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Aftersales Service Manual Gearbox-Retarder-System GO170 - GO210 with R 115 E

Aftersales Service Manual Gearbox-Retarder-System cbtd 2000-01 53.2687.10

9RLWK7XUER*PE+ &R.* Product unit retarder

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Content

1

Preface ....................................................................................................1/1

2

General....................................................................................................2/1 2.1 2.2 2.3 2.4 2.5 2.6

3

Maintenance............................................................................................3/1 3.1 3.2 3.3 3.4 3.5

4

Illustration Gearbox-Retarder-System ............................................................. 2.1/1 Function and Operation Scheme Gearbox ...................................................... 2.2/1 Function and Operation Scheme Retarder ...................................................... 2.3/1 Gearbox Identification...................................................................................... 2.4/1 Retarder Identification...................................................................................... 2.5/1 Retarder Control-Unit Identification ................................................................. 2.6/1

Maintenance Work / Oil Change Intervals ....................................................... 3.1/1 Checking Oil Level of Gearbox ........................................................................ 3.2/1 Checking Oil Level of Retarder........................................................................ 3.3/1 Oil Change of Gearbox .................................................................................... 3.4/1 Oil Change of Retarder.................................................................................... 3.5/1

Diagnosis / Troubleshooting Gearbox .....................................................4/1 4.1 Troubleshooting Diagram A to E...................................................................... 4.1/1


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Content

5

7DEOHRI&RQWHQWV (Continue)

Diagnosis / Troubleshooting Retarder.....................................................5/1 5.1 Troubleshooting Diagram A to C ..................................................................... 5.1/1 Electrical Connectrions Diagram ..................................................................... 5.1/6 5.2 Troubleshooting and Remedies....................................................................... 5.2/1 5.3 Illustration Control System............................................................................... 5.3/1 5.4 Checking Supply-Air Pressure......................................................................... 5.4/1 5.5 Checking Constant-Air Pressure (py)............................................................... 5.5/1 5.6 Checking Control Current of Proportional Valve.............................................. 5.6/1 5.7 Checking Temperature Adaption ..................................................................... 5.7/1 5.8 Checking Pressure Sensor .............................................................................. 5.8/1 5.9 Checking Pump Pressure ................................................................................ 5.9/1 5.10 Table of Measurements ................................................................................. 5.10/1 5.11 Operational Check ......................................................................................... 5.11/1

6

Removing, Installing Gearbox .................................................................6/1 6.1 Removing, Installing Gearbox.......................................................................... 6.1/1

7

Removing, Installing Retarder .................................................................7/1 7.1 Removing, Installing Retarder ......................................................................... 7.1/1



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Content

8

Repair Gearbox .......................................................................................8/1 8.1 Overall Illustration of Main Components.......................................................... 8.1/1 8.2 Removing, Installing Front Housing Cover, Cover Countershaft and Closing Cover 5./6.-Gear ................................................................................. 8.2/1 8.3 Removing, Installing Shift ................................................................................ 8.3/1 8.4 Removing, Installing Breather.......................................................................... 8.4/1 8.5 Removing, Installing Sensor/Switch at Gearbox.............................................. 8.5/1 8.6 Removing, Installing Clutch Servo and Adjusting Wear Indicator .......................................................................... 8.6/1 8.7 Removing, Installing Output Flange Renewing Radial Shaft Sealing Ring............................................................... 8.7/1

9

Repair Retarder.......................................................................................9/1 9.1 9.2 9.3 9.4 9.5 9.6

Overall Illustration of Main Components.......................................................... 9.1/1 Removing, Checking and Installing Casing Ventlation .................................... 9.2/1 Removing, Cleaning and Installing Silencer .................................................... 9.3/1 Removing, Installing Water Neck..................................................................... 9.4/1 Removing, Checking, Installing Heat Exchanger............................................. 9.5/1 Removing, Installing Oil Tank Cover ............................................................... 9.6/1 A Top Oil Tank Cover ..................................................................................... 9.6/1 B Bottom Oil Tank Cover ................................................................................ 9.6/2



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Content

10

Control Parts Retarder ..........................................................................10/1 10.1 10.2 10.3 10.4

11

Removing, Installing Proportional Valve ........................................................ 10.1/1 Removing, Installing Oil Temperature Pick-Up.............................................. 10.2/1 Removing, Installing Cooling-Water Temperature Pick-up............................ 10.3/1 Removing, Installing Pressure Sensor........................................................... 10.4/1

Annex ....................................................................................................11/1 Data Sheet Conversion Table Operating Specifications: - Oil Specifications Gearbox - Oil Specifications Retarder - Cooling Water Quality Spare Parts Lists Other Information



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Preface

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The present service manual serves as training material for the training. The information and instructions which are given to you furthermore provide the basis for appropriate and professional maintenance and repair at the gearbox-retarder-system. We ask you firmly to notice the safety and warning notes which you will find in these instructions.

Caution! is associated for safety instructions and for warning notes at dangerous situation for persons, at reduction of quality of workmanship and the possibility of damage to property.

Note is associated for general notices for a better handling during maintenance of the gearbox-retarder-system.


Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10 Page 1/1

9RLWK7XUER*PE+ &R.* 3URGXFWXQLWUHWDUGHU

Preface

3UHIDFH (Continue)

Caution! •

The switched-on retarder will not secure the parked vehicle!

•

During a failure of the Retarders, or while the temperature-adaptation is effective, the vehiclespeed must be settled by using the service-brake and the lowest possible gear is in use (increase of the engine-speed). This vehicle condition must be held as long as the retarder again is available with its full performance.

•

Unauthorized changes at the gearbox-retarder-system as well as the use of spare parts, accessories, attachments and special-productions, not tested and released from Voith, can influence the security of the entire vehicle negatively. No liability takes place for damages resulting from it

•

The gearbox-retarder-system is built after the state-of -the-art technology and the recognized safety-related rules. Nevertheless dangers and damages can originate during improper use, maintenance and repair.

•

We will take on no liability for injuries and/or damages, that originate through non-observance of the security-hints of the service manual or through injuries of the diligence-duty with the handling, at the service, with the care and maintenance or repair of the gearbox-retarder-system.

•

Repair and maintenance work may only be enforced by qualified specialist-staff.


Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10 Page 1/2.


Preface

3UHIDFH (Continue)

Note •

The used position numbers used in this manual corresponds to the position numbers in the spare parts lists in chapter 9 „Annex“. Exception: Items or parts with one -, as well as two-digit position-numbers are no spare parts and not listed in the spare parts lists. Items and parts from the retarder sector shown with an oblique number are no spare parts and therefore not listed in the spare parts lists.

•

The terms of the parts for the gearbox correspond to the DaimlerChrysler-EPC-documentation. Example:

26

gearbox-design-group

/

100 image board

/

35 part in drawing

•

Inevitably, it is impossible for us to warn at each position in these service manual to assess all situations which might entail the risk of injury for the person carrying out the work. It is therefore imperative that any person carrying out repair work on the gearbox-retarder-system uses his professional knowledge to make sure that his own safety is not endangered and that the retarder suffers no negative effects, in particular safety-wise, through the chosen working procedure. For these reasons, no liability can be assumed for damage incurred.

•

The pertinent accident-prevention-regulation, other broadly rules of the security-technology and working-medicine and the traffic admission law are to be kept. We are not liable for damages, that originate through contempt of these rugulations.




Preface

3UHIDFH (Continue)

•

With the contact with oils, greases and other chemical substances, the current safety regulations for these products are to be heeded!

•

Caution with the contact with hot fuels! Danger of burn and scald!

•

Please read the hints in the operation manual to the safe, proper and economic operation of the retarder gearbox-retarder-system.

•

Should you have any queries and queries about the working steps not described in this manual, please contact the responsible person in the appropriate organisation of the country involved or: DaimlerChrysler AG Business unit gearbox Sales Hauptstraße 107 D-76568 Gaggenau

Voith Turbo GmbH & Co. KG Production group retarder Voithstraße 1 Post box 15 55 D-74555 Crailsheim

Telephone 07225 / 61-65 56 Fax 07225 / 61-65 51 e-mail: [email protected]

Telephone 07951 / 32-401, -422 Fax 07951 / 32-756 e-mail: [email protected]

Copyright October 1999 - Voith Turbo / DaimlerChrysler




General

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2.1

Illustration Gearbox-Retarder-System........................................................2.1/1

2.2

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

2.3

Function and Operation Scheme Retarder.................................................2.3/1

2.4

Gearbox Identification ................................................................................2.4/1

2.5

Retarder Identification ................................................................................2.5/1

2.6

Retarder Control-Unit Identification ............................................................2.6/1




General

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Illustration gearbox-retarder-system

26/250/047 26/100/116 Screw plug oil sieve M38x1,5 Inhex.-head, w.a.f. 17 (removing height 120 mm) 26/100/122 Oil filler plug gearbox M24x1,5 Inhex.-head, w.a.f. 14 26/100/125 Oil drain plug gearbox M24x1,5 Inhex.-head, w.a.f. 14 (bottom) 26/100/206 Speedometer sensor 26/250/047 Switch for starter lock * 26/250/068 Inductive sensor for overspeed protection * 26/400/083 Oil temperature pick-up gearbox * 26/400/089 Switch reversing light * 3500 Screw plug with sieve M30x1,5 Inhex.-head, w.a.f. 17 3700 Proportional valve retarder control

26/100/125 26/400/083

26/400/089

26/100/122

26/250/068

26/100/125

26/100/116

3700

3500 26/100/206

* = optional M+P-07A-1708 M+P-07A-1708

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

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Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10 Page 2.1/1


General

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Illustration gearbox-retarder-system (Continue) 25/250/068 26/150/ 26/250/ 26/250/047 26/250/068 26/350/ 26/400/089 3700 4100

6400

26/350/

Clutch servo * Drive shaft Clutch wear indicator * Switch for starter lock * Inductive sensor for overspeed protection * Shift Switch reversing light * Proportional valve retarder control Oil filler screw retarder M30x1,5 Inhex.-head, w.a.f. 17 Heat exchanger retarder

4100

6400

3700

* = option

26/150/

25/250/068

26/250/047

26/250/068

26/250/

26/400/089

M+P-07A-1710

Remark: Terms for items from DaimlerChrysler-EPC-documentation

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General

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Illustration gearbox-retarder-system (Continue) 100/1 Retarder data plate 103 Screw plug Measure point pump pressure M12x1,5 Inhex.-head, w.a.f. 6 107 Oil drain plug retarder M24x1,5 Inhex.-head, w.a.f. 12 3500 Screw plug with sieve M30x1,5 Inhex.-head, w.a.f. 17 3700 Proportional valve 4200 Oil drain plug oil tank M24x1,5 Inhex.-head, w.a.f. 12 6400 Heat exchanger

3700 100/1

3500

103 6400

107 4200 M+P-07A-1484

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General

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Illustration gearbox force diagram



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General


Illustration gearbox-longitudinal section

9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

10

11 18

5

7

12

18

13

4

14

3

15

18

2

16

1

17

19

18

6

8

1. Gear wheel 2. Gear wheel 3. Gear wheel 4. Gear wheel 5. Gear wheel Reverse gear wheel Countershaft Oil pump Drive shaft Pilot bearing Switch lever Switch rails Sliding sleeve Synchromesh ring Synchromesh body Synchromesh cone Mainshaft Actuating lever Fly wheel



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General


Illustration gearbox-longitudinal section

9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

10

11 18

5

7

12

18

13

4

14

3

15

18

2

16

1

17

19

18

6

8

1. Gear wheel 2. Gear wheel 3. Gear wheel 4. Gear wheel 5. Gear wheel Reverse gear wheel Countershaft Oil pump Drive shaft Pilot bearing Switch lever Switch rails Sliding sleeve Synchromesh ring Synchromesh body Synchromesh cone Mainshaft Actuating lever Fly wheel



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General


Illustration gearbox-sectional view

11

12

20

25 21

26

27

22

23

18

7

17

24

28

7 11 12 17 18 20 21 22 23 24 25 26 27 28

Countershaft Switch lever Switch rails Mainshaft Actuating lever Cross shift Reverse gear lock Actuating lever bolt Gearbox housing Loose wheel bearing Shift link (option) Shift ramifications Cam follower Reverse idler gear



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General

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Illustration retarder

70

47

15

17

4

18 23

26

42

A R

21

72

36

25 20 2

1/1

1

1/2

63

19

46 22 6 8

69

44 64

4

16

62 43 55

41

Oil sump Supply-air pressure p V Constant-air pressure p y

Coolant (water) Pump pressure p P

FD914be

Note The reference numbers indicated in section 2.3 are not identical with the reference numbers of the spare parts lists. 1 1/1 1/2 2 4 6 8 15 16 17 18 19 20 21 22 23 25 26 36 41 42 43 44 46 47 55 62 63 64 69 70 72

Heat exchanger complete Retarder oil-cooling circuit Gearbox oil-cooling circuit Control unit Connection Terminal 15 Fuse (8A) Connection Ground ABS-signal Retarder stage switch Retarder pilot light Stop light relay Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Ventilation Casing ventilation Air pressure line “A” constant-air pressure (py) Air pressure line supply-air pressure (pv) Ventilation line “R” Oil duct Oil tank Oil sump Stator Rotor Speedometer signal Oil-drain plugs Pressure regulating valve Check valve (inlet) Check valve (outlet) Plug ISO-interface Plug additional functions Pressure sensor



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General

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Description of the function 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. The switched-on retarder will not secure the parked vehicle. In the event of a retarder failure or when the temperature adaption is effective, the service brake must be used to regulate the vehicle speed.




General


Action of the retarder R 115 E with Digiprop control system

c

A retarder stage switch (16) with 5 switch stages is used to operate the Voith retarder 115 E. In a special version, the retarder stage switch (16) in conjunction with ABS can be combined with a 3-stage treadle brake valve or a pressure switch unit for the service brake. When the retarder stage switch (16) is shifted to position 1, the function „Constant Speed“ is activated. The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit of the maximum possible braking torque.

a

b

If the retarder is switched-off (position 0), or if a braking stage is engaged (position 2 to 5), the memorized „Constant Speed“ is deleted. If the function „Constant Speed“ is re-activated the new present speed is memorized. When shifting the retarder stage switch (16) into position 2 to 5, the retarder brakes in braking stage 1 to 4. In the maximum position of the retarder stage switch (16) the braking torque of the Voith retarder is at maximum.

FD299

The hydrodynamic principle a Rotor (46) b Stator (44) c Oil flow

The control medium for the Voith retarder 115 E is compressed air, which is taken from the vehicle air-tank for auxiliary equipment. When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2). From this input signal, the control unit (2) provides a control current which is passed on to the proportional valve (21). The proportional valve (21), depending on the magnitude of the control current, provides a constant-air pressure (py) on the oil sump (43). The constant-air pressure (py) in the oil sump (43), depending on the operating conditions (prop-shaft speed), forces a certain quantity of oil into the working chamber between rotor (46) and stator (44). The rotor (46) is connected with the drive shaft of the retarder, the stator (44) is fixed to the retarder housing.




