Professional Documents
Culture Documents
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
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
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.
• 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.
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.
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.
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:
Direct dials:
Customer service line and spare parts:
32-401
32-422
32-1860
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
6400
100
11001
Illustration: Voith Retarder R115 E
5500/1
103 Screw plug
M 12 x 1,5
107 Oil drain plug 3700
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 3500
5500/1 Ventilation
6400 Heat exchanger
103
6400
107
4200
11002
Illustration: Voith Retarder 115 E
a) Type of Retarder
b) Serial number a b
6-digit number
c) Year of manufacturing
d) Retarder ratio (iRet)
e) Customer-item number
Type R 115 E
f) Voith-item number
8-digit number Serial No
Year of Man. c
d
Cust. item No
Voith-item-No
Notice Kd.
Voi
-S
ac
-S
th
h-
ac
h-
Nr.
Nr.
11003e
Illustration: Retarder Data Plate
Aftersales Service Manual Voith Retarder 115 E General – Retarder Data Plate
15300009710 / cbtsd 02-11 Page 12
General – Data Plate of Retarder-Control
1. Basic-number
8-digit number
The last two digits show the
software version. Ba
s
Co is-N
Example: .12 = version 1.2 Se de-N r.:
rie r.:
VO n- 53
IT Nr.
2. Code-number H : .
xx xxxx
x .12
xx
3-digit number xx
/
Notice Basic-No.:
Please, always quote the retarder data and
Code-No.:
retarder control unit data when submitting Serial-No.:
queries or ordering spare parts. VOITH
In this case a quick and working is possible.
11004e
Aftersales Service Manual Voith Retarder 115 E General – Data Plate of Retarder-Control
15300009710 / cbtsd 02-11 Page 13
General – Data Plate of Retarder-Control
Unit VERA
0
*0
84
20 *
54
5/
*9
information:
45
/2
TD
2
*7
e1
.S
RA 1
E - 0
V 08 3
it 2- X
1. Serial-number U n 200
l
t ro / 2 0
n X 3. 2
Co XX 76 X
4-digit number / date er .
X .2
7
r d No 6
t a ia l- o . . 1
e
R e r rt -N - N o X
2. Spare-part-number S a M
P E
BO
O
UR
8-digit number
T
H
IT
VO
3. OEM-number
Notice
VOITH T URBO
e1*72/245*95/54*2084*00
Serial-No. XXXX / 2002-08-01
Part-No. 67.2763.20
OEM-No.
X1 X2 X3
11005
Aftersales Service Manual Voith Retarder 115 E General – Data Plate of Retarder-Control
15300009710 / cbtsd 02-11 Page 14
General – Function- and Operation Scheme
26 A R
42 21
23 72
36
25
20
1/1 1 1/2
63
Vehicle
electronic
19
46
22
44
62
64
43
55 41
11006e
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.
Aftersales Service Manual Voith Retarder 115 E General - Function- and Operation Scheme
15300009710 / cbtsd 02-11 Page 15
General – Function- and Operation Scheme
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.
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.
Aftersales Service Manual Voith Retarder 115 E General – Function- and Operation Scheme
15300009710 / cbtsd 02-11 Page 16
General – Function- and Operation Scheme
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.
The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder.
Aftersales Service Manual Voith Retarder 115 E General – Function- and Operation Scheme
15300009710 / cbtsd 02-11 Page 17
General – Function- and Operation Scheme
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.
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.
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.
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.
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.
Aftersales Service Manual Voith Retarder 115 E General – Function- and Operation Scheme
15300009710 / cbtsd 02-11 Page 18
Maintenance
3. Maintenance
3.1 Maintenance Work / Oil Change Intervals ..................................................20
3.2 Inspection of Oil Level.................................................................................23
3.3 Oil Change ..................................................................................................26
Please note the following data into the service overview of the Operation Manual
„Gearbox-Retarder-System / GO170 - GO210 with R 115 E”:
Aftersales Service Manual Voith Retarder 115 E Maintenance – Maintenance Work / Oil Change Intervals
15300009710 / cbtsd 02-11 Page 20
Maintenance – Maintenance Work / Oil Change Intervals
Classification let- HD HC HC
ter
to DIN 51502
Please take into account the oil recommendation list (Voith code number 67.2246.11).
Aftersales Service Manual Voith Retarder 115 E Maintenance – Maintenance Work / Oil Change Intervals
15300009710 / cbtsd 02-11 Page 21
Maintenance – Maintenance Work / Oil Change Intervals
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.
Aftersales Service Manual Voith Retarder 115 E Maintenance – Maintenance Work / Oil Change Intervals
15300009710 / cbtsd 02-11 Page 22
Maintenance – 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.
Aftersales Service Manual Voith Retarder 115 E Maintenance – Inspection of Oil Level
15300009710 / cbtsd 02-11 Page 23
Maintenance – Inspection of Oil Level
Work scope
107
1. Push a clean vessel under retarder.
4200 11007
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)!
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.
Aftersales Service Manual Voith Retarder 115 E Maintenance – Inspection of Oil Level
15300009710 / cbtsd 02-11 Page 24
Maintenance – Inspection of Oil Level
Caution!
The retarder must only be filled with oil via the bore of the oil filler plug (4100)!
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).
Notice
With determined lacking oil quantity check retarder for possible outer leak.
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)
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.
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.
