut M 8, w.a.f. 13 18 Nm 4100 Oil filler plug / screw plug M 30 x 1,5, Inhex.-head, w.a.f. 17 With integrated sealing ring: 100 Nm With a loose sealing ring: 100 Nm 4200 Oil drain plug M 24 x 1,5, Inhex.-head, w.a.f. 12 With integrated sealing ring: 47 Nm With a loose sealing ring: 80 Nm Appendix Tightening Torques Appendix Tightening Torques Page 147 Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
Pos.-Nr.: Bezeichnung Abmessungen Anziehdrehmoment 5200 Temperature sensor oil / water M 14 x 1,5, Hex.-head, w.a.f. 21 28 Nm with copper sealing ring 6600 Combined hex.-head screw M 14 x 45, Hex.-head, w.a.f. 22 Initial Torque: 50 Nm Final torque: 30turning angle 9000 Pressure sensor M 16 x 1,5, Hex.-head, w.a.f. 27 30 Nm 20200 Combined hex.-head screw M 8 x 80, Hex.-head, w.a.f. 13 30 Nm 20300 Screx plug M 14 x 1,5, Hex.-head, w.a.f. 13 32 Nm 25200 Hex.-head screw M 10 x 70, Hex.-head, w.a.f. 16 58 Nm 25300 Hex.-head screw M 10 x 60, Hex.-head, w.a.f. 16 58 Nm