General


The rotation of the retarder sets the oil in motion and circulates it in a closed circuit between the rotor (46) and stator (44). The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking of the rotor (46) and consequently to braking of the vehicle. During braking, the deceleration energy is transformed into heat. To dissipate this heat, part of the oil in the working circuit is pumped continuously by the rotor (46) through the heat exchanger (1) and filling ducts and returned to the circuit again. In the heat exchanger (1), the heat energy of the oil is transferred to the cooling water of the vehicle and dissipated via the vehicle radiator to the ambient air. The gearbox- and retarder oil reservoires 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. Temperature pick-ups, water (19), oil (20) The temperature pick-ups are installed in the cooling system of the vehicle (cooling-return circle from the retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and oil temperature to the control unit (2). To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarder braking torque is 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 adaption 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.




General


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. 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.

Note If the check valve (outlet) must be renewed during a repair operation, please contact Voith Turbo or a responsible contract party.




General

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The gearbox identification (data plate) s located at the side of the retarder-gearbox-system on the right in direction of travel (see illustration 2 – example).

Note For queries or when ordering spare parts we need the data of the gearbox. Only with this data a fast and effective run time is possible.

DAIMLERCHRYSLER Indic.

Serial No

Ratio 1. gear Number of gears Input torque (x 10) Gearbox-Bus

Unit Series Version Left hand drive 71 4. 692 L

GO 170 - 6 / 8,2

Code

DAIMLERCHRYSLER M-Code

Indic.

GO 170-6/8,2

Code

G 714.100 L

Serial No

Gearbox number Gearbox part-No

Version No

M-Code Variant No

M+P-07A-1704e

M+P-07A-1705e

Illustration 1


Illustration 2



General

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The retarder identification (data plate) is located at the gearbox-retarder-system on the right in direction of travel (see Illustration 2).

Note Retarder ratio (i Ret)

For queries or when ordering spare parts we need the data of the retarder. Only with this data a fast and effective run time is possible.

Serial-Number (Brake-Number) 6-digit number

Serial-No

000000

CW/Year

45/1999

Date of production Serial-No CW/Year

Voith Item-Number 8-digit number

M+P-07A-1706e

M+P-07A-1707

Illustration 1

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DaimlerChrysler part-number

Illustration 2



General

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The Digiprop-control unit identification (data plate) is located at the control unit and provides the following information: 1. Voith-number 8-digit number The software version can be identified by the last two numbers. Example: .12 = version 1.2 2. Code-number 3-digit number (Adjustment of the control unit)

Vo it Co h-N Se de-Nr.: Kurien- r.: nd Nr. en : -N r.:

53 . xx xxxx x .12 xx xx /D atu m

3. Serial-number 5-digit number with date of coding 4. Client-number (DaimlerChrysler part-number)

Note For queries or when ordering spare parts we need the data of the control unit. Only with this data a fast and effective run time is possible.


Voith no.: Code no.: Serial no.: Client no.:

Date:

M+P07A-1617a



Maintenance

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3.1

Maintenance Work / Oil Change Intervals..................................................3.1/1

3.2

Checking Oil Level at Gearbox...................................................................3.2/1

3.3

Checking Oil Level at Retarder ..................................................................3.3/1

3.4

Oil Change at Gearbox...............................................................................3.4/1

3.5

Oil Change at Retarder ..............................................................................3.5/1


Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10 Page 3.1


Maintenance

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Maintenance work The following maintenance work has to be carried out at each oil change (gearbox and retarder): -

Clean the oil sieve (gearbox) Clean the sieve for the pressure regulating valve (retarder) Check fastening screws of the retarder heat exchanger Check all screw plugs on leak and correct fitment Carry out visual inspection on 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

0DLQWHQDQFH:RUN2LO&KDQJH,QWHUYDOV (Continue)

Retarder 6)

Gearbox Single-grade mineral oil 1)

Synthetic oil 1)

Single-grade mineral oil 2)

Synthetic oil 2)

Synthetic oil 3)

Normal duty

100 000 km 4)

300 000 km 5)

135 000 km 4)

180 000 km 5)

300 000 km 5)

Heavy duty

50 000 km 4)

300 000 km 5)

60 000 km 4)

90 000 km 5)

300 000 km 5)

1) according to Operating Specifications, page 11/4 - 11/7 2) according to Operating Specifications, page 11/8 - 11/12 3) according to Operating Specifications, page 11/13 4) change oil at the latest after 1 year, if fewer kilometres are travelled 5) change oil at the latest after 2 years, if fewer kilometres are travelled 6) The oil change intervals for the retarder oils (see note 2) may adapted to the oil change intervals of the single-grade mineral oils for the gearbox –




Maintenance

0DLQWHQDQFH:RUN2LO&KDQJH,QWHUYDOV (Continue)

1. „Normal duty“ Example: – Long distance traffic 2. „Heavy duty“ Subject to more than normal stress. Example: – Use in regions with high ambient temperature (e.g. Saudi-Arabia) – High max. permissible weight with low rated engine power (< 5,9 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 the service departement.




Maintenance

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Illustration checking oil level 26/100/122 Oil filler plug M24x1,5 Inhex.-head, w.a.f. 14, 47 Nm 26/100/128 Sealing ring A24x29 renew

26/100/122 26/100/128

M+P-07A-1716a





Maintenance

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Note For satisfactory gearbox operation, it is important to adhere to the specified service filling (see annex) for operating the retarder in the relevant application. For the oil level check, the temperature of the gearbox oil must have reached the operating temperature. The oil level check must be carried out with the vehicle in a horizontal position.

Caution! Risk of injury! The oil filler plug is hot! Oil temperature!




Maintenance

&KHFNLQJ2LO/HYHODW*HDUER[ (Continue)

Job scope

Caution! Risk of injury!

26/100/122

The oil filler plug is hot! Oil temperature!

26/100/128 1. Screw out oil filler plug (26/100/122) and remove sealing ring (26/100/128). The oil level is correct, if the oil level is at the lower edge of the oil check hole (see illustration right). 2. Top up slowly any lacking oil through the hole for the oil filler plug according to the Operation Specifications.


Note If there is any lacking oil, the gearbox must be checked for outer leaks.

3. Screw in oil filler plug with new sealing ring and screw them tight. Tightening torque oil filler plug (26/100/122) 47 Nm




Maintenance

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Illustration checking oil level A Oil drain and measure method 107 Oil drin plug M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm) 4200 Oil drin plug M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm)

4200 107

M+P-07A-1712




Maintenance

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Illustration checking oil level B With oil check plug

4100

109 Oil check plug M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm) 4100 Oil filling plug M30x1,5 Inhex.-head, w.a.f. 17 100 Nm (150 Nm)

109 M+P-07A-1713




Maintenance


Note Two methods are available for checking the oil level: A Oil drain and measure method B With oil check plug 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 (see annex) for operating the retarder in the relevant application. For the oil level check, the temperature of the gearbox oil must have reached the operating temperature. The oil level check must be carried out with the vehicle in a horizontal position.

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 during the oil level check for possible damages; replace completely if necessary.




Maintenance


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 generel to renew.

A Oil drain and measure method Job scope 1. Push a clean vessel under retarder.

Caution! Risk of injury! The oil drain plugs (107, 4200) and oil filler plug (4100) are hot! Oil temperature! During the oil level check the retarder mustbe switched-off! 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.

4200 107

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) 65 Nm (80 Nm)




Maintenance


5. Measure drained oil. 6. Top up any lacking oil according to the Operating Specifications, chapter 3.1: „Oil Change Intervals“ and chapter 11: „Annex“. 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).

Caution! The retarder must only be filled with oil via the bore of the oil filler plug (4100)!

Note 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 (150 Nm)

Caution! Operate the retarder, after checking oil level, first time during a trail run at a speed of minimum 50 km/h 5 times for approx. 5 seconds each time in position 2 at the retarder stage switch (corresponds braking stage 1).




Maintenance


B With oil check plug Job scope 1. Switch vehicle ignition system „OFF“ and then „ON“ again (reset). 2. Operate the retarder in stand-still in switch position 2 at the retarder stage switch (corresponds braking stage 1) and switch it off after approx. 5 seconds. Repeat this procedure twice. 3. Switch off the retarder and wait 5 minutes.

Caution! Risk of injury! The oil check plug (109) and oil filler plug (4100) are hot! Oil temperature!

4100

While the oil level is being checked, the retarder must be switched off! If the retarder is switched-on during working step 4 and screwed out oil drain plugs and/or oil filler plug, high risk of injury exist by hot leaving oil (increased pressure)! 4. Screw out oil check plug (109). The oil level is correct, if it is at the lower edge of the oil check hole (see illustration).

Caution!

109

The retarder must only be filled with oil via the bore of the oil filler plug (4100)!



M+P-07A-1713


Maintenance


5. Fill in slowly the quantity of oil, via the bore of the oil filler plug, specified in accordance to the Operating Specifications.

Note With determined lacking oil quantity check retarder for possible outer leak.

6. Check sealing ring of oil check plug for possible damages, renew oil check plug if necessary. 7. Screw in oil check plug and screw it tight. Tightening torque oil check plug (109): 65 Nm (80 Nm) 8. Check sealing ring of oil filler plug (4100) 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 (150 Nm)




Maintenance

2LO&KDQJHDW*HDUER[

Illustration oil change 26/100/107 Oil sieve clean sieve with appropriate cleaning agent (Benzine) 26/100/113 Spring 26/100/116 Screw plug (oil sieve) M38x1,5 Inhex.-head, w.a.f. 17, 60 Nm 26/100/119 Sealing ring A38x46 renew 26/100/122 Oil filler plug M24x1,5 Inhex.-head, w.a.f. 14, 47 Nm 26/100/125 Oil drain plug M24x1,5 Inhex.-head, w.a.f. 14, 47 Nm 26/100/128 Sealing ring A24x29 renew

26/100/122

26/100/128

26/100/116 26/100/119 26/100/107 26/100/113

26/100/128 26/100/125

Lubricants and cleaning agents Sieve in screw plug

Benzine

26/100/128 26/100/125

M+P-07A-1715





Maintenance

2LO&KDQJHDW*HDUER[ (Continue)

Note The gearbox- and retarder oil reservoires 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 below) and to use only oils specified in the Operating Specifications (see annex) for operating the retarder in the relevant application. For draining the oil the temperature of the gearbox oil must have reached the operating temperature.

Caution! Risk of injury! The oil drain plugs are hot! Oil temperature!

Oil filling Service filling (oil change)

12,5 litre

New filling

13,0 litre




Maintenance

2LO&KDQJHDW*HDUER[ (Continue)

Job scope

26/100/122

1. Push an oil pan under the gearbox.

26/100/128

26/100/116 26/100/119 26/100/107 26/100/113

Caution! Risk of injury! The oil drain plugs (26/100/125) are hot! Oil temperature!

26/100/128 26/100/125

2. Screw out oil drain plugs (26/100/125), remove sealing rings (26/100/128) and drain oil. 3. Screw the oil drain plugs (26/100/125) with new sealing rings tight. Tightening torque oil drain plugs (26/100/125): 47 Nm

26/100/128 26/100/125

M+P-07A-1715b

4. Screw out screw plugs (26/100/116) and remove sealing rings (26/100/119). 5. Clean oil sieve (26/100/107) with appropriate cleaning agent (Benzine) and blow it out with compressed-air. Check cleaned sieve for possible damages, renew if necessary.

Remark: Terms of items from DaimlerChrysler-EPC-documentation

6. Fix spring (26/100/113) with oil sieve (100/107) in bore of screw plug (26/100/116). 7. Screw the screw plug (26/100/116) with new sealing ring tight. Tightening torque screw plug oil sieve (26/100/116): 60 Nm 8. Screw out oil filler plug (26/100/122) and remove sealing ring (26/100/128). 9. Fill in slowly oil via the bore of the oil filler plug according to the Operating Specifications. 10. Screw the oil filler plug (26/100/122) with new sealing ring tight. Tightening torque oil filler plug (100/122): 47 Nm




Maintenance

2LO&KDQJHDW5HWDUGHU

Illustration oil change retarder

4100

107 Oil drain plug M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm) 3500 Screw plug with sieve M30x1,5 Inhex.-head, w.a.f. 17 100 Nm (150 Nm), Clean sieve with appropriate cleaning agent and blow out with compressed-air 4100 Oil filler plug M30x1,5 Inhex.-head, w.a.f. 17 100 Nm (150 Nm) 4200 Oil drain plug oil tank M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm)

Lubricants and cleaning agents O-rings

Silicone- free and non-corrosive grease

Sieve in screw plug

107

Benzine

3500

4200

4200 M+P-07A-1488




Maintenance

2LO&KDQJHDW5HWDUGHU (Continue)

Note The gearbox- and retarder oil reservoires 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 on next page) and to use only oils specified in the Operating Specifications, chapter 3.1 „Oil Change Intervals“ and chapter 11: „Annex“ 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!

Caution! 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 during the oil level check for possible damages; replace completely if necessary.




Maintenance


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 generel to renew.

Oil filling with heat exchanger Service filling (oil change, oil level check)

7,0 litre

After complete taking apart and cleaning as well as emptied heat exchanger (corresponds new filling)

7,8 litre

Job scope 1. Push an oil collecting pan under the retarder.

Caution! Risk of injury! 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 sealing rings of oil drain plugs on possible damages, renew oil drain plugs if necessary.

107

4. Screw the oil drain plugs tight. Tightening torque oil drain plugs (107, 4200): 65 Nm (80 Nm)

4200

4200 M+P-07A-1489




Maintenance


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 sealing ring of screw plug with sieve on possible damages, renew screw plug if necessary. 8. Fit screw plug with sieve and screw it tight. Tightening torque screw plug (3500): 100 Nm (150 Nm)

3500

9. Screw out oil filler plug (4100).

M+P-07A-1490

Achtung! The retarder must only be filled with oil via the bore of the oil filler plug (4100)!

10. Fill in slowly in the bore of the oil filler plug, over a time period longer than 3 minutes, the quantity of oil specified (see table page 3.5/3 in this chapter) according the Operation Specifications, chapter 3.1: „Oil Change Intervals“ and chapter 11: „Annex“. This working step is necessary for the correct bleeding of the retarder system.




Maintenance


11. Check 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 (150 Nm)

Caution! Operate the retarder after the oil change first during the trial run 5 times with a speed of minimum 50 km/h each time for approx. 5 seconds in position 2 at the retarder stage switch (corresponds braking stage 1).