Aftersales Service Manual Voith Retarder 115 E Maintenance – Inspection of Oil Level
15300009710 / cbtsd 02-11 Page 25
Maintenance – 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!
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.
11008
Work scope
The oil drain plugs (107, 4200) are hot! Oil temperature!
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)
107
4200 4200
11009
11010
Attention!
The retarder must only be filled with oil via the bore of the 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.
11011
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)
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.
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.
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 (pv) .............................................................77
4.6 Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) ...............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
18
(Voith-Wiringharness Digiprop without
.
87 87a 30
- +
CAN) + - + -
2 Control unit .
4 Connection terminal 15
.
15 ABS-signal
16 Retarder stage switch
17 X3 X2
17 Retarder pilot light
18 Brake light relay
.4 8 11 10 12 7 9 4 5 6 1 2 3 2 3 1 6 5 4 9 8 7
2
19 Temperature sensor
cooling water 18 17 16 6 5 4 9 8 10 11 12 13 14 15 7 3 2 1
X1
20 Temperature sensor oil
21 Proportional valve
47 Speedometer signal
7 6 5 2 3 8 4 4
69 Plug ISO-interface 3 2 1 4
69
70 Plug optional function
72 Pressure sensor
(OEM-specific) 16
11012
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Elektrical Connections Diagram
15300009710 / cbtsd 02-11 Page 33
Diagnosis / Troubleshooting – Elektrical Connections Diagram
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 17 X3 X2
(OEM-specific) .4 12 8 11 10 7 9 4 5 6 1 2 3 2 3 1 6 5 4 9 8 7
2
18 17 16 6 5 4 9 8 10 11 12 13 14 15 7 3 2 1
X1
CAN
4
16
11013
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Elektrical Connections Diagram
15300009710 / cbtsd 02-11 Page 34
Diagnosis / Troubleshooting – Elektrical Connections Diagram
VERA „general“
P U 72
2 Control unit 80 21 20 19 81 82
1 2 4
4 Connection terminal 15
15 ABS-signal
+ - + - + - + -
16 Retarder stage switch
18
17 Retarder pilot light
87 87a 30
18 Brake light relais
19 Temperature sensor
cooling water
20 Temperature sensor oil X3 X2
9 7 8 10 11 12 3 4 5 6 2 1 8 7 6 4 5 9 3 2 1
21 Proportional valve
47 Speedometer signal 2
17
72 Pressure sensor
(OEM-specific)
.4 16 15 4 5 6 8 9 18 10 17 11 12 13 14 7 3 2 1
X1
80 On/off valve
81 Input (3 times)
CAN
82 Output (3 times) 4
83 ISO-diagnosis
83
16 47 15
11014
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Elektrical Connections Diagram
15300009710 / cbtsd 02-11 Page 35
Diagnosis / Troubleshooting – Elektrical Connections Diagram
VERA „DAFBUS“
72 21 20 19 90 94 91 96
2 Control unit P U
4 Connection terminal 15 1 2 4
87 87a 30
cooling water
20 Temperature sensor oil
21 Proportional valve
72 Pressure sensor X3 X2
(OEM-specific) 9 7 8 10 11 12 3 4 5 6 2 1 8 7 6 1 9 2 3 4 5
90 Fan relais 2 95
93
.4
91 Brake valve
16 15 4 5 6 8 9 10 18 17 11 12 13 14 7 3 2 1
92 Diagnosis K-Lead X1
93 Fault light
94 Operating light
95 Foot Off/On CAN
4
96 Indication light
92
16
11015
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Elektrical Connections Diagram
15300009710 / cbtsd 02-11 Page 36
Diagnosis / Troubleshooting – Overview of Control Parts
11 33
Notice 71
32 61
The given position-numbers are not identical
with position-numbers of spare parts lists.
R
36 P
25 A 26
1 Heat exchanger
21 31
2 Control unit (e.g. Digiprop/
VERA)
35 34
11 Connection control current of
proportional valve
19 Temperature sensor
cooling water
20 Temperature sensor oil 40
21 Proportional valve 2
39 20
25 Compressed-air pressure line
constant-air pressure (py) 19
26 Compressed-air pressure line
suppla-air pressure (pv)
31 Compressed-air pressure line
(pressure regulator - four-
circuit protection valve)
32 Compressed-air pressure line
(four-circuit protection valve - 72
air tank for auxiliary equip- 1
ment) with with test connec-
tion
11016
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)
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Overview of Control Parts
15300009710 / cbtsd 02-11 Page 37
Diagnosis / Troubleshooting – Troubleshooting Diagram
A
* Notice:
* Retarder OEM-specific is an on-board-diagnosis
Pilot Light possible (display).
(Standard Notice the information from the vehicle
version) manufacturer to it.
11017e
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Troubleshooting Diagram
15300009710 / cbtsd 02-11 Seite 38
Diagnosis / Troubleshooting – Troubleshooting Diagram
Permanent light in
position 0 after no function? flashes?
lamp test?
Activate Check
Temperature
flash code fuse
adaption
and read out
fault code *
ABS or
idle switch
active?
OK NOK
* Notice the information of the
vehicle manufacturer
Check
temp.-sensors Instruct driver!
(oil / water)
(page 90 ff)
OK NOK
11018e
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Troubleshooting Diagram
15300009710 / cbtsd 02-11 Page 39
Diagnosis / Troubleshooting – Troubleshooting Diagram
Prior work
• Check whether running in instruction was carried out after oil change, carry out if necessary
B
Oil leak via ventilation
and / or non or
too low
brake efficiency
Outer Leak
(apart ventilation)
Repair
No Yes Retarder
Check retarder
oil level
(page 23 ff)
Check p (dynam.)
At complaint "non or and py (statisch) check py (static)
too low braking (page 78 ff)
OK NOK Water in oil
(page 78 ff)
efficiency": For examination the retarder For examination the retarder (emulsion)
oil level must be correct! oil level must be correct!
Consultation Voith
OK NOK Check Yes No
At complaint OK NOK heat exchanger
"Oil leak via
(page 124 ff)
ventilation":
continue with
checking casing Check
ventilation retarder oil level
too too
Check low high
gear box oil level
Check p (dynamic)
casing ventilation NOK OK NOK
(page 112 ff) py (static)
NOK
OK NOK
Check
gear box oil level
Check control too too
current of prop. high low
Check Replace valve as well as
proportional valve casing ventilation leads und Check
(page 86 ff) (page 112 ff) plug connections Correct gearbox oil level
Correct
NOK OK (page 86 ff) retarder- and
retarder- and
gearbox oil level NOK OK
OK NOK If problem occours again: gearbox oil level
Consultation Voith
Outlet valve
Replace .11 and higher?
proportinal valve
(page 140) Yes No Check Correct
If problem occours again: gearbox oil level
Consultation Voith
retarder oil level
too too
Check supply-
Check temperature high low
air pressure
(page 77) adaption or
temp.-sensors (oil/water)
OK NOK and pressure sensor or
Replace
leads
outlet valve Correct
(page 136 ff)
(page 88 ff) Check
Check vehicle retarder- and
If problem occours again: gearbox ventilation
Replace Proportional valve or compressed-air OK NOK gearbox oil level
proportional valve. system
damping plate
mechanically defect NOK OK
OK NOK
Consultation Replace
Voith temperature sensors
Compressed-air pressure Contact Correct retarder-
or leads Repair gearbox
line to prop. valve vehicle and gearbox
interrupted or (page 141, 142) ventilation;
manufacturer oil level
leaking correct retarder- and If problem occours again:
gearbox oil level Consultation Voith
11019e
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Troubleshooting Diagram
15300009710 / cbtsd 02-11 Seite 40
Diagnosis / Troubleshooting – Troubleshooting and remedies
• Battery voltage 18 - 32 V
• Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found
satisfactory.
• 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).
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Troubleshooting and remedies
15300009710 / cbtsd 02-11 Page 41
Diagnosis / Troubleshooting – Troubleshooting and remedies
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.
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Troubleshooting and remedies
15300009710 / cbtsd 02-11 Page 42
Diagnosis / Troubleshooting – Troubleshooting and remedies
Note
7 Terminal 15
8 Retarder stage switch, Position 5 11020
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“
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies
1 Not operational
2 Proportional valve -
3 Proportional valve +
4 Cooling-water temperature-sensor - 7 4 1
5 Cooling-water temperature-sensor + 8 5 2
6 Not operational 9 6 3
7 Not in use
8 Oil-temperature sensor - 11021
9 Oil-temperature sensor +
6 Pressure-sensor ground 12 9 6 3
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Diagnosis / Troubleshooting – Troubleshooting and remedies
1 K-lead
2 L-lead
3 Terminal 15
4 Terminal 31 4 3
2 1
11024
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Note
1 CAN-LOW
2 CAN-GROUND
3 CAN-HIGH
16 13 10 7 4 1
4 Retarder stage switch, Position 0
5 Retarder stage switch, Position 1 17 14 11 8 5 2
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Diagnosis / Troubleshooting – Troubleshooting and remedies
1 Cooling-water temperature-sensor -
2 Cooling-water temperature-sensor +
3 Proportional valve +
10 7 4 1
4 Proportional valve -
5 Oil-temperature sensor + 11 8 5 2
6 Oil-temperature sensor - 12 9 6 3
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Diagnosis / Troubleshooting – Troubleshooting and remedies
11028
1 Proportional valve +
2 Proportional valve – 4 2
3 Not in use 1 3
4 Not in use
11029
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Diagnosis / Troubleshooting – Troubleshooting and remedies
1 Not in use
2 Position 5
3 Position 4
4 Retarder stage switch + 5 6 7 8
5 Position 3 1 2 3 4
6 Position 2
7 Position 1
8 Bridge to pin 4 11030
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Special tool
53.8224.10
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.
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Diagnosis / Troubleshooting – Troubleshooting and remedies
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.
Requirements
1. L-lead of service interface connected to ground ≥ 2s. For this pupose, press „L - pushbutton“ on
service cable
Meaning
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Diagnosis / Troubleshooting – Troubleshooting and remedies
The blinking code can be triggered with the retarder stage switch during the service function
(vehicle ignition system ON and v = 0):
There is a break of 3 seconds before and after each blinking code output, during this time the retarder
pilot light is switched off.
The number of tens units first indicated as long ON time: each 2 seconds
0,5 sec
0,5 sec
0,5 sec
2 sec
2 sec
1 sec
1 sec
1 sec
1 sec
The number of single unit then is indicated as short ON time: each 0,5 seconds
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.
11031
Is there only one stored fault, the retarder pilot light is OFF after the output (only for Digiprop).