Diagnosis /

'LDJQRVLV7URXEOHVKRRWLQJ*HDUER[

Troubleshooting 4.1

Troubleshooting Diagram ...........................................................................4.1/1 Troubleshooting Master System .................................................................................... 4.1/1 Troubleshooting Diagram A to E.................................................................................... 4.1/2




Diagnosis /

7URXEOHVKRRWLQJ'LDJUDP

Troubleshooting Illustration troubleshooting master-system

see troubleshooting diagram at page 4.1/2

Please contact DaimlerChrysler


at gearbox?

Complaint

at retarder?


at the gearbox-retardersystem, but I am not sure



Diagnosis / Troubleshooting

7URXEOHVKRRWLQJ'LDJUDP (Continue)

A1 A2* A3*

E

*Begin of troubleshooting at A1

B

leaks

elektrical function

shiftability

Complaint Gearbox

no traction

noices

D 'DLPOHU&KU\VOHU$* 3RZHUWUDLQ%XVLQHVV8QLW 7UDQVPLVVLRQV

C Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10 Page 4.1/2


Diagnosis /

Troubleshooting


Illustration troubleshooting diagram A1

A1 leaks

Check residual oil quantity. Contact product unit gearbox if residual oil quantity smaller 50%.

at the drive shaft? YES

NO

at radial shaft sealing ring?

at countershaft cover?

YES

YES

NO

Renew radial shaft sealing ring (chapter 8.2)

seal new with released surface sealant (chapter 8.2)

NO

at cover 5./6.gear? (only GO 210) NO

YES

at O-rings? YES

A2

NO

at O-ring? YES

Renew O-rings (chapter 8.2)

at surface / surface sealant? YES

NO


NO

at the micro capsulated screws? YES



Contact product unit gearbox

use new micro encapsulated screws


NO



Diagnosis /


Troubleshooting Illustration troubleshooting diagram A2

A2 leaks

at cover oil pump? YES


NO

at parting surface of housing? YES

NO

am Gehäuseteil?


YES

NO

at cover of gearbox selecting fork right and left? YES

seal new with surface sealant (chapter 8.3)

NO

Threaded components / shift rocker arm bearing ? NO

Filler cap?

NO

YES


YES

Radial shaft sealing rings of cross shift? Radial shaft sealing ring left side? YES

YES

NO

Sensor / switch?

NO

NO

Seal parts new, renew if necessary

YES

A3 renew radial shaft sealing ring (chapter 8.3)

Radial shaft sealing ring right side? YES

Renew cross shift complete (chapter 8.3)


Check sensor / switch for leak leaky

NO


Renew parts and seal them


sealed

Seal parts new


Diagnosis /


Troubleshooting Illustration troubleshooting diagram A3

A3 leaks

at breather? Breather correct mounted? YES

Check oil level and correct if necessary (chapter 3.2)

YES

NO

Cover / flanges leak?

NO

YES

Renew breather (chapter 8.4)

NO

Cover / flanges damaged? YES

Paper gasket at cross shift leaks between inner and outer cover?

NO

YES Replace cover / flanges (chapter 8.2)

Seal new cover / flanges (chapter 8.2)

Paper gasket damaged

YES



NO



NO

Seal new with released liquid sealant




Illustration troubleshooting diagram B

B

Shiftability

Selectability?

YES

NO

Shift at still stand heavy handling?

outer shift smooth? NO

YES

Smooth shifting of gear? NO


NO

Does clutch disconnect?

Reverse gear heavy handling?


YES

YES


YES


NO

NO


YES

Adjust clutch according to vehicle manufacturer instructions

Clutch servo in function? YES




NO

Change clutch servo (chapter 8.6)


Diagnosis /

Troubleshooting


Illustration troubleshooting diagram C

C

Noices

noices when shifting? YES

NO

Noices during operation in pulling action?

in reverse gear?

YES

Check for clutch disconnect according to vehicle manufacturer instructions

NO

scratching when shifting? YES

Ambient temperature? COLD

does not appear at operation temperature

YES

NO


WARM

Check outer shift for easy handling

NO

Check oil level (chapter 3.2), if OK, contact product unit gearbox

Noices during stress cycle? NO

Noices during operation in retarder operation? YES


Rattleing in idle speed?

Check and adjust according to the vehicle manufacturer instructions: - Idle speed of engine - torsional absorption of clutch

3RZHUWUDLQ%XVLQHVV8QLW 7UDQVPLVVLRQV



NO

YES

'DLPOHU&KU\VOHU$*

YES

NO



Diagnosis /

Troubleshooting


Illustration troubleshooting diagram D

D no traction

Gear shifted at gearbox? (check at gearbox) YES



NO

Adjust again outer shift according to the vehicle manufacturer instructions



Diagnosis /

Troubleshooting


Illustration troubleshooting diagram E

E electrical function

Does switch exist (switch for reverse gear position or neutral position) YES

NO

Sensors available?

Check contacts of components OK

functioning?

YES


NOK

YES

Check contacts of components

Renew components

NO

Renew components

OK




NOK

Renew components

functioning?

YES

NO

NO

Renew components



Diagnosis /

'LDJQRVLV7URXEOHVKRRWLQJ5HWDUGHU

Troubleshooting 5.1

Troubleshooting Diagram ...........................................................................5.1/1 Troubleshooting Master System ........................................................................5.1/1 Troubleshooting Diagram A to C .......................................................................5.1/2 Electrical Connections Diagram ........................................................................5.1/6

5.2

Troubleshooting and Remedies .................................................................5.2/1

5.3

Illustration Control System .........................................................................5.3/1

5.4

Checking Supply-Air Pressure ...................................................................5.4/1

5.5

Checking Constant-Air Pressure (py) .........................................................5.5/1

5.6

Checking Control Current of Proportional Valve ........................................5.6/1

5.7

Checking Temperature Adaption................................................................5.7/1

5.8

Checking Pressure Sensor.........................................................................5.8/1

5.9

Checking Pump Pressure...........................................................................5.9/1

5.10

Table of Measurements..............................................................................5.10/1

5.11

Operational Check......................................................................................5.11/1




Diagnosis /

7URXEOHVKRRWLQJ'LDJUDP

Troubleshooting Illustration troubleshooting master system


Please contact DaimlerChrysler


at gearbox?

Complaint

at retarder?


at the gearbox-retardersystem, but I am not sure





A Oil loss through ventilation

Complaint Retarder R 115 E

Retarder pilot light

B

No respectively insufficient retarder braking effect

C 'DLPOHU&KU\VOHU$* 3RZHUWUDLQ%XVLQHVV8QLW 7UDQVPLVVLRQV





Illustration troubleshooting diagram group

Note It is important that the specific service filling is kept for a trouble-free operation of the retarder (see chapter 3.5 „Oil Change“ and chapter 11 „Annex“).

A Oil loss through ventilation

Check retarder oil level OK

Water in oil? (emulsion) NO

YES

NOK

Water in oil? (emulsion) YES

Check heat exchanger (chapter 9.5)

NO

Check retarder oil level

Contact Voith service partner

too high

too low

Check gearbox oil level

Check gearbox oil level NOK

Check gearbox oil level too high

Correct retarder- and gearbox oil level

OK

OK

Correct retarder oil level

too low

Check casing ventilation (chapter 9.2) OK


Check control unit (chapter 5.4 - 5.9)

NOK

Check gearbox oil level

NOK

too high

Replace casing ventilation

too low



M+P-07A-1763 ae






B Retarder pilot light

Permanent light in position 0 after light test?

no function?

flashes?

Activate blinking code and read out fault code (chapter 5.2)

Check retarder pilot light and renew, if necessary

Temperature adaption

Rectify fault and delete fault memory (chapter 5.2)

Check operation (during braking with retarder nominal engine speed, if possible)


OK

Check temperature pick-up oil / water (chapter 5.7) OK

Check vehicle cooling system: -coolant level -thermostat -coolant pump -radiator fan -radiator grill for dirtiness


NOK

Driver instruction!

NOK

Replace temperature pick-ups (chapter 10.2, 10.3)





C No respectively too insufficient retarder braking effect

Check retarder oil level OK

Water in oil? (emulsion) NO

YES

Water in oil? (emulsion) YES

Check heat exchanger

Check retarder oil level

NOK

too high

Check pump pressure (chapter 5.9) OK

NO

(chapter 9.5)

Check constantair pressure (py) (chapter 5.5) OK

NOK


NOK

too low

Check gearbox oil level OK



Check current of proportinal valve (chapter 5.6) OK

Check supply-air pressure (chapter 5.4) OK

Correct retarder oil level

NOK

OK

Proportional valve or damping plate mechanically defect

Check vehicle compressed-air pressure system OK




NOK

Check gearbox oil level too high

Check temperature adaption/ pressure sensor (chapter 5.7 / 5.8)

NOK

NOK


too low


NOK


Contact vehicle manufacturer



Diagnosis /

Troubleshooting


Electrical connections diagram R 115 E (Voith-wiring harness)

P 1

Control unit Connection Terminal 15 ABS-signal Retarder stage switch Retarder pilot light Stop light relais Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Speedometer signal Plug ISO-Interface Plug optional functions Pressure sensor

72

4

70

14 13 11 12 10 1

9

5

47 15 8 4

3

2

7

21

19

20

6

18 87 87a 30

2 4 15 16 17 18 19 20 21 47 69 70 72

U 2

. .

17

2 1

-

+

+

+

-

.

X3

.4

-

8 11 10 12 7

9

4

5

6

1

2

X2

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

7

6

5

2

3

8

4

4 3

2

1

4

69

16

FD983a




Diagnosis /

7URXEOHVKRRWLQJDQG5HPHGLHV

Troubleshooting Troubleshooting and remedies Requirements for check

l l l l l

Battery voltage 18 - 32 V Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory. Fuse for retarder control unit checked and found satisfactory. Compressed-air pressure 6 - 11 bar For check with the multimeter, pin 15 (plug X1) on the control unit (2) must be connected to pin 15 ground (terminal 31), at pin 7 (plug X1) and pin 13 (plug X1) must be connected terminal 15

Note Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary (see table, chapter 3.5, page 3.5/3).





7URXEOHVKRRWLQJDQG5HPHGLHV (Continue)

Note The retarder pilot light additionally has the function of a fault code: - 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 the ignition is switched off and on, the retarder is in operation again and the retarder pilot light goes off. If a serious fault remains present or reoccurs, the retarder switches off again and the retarder pilot light comes on permanently in position 0 to 5 of the retarder stage switch.




Diagnosis /

Troubleshooting


Connector arrangement and pin assignment

Note All plugs illustrated from plug-in side (i.e. leads at back).

Plug X1 control unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Not in use Not in use Not in use Retarder stage switch, Position 2 Retarder stage switch, Position 1 Retarder stage switch, Position 1 Terminal 15 Retarder stage switch, Position 4 Retarder stage switch, Position 3 Retarder stage switch + ISO-interface, L-lead ISO-interface, K-lead connected with terminal 15 Not in use Terminal 31 Output / high side 2 „HS2“ Not in use Output / high side 1 „HS1“


16

13

10

7

4

1

17

14

11

8

5

2

18

15

12

9

6

3

FD846



Diagnosis /

Troubleshooting


Plug X2 control unit 1 2 3 4 5 6 7 8 9

Not operational Proportional valve Proportional valve + Cooling-water temperature pick-up Cooling-water temperature pick-up + Not operational Not in use Oil temperature pick-up Oil temperature pick-up +

7

4

1

8

5

2

9

6

3

FD848

Plug X3 control unit 1 2 3 4 5 6 7 8 9 10 11 12

Input / pull up „DIU 1“ Speedometer signal ABS-signal Input / pull down „DID 2“ Input / pull down „DID 1“ Pressure sensor ground Pressure sensor signal voltage Retarder pilot light Input / pull down „DID 3“ Pressure sensor supply voltage Stop light relais Input / pull down / PWM-in „DID4“


10

7

4

1

11

8

5

2

12

9

6

3

FD847





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

Retarder stage switch + Input / pull down „DID 1“ Input / pull down „DID 2“ Input / pull down „DID 3“ Input / pull down / PWM -in „DID 4“ Input / pull up „DIU 1“ Pressure sensor ground Pressure sensor signal voltage Pressure sensor supply voltage Output / high side „HS1“ Output / high side 2 „HS2“ No function Terminal 15 Terminal 31

2

4

6

8

10

12

14

1

3

5

7

9

11

13

FD849

Plug ISO-interface 1 2 3 4

K-lead L-lead Terminal 15 Terminal 31

4

3

2

1

FD854




Diagnosis /

Troubleshooting


Plug cooling-water temperature pick-up Plug oil temperature pick-up

FD851

Plug proportional valve 1 2 3 4

Proportional valve + Proportional valve – No function No function

4 1

2 3

FD850




Diagnosis /

Troubleshooting


Plug retarder stage switch 1 2 3 4 5 6 7 8

Not operational Position 5 Position 4 Retarder stage switch + Position 3 Position 2 Position 1 Bridge to pin 4

5

6

7

8

1

2

3

4

FD853






A. With fault code Special tool

53.8224.10

Commercially available tool Multimeter

recommended: Fluke 87

Note The blinking code of the retarder pilot light with service-cable can be used to obtain a read-out from the fault memory.




Diagnosis /

Troubleshooting


Fault memory readout via retarder pilot light blinking code

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 of the control unit service cable or retarder stage switch. Fault memory readout with service cable

Requirements

l l 1. 2. 3.

Retarder stage switch in position O. Vehicle at standstill, ignition ON Service interface L-lead connected to ground ≥ 2s. For this pupose, press „L - pushbutton“ at service cable First fault as blinking code output. Item 2 and 3 repeated for more blinking code outputs.

Meaning

l l

Long blinking signals (2 sec.) tens unit. Short blinking signals (0,5 sec.) single unit.




Diagnosis /

Troubleshooting


Fault memory read out with retarder stage switch

Display example for fault code 23:

1 sec

0,5 sec

1 sec

0,5 sec

1 sec

There is a break of 3 seconds before and after each blinking code output, during this time the retarder pilot light is switched off.

0,5 sec

2 sec

Retarder stage switch in position 0 Retarder stage switch in position 1 (≥ 2 seconds) Retarder stage switch in position 0 First fault as blinking code Items from ...3 for more blinking code outputs

2 sec

1. 2. 3. 4. 5.

1 sec

The blinking code can be triggered with the retarder stage switch during the service function (vehicle ignition system ON and v = 0):

99-03-fd1620

Display example for fault code 23

The number of tens units first indicated as long ON time: The number of single unit then is indicated as short ON time: Breaks between each ON time:

each 2 seconds each 0,5 seconds each 1 second

E Retarder pilot light ON A Retarder pilot light OFF t Time

If an actual fault is available (before triggering the blinking code the retarder pilot light is switched ON) the retarder pilot light switches to permanent light again after the blinking code. Is only one stored fault available, the retarder pilot light is OFF after the output.




Diagnosis /

Troubleshooting


Delete fault memory 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.






Note Meaning of entries in „Measurement/test connection“ column: X 1/15 Ω X3/11 Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3

Fault

Code

Fault text

Fault class

Trigger time

Requirement / Operation

Stop light relay/

slight

1s

- Ignition: OFF - Pull plug X3 out of control unit

Short circuit to ground

2)

Result/ Set point

Cause/ Remedy 2)

Relay is installed: 250-350 Ω

Check lead, plugs and relay or consumers

Test step

01

1)

Measurement/ Test connection1)

X 3/11 Ω X 1/15

X 1/15 = ground control unit Only, if no fault is recognizable after a complete check of the periphery: change control unit.





Fault


Fault text

Fault class

Trigger time


03

HS 1 output Short circuit

slight

1s

04

HS 2 output Short circuit

slight

05

Terminal 15 Undervoltage

06

Terminal 15 Overvoltage

Code

Measurement/ Test connection

Result/ Set point

Cause/ Remedy


X 1/18 Ω X 1/15



1s


X 1/16 Ω X 1/15



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

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)

Test step





Fault

Code

Fault text


Fault class

Trigger time


1s



Result/ Set point

Cause/ Remedy

20°C ± 10°C = 1039 - 1117Ω

Check lead and sensor

Test step

08 09

Cooling-water temperature pick-up Discontinuity / Short circuit to battery

serious/ slight *

X 2/5 Ω X 2/4

60°C ± 10°C = 1099 - 1271Ω 80°C ± 10°C = 1271 - 1347Ω Notice: The measuring in one temperature range normally is sufficient.

*

Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.





Fault

Code

Fault text


Fault class

Trigger time


1s



Result/ Set point

Cause/ Remedy

20°C ± 10°C = 1039 - 1117Ω

Check lead and sensor

Test step

11 12

Oil temperature pick-up Discontinuity / Short circuit to battery

serious/ slight *

X 2/9 Ω X 2/8

60°C ± 10°C = 1099 - 1271Ω 80°C ± 10°C = 1271 - 1347Ω Notice: The measuring in one temperature range normally is sufficient.

*

Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.





Fault Code 13

13

13


Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Retarder stage switch Undefined switch state

serious

100 ms

- Ignition: ON - Retarder stage switch: Position 0

X 1/10 V X 1/15

≥ 17,5 V

Check lead, plug and retarder stage switch

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

0V 0V 0V 0V 0V


X 1/10 V X 1/15 X 1/6 V X 1/15

≥ 17,5 V ≥ 17,5 V

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

0V 0V 0V 0V


X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15

≥ 17,5 V ≥ 17,5 V ≥ 17,5 V

X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15

0V 0V 0V

Test step 1

2

3







Fault Code 13

13

13

Fault text


Fault class

Trigger time



Result/ Set point

Cause/ Remedy

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

≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V


X 1/9 V X 1/15 X 1/8 V X 1/15

0V 0V

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

≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V

X 1/8 V X 1/15

0V

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

Test step 4

5

6










Fault


Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

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

0V

Check lead and plug

15

Retarder stage switch Short circuit to battery

serious

1s

- Ignition: OFF - Pull plug X1 out of control unit - Retarder stage switch: Position 5

X 1/10 Ω X 1/15

Resistor infinite

Single check of stages for short circuit

16

Speedometer signal Discontinuity

serious

2s

- Ignition: ON

≤ 1V

Check lead and speedometer

Code

Test step


X 3/2 V X 1/15




Fault


Fault text

Fault class

Trigger time


18

Speedometer signal Short circuit to battery undefined signal

serious

2s


19

ABS Short circuit to ground

serious

60 s

21

ABS-Signal undefined

serious

22

Internal fault ABS-current path

23

Proportional valve Fault No. 1: Short circuit to battery

Code


Result/ Set point

Cause/ Remedy

X 3/2 V X 1/15

≤ 9V

Check lead and speedometer

- Ignition: ON

X 3/3 V X 1/15

≥ 3,5 V

Check lead, relay and ABS-control unit

60 s

- Ignition: ON

X 3/3 V X 1/15

≥ 16,5 V

Check lead, relay and ABS-control unit

serious

1s

-

serious

1s


Test step



X 2/3 V X 1/15

≤ 10 V

Replace control unit Check lead



Fault

Code


Fault text

Fault class

Trigger time


Proportional valve Fault No. 2: - Short circuit proportional valve magnetic - Short circuit connection lead proportional valve - Discontinuity proportional valve magnetic Valve magnetic - Discontinuity connection lead proportional valve - Short circuit to ground at proportional valve - Prop.- and shift valve interchanged

serious

1s

- Ignition: ON - Pull plug X2 out of control unit



Result/ Set point

Cause/ Remedy

X 2/2 Ω X 2/3

18-25 Ω

Check lead and proportional valve (valve block)

X 2/3 Ω X 1/15

Resistor infinite

Check lead and proportional valve (valve block)

Test step

24

1

24

2





Fault

Code 24


Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Resistor infinite

Check lead and valve block

Test step 3


X 2/2 Ω X 1/15

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

2s


28

Terminal 30 Undervoltage

serious

60 s




X 1/13 V X 1/15

≥ 17,5 V

Check lead, plug and fuse



Fault


Fault text

Fault class

Trigger time

29

Fault control unit

serious

180 ms


31

Control unit: Coding fault

serious

100 ms

Provide new parameters for control unit

32

Retarder pilot light: Discontinuity / Short circuit to ground

serious

3s


X 3/8 V X 1/15

≥ 17,5 V

Check lead, retarder pilot light and fuse

33

Retarder pilot light: Short circuit to battery

serious

3s


X 3/8 V X 1/15

≤ 2V

Check lead and retarder pilot light

35

Fault control unit

serious

500 ms / 123 s

Code



Result/ Set point

Cause/ Remedy

Test step






Fault

Code

Fault text

Fault class

Trigger time

Fault foot operation

slight

100 ms / 1 s

Fault constant-air pressure

slight

1 s to 10 s



Result/ Set point

Cause/ Remedy

Test step

37

38


1

Check installation in accordance with OEM - as well as Voith requirements Ignition: ON Position 0

X 3/7 V X 1/15 and X 3/10 V X 1/15

0,3-0,7 V

Pressure sensor wiring harness

4,75-5,25 V If deviation: step 2

2


Troubleshooting in wiring harness, pressure sensor, proportional valve, supply-air pressure, ECU (Contact Voith)





B. Without fault code

Note Retarder faults without fault code are not recognized electronically.




Diagnosis /

,OOXVWUDWLRQ&RQWURO6\VWHP

Troubleshooting Illustration control system 11 33 71

Note

32

25

61

A

The reference numbers indicated in section 5.3 are not identical with the reference numbers of the spare parts lists.

P R

21

26

36

1 2 11 19 20 21 25 26 31

32

33 34 35 36 39

40 61 71

Heat exchanger Control unit Connection proportional valve current Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Constant-air pressure line py (connection A) Supply-air pressure line pv (connection P) Compressed-air line (pressure regulator-four circuit protection valve) Compressed-air line (four circuit protection valve air tank for auxiliary equipment) with test connection Compressed-air line (Brake circuit 1) Compressed-air line (Brake circuit 2) Compressed-air line (Parking brake) Ventilation line (Connection R) Electrical lead (cooling-water temperature pick-up to control unit, 2-wires) Electrical lead (oil temperature pick-up to control unit, 2-wires) Four-circuit protection valve Air tank for auxiliary equipment


31 35

34 40

2

20

39 29

1

FD919



Diagnosis /

&KHFNLQJ6XSSO\$LU3UHVVXUH

Troubleshooting Job scope test 1.

Connect suitable test pressure gauge to test connection of compressed-air line (32) (four circuit protection valve - air tank for auxiliary equipment) and check supply-air pressure pv.. Minimum pressure:

6 bar

Maximum pressure:

11 bar

Note If the pressure is not within the specified range, the compressed-air pressure installation must be checked to the manufacturer´s data.



32 FD122


Diagnosis /

&KHFNLQJ&RQVWDQW$LU3UHVVXUHS\

Troubleshooting Requirements for check

l

Retarder stage switch in position 0

l

Vehicle ignition system OFF

Special tool

53.1403.10

Compressed-air gauge 0-6 bar





&KHFNLQJ&RQVWDQW$LU3UHVVXUHS\ (Continue)

Caution! Two versions of screw plugs (103) 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 during the oil level check for possible damages; replace completely 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 generel to renew.




Diagnosis /

Troubleshooting

&KHFNLQJ&RQVWDQW$LU3UHVVXUHS\ (Continue)

Job scope test

4100

1. Screw out oil filler plug (4100).

M+P-07A-1488c

2. Connect pressure gauge (99/1) to bore of oil filler plug (4100).

99/1 3. operate retarder in braking stage 5 and compare read-off value with the values of the constant-air pressure (py) according to table see page 5.10/1. 4. Check sealing ring of screw plug for damages; replace if necessary. 5. Disconnect pressure gauge (99/1). Fit oil filler plug (4100) and screw it tight. Tightening torque oil filler plug (4100): 100 Nm (150 Nm)

M+P-07A-1488b

99/1 Pressure gauge 53.1403.10




Diagnosis /

&KHFNLQJ&RQWURO&XUUHQWRI3URSRUWLRQDO9DOYH

Troubleshooting Requirements for check • • • •

Battery voltage 18 - 32 V Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory. Fuse for retarder control unit checked and found satisfactory. Plug at valve block and socket checked for damage as well as wear (notch scratches).

Special tool

53.8198.10

Measuring adapter







&KHFNLQJ&RQWURO&XUUHQWRI3URSRUWLRQDO9DOYH (Continue)

Job scope test

21

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) to the measuring socket 1. Switch position: mA or A

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 5.10/1.

98/8

99/3 FD923

99/3 Measuring adapter „Prop current“ 53.8198.10 99/8 Multimeter




Diagnosis /

&KHFNLQJ7HPSHUDWXUH$GDSWLRQ

Troubleshooting Requirements for check

l l l l l

Battery voltage 18 - 32 V Vehicle ignition system OFF Pressure gauge constant-air pressure (99/9) connected Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory. Fuse for retarder control unit checked and found satisfactory.

Special tool

Wasser

Öl

53.8207.10

Temperature simulator


53.8279.10

Adapter cable




&KHFNLQJ7HPSHUDWXUH$GDSWLRQ (Continue)

Arbeitsumfang Prüfung 1. Connect temperature simulator (99/2) with adapter cable (98/5) to plug temperature simulator (57).

Note

57

98/5

99/2

Mind the correct connection of the plugs for cooling-water and oil! 2. Set the rotary switch of the temperature simulator (99/2) to 95°C cooling water temperature and 165°C oil temperature. Operate the retarder at the highest braking stage. 3. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. The constant-air pressure py must drop temporary below the set maximum pressure. Set rotary switch of the temperature simulator (99/2) to 125oC cooling water temperature. There must be no more output of constant-air pressure py.

FD1455

99/2 Temperature simulator 53.8207.10 98/5 Adapter cable 53.8279.10

Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature. 4. Set the rotary switch of the temperature simulator (99/2) to 185oC oil temperature.rThe constant-air pressure must drop temporary below the set maximum pressure. Set the rotary switch of the temperature simulator (99/2) to 225oC oil temperature. There must be no more output of constant-air pressure py. 5. Reconnect electrical lead (57) to temperature pick-up cooling-water and oil.




Diagnosis /

&KHFNLQJ3UHVVXUH6HQVRU

Troubleshooting Requirements for check • • •

Ignition ON Pressure gauge constant-air pressure connected Retarder stage switch in position 0

Special tool

53.8198.10

Measuring adapter







&KHFNLQJ3UHVVXUH6HQVRU (Continue)

Job scope test 1. Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3).

98/8

2. Connect plug of measuring adapter to pressure sensor (38). 3. Connect electrical lead Ground of Multimeter (98/8) to measuring socket 4 of adapter. 38

4. Turn switch „Propvalve“ at measuring adapter (99/3) downwards (not in position „I“). 5. Connect electrical lead Positive of Multimeter to measuring socket 1. 99/3

6. The measured voltage must be between 4,75 and 5,25 V.

99-03-923a

7. Connect electrical lead Positive of Multimeter to measuring socket 2. 8. Compare measured voltage in conjunction of constant-air pressure with the following values: 0 bar = 0,3 - 0,7 V 2,5 bar = 2,8 - 3,2 V

98/8

9. After disconnecting the measuring adapter connect electrical lead again to pressure sensor.

38

99/3 99-03-923b




Diagnosis /

&KHFNLQJ3XPS3UHVVXUH

Troubleshooting Prior jobs • •

Retarder stage switch in braking stage 0 Ignition OFF 103

Screw plug (measuring point pump pressure) M12x1,5 Inhex.-head, w.a.f. 6 13 Nm (20 Nm)

103

Note The pump pressure check provides information on internal leaks and on the correct operation of the retarder. Special tool

53.4788.10

Oil pressure gauge 0-25 bar


M+P-07A-1491




&KHFNLQJ3XPS3UHVVXUH (Continue)

Requirements for check

l l l l l l

Battery voltage 18 - 32 V Vehicle electrical system checked in accordance with the Operating Manual for the vehicle and found satisfactory. Fuse for retarder control unit checked and found satisfactory. Compressed-air pressure 6 - 11 bar No external leaks at the retarder Retarder stage switch in braking stage 0

Caution! Two versions of screw plugs (103) 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 during the oil level check for possible damages; replace completely 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 generel to renew.




Diagnosis /

Troubleshooting


Caution! Risk of injury!

103 103

The screw plug (103) and the oil is hot!

Caution! Easy oil-exit is caused constructively, but has no effect on the function of the retarder, however.

Job scope test 1. Screw out screw plug (103). 2. Connect up pressure gauge (99/1) to the retarder housing.

99/1

M+P-07A-1493




Diagnosis /

Troubleshooting


3. Drive the vehicle with a prop shaft speed of v ps = 1000 r.p.m. Put in direct gear (gear ratio 1:1), and drive with an engine speed of 1000 r.p.m. 4. Shift the retarder stage switch to position 5 while on the move and read pump pressure off test pressure gauge (99/1) at prop shaft speed vps = 1000 r.p.m. 5. Compare read-off pump pressure with the value of dynamic pump pressure according to the table see page 5.10/1.

Caution! If the constant-air pressure (py) is obtained in the test at stillstand (see chapter 5.5), but the minimum value of the dynamic pump pressure is not reached, please contact your Voith service partner.