Display example for fault code 23 (Digiprop)
E Retarder pilot light ON
A Retarder pilot light OFF
t Time
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Diagnosis / Troubleshooting – Troubleshooting and remedies
The number of tens units first indicated as long ON time: each 2 seconds
2 sec
2 sec
Breaks between each ON time: each 1 second
1 sec
11032
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Version Digiprop
Note
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test Set point Remedy 2)
connection1)
01 Stop light relay/ slight 1s - Ignition: OFF X 3/11 Ω X 1/15 Relay is Check lead, plugs
- Pull plug X3 out of installed: and relay or
Short circuit to control unit 250-350 Ω consumers
ground
1)
X 1/15 = ground control unit
2)
Only, if no fault is recognizable after a complete check of the periphery: change control unit.
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
03 HS 1 output slight 1s - Ignition: OFF X 1/18 Ω X 1/15 Relay is Check lead, plugs
Short circuit - Pull plug X1 out of installed: and relay
control unit 250-350 Ω or consumers
04 HS 2 output slight 1s - Ignition: OFF X 1/16 Ω X 1/15 Relay is Check lead, plugs
Short circuit - Pull plug X1 out of installed: and relay
control unit 250-350 Ω or consumers
05 Terminal 15 serious 60 s - Ignition: OFF X 1/7 V X 1/15 ≥ 17,5 V Check lead, plugs
Undervoltage - Pull plug X1 out of and fuses
control unit
- Ignition: ON
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
08 Cooling-water 1s - Ignition: OFF X 2/5 Ω X 2/4 20°C ± 10°C = Check lead and
09 temperature - Pull plug X2 out of 1039 - 1117Ω sensor
sensor serious/ control unit
Discontinuity / slight * 60°C ± 10°C =
Short circuit to 1194 - 1271Ω
battery
80°C ± 10°C =
1271 - 1347Ω
Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.
* Fault is in serious class, if temperature sensor for oil and water are defect at the same time.
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
11 Oil temperature 1s - Ignition: OFF X 2/9 Ω X 2/8 20°C ± 10°C = Check lead and
12 sensor serious/ - Pull plug X2 out of 1039 - 1117Ω sensor
Discontinuity / slight * control unit
Short circuit to 60°C ± 10°C =
battery 1194 - 1271Ω
80°C ± 10°C =
1271 - 1347Ω
Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.
* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
13 1 Retarder stage serious 1s - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and
switch - Retarder stage retarder stage switch
Undefined switch: X 1/6 V X 1/15 0V
switch state Position 0 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V
X 1/8 V X 1/15 0V
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Operati- Measurement/ Result/ Cause/
class on Test connec- Set point Remedy
tion
14 Retarder stage serious 10 s - Ignition: OFF X 1/10 V X 1/15 0V Check lead and
switch - Pull plug X1 out of plug
Short circuit to control unit
battery - Ignition: ON
- Retarder stage switch:
Position 0
15 Retarder stage serious 1s - Ignition: OFF X 1/10 Ω X 1/15 Resistor Single check of
switch - Pull plug X1 out of endless stages for
Short circuit to control unit short circuit
battery - Retarder stage switch:
Position 5
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
18 Speedometer signal serious 2s - Ignition: OFF X 3/2 V X 1/15 ≤ 9V Check lead and
Short circuit to battery - Pull plug X3 out of speedometer
undefined signal control unit
- Ignition: ON
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
24 1 Proportional valve serious 1s - Ignition: ON X 2/2 Ω X 2/3 18-25 Ω Check lead and
Fault No. 2: - Pull plug X2 out proportional
- Short circuit proportional of control unit valve
valve magnetic (valve block)
- 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
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
32 Retarder pilot light: serious 3s - Ignition: OFF X 3/8 V X 1/15 ≥ 17,5 V Check lead,
Discontinuity / - Pull plug X3 out of retarder pilot
Short circuit to ground control unit light and fuse
- Ignition: ON
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
33 Retarder pilot light: serious 3s - Ignition: ON X 3/8 V X 1/15 ≤ 2V Check lead and
Short circuit to battery - Retarder stage retarder pilot
switch: light
Position 1
2 Troubleshooting in
wiring harness,
pressure sensor,
proportional valve,
supply-air pressure,
ECU
(Contact Voith)
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Version VERA
Note
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
5 1 Proportional- heavy 1s - Ignition: OFF X 3/3 Ω X 3/4 18 ... 25 Ω Check electrical lead
valve chasssis - disconnect and proportional valve
ground end, plug X3
interruption,
short circuit,
connecting lead
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
6 1 Proportional- heavy 1s - Ignition: OFF X 3/3 V X 1/14 ≤10 V Check electrical lead
valve - Pull off plug X1, and plug
battery short cir- X3
cuit - Ignition: ON
9 1 Terminal 15 heavy 60s - Ignition: OFF X 1/7 V X 1/14 ≥ 17,5 V Check electrical lead,
undervoltage - Pull off plug X1 fuse and plug
- Ignition: ON
10 1 Terminal 15 heavy 10s - Ignition: OFF X 1/7 V X 1/14 ≤ 32,5 V Check electrical unit
overvoltage - Pull off plug X1, of vehicle (see manu-
X3 facturer´s instruc-
- Ignition: ON tions)
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
11 1 Retarder stage heavy 2s - Ignition: ON X 1/10 V X 1/14 ≥ 17,5 V Check electrical lead,
switch - Retarder stage X 1/5 V X 1/14 0V plug and retarder sta-
undefined con- switch: position 0 X 1/6 V X 1/14 0V ge switch
dition X 1/8 V X 1/14 0V
X 1/9 V X 1/14 0V
X 1/18 V X 1/14 0V
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
12 1 Retarder stage heavy 1s - Ignition: OFF X 1/10 Ω X 1/14 Resistor endless Check each stage on
switch - Pull off plug X1 chsssis ground end
chasssis ground - Retarder stage
end switch: position 5
13 1 Retarder stage heavy 10s - Ignition: OFF X 1/10 V X 1/14 0V Check electrical lead
switch - Pull off plug X1 and plug
battery shortcir- - Retarder stage
cuit switch: position 0
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
17 1 Cooling-water light 1s - Ignition: OFF X 3/1 Ω X 3/2 20°C ± 10 °C = Check electrical lead,
temperature - Pull off plug X3 1039 - 1117Ω sensor and plug
sensor
60°C ± 10 °C =
interruption
1194 - 1271Ω
80°C ± 10 °C =
1271 - 1347Ω
Note:
The measuring in
one temperature
range normally is
sufficient.
18 1 Cooling-water light 1s - Ignition: OFF X 3/2 Ω X 1/14 Resistor endless Check electrical lead
temperature - Pull off plug X1,
sensor X3
chasssis ground
end
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
19 1 Oil-temperature light 1s - Ignition: OFF X 3/5 Ω X 3/6 20°C ± 10 °C = Check electrical lead
sensor - Pull off plug X3 1039 - 1117Ω and plug
interruption
60°C ± 10 °C =
1194 - 1271Ω
80°C ± 10 °C =
1271 - 1347Ω
Note:
The measuring in
one temperature
range normally is
sufficient.
20 1 Oil-temperature light 1s - Ignition: OFF X 3/5 Ω X 1/14 Resistor endless Check electrical lead
sensor - Pull off plug X1, and plug
chasssis ground X3
end
22 1 Speedometer heavy 2s - Ignition: OFF X 1/11 V X 1/14 ≤9V Check electrical lead
signal - Pull off plug X1 and speedometer
battery shortcir- - Ignition: ON
cuit
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
23 1 Retarder pilot heavy 1s - Ignition: OFF X 1/15 V X 1/14 ≥ 17,5 V Check electrical lead
light - Pull off plug X1 and fuse
interruption, - Ignition: ON
chasssis ground
end
24 1 Retarder pilot heavy 3s - Ignition: ON X 1/15 V X 1/14 ≤2V Check electrical lead
light - Retarder stage and retarder pilot
interruption, switch: position 1 light
battery shortcir-
cuit
25 1 Pressure sensor light 0,5s - Ignition: ON X 3/8 V X 3/9 4,75 ... 5,25 V Check electrical lead
fault (supply)
26 1 Pressure sensor light 1s - Ignition: OFF X 3/7 Ω X 1/14 Resistor endless Check electrical lead
interruption, - Pull off plug X1, and pressure-sensor
chasssis ground X3
end
27 1 Pressure sensor light 1s - Ignition: ON X 3/9 V X 3/8 4,75 ... 5,25 V Check electrical lead
battery shortcir- and pressure-sensor
cuit
28 1 Pressure sensor light 10s - Ignition: ON X 3/7 V X 3/8 0,3 ... 0,7 V Check electrical lead
unplausible - Retarder stage and pressure-sensor
signal switch: position 0
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
29 1 ABS heavy 60s - Ignition: ON X 1/13 V X 1/14 ≥ 3,5 V Check electrical lead,
chasssis ground relay and ABS-con-
end trol unit
33 1 Brake light relay light 1s - Ignition: OFF X 1/16 Ω X 1/14 At installed relay Check electrical lead
chasssis ground - Pull off plug X1 250-350 Ω plug and relay or con-
end sumer
34 1 Brake light relay light 1s - Ignition: OFF X 1/16 Ω X 1/14 < 1,5kΩ Check electrical lead
interruption, - Pull off plug X1 plug and relay or con-
battery shortcir- sumer
cuit
35 1 Output 1 light 1s - Ignition: OFF X 2/1 Ω X 1/14 At installed con- Check electrical lead
(OUT-1) - Pull off plug X2 sumer plug and relay or con-
chasssis ground > 150Ω sumer
end
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
36 1 Output 1 light 1s - Ignition: OFF X 2/1 Ω X 1/14 < 3kΩ Check electrical lead
(OUT-1) - Pull off plug X2 plug and relay or con-
interruption, sumer
battery short cir-
cuit
37 1 Output 2 light 1s - Ignition: OFF X 2/2 Ω X 1/14 At installed con- Check electrical lead
(OUT-2) - Pull off plug X2 sumer plug and relay or con-
chasssis ground > 150 Ω sumer
end
38 1 Output 2 light 1s - Ignition: OFF X 2/2 Ω X 1/14 < 3kΩ Check electrical lead
(OUT-2) - Pull off plug X2 plug and relay or con-
interruption, sumer
battery shortcir-
cuit
39 1 Output 3 light 1s - Ignition: OFF X 2/3 Ω X 1/14 At installed con- Check electrical lead
(OUT-3) - Pull off plug X2 sumer plug and relay or con-
chasssis ground > 150Ω sumer
end
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy
40 1 Output 3 light 1s - Ignition: OFF X 2/3 Ω X 1/14 < 3kΩ Check electrical lead
(OUT-3) - Pull off plug X2 plug and relay or con-
interruption, sumer
battery shortcir-
cuit
46 1 Retarder foot- light 500ms - Ignition: ON X 2/4 V X 1/14 > 0,4 V Check analoge foot-
switch pedal, electrical lead
chasssis ground and plug
end (IN-3)
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Diagnosis / Troubleshooting – Troubleshooting and remedies
Hinweis
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Diagnosis / Troubleshooting – Checking Supply-Air Pressure (pv)
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 (pv).