Caution! Risk of injury! Hot oil can leave when disconnecting the presure gauge!

6. Check sealing ring of screw plug for damages; renew if necessary. 7. Disconnect pressure gauge. Screw in screw plug tight. Tightening torque screw plug (103): 13 Nm (20 Nm).




7DEOHRI0HDVXUHPHQWV


Code number 2)

Control current mA1) 3) 5)

Constant-air pressure (py) (static) 4) 1) set value [bar]

Pump pressure (dynamic) 1) vps = 1000 r.p.m. minimum value [bar]

055

396 - 596

2,10 - 2,30

17

056 - 058

409 - 609

2,30 - 2,50

19

059, 079, 080

440 - 640

2,75 - 2,95

23

1) 2) 3) 4) 5)

Retarder stage switch in highest braking stage! The code number is to be found on the control unit If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!). Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure). The values are not steadily because of continuous control in the closed loop (however within the stated range).

Note These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.




Diagnosis /

2SHUDWLRQDO&KHFN

Troubleshooting Requirements for check • • • •

Battery voltage 18 - 32 V Electrical system checked in accordance with the Operating Manual for the vehicle and found satisfactory. Constant-air pressure 6 -11 bar Retarder oil level satisfactory

The following operational states are indicated by the retarder pilot light: Retarder pilot light without indication The retarder is switched off. There is no fault in the memory. Retarder pilot light permanently on The retarder is switched on, i.e., one of the four possible retarder braking stages or „Constant Speed“ operation has been selected with the retarder stage switch. The retarder pilot light additionally has the function of a fault indicator. -

slight fault Continous light in position 0 - 5 of the retarder stage switch, braking operations are possible (partly with reduced braking torque).

-

serious fault The retarder pilot light shows permanent light in position 0 - 5 of the retarder stage switch. There are no more braking operations possible - the retarder is switched off.





2SHUDWLRQDO&KHFN (Continue)

Note If the ignition is switched off and on again, the retarder is in operation and the retarder pilot light is going off. If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch.

Retarder pilot light flashes -

during retarder braking The temperature adaption is effective - the retarder regulates back its braking torque. These flash function however, is only realized at defined regulation variants!





Test step 1

2

2SHUDWLRQDO&KHFN (Continue)

Scope of check Retarder pilot light

Retarder


Requirement / Operation Ignition: ON

Vehicle on move - Shift retarder stage switch to stage 1 to 5.

Result / Set point

Note, Cause / Remedy

Retarder pilot light comes on and goes off after approx. 5 sec.

Retarder pilot light trouble-free

Retarder pilot light does not come on, or does not go off.

Troubleshooting as on page 5.1/2

Retarder pilot light comes on, retarder brakes in stages 1 to 5.

Retarder operates trouble-free.

Retarder pilot light does not come on, or retarder does not brake properly.

Troubleshooting as on page 5.1/2



Gearbox Remo-

5HPRYLQJ,QVWDOOLQJ*HDUER[

ving, Installing 6.1

Removing, Installing Gearbox ....................................................................6.1/1



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Gearbox, Remo-

ving, Installing

5HPRYLQJ,QVWDOOLQJ*HDUER[ (Continue)

Illustration removing, installing gearbox Prior jobs • Ignition OFF • Shift linkage removed • Clutch output cylinder removed • Engine bonnet removed, if necessary • Engine compartment enclosed casing removed, if necessary • Clutch servo removed, if necessary (chapter 8.6) Weight in kg: approx.195 kg without clutch housing

6

5

21 19 26

7 3

3

Achtung Verletzungsgefahr! Secure vehicle, engine and gearbox propper!

1 3 4 5 6 7 19 20 21 26 25/250/119

Plug switch reversing light Connecting piece Plug speedometer sensor Hex.-head nut, renew Propeller shaft Plug switch for starter lock Plug cooling-water temperature pick-up Plug oil temperature pick-up Plug proportional valve Compressed-air line supply-air pressure Hex.-head screw M10x45, 45 Nm


20 4 1 25/250/119 M+P-07A-1773




Gearbox Remo-

ving, Installing


Workshop equipment Gearbox lifter Nr. 554 Manufacturer: e. g. Fa. Kirner Obersteinstraße 139 D-55602 Kirn Tel. 06752 / 93110 Fax 06752 / 71751

M+P-07A-1775



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Gearbox Remo-

ving, Installing


Adapter for gearbox lifter Nr. WBM 0079.06 Manufacturer: e. g. Fa. Wagner Dieselstraße 9-11 D-70829 Gerlingen Tel. 07156 / 22013 Fax 07156 / 22014

M+P-07A-1776

Commercially available equipments Wheel gripper tool

RG 5/2HD2


z. B. Fa. Hywema


9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Gearbox Removing, Installing


Removing, installing 1. Lift the vehicle with 4 wheel gripper to the wished working height. 2. Drain coolant (heed the statements of the vehicle-manufacturer). 3. Drain oil of gearbox and retarder (chapter 3.4 and 3.5). 4. Prop up engine with suitable device, (heed the statements of the vehicle-manufacturer). 5. Remove eventually existing cross bars, which are in the way with the removal of the gearbox. Note for installation Tightening torque: 55-65 Nm 6. Remove connecting pieces (3) from heat exchanger. 7. Pull the plug (19) from cooling-water temperature pick-up. 8. Pull the plug (20) from the oil temperature pick-up. 9. Remove compressed-air line (26) from proportional valve. 10. Pull the plug (21) from proportional valve. 11. Pull the plug (1) from switch reversing light. 12. Pull the plug (4) from speedometer sensor. 13. Pull the plug (7) from switch for starter lock.



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Gearbox Remo-

ving, Installing


14. Remove propeller shaft (6) from retarder. Note for installation: Use new self-locking hex.-head nuts. Tightening torque according to vehicle manufacturer instructions. 15. Screw out hex.-head screws from bracket / engine bearing right and left. Note for installation: Tightening torque: 180-210 Nm 16. Screw out top hex.-head screw from clutch housing / engine. Note for installation: Tightening torque: 39-46 Nm 17. Remove both rear engine bearing brackets. Note for installation: Tightening torque: 165-195 Nm 18. Drive gearbox lifter with adapter below the gearbox, adjust gearbox lifter and secure with safety chain. Slightly lift the gearbox. 19. Screw out bottom hex.-head screw from clutch housing / engine. Note for installation: Tightening torque: 39-46 Nm 20. Lift the gearbox higher and drive out it to the rear.



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Gearbox Removing, Installing


21. Clean all parts, check for wear, and renew parts if necessary. 22. Install in reverse sequence. 23. Top up coolant according to the vehicle manufacturer instructions. Heed the cooling water-quality in chapter 11. 24. Top up oil of gearbox and retarder. Therefore heed chapter 3.4 and 3.5. 25. Enforce a visual examination on leaks after taken place test drive.

Note Connections as hoses, hose ties, screws and nuts, plugs and terminals must be in propper conditions. Defective parts must be renewed. Clean the drive shaft and grease it wafer-thin. Therefore see Operating Specifications of vehicle manufacturer. Engage retaining ring before installation of the clutch output cylinder by pulling at the clutch release fork. Check the function by pushing. Check gearbox oil level: See chapters 3.2: „Checking Oil Level of Gearbox” and 3.3: „Checking Oil Level of Retarder“. Top up coolant: See statements of the vehicle-manufacturer.



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Retarder Remo-

5HPRYLQJ,QVWDOOLQJ5HWDUGHU

ving, Installing 7.1

Removing, Installing Retarder ....................................................................7.1/1




Retarder Remo-

5HPRYLQJ,QVWDOOLQJ5HWDUGHU

ving, Installing Illustration removing, installing retarder 25000 (26/860/020*)

Prior jobs • • • •

Gearbox (with retarder) removed (see chapter 6.1) Connecting pieces removed (see chapter 9.4) Speedometer sensor removed (see chapter 8.5) Output flange removed (see chapter 8.7) 850 Outer race Remove only, if taper roller bearing is renewed or a new balance washer is added (DC-tool) 850/001 Taper roller bearing 4100 Screw plug M30x1,5 Inhex.-head, w.a.f. 17 100 Nm (150 Nm) 25000 Balance washer 25100 O-ring, renew coat with silicone-free and noncorrosive grease for installation 25200 Hex.-head screw M10x70 Hex.-head, w.a.f. 15 58 Nm 25300 Hex.-head screw M10x60 Hex.-head, w.a.f. 15, 58 Nm


25300 25300

850

25200

25100 (26/860/023*)

4100

25200

850/001 M+P-07A-1497

* DaimlerChrysler position number



Retarder Removing, Installing

5HPRYLQJ,QVWDOOLQJ5HWDUGHU (Continue)

Special tools

67.2713.10

Control device

on inquiry

67.3056.10

Measuring device

Puller for outer race

on inquiry Impact tool for outer race

M10

Tool for local fabrication

15

80

Material: St37-2, DIN 17100 (1.80)

0073ae

Threaded bolt M10x80




Retarder Remo-

ving, Installing


Lubricants and locking agents O-rings

Silicone-free and non-corrosive grease

Retarder housing

Omnifit FD10-1042

Caution! The measuring device 67.3056.10 has to be calibrated annually! The workshop using this device is responsible for calibration and the propper condition of the device. Two versions of 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 during the oil level check for possible damages; replace completely 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 generelly to be renew.




Service-

Retarder Remo-

ving, Installing

5HPRYLQJ,QVWDOOLQJ5HWDUGHU (Continue) 25200

25300

Caution! Risk of injury! Secure retarder before working step 1 (prop up)!

Caution! Remove speedometer sensor before working step 1 (see chapter 8.5)!

25200

Removing, installing 1. Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove retarder with suitable lifter device from gearbox.

M+P-07A-1498

2. Remove O-rings (25100) from gearbox.

25000 850

Note You must execute the following working-step only, if: - a new retarder is installed - the taper roller bearing (850/001) is renewed or - the gearbox is renewed 3. Dismantle outer race (850) with puller for outer race (DaimlerChrysler tool F3 6280 0 486 285) and remove balance washer (25000).



850/1

25100

M+P-07A-1499




Installing 1.

Determine the thickness of the balance washer like follows:

a

Note Determine the thickness of the balance washer only, if: - one or both taper roller bearings of the retarder was renewed - the retarder was dismantled or changed or - the gearbox was dismantled or changed

M+P-07A-1444

The following described measurements may only being carried out at room temperature! 1.1

Take measuremnets of the spacing „a” between the surface of the gearbox housing (320) on retarder side and the surface of the balance washer. Note down the measured value as dimension „a“.

1.2

Place measuring device (98/1) on supporting plate (60).

1.3

Push vernier caliper (61) at measuring plate (62) and set to zero by using the reset key (63).

61 62

63

60

M+P-07A-1976

98/1 Measuring device 67.3056.10






1.4

Place outer race (850) on taper roller bearing (850/1).

1.5

Place measuring plate (62) on outer race (850) and check correct and gap-free seat by rotation.

62 Then press with one hand powerful onto the measuring plate (62) and turn the driving wheel (arrow) 2 turns clockwise and 2 turns counter-clockwise.

850 850/1

M+P-07A-1977

1.6

Place the measuring device (98/1) in the way on the retarder housing, that both plastic bolts mesh in the flat surface.

1.7

Place vernier caliper (61) at measuring plate (62) and read-off value.

61 62

Note

98/1

The measured value must be between +0,86 mm and -0,28 mm, contact Voith if necessary. 1.8

Calculate dimension „b“. Dimension „b“ plus or minus the read-off value from working step 1.7 (heed sign at scale). Note down the calculated value as dimension b.

M+P-07A-1978

98/1 Measuring device 67.3056.10




Retarder Removing, Installing 1.9


Place again the measuring device at the supporting plate (60).

1.10 Push vernier caliper (61) at measuring plate (60) and check, if zero position still is set.

61 62 Note

63

60

The measuring device must display zero, if necessary press reset key to repeat measuring procedure.

1.11 Calculate thickness of balance washer. M+P-07A-1976

Thickness of balance washer = dimension „a“ minus dimension „b“ minus 0,02 mm 2.

Place balance washer (25000) into gearbox housing (if dismantled).

Note

25000 850

If taper roller bearing was renewed, renew also outer race (850).

3.

Place outer race (850 - if removed) into the gearbox housing and knock it in with the impact tool for the outer race (DaimlerChrysler tool) as far as it will go. M+P-07A-1446




Retarder Removing, Installing 4.


Clean sealing surface of retarder housing (1).

1

M+P-07A-1501

5.

Turn the gearbox until the sealing surface does show upwards (gearbox is in vertically position).

6.

Clean sealing surface of gearbox housing and coat it with locking agent Omnifit FD10-1042.

7.

Coat O-rings (25100) with silicone-free and non-corrosive grease and place into the gearbox.

8.

Screw in two threaded bolts M10x80 (see arrows) into the gearbox housing. The threaded bolts are required so that the sealing surfaces (gearbox/retarder) can be installed congruent.

25100

M+P-07A-1448






Place retarder at gearbox and screw it tight with 5 hex.-head screws (25200). Tightening torque hex.-head screws 58 Nm

10.

Unscrew the two threaded bolts M10x80 again.

11.

Screw in the 17 hex.-head screws (25300) and screw them tight. Tightening torque hex.-head screws 58 Nm

25200 25200 25200

25300 M+P-07A-1502a

12.

Turn gearbox with fixed retarder in the horizontally position again.

13.

Screw out screw plugs (4100) out of retarder housing.

4100

M+P-07A-1497a






Press threaded spindle of control device (98/2) into direction of arrow as far as it will go.

98/2 4100

M+P-07A-1997 M+P-07A-1503

98/2 Control device 67.2713.10

15.

Screw control device (98/2) via „A“ hand tight into the retarder housing.

16.

Screw control device (98/2) via „B“ into the drive shaft until it is turning too.

A 98/2

Note

B

Over the threaded bore of the speedometer sensor (arrow) can be determined, if the impulse ring itself and so the drive shaft turns.

M+P-07A-1979







17.

Fix the holder (99/8) with dial gauge at retarder housing.

18.

Place test prod with initial tension at surface (arrow) of control device (98/2) and set scale of dial gauge to zero.

4100

98/2

99/8

M+P-07A-1980 M+P-07A-1503

98/2 Control device 67.2713.10 19.

Check gap of taper roller bearings as following:

0HDVXUHPHQW 19.1 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with compressed-air (approx. 6 to 8 bar). 19.2 Turn shaft of the control device (64) three times about its own axis.