• Minimum pressure: 6 bar
• Maximum pressure: 11 bar
Notice
If pressure is not within the specified range, the compressed-air system must be checked according to 32
11033
the manufacturer´s data.
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
r.
Notice
11034
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
• Vehicle electrical system (e.g. battery voltage, fuse etc.) checked in accordance with the Owner´s
Manual for the vehicle and found satisfactory
Special tools:
H53.478810
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
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.
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
The oil filler plug (4100) and the retarder are hot! oil temperature!
11035
2. Connect air-pressure gauge (99/7) to bore of oil filler plug (4100). 99/7
11036
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
The screw plug (103) and the oil are hot! Oil temperature!
103
11037
Attention!
Easy oil-exit is caused constructively, but has no effect on function of retarder, however.
99/1
4. Connect oil-pressure gauge (99/1) to bore of screw plug (103).
11038
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
5. Drive the vehicle with a prop shaft speed of vps = 1000 r.p.m.
Notice
6. Shift the retarder stage switch to position 5 while on move at prop shaft speed vps = 1000 r.p.m. and
read-off pump pressure (pdyn) of oil-pressure gauge (99/1).
7. Compare read-off pump pressure with the minimum value of dynamic pump pressure (pdyn)
according to the table see pages 93 ff.
8. Compare read-off constant-air pressure (py) with determined value of constant-air pressure (py)
according tables on pages 93 ff.
Attention!
If the nominal value of the constant-air pressure (py) 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 (py), either a
leak of the retarder or a defect is due to the control (see troubleshooting diagram).
The constant-air pressure (py) must not change during the drive.
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
99/1
11039
103
Notice
Check sealing ring of screw plug (103) for a possible damage, replace screw plug (103) if necessary.
11040
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
The screwing of the air-pressure gauge and the retarder are hot!
11041
4100
Notice
Check sealing ring of oil filler plug (4100) for a possible damage, replace oil filler plug (4100), if necessary.
11042
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Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve
• Battery voltag 24 - 28 V
• Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle 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
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve
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Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve
1. Disconnect plug at proportional valve (21) and connect with measuring adapter (99/3).
21
2. Connect plug of measuring adapter (99/3) with the proportional valve (21).
3. Connect the Multimeter (98/8). Switch position: mA. 98/8
99/3
11043
98/8 Multimeter
99/3 Measuring adapter 53.8198.10
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve
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Diagnosis / Troubleshooting – Checking Pressure Sensor
• Electrical lead and plug-in connection checked (visual examination) and found satisfactory
Special tool:
Measuring adapter
99/3
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Pressure Sensor
15300009710 / cbtsd 02-11 Page 88
Diagnosis / Troubleshooting – Checking Pressure Sensor
1. Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3).
98/8
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“.
38
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. 99/3
11044
Notice
98/8 Multimeter
If there is an error (wire or sensor), the supply voltage is switched off by the control unit. Check the wire 99/3 Measuring adapter 53.8198.10
or the sensor and replace the defect part, if necessary.
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Pressure Sensor
15300009710 / cbtsd 02-11 Page 89
Diagnosis / Troubleshooting – Checking Temperature Adaption
• Battery voltage 24 - 28 V
• Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found
satisfactory
• Electrical lead and plug-in connection checked (visual examination) and found satisfactory
Special tool:
Temperature simulator
99/2
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Temperature Adaption
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Diagnosis / Troubleshooting – Checking Temperature Adaption
1. Disconnect electrical lead cooling water (39) and electrical lead oil (40) to cooling-water tempera- 39
40
ture-sensors (19) and oil (20) and connect these to the temperature simulator (99/2).
99/2
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.
Wasser Öl
11045
99/2 Temperature simulator 53.8207.10
2. Set rotary switch of temperature simulator (99/2) to 95°C cooling water temperature and 165°C oil
temperature.
3. Switch-on vehicle ignition!
4. Operate retarder at highest braking stage.
Constant-air pressure (py) control current must reach values given on table on pages 93 ff.
5. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. The
constant-air pressure py must drop below the set maximum pressure. Set rotary switch of
temperature simulator (99/2) to 125oC cooling water temperature.
There must be no more output of constant-air pressure py.
6. Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature.
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Temperature Adaption
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Diagnosis / Troubleshooting – Checking Temperature Adaption
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Temperature Adaption
15300009710 / cbtsd 02-11 Page 92
Diagnosis / Troubleshooting – Table of Measurements
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 93
Diagnosis / Troubleshooting – Table of Measurements
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 94
Diagnosis / Troubleshooting – Table of Measurements
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 95
Diagnosis / Troubleshooting – Table of Measurements
VERA DAFBUS
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 96
Diagnosis / Troubleshooting – Table of Measurements
5
4,5
4
3,5
3
[ V ] 2,5
2
1,5
1
0,5
0
0,5 1 1,5 2 2,5 3 3,5 4
0
[ BAR ]
11046
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right
to make further modifications.