98/2

19.3 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time about 360°. Make marking at surface of control device at the point you can read-off the lowest value of the dial gauge. 19.4 Place test prod with initial tension at the marked position and set scale of dial gauge to zero. Seite 4/1Service-Handbuch VOITH Retarder 115 E



64

M+P-07A-1981



Retarder Remo-

ving, Installing


0HDVXUHPHQW

4100

19.5 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with compressed-air (approx. 6 to 8 bar). 19.6 Turn shaft of the control device (64) three times about its own axis. 19.7 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time about 360°. The smallest value corresponds the bearing gap.

98/2

Set value: 0,02 to 0,12 mm, contact Voith if necessary.

64

M+P-07A-1982 M+P-07A-1503

98/2 Control device 67.2713.10 Caution!

If the set value is not reached, the retarder must be removed and be installed again with another corresponding balance washer. To this all working steps described in this chapter must be carried out once again.

4100 20.

Remove control device again.

21.

Check sealing ring of screw plug (4100) on damages; renew if necessary.

22.

Screw in screw plug (4100) again and screw it tight. Tightening torque: 100 Nm (150 Nm)



M+P-07A-1497a


Repair

5HSDLU*HDUER[

Gearbox 8.1

Overall Illustration of Main Components ....................................................8.1/1

8.2

Removing, Installing Front Housing Cover, Cover Countershaft and Closing Cover 5./6.- Gear...........................................................................8.2/1

8.3

Removing, Installing Shift...........................................................................8.3/1

8.4

Removing, Installing Breather ....................................................................8.4/1

8.5

Removing, Installing Sensor/Switch at Gearbox ........................................8.5/1

8.6

Removing, Installing Clutch Servo and Adjusting Wear Indicator .....................................................................8.6/1

8.7

Removing, Installing Output Flange Renewing Radial Shaft Sealing Ring .........................................................8.7/1




Repair

2YHUDOO,OOXVWUDWLRQRI0DLQ&RPSRQHQWV

Gearbox Illustration main components gearbox GO170 - GO210

26/350/083

26/350/080

26/100/056

26/250/047 26/100/206

26/100/053 26/350/101

26/100/059

26/860/026

26/100/032 26/860/017 26/860/014

25/250/020 26/100/038

26/860/026

26/100/014 26/100/008

26/100/197 26/100/200

26/100/203

26/100/194

26/100/023 26/100/029

26/100/128

26/400/083

26/100/128

26/400/089 26/100/122

26/100/128

26/100/125

26/100/125 25/250/113

25/250/008

26/350/071

26/250/068

26/100/113 26/100/116 26/100/107 26/100/119

26/350/ 25/250/068 26/350/065 25/250/110

25/250/008 25/250/020 25/250/068 25/250/110 25/250/113 26/100/008 26/100/014 26/100/023 26/100/029 26/100/032 26/100/038 26/100/053 26/100/056 26/100/059 26/100/107 26/100/113 26/100/116 26/100/119

Clutch housing Hex.-head screw Clutch servo Cover metal sheet Hex.-head screw Front housing cover O-ring Radial shaft sealing ring Hex.-head screw Countershaft cover Hex.-head screw Closing cover 5./6.-gear O-ring Hex.-head screw Oil sieve Spring Screw plug Sealing ring

* = option


26/100/122 26/100/125 26/100/128 26/100/194 26/100/197 26/100/200 26/100/203 26/100/206 26/250/047 26/250/068 26/350/065 26/350/071 26/350/080 26/350/083 26/350/101 26/350/ 26/400/083 26/400/089 26/860/014 26/860/017 26/860/026

Oil filler plug Oil drain plug Sealing ring Sealing ring Anti-fatigue screw O-ring O-ring Speedometer sensor Switch starter lock * Inductive sensor for overspeed protection * Hex.-head screw Breather complete Cover bearing reverse gear end stop Radial shaft sealing ring Hex.-head screw Shift Oil temperature pick-up gearbox * Switch reversing light * Radial shaft sealing ring Radial shaft sealing ring Hex.-head screw



Repair

Gearbox

5HPRYLQJ,QVWDOOLQJ)URQW+RXVLQJ&RYHU&RYHU &RXQWHUVKDIWDQG&ORVLQJ&RYHU*HDU (Cont.)

Prior jobs • • • •

Gearbox removed (chapter 6.1) Gearbox housing removed Clutch servo removed (chapter 8.6) Clutch release removed 26/100/008 Housing cover front, coat with sealant Omnifit FD10-1042 26/100/014 O-ring, renew coat with silicone-free and noncorrosive grease for installation 26/100/023 Radial shaft sealing ring, renew 26/100/029 Hex.-head screw 30 Nm 26/100/032 Cover countershaft, coat with sealant Omnifit FD10-1042 26/100/038 Hex.-head screw M10x35 30 Nm 26/100/053 Closing cover 5./6.- gear 26/100/056 O-ring, renew coat with silicone-free and noncorrosive grease for installation 26/100/059 Hex.-head screw 30 Nm

26/100/056 26/100/053 26/100/059 26/100/023 26/100/008 26/100/014 26/100/032 26/100/038 26/100/029 M+P-07A-1774





Repair

Gearbox


Sealants and Lubricants Runddichtringe Gehäusedeckel Vorgelegewellendeckel Verschlußdeckel 5./6.-Gang

Silicon- und säurefreies Fett Omnifit FD10-1042

To remove, to install 1. Only with gearbox G0210: 1.1 Screw out hex.-head screws (26/100/059). 1.2 Remove closing cover 5./6.-gear (26/100/053) with O-ring (26/100/056) ab. Clean sealing surface.

26/100/056 26/100/053 26/100/059

Note for installation Coat new O-ring (26/100/56) with silicone-free and non-corrosive grease. Tightening torque: 30 Nm

M+P-07A-1779





Repair

Gearbox


Note Do not damage oil spin disk in front housing cover (26/100/008)! Therefore perform working step 2 to 5 only with gearbox in vertical positioned gearbox (drive shaft up). 2.

Screw out hex.-head screw (26/100/029).

3.

Remove front housing cover (26/100/008). Clean sealing surface.

26/100/008

26/100/029 M+P-07A-1781

4.

Remove O-ring (26/100/014).

5.

Remove radial shaft sealing ring (26/100/023). Note for installation Install new radial shaft sealing ring (26/100/023) pin drift, thus the sealing lip shows upwards Coat new O-ring (26/100/014) with silicone-free and non-corrosive grease. Coat sealing surfaces of housing cover with sealant Omnifit FD10-1042. Tightening torque: 30 Nm

26/100/023 26/100/014

M+P-07A-1778





Repair Gearbox


6.

Screw out hex.-head screws (26/100/038).

7.

Remove countershaft cover (26/100/032). Clean sealing surface. Note for installation Coat sealing surfaces of housing cover with sealant Omnifit FD10-1042. Tightening torque: 30 Nm

8.

26/100/032 26/100/038

Install in reverse sequence.

M+P-07A-1780





Repair

5HPRYLQJ,QVWDOOLQJ6KLIW

Gearbox Prior jobs • •

Gearbox selector rod removed Switch for starter lock removed (if available)

26/350/065 Hex.-head screw M8x60 16-21 Nm 26/350/080 Bearing cover of reverse gear end stop, coat with sealant Omnifit FD10-1040 26/350/083 Radial shaft sealing ring, renew 26/350/101 Hex.-head screw 16-21 Nm 26/350/x Shift, coat with sealant Omnifit FD10-1040

26/350/083

26/350/080

26/350/101

Sealant Cover bearing of reverse gear end stop, shift

Omnifit FD10-1042

26/350/x 26/350/65

M+P-07A-1777





Repair

Gearbox

5HPRYLQJ,QVWDOOLQJ6KLIW (Continue)

To remove, to install 1.

Switch gearbox in neutral position.

2.


3.

Remove bearing cover reverse gear end stop (26/350/080).

4.

Remove radial shaft sealing ring (26/350/083). Note for installation Knock in new radial shaft sealing ring with suitable pin drift. Coat sealing surface of bearing cover reverse gear end stop with sealant Omnifit FD10-1042. Tightening torque: 16-21 Nm

5.


6.

Remove shift (26/350/X). Note for installation Coat sealing surface of shift with sealant Omnifit FD10-1042. Tightening torque: 16-21 Nm

7.

Install in reverse sequence.




Repair

5HPRYLQJ,QVWDOOLQJ%UHDWKHU


1 2

Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary 26/350/071 1 2 3 4 5

26/350/071

Breather complete Hex.-head screw 20 Nm Spring washer Bush Oil sieve Neck

3 4 5

M+P-07A-1782





Repair

5HPRYLQJ,QVWDOOLQJ6HQVRU6ZLWFKDW*HDUER[


Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary 26/100/89 Switch reverse gear * 40-52 Nm 26/100/206 Speedometer sensor 32-42 Nm 26/250/47 Switch for starter lock * 26/250/68 Induktive sensor for overspeed protection * 26/400/83 Oil temperature pick-up gearbox * 40Nm

26/250/047

* = option

26/100/206 26/100/089 26/250/068

26/400/083 M+P-07A-1772





Repair

Gearbox

5HPRYLQJ,QVWDOOLQJ&OXWFK6HUYRDQG $GMXVWLQJ:HDU,QGLFDWRU

Prior jobs • •

Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary 25/250/068 25/250/113 35 25/250/110 38 39 40 41 42 43 44 45

Clutch servo Hex.-head screw, 40 Nm Tappet Cover metal sheet Spacer Neck Sealing rings, renew Compressed-air pressure line Hydraulic pipe Banjo bolt Closing cover Banjo bolt

25/250/113 38

39

42 45 44

40 41 25/250/068 35

40

43

25/250/110 M+P-07A-1798





Repair Gearbox

5HPRYLQJ,QVWDOOLQJ&OXWFK6HUYRDQG $GMXVWLQJ:HDU,QGLFDWRU(Continue)

To remove 1.

Remove compressed-air pressure line (41) and hydraulic pipe (42) from clutch servo.

42

41 M+P-07A-1799

2.

25/250/068

Screw out hex.-head screws (25/250/113) and remove clutch servo (25/250/068) with the cover metal sheet (25/250/110).

25/250/113

M+P-07A-1800





Repair Gearbox


To install 1. Snap in by hand the clutch release bearing, with the help of the clutch release fork (arrow), through the opening of the clutch housing into the stress ring of the clutch.

M+P-07A-1801

2. Align clutch servo (25/250/068) with cover metal sheet (25/250/110) at clutch dome.

25/250/068

3. Screw the hex.-head screws (25/250/113) tight. Tightening torque: 40 Nm.

25/250/113

M+P-07A-1800





Repair

Gearbox


4.

Install compressed-air pressure line (41) with banjo bvolt (43) and new sealing ring (40) to clutch servo (25/250/71).

5.

Install hydraulic pipe (42) with spacer (38), neck (39), banjo bolt (45) and closing cover (44) to clutch servo (37).

6.

Bleed hydraulically clutch actuation.

42 44 45 39

38

43 40 25/250/71

41 M+P-07A-1803


Adjust mechanical wear indicator:

7.1 Pull cover cap (54) off.

51

52 53

54

7.2 Release hex.-head nut (52). 7.3 Screw in wear indicator (53) as far as the indicator (51) is flush with the wear indicator (arrow). 7.4 Fit cover cap (54).

M+P-07A-1804




Repair Gearbox 8.


Wear control:

8.1 Pull cover cap (54) off.

54 8.2 Check wear of clutch disk.

Note The clutch disk is wear out, if the back edge of the indicator (51) is flush with the back edge of the wear indicator (arrow).

51 M+P-07A-1805

8.3 Fit cover cap (54).




Repair Gearbox

5HPRYLQJ,QVWDOOLQJ2XWSXW)ODQJH 5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ

Prior jobs • •

31

Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary

26/100/197 32

26/860/014 Radial shaft sealing ring, renew 26/860/017 Radial shaft sealing ring, renew 26/100/194 O-ring, renew coat with silicone-free and noncorrosive grease for installation 26/100/197 Anti-fatigue screw, renew 450 Nm 26/100/200 O-ring, renew coat with silicone-free and noncorrosive grease for installation 26/100/203 O-ring, renew coat with silicone-free and noncorrosive grease for installation 31 Hex.-head nut, renew 32 Propeller shaft

26/100/200 26/100/194 26/100/203 26/860/017 26/860/014

Lubricants O-ring


M+P-07A-1797





Repair Gearbox

5HPRYLQJ,QVWDOOLQJ2XWSXW)ODQJH 5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ(Continue)

To remove, to install 1. Remove propeller shaft from output flange. Note for installation Use new self-locking hex.-head nut (31). Tightening torque according to vehicle manufacturer instructions. 2. Screw out anti-fatigue screw (26/100/197) and remove O-rings (26/100/194), (26/100/200) and 100/203). Note for installation Coat new O-rings (26/100/200 und 26/100/203) with silicone-free and non-corrosive grease and use new anti-fatigue screw. Tightening torque: 396 - 484 Nm. 3. Pull off output flange. 4. Remove radial shaft sealing rings (26/860/014 and 26/860/017). Note for installation Install new radial shaft sealing rings (26/860/014 and 26/860/017) with suitable pin drift. 5. Install in reverse sequence.




Repair

5HSDLU5HWDUGHU

Retarder 9.1

Overall Illustration of Main Components ....................................................9.1/1

9.2

Removing, Checking and Installing Casing Ventilation ..............................9.2/1

9.3

Removing, Cleaning and Installing Silencer...............................................9.3/1

9.4

Removing, Installing Water Neck ...............................................................9.4/1

9.5

Removing, Checking and Installing Heat Exchanger .................................9.5/1

9.6

Removing, Installing Oil Tank Cover ..........................................................9.6/1 A Top Oil Tank Cover ......................................................................................9.6/1 B Bottom Oil Tank Cover .................................................................................9.6/2




Repair

2YHUDOO,OOXVWUDWLRQRI0DLQ&RPSRQHQWV

Retarder Illustration main components R 115 E

6101 3300

3300 2800/1

4100

6100 6101 9000 3850 3850 3800

3100 2000/1 3900 8000

6600 6700

4000 5400 5500 5600

3700 2900

2300

7500

2301

25000

109 850 6400 7300

20100 20000 20300

7600

5200 5300

20200

7500 103

2600

7300

20300

3500

5200 5300

2500/1 3100 4200

20100

4100 107

4200

6700 6600 20000 20200

6700 6600

20300 M+P-07A-1504b

103 107 109 850 2000/1 2300 2301 2500/1 2600 2800/1 2900 3100 3300 3500 3700 3800 3850 3900 4000 4100 4200 5200

Screw plug M12x1,5, Inhex.-head, w.a.f. 6 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 Outer race Top cover Casing ventilation Bgr. D30x38, die casting O-ring 55x3 Bottom cover Bottom gasket Cover casing ventilation Bgr. Gasket Combined hex.-head screw M8x30, w.a.f. 13 Combined hex.-head screw M8x30, w.a.f. 13 Screw plug with sieve, M30x1,5, Inhex.-head, w.a.f. 17 Proportional valve Damping plate O-ring 16x3 Combined hex.-head screw M8x20, w.a.f. 13 Hex.-head nut M8 Screw plug M30x1,5, Inhex.-head, w.a.f. 17 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 Temperature pick-up


5300 5400 5500 5600 6100 6101 6400 6600 6700 7200 7300 7400 7500 7600 7800 8000 9000 20000 20200 20300 25000

Sealing ring A14x20 Corrugated spring Disc (silencer) D30x4 Circlip Pipe O-ring 15,3x2,4 Heat exchanger Hex.-head screw M14x40, w.a.f. 19 alternative: hex.-head screw with flange M14x40 Washer Throttle disc 39/15x3 O-ring 15x4 O-ring 40x2 O-ring 45x5 O-ring 25x4 O-ring 34x3 Intermediate plate 196x144x2 Pressure sensor 0-4 bar Water neck Combined hex.-head screw M8x80, w.a.f. 13 Hex.-head screw M14x1,5, w.a.f. 6 Shim (selection row)



Repair

Retarder

5HPRYLQJ&KHFNLQJDQG,QVWDOOLQJ &DVLQJ9HQWLODWLRQ

Illustration casing ventilation

Note This step can be performed with the retarder removed or installed.