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 97
Diagnosis / Troubleshooting – Table of Measurements
Temperature Resistor
Notice
Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 98
Removing, Installing Retarder
Prior work
25300
• Cooling water drained *
25000
25300
• Oil drained of retarder 850
(see page 26)
• Waterneck removed
(see page 123)
25200
Notice
15
M10
FJ 6280 0
486 265
80
67.3224.10 67.3319.10 67.3320.10 Material: St37-2, DIN 17100 (1.80)
28028e
Achtung!
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. 25200
25300
4100
25200
11049
Notice
25000
Carry out following working step, if: 850
- taper roller bearing (800) is renewed
- Retarder is installed at gearbox 98/4
265
00
628
486
FJ
- Retarder was repaired 25100
- Gearbox was repaired
11050
3. Pull off outer ring (850) with puller bearing outer ring (98/4) and remove shim (25000). 98/4 Puller bearing outer ring 67.3320.10
Assembling
Notice
Attention!
The measurings described below may only carried out at ambient temperature and with the retarder in
vertical position (see illustration)!
1.1 Measure the distance "B" between bearing surface on retarder side of the gearbox and the bearing B
surface of the shim and note value.
11051
1.2 Put the bearing outer ring (850) on the taper roller bearing (850/1).
850
850/1
11052
1.3 Put measuring device (98/1) on gearbox and tighten hex.-head screws handtight (3 Nm).
Pos.1 Pos. 2
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.
98/1
11053
98/1 Measuring device 67.3224.10
1.6 Set the vernier depth gauge on gearbox seperation area and zero vernier depth gauge.
11054
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".
11055
Notice
The thicker shim must always be placed first in the gearbox housing.
Notice 25000
If taper roller bearing was replaced, also replace the bearing outer ring (850). 850
98/3
Notice 11056
If necessary warm housing for the simpler assembly in the area of the bearing outer ring to 98/3 Drive in tool 67.3319.10
approx. 80°C.
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.
11057
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.
25100
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.
11058
9. Place retarder at gearbox and fix this with 5 hex.-head screws (25200).
Tightening torque hex.-head screws (25200): 58 Nm 25200
25200
10. Screw out again the two threaded bolts M 10 x 80.
11. Insert the 17 hex.-head screws (25300) and tighten them. 25200
Tightening torque hex.-head screws (25300): 58 Nm
25300
11059
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
2500 2105
2106
3100 1700
4200 1600
3100
2100 11060
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Overall Illustration of Main Components
15300009710 / cbtsd 02-11 Page 111
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Notice
Prior jobs
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 112
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 113
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Ø 40,5 mm
7 mm
Ø 60 mm
Material: St 37
Weight: 0,085 kg 28049e
Notice
The test ring also can be ordered with Voith item-number 67.2757.10 at Voith Turbo GmbH&Co. KG.
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 114
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Removing
3300
11063
2900
11064
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 115
Repair Retarder – Removing, Checking and Installing Casing Ventilation
6100
6101
11065
4. Use impact puller (99/5) and adapter (98/7) to extract valve insert of retarder housing (100).
99/5
100
98/7
11066
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 116
Repair Retarder – Removing, Checking and Installing Casing Ventilation
5. Take float (2300/2) and float cage (2300/3) out of retarder housing (100).
2300/2
100
2300/3
11067
6. Lever out O-Ring (2301) of groove of valve insert (2300/1) and remove this.
2300/1
2301
11068
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
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Repair Retarder – Removing, Checking and Installing Casing Ventilation
Checking
Notice
11069
Oil has penetrated into the float, the retarder is impaired in its operation.
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 99/7
sealing edge is not damaged, the fluid level must not alter in the course of 1 minute. 2300/2
If necessary, renew complete casing ventilation.
2300/1
11070
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 118
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Installing
1. Coat new O-ring (2301) with silicon-free and non-corrosive grease and pull on valve insert (2300/1).
2300/1
2301
11071
2. Insert float (2300/2) and float cage (2300/3) in valve insert (2300/1).
2300/1
2300/2
2300/3
11072
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
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Repair Retarder – Removing, Checking and Installing Casing Ventilation
3. Coat bore of casingventilation in retarder housing (100) with silicon-free and non-corrosive grease.
4. Insert casing ventilation in retarder housing (100).
99/5
5. Use the impact puller (99/5) and adapter (98/9) to knock in the casing ventilation. 100
98/7
11073
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. 2000
11074
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 120
Repair Retarder – Removing, Checking and Installing Casing Ventilation
2900
11075
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. 6100
12. Screw in combined hex.-head screws (3300) and screw them tight.
Tightening torque combined hex.-head screw (3300): 30 Nm. 3300
2800
11076
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 121
Repair Retarder – Removing, Cleaning and Installing Silencer
Notice 5400
This work step can be performed with retarder
5500
installed or removed.
5600
th-S
h-
ac
h-
Nr.
Nr.
Voi
Silencer Benzine
11077
Illustration: Silencer
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Cleaning and Installing Silencer
15300009710 / cbtsd 02-11 Page 122
Repair Retarder – Removing and Installing Water Neck
h-
Nr
.