Prior jobs • • •

Ignition OFF Retarder OFF Proportional valve and damping plate removed (chapter 10.1)

Caution! Risk of injury! The retarder housing is hot!




Repair Retarder 2300 2300/1 2300/2 2300/3 2301

2800/1 2900 3300

6100 6101

Casing ventilation D30x38 Valve insert Float specified weight 11g ± 1 g Float cage O-ring 55x3, renew, coat with silicone-free and noncorrosive grease for installation Cover casing ventilation Gasket casing ventilation, renew Hex.-head screw M8x80 Hex.-head, w.a.f. 13 renew, 25 Nm Pipe O-ring 15,2x2,4, renew coat with silicone-free and noncorrosive grease for installation

Lubricants and sealing agents O-ring

5HPRYLQJ&KHFNLQJDQG,QVWDOOLQJ &DVLQJ9HQWLODWLRQ(Continue)

3300 6101 6100

2800/1 6101 2900 2300/1 2300

2301 2300/2 2300/3

silicone-free and non-corrosive grease

Float

Methylated Spirit

M+P-07A-1505




Repair

Retarder Special tools

5HPRYLQJ&KHFNLQJDQG,QVWDOOLQJ &DVLQJ9HQWLODWLRQ(Continue) Tool for local fabrication

60 mm

53.7712.10

53.9428.10

Material: St 37 Weight 0,085 kg

7 mm

40,5 mm

M+P-07A-1758 a

Note The test ring can also be ordered from Voith Turbo - Voith code number 67.2757.10.




Repair

Retarder


To remove 1. Screw out hex.-head screws (3300).

3300

M+P-07A-1506

2. Remove cover (2800/1) with gasket (2900) from retarder housing. Clean sealing surface.

2800/1

2900

M+P-07A-1507




Repair

Retarder


3. Remove pipe (6100) and O-rings (6101).

6101 6100 6101

M+P-07A-1508

4. Use the impact tool (99/5) and adapter (98/9) to extract the valve insert of the retarder housing (1).

99/5

1

98/9

M+P-07A-1509

99/5 Impact tool 53.7712.10




Repair Retarder


5. Take float (2300/2) and float cage (2300/3) out of the retarder housing (1).

2300/2 1

2300/3

M+P-07A-1510

6. Lever O-ring (2301) out of the groove of valve isert (2300/1) and pull it off.

2300/1

2301 M+P-07A-1020




Repair Retarder


To check 1. Check the float (2300/2) for damages to the surface and sealing surface (arrow). 2. Weight the float (2300/2). Specified weight 11 g ± 1 g. If the weight is more than the specified weight renew complete casing ventilation.

2300/2

2300/2

Note Oil has penetrated into the float, the retarder is impaired in its operation. FD194 FD194

3. Check sealing edge of shaft sealing ring (arrow) in the valve insert (2300/1). Put down the valve insert (2300/1) on the float (2300/2) than weigh down the valve insert with the 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 the complete casing ventilation.

99/7 2300/2

2300/1

M+P-07A-1730




Repair Retarder


To install 1. Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on to the valve insert (2300/1).

99/5

1

2. Insert the float (2300/2) and float cage (2300/3) into the valve seat. 3. Insert the casing ventilation into the retarder housing.

98/9

4. Use the impact puller (99/5) and adapter (98/9) to knock in the casing ventilation (2300).

M+P-07A-1509

99/5 Impact tool 53.7712.10 98/9 Adapter 53.9428.10 5. Put pipe (6100) with new O-rings in cover (2000).

2000 6100

M+P-07A-1511




Repair Retarder 6.


Place cover (2800/1) with new gasket into air-pipe (6100) on the retarder housing and screw the hex.-head screws (3300) tight. Tightening torque hex.-head screws: 25 Nm.

6100 3300 2800/1

M+P-07A-1512




Repair

5HPRYLQJ&OHDQLQJDQG,QVWDOOLQJ6LOHQFHU

Retarder Illustration Silencer

Note

5400

This step can be performed with the retarder removed or in situ.

5500 5600

5400 5500

5600

Corrugated spring Disc (Silencer) D30x4, clean with suitable cleaning agent (Benzine) and blast out with compressed-air Circlip JL30x1,2 konvex side must face the silencer

Cleaning agents Silencer

Benzine

M+P-07A-1456




Repair

5HPRYLQJDQG,QVWDOOLQJ:DWHU1HFN

Retarder Prior jobs • • •

Ignition OFF Retarder OFF Cooling-water drained

20000 20100 20200

20300

Water neck Gasket, renew Hex.-head screw M8x80 Hex.-head, w.a.f. 13 28 Nm Hex.-head screw M14x1,5 Inhex head, w.a.f. 6 28 Nm

20100 20000 20200

20100 20000 20200

M+P-07A-1568




Repair

Retarder

5HPRYLQJ&KHFNLQJDQG,QVWDOOLQJ +HDW([FKDQJHU

Illustration heat exchanger

6700 7500

6600

7300 7600 6400 7500 7300 4200

6700 6600

4200

107 M+P-07A-1513

Note The heat exchanger can also be removed with installed retarder. Prior jobs • •

Ignition OFF Retarder removed (see chapter 7.1)

With retarder installed: • Proportional valve and damping plate removed (see chapter 10.1) • Oil drained from retarder (see chapter 3.4) • Cooling-water drained • Water neck removed (see chapter 9.4)

107 4200 6400 6600

Oil-drain plug retarder M24x1,5, Inhex.-head, w.a.f. 12, 65 Nm (80 Nm) Oil-drain plug oil tank M24x1,5, Inhex.-head, w.a.f. 12, 65 Nm (80 Nm) Heat exchanger Hex.-head screw M14x40, w.a.f. 19, renew Initial torque: 35 Nm Final turn: 30° turn alternative: hex.-head screw M14x40 with flange, w.a.f. 19, renew

6700 7300 7500 7600

Washer, renew O-ring 15x4, renew coat with silicone-free and non-corrosive grease for installation O-ring 45x5, renew coat with silicone-free and non-corrosive grease for installation O-ring 25x4, renew coat with silicone-free and non-corrosive grease for installation

Lubricant O-ring





Repair Retarder

5HPRYLQJ&KHFNLQJDQG,QVWDOOLQJ +HDW([FKDQJHU(Continue)

Caution! 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


Special tool

67.1948.10

Pressure-test equipment

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



Repair Retarder


Note If this job 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. Pull cooling-water hoses off the heat exchanger.

107

4200

4200 M+P-07A-1489




Repair

Retarder


To remove 1. Screw out the four hex.-head screws (6600).

6400

2. Remove heat exchanger (6400).

6600

6600 6600

M+P-07A-1514

3. Remove O-rings (7300, 7500 and 7600).

7500 7300 7300 7600 7500 7300 M+P-07A-1515




Repair Retarder


To check 1. Fit pressure-test equipment (99/6) together with O-rings to heat exchanger (6400) and connect compressed-air line to bottom connection (arrow).

99/6

6400

2. Fill heat exchanger (6400) on water side with hot water (approx. 70 oC). 3. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the heat exchanger).

Note M+P-07A-1580

If air bubbles form in the hot water or has outer leaks, the heat exchanger must be renewed. 99/6 Pressure-test equipment 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

Note If air bubbles form in the hot water, the heat exchanger leaks and must be renewed. 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.



M+P-07A-1581

99/6 Pressure-test equipment 67.1498.10


Repair Retarder


Einbauen 1. Fit new O-rings (7300, 7500 and 7600) in the bores.

7600 7500

2. Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) tight.

7300

Initial torque: 35 Nm Final turn: 30° turn

7300

7500 7300 M+P-07A-1516

6600 2400

6600

6600

6600 M+P-07A-1517




Repair Retarder


3. Install the retarder, if necessary (see chapter 7: „Removing, Installing Retarder“). 4. If available, open the check valves in the flow and return pipe of the cooling-water section. Fill in cooling-water and bleed cooling-water circuit.

Caution! 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. 5. Flush the retarder, if the heat exchanger has leaked: 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. -

Check sealing rings of oil-drain plugs for possible damages; renew oil-drain plug if necessary.

107

4200

4200 M+P-07A-1489




Repair Retarder


-

Screw oil-drain plug tight Tightening torque oil-drain plug (107, 4200): 65 Nm (80)

-

Fill in retarder oil (chapter 3.5)

6. If heat exchanger had been leaking, deoil cooling- and heating system of vehicle according to the vehicle manufacturer instructions.




Repair

5HPRYLQJDQG,QVWDOOLQJ2LO7DQN&RYHU

Retarder A Top oil tank cover

6101

Prior jobs • •

Ignition OFF Retarder OFF

3300

6100

9000

6101 Note

3100 This job sequence can also be performed with the retarder installed.

2000/1 Caution! Risk of injury! The retarder housing is hot! 2000/1 3100

3300

6100 6101

8000 9000

8000

Top cover Hex.-head screw M8x30 Hex.-head, w.a.f. 13 renew, 25 Nm Hex.-head screw M8x80 Hex.-head, w.a.f. 13 renew, 25 Nm Pipe O-ring 15,2x2,4, renew coat with silicone-free and noncorrosive grease for installation Intermediate plate Pressure sensor


M+P-07A-1518



Repair

Retarder

5HPRYLQJDQG,QVWDOOLQJ2LO7DQN&RYHU (Continue)

Illustration oil tank cover B Bottom oil tank cover Prior jobs • • •

Ignition OFF Retarder OFF Retarder oil drained (see chapter 3.4) 2500/1 2600 3100

4200

Bottom cover Bottom gasket, renew Hex.-head screw M8x30 Hex.-head, w.a.f. 13 renew, heed tightening sequence! 25 Nm Oil drain plug oil tank M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm)

2600

2500/1 3100 4200



M+P-07A-1519


Repair Retarder


Caution! 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 ring must be checked during for possible damages during the installation of the oil tank cover; 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


Note for installation Heed the mounting position of the gasket and the cover. Tighten all hex.-head screws in defined sequence from 1 to 17 initially with 14 - 19 Nm torque. Then tighten in the same sequence with 25 Nm torque.

6 5 4

7

3

8 1

2

17

9

16

10 15

11 14

12 13 M+P-07A-1368




Control Parts

&RQWURO3DUWV5HWDUGHU

Retarder 10.1

Removing, Installing Proportional Valve...................................................10.1

10.2

Removing, Installing Oil Temperature Pick-Up ........................................10.2

10.3

Removing, Installing Cooling-Water Temperatur Pick-Up........................10.3

10.4

Removing, Installing Pressure Sensor .....................................................10.4




Control Parts

5HPRYLQJ,QVWDOOLQJ3URSRUWLRQDO9DOYH

Retarder Illustration proportional valve

3850

Removing, installing proportional valve Prior jobs • • • •

Ignition OFF Retarder OFF Supply-air discharged Plug at proportional valve and socket checked for damages as well as wear (notch scratches)

26 39 3700 3800 3850 3900

4000

Constant-air pressure line pv Electrical lead Proportional valve Damping plate, renew if necessary O-ring 16x3, renew Hex.-head screw M8x20 Hex.-head, w.a.f. 13 renew, 30 Nm Hex.-head nut M8, renew, 18 Nm

3800 3850 3900 4000 39 3900 3700 26

4000

Caution! If, during repair work the hex.-head nuts (4000) or the hex.-head screws (3900) have to be unscrewed the antivibration plate also has to be checked on mechanical and aging damages and to be renewed, if necessary.




Control Parts Retarder

5HPRYLQJDQG,QVWDOOLQJ&RROLQJ:DWHU 7HPSHUDWXUH3LFN8S

Removing, installing cooling-water temperature pick-up Prior jobs • • •

Ignition OFF Retarder OFF Cooling-water drained

5200 5300

Cooling-water temperature pick-up, 28 Nm Sealing ring A14x20, renew

5200 5300

Caution! Risk of injury! The coolant is hot!