20100
ac .
.-S Nr
Kd h-
ac
-S
ith
Vo
20000
20200
11078
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing and Installing Water Neck
15300009710 / cbtsd 02-11 Page 123
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Notice
If necessary, the heat exchanger can be removed also with mounted retarder.
Prior jobs
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.
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 124
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Lubricant
11079
O-rings silicon-free and
Illustration: Removing heat exchanger
non-corrosive grease
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 125
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Attention!
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.
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.
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 126
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Special tool
67.1948.10
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
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 127
Repair Retarder – Removing, Checking, Installing Heat Exchanger
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. 107
4200 4200
11080
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 128
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Removing
1. Screw out hte four hex.-head screws (6600) and remove washers (6700).
2. Remove heat exchanger (6400). 6400
6600
6700
6700
6600
6700
6600 11081
7500
7300
7300
7600
7500
7300
11082
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 129
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Checking
1. Install pressure test plate (99/6) with O-rings at heat exchanger (6400) and connect compressd-air
99/6 6400
pressure lines to bottom connection (arrow).
2. Fill heat exchanger (6400) on water side with hot water (approx. 70oC).
3. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the
heat exchanger).
Notice
If air bubbles form in the hot water the heat exchanger is leaking and must be exchanged.
11083
99/6 Pressure test plate 67.1948.10
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
11084
flush it out with hot water in the water section of the heat exchanger.
99/6 Pressure test plate 67.1948.10
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 130
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Installing
1. Fit new O-rings (7300, 7500 and 7600) in the bores and coat them with silicon-free and
non-corrosive grease. 7600
7500
7300
7300
7500
7300
11085
2. Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) with
washers (6700) tight.
6400
Initial torque: 50 Nm
6600
6700
6700
6600
6700
6600 11086
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 131
Repair Retarder – Removing, Checking, Installing Heat Exchanger
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.
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 132
Repair Retarder - Removing, Installing Oil Tank Cover
3100
Notice
8000
Lubricant
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Oil Tank Cover
15300009710 / cbtsd 02-11 Page 133
Repair Retarder – Removing, Installing Oil Tank Cover
Prior jobs
4200
11089
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Oil Tank Cover
15300009710 / cbtsd 02-11 Page 134
Repair Retarder – Removing, Installing Oil Tank Cover
Attention!
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.
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.
Installation note
Pay attention to the mounting position of the gasket and the cover!
6
Tighten all combined-hex.-head screws in specified sequence 1 to 17 first with 14 to 19 Nm.
5 7
The combined-hex.-head screws are then tightened in the same sequence with 30 Nm. 4 3 8
7 2 1 9
16 10
15 11
14 12
13 11090
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Oil Tank Cover
15300009710 / cbtsd 02-11 Seite 135
Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
Vo
.-S
ith
ac
-S
h-
ac
Nr
h-
.
Nr
.
installation
2105
2105 O-ring 34 x 3, renew,
coat with silicon-free and
non-corrosive grease for 2106
installation 1700
1600
2106 O-ring 54 x 3, renew,
coat with silicon-free and 2100 3100
non-corrosive grease for
installation
3100 Combined hex.-head screw
M 8 x 30
hex.-head, w.a.f. 13
30 Nm 11091
Illustration: Non-Return Valve (Outlet)
Lubricant
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
15300009710 / cbtsd 02-11 Page 136
Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
Special tool
153.00005210
Puller
non-return valve (outlet)
71/1
Aftersales Service Manual Voith Retarder 115 E Repair Retarder - Removing, Installing Non-Return Valve (Outlet)
15300009710 / cbtsd 02-11 Page 137
Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
Removing
71/1
11092
71/1 Puller
Installing
Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
15300009710 / cbtsd 02-11 Page 138
Control Parts
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
Lunbricant
Aftersales Service Manual Voith Retarder 115 E Control Parts – Removing, Installing Proportional Valve and Damping Plate
15300009710 / cbtsd 02-11 Page 140
Control Parts – Removing, Installing Temperature Sensor Cooling Water
Notice
Aftersales Service Manual Voith Retarder 115 E Control Parts – Removing, Installing Temperature Sensor Cooling Water
15300009710 / cbtsd 02-11 Page 141
Control Parts – Removing, Installing Temperature Sensor Oil
11095
Aftersales Service Manual Voith Retarder 115 E Control Parts – Removing, Installing Temperature Sensor Oil
15300009710 / cbtsd 02-11 Page 142
Control Parts – Removing, Installing Pressure Sensor
Prior jobs
11096
Aftersales Service Manual Voith Retarder 115 E Control Parts – Removing, Installing Pressure Sensor
15300009710 / cbtsd 02-11 Page 143
Appendix
8. Appendix
8.1 Retarder Data Sheet .................................................................................145
8.2 Tightening Torques ...................................................................................146
Max. possible braking torque at prop shaft M (Br) max at retarder ratio 1:2.03 * 3700 Nm
Service filling:
Weight of unit (with het exchanger unit and service filling) approx. 73 kg
Aftersales Service Manual Voith Retarder 115 E Appendix – Retarder Data Sheet
15300009710 / cbtsd 02-11 Page 145
Appendix – Tightening Torques
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
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
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
5200 Temperature sensor oil / water M 14 x 1,5, Hex.-head, w.a.f. 21 28 Nm with copper sealing ring