Note Please, bear in mind to the instructions regarding the quality of coolant given from the vehicle manufacturer or Voith Turbo. M+P-07A-1569




Control Parts Retarder

5HPRYLQJDQG,QVWDOOLQJ 2LO7HPSHUDWXUH3LFN8S

Prior jobs • •


32 5200 5300

Electrical lead Oil temperature pick-up, 28 Nm Sealing ring A14x20, renew

5300 5200 32

M+P-07A-1495




Control Parts

5HPRYLQJDQG,QVWDOOLQJ3UHVVXUH6HQVRU

Retarder Prior jobs • •


9000

9000

Pressure sensor, 30 Nm

M+P-07A-1496




Annex

Data Sheet:

$QQH[

- Gearbox / Retarder

Conversion Tables Operating Specifications: - Oil Specifications Gearbox - Oil Specifications Retarder - Cooling Water Quality Spare Parts Lists Other Information



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Annex

'DWD6KHHW

GO170-6 – R 115 E

GO190-6 – R 115 E

Gearbox input power up to [kW] max. input torque [Nm] (Standard value depending on respective use)

Ratio range / expanded scale

320

1750

1900

8,17 - 1,00 8,17

Braking torque up to [Nm] / Braking power up to [kW] Permissible vehicle cross weight [t]


GO210-6 – R 115 E

2100

6,53 - 0,80 8,16

3750 / 700

W

W


9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Annex

Ratio

'DWD6KHHW (Continue)

GO170-6 – R 115 E

GO190-6 – R 115 E

GO210-6 – R 115 E

1. gear

8,170

8,170

6,528

2. gear

4,650

4,650

3,711

3. gear

2,790

2,790

2,231

4. gear

1,810

1,810

1,443

5. gear

1,250

1,250

1,000

6. gear

1,000

1,000

0,799

Reverse-gear

7,683

7,683

6,136



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Annex

&RQYHUVLRQ7DEOHV

D

GB

USA

D

GB

USA

-37 °C

- 34,6 °F

-34,6 °F

18 Nm

12.6 lbf-ft

12.6 lbf-ft

-45 °C

-49 °F

-49 °F

19 Nm

13.3 lbf-ft

13.3 lbf-ft

10 oC

50 oF

50 oF

20 Nm

14 lbf-ft

14 lbf-ft

20 oC

68 oF

68 oF

21 Nm

14.7 lbf-ft

14.7 lbf-ft

60 oC

140 oF

140 oF

25 Nm

18 lbf-ft

18 lbf-ft

80 oC

176 oF

176 oF

28 Nm

19.6 lbf-ft

19.6 lbf-ft

95 oC

203 oF

203 oF

30 Nm

21 lbf-ft

21 lbf-ft

105 oC

221 oF

221 oF

32 Nm

22.4 lbf-ft

22.4 lbf-ft

125 oC

257 oF

257 oF

35 Nm

24.5 lbf-ft

24.5 lbf-ft

165 °C

329 °F

329 °F

39 Nm

27.3 lbf-ft

27.3 lbf-ft

185 oC

365 oF

365 oF

40 Nm

28 lbf-ft

28 lbf-ft

225 oC

437 oF

437 oF

42 Nm

29.4 lbf-ft

29.4 lbf-ft

13 Nm

9.1 lbf-ft

9.1 lbf-ft

45 Nm

31.5 lbf-ft

31.5 lbf-ft

14 Nm

9.8 lbf-ft

9.8 lbf-ft

46 Nm

32.2 lbf-ft

32.2 lbf-ft

16 Nm

11.2 lbf-ft

11.2 lbf-ft

47 Nm

32.9 lbf-ft

32.9 lbf-ft



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Annex

&RQYHUVLRQ7DEOHV (Continue)

D

GB

USA

D

GB

USA

52 Nm

36.4 lbf-ft

36.4 lbf-ft

2100 Nm

1,470 lbf-ft

1,470 lbf-ft

55 Nm

38.5 lbf-ft

38.5 lbf-ft

3750 Nm

2,625 lbf-ft

2,625 lbf-ft

58 Nm

40.6 lbf-ft

40.6 lbf-ft

2,10 bar

30.45 psi

30.45 psi

60 Nm

42 lbf-ft

42 lbf-ft

2,30 bar

33.35 psi

33.35 psi

65 Nm

45.5 lbf-ft

45.5 lbf-ft

2,50 bar

36.25 psi

36.25 psi

80 Nm

56 lbf-ft

56 lbf-ft

2,75 bar

39.88 psi

39.88 psi

100 Nm

70 lbf-ft

70 lbf-ft

2,95 bar

42.78 psi

42.78 psi

150 Nm

105 lbf-ft

105 lbf-ft

4 bar

58 psi

58 psi

165 Nm

115.5 lbf-ft

115.5 lbf-ft

6 bar

87 psi

87 psi

180 Nm

126 lbf-ft

126 lbf-ft

8 bar

116 psi

116 psi

195 Nm

136.5 lbf-ft

136.5 lbf-ft

11 bar

159.5 psi

159.5 psi

210 Nm

147 lbf-ft

147 lbf-ft

17 bar

246.5 psi

246.5 psi

450 Nm

315 lbf-ft

315 lbf-ft

19 bar

275.5 psi

275.5 psi

1750 Nm

1,225 lbf-ft

1,225 lbf-ft

23 bar

333.5 psi

333.5 psi

1900 Nm

1,330 lbf-ft

1,330 lbf-ft

25 bar

362.5 psi

362.5 psi



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Annex

&RQYHUVLRQ7DEOHV (Continue)

D

GB

USA

D

GB

USA

7 litre

1.54 gal

1.85 gal

50.000 km

31,070 miles

31,070 miles

7,8 litre

1.72 gal

2.06 gal

60.000 km

37,284 miles

37,284 miles

12,5 litre

2.75 gal

3.30 gal

90.000 km

55,926 miles

55,926 miles

13 litre

2.86 gal

3.43 gal

100.000 km

62,140 miles

62,140 miles

135.000 km

83,889 miles

83,889 miles

1g

15.4 grains

15.4 grains

180.000 km

111,852 miles

111,852 miles

11 g

169.4 grains

169.4 grains

300.000 km

186,420 miles

186,420 miles

195 Kg

430 pounds

430 pounds

50 Km/h

31 miles/h

31 miles/h

0,02 mm

0.0008 inch

0.0008 inch

0,12 mm

0.0048 inch

0.0048 inch

0,28 mm

0.0112 inch

0.0112 inch

0,86 mm

0.0344 inch

0.0344 inch

131,31 mm

5.2524 inch

5.2524 inch



9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Annex

2SHUDWLQJ6SHFLILFDWLRQV

Operating specification

Caution! Risk of poisoning! Fuels are harmful to health! If a fuel was swallowed, visit immediately a doctor! Keep fuels away of children!

Mineral oil for use in gearbox: SAE 80, 80W, 80W/85W Type of oil

Supplier

Addinol Gear Oil GS

Addinol Mineralöl, Krumpa

Agip Rotra Hy DB

Agip Petroli, Rom/Italien

Antar EP

Elf Lubrifiants, Paris/Frankreich

Aral-Gear Oil EP

Aral Lubricants, Bochum

Armorine BM

Armorine, Lanester Cedex/ Frankreich

Aseol Gepress 11-508

Shell Aseal, Bern/Schweiz

Autol Gear Oil D8

Agip Schmiertechnik, Würzburg

Avia Gear Oil MZ

Avia Mineralöl, München

Aviaricon Gold MZ

Emil Finke Mineralölwerk, Bremen

BayWa Multi Purpose Gear BayWa, München Oil


BP Energear EP

BP Oil International, London/England

BP Energear FE GL4


BP Gear Oil EP


Calpam Multi Purpose Gear Oil

Calpam Mineralöl-Gesellschaft, Aschaffenburg


9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Annex

2SHUDWLQJ6SHFLILFDWLRQV (Continue)

Mineral oil for use in gearbox: SAE 80, 80W, 80W/85W Type of oil Type of oil

Supplier

Supplier

Fina Pontonic N

Fina Europe, Brüssel/Belgien

Frontol Gear Oil MZ M

BP Schmierstoff, Hamburg

Caltez Universal Gear Oil HD

Caltez (UK) Limited, London/England

Carrier Hykomol

MOL Hungarian Oil and Gas Co., Kornárom/Ungarn

Fuchs Titan Gear MP

Fuchs Mineralölwerke, Mannheim

Castrol EP

Castrol, Swindon/England

Galp Transoil

Petroleos de Portugal, Petrogal, Lissabon/Portugal

Condat Gear A

Condat, Chasse-sur Rhône/Frankreich

Geartex EP-A

Texaco Services (Europe), Brüssel/Belgien

CS 80 M-EP

Repso Distribución, Madrid/ Spanien

Gulf Gear Lubricant (EP)

SAEL, Madrid/Spanien

Deagear EP-A

DEA Mineralöl, Hamburg

Gulf Ultragear 4000 (GB)

Gulf Oil (GB), Cheltenham/ England

Dearon EP-A

DEA Mineralöl, Hamburg

H.o.B.- Gear Oil ML

H. o.B. Burrenkopf, Köln

Deutz Öl GO-MP

Klöckner Energiehandel, Köln

Hafa MPB

Hafa, Paris/Frankreich

Divinal Multi Purpose Gear Oil

Zeller+Gmelin, Eislingen

Homberg Gear Oil MZ

J. & A. Homberg, Wuppertal

Hyperol Multi Purpose Gear Oil

Hyperol Mineralöl-Vertrieb, Stuttgart

Igol Trans EPA

Igol France, Paris/Frankreich

Ina Transmol DB

INA Rafinerija Zagreb, Zagreb/Kroatien

IP Pontiax DB

Italiana Petroli, Genua/Italien

Kompressol Multi Purpose Gear Oil

Kompressol-Öl, Köln

Dragon Gear TM Ellmo-Multi Purpose Gear Oil

Ssang Yong Oil Refining, Seoul/Rep. Korea Eller-Montan-Comp., Duisburg

Engen Gearlube HP

Engen Petroleum, Kapstadt/Südafrika

Ertoil Transmissiones F

Ertoil, Madrid/Spanien

Esso Gear Oil GP-D

Esso, Hamburg



9RLWK7XUER*PE+ &R.*

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Annex


Mineral oil for use in gearbox: SAE 80, 80W, 80W/85W Type of oil Type of oil

Supplier

Supplier

Leprince & Siveke, Herford

Pennasol Multi Purpose Gear Oil GL4

Mineralöl-Raffinerie Dollbergen

Leprinzol SP Mac MP-Gear Oil

Deutsche Shell, Hamburg

Petrol Transol GL4

Petrol d. d., Ljubljana/Slowenien

megol Multi Purpose Gear Oil GL4

Meguin, Saarlouis

Petramin Gear Oil MB

Petramin Lubricating Oil, Jeddah/Saudi-Arabien

MHG-Manual-Gear Oil EP

MHG, Sulzbach-Rosenberg

Q8 T 35

Mobilube GX-A

Mobil Schmierstoff, Hamburg

Kuwait Petroleum, Hoogvliet RT/Niederlande

Motorex Gear Oil EP

Bucher, Langenthal/Schweiz

Raloy Transmission EP

Raloy Lubricantes, Santiago Tianguistenco/Mexico

Neste Gear EP

Neste Oy Lubrication, Espoo/Finnland

Rexol MBG

Ryazan Oil Refinery, Ryazan/Rußland

Oest Multi Purpose Gear Oil

Oest Mineralölwerke, Freudenstadt

Rored EPA

Pertamina, Jakarta/Indonesien

OMV Gear Oil MP

OMV, Wien/Österreich

Selectol Multi Purpose Gear Oil

Käppler, Stuttgart

Optimol Multi Purpose Gear Oil

Optimol Ölwerke Industrie GmbH, München

Orly XP Luna

Orly International, Vieux-Thann/Frankreich

P. O. Keban EP MB

Shell Spirax MA

Shell International, London/ England

Sonolgear DBM

Sonol Israel, Haifa/Israel

Petrol Ofisi, Bakanlikar-Ankara/Türkei

Spirol XEP

Bharat Petroleum Carpn., Bombay/Indien

Panolin EP Gear GL4

Panolin, Madetswill/Schweiz

Tor Multi Purpose Gear Oil

De Oliebron, Zwijndrecht/Niederlande

Parnas Parnalube GP

Parnas/Saksan, Athen/Griechenland

Total EP

Total Deutschland, Düsseldorf



9RLWK7XUER*PE+ &R.*

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Annex


Mineral oil for use in gearbox: SAE 80, 80W, 80W/85W Type of oil

Type of oil Supplier

Supplier

York 791

Ginouves Georges La Farlède/Frankreich

Zenex Gear Oil ZP

Zenex Oil, Rivonia/Südafrika

Tranself EP

Elf Lubrifiants, Paris/Frankreich

Triathlon Gear

Würth, Künzelsau

Unil EP

Unil Deutschland, Bremen

Unil Opal Gear EP

Unil-Opal, Rueil-Malmaison/ Frankreich

Valvoline X-18

Valvoline International Europe, Dardrecht/Niederlande

Veba Movara EP-Gear Oil

Veba Öl, Gelsenkirchen

Veedol Multigear

Veedol International, Swindon/England

Westfalen Grado Gear Oil

Westfalen AG, Münster

Wintershall Wiolin Multi Purpose Gear Oil

Schmierstoffraffinerie Salzbergen

Veedol Synmesh-AT

Burmah Oil Technology

Castrol Syntrans-AT

Burmah Oil Technology

Westfalen Grado Gear Oil

Westfalen AG, Münster

Deagear Synth

DEA Mineralöl GmbH

Wisura GL

Wisura Mineralölwerk, Bremen

WLZ-Raiffeisen Multi Purpose Gear Oil

WLZ-Raiffeisen, Stuttgart


Synthetic oil for use in gearbox: Type of oil

Supplier

MB 235.11 Manual Gear Oil DaimlerChrysler AG, Stuttgart A 001 989 2803


9RLWK7XUER*PE+ &R.*

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Annex


The type of oil admitted for the retarder operation must meet the following specifications: Classification group Identification letters to DIN 51502

Viskosity class to DIN 51511

Performance class

Single-grademineral oil 1)

HD

SAE 10W SAE 20W 20 SAE 30

API - CC/SF and higher

Synthetic oil/ part-synthetic oil 1)

HC

SAE 0W40 SAE 5W30 SAE 5W40 SAE 5W50 SAE10W30 SAE10W40

API - CC/SF and higher

Synthetic oil 2)

HC

SAE 75W-80W

see page 11/13

1)

The statements of the vehicle-manufacturer are valid respecting the choice of oil types. If no statements are available, the oils documented on the following pages are to be used.

2)

Here is only allowed to use the synthetic oil documented on page 11/13.



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Annex


Mineral oil for use in retarder: SAE 10W, 20W 20, 30 Type of oil Type of oil

Supplier

Agip Diesel Sigma S

Agip

Agip Engine oil HD

Agip

Aral Basic Turboral

Aral

Avia Special HDC

Avia

Avia Engine Oil HD

Avia

BP Vanellus C3

BP

Castrol CRD-DB

Burmah Oil

DEA Cronus Super

DEA

DEA Rigis

DEA

Elf Performance XC

Elf

Elf Performance XR

Elf

Elf Performance 3D

Elf

Elf Performance Super D

Elf

Essolube X 301

Esso

Essolube X 201

Esso


Supplier

Fina Kappa Super

Fina

Fina Kappa TC

Fina

SAE 30 Serie III

Krafft

Mobil Delvac 1300-Serie

Mobil Oil

Extra

Motorex

Cobra

Motorex

Multimiles R/5 mono

Multimiles

Repsol Serie 3 SAE 10W

Repsol

Repsol Serie 3 SAE 30

Repsol

CS Mizar Serie 3 SAE 10W Repsol CS Mizar Serie 3 SAE30

Repsol

CS Mizar HD SAE 20W

Repsol

Shell Rimula X Monograde Shell Shell Rotella MX

Shell

Glap Diesel

Sofomil

Glap Orion

Sofomil

Wintershall Rekord 10W

SRS


9RLWK7XUER*PE+ &R.*

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Annex


Mineral oil for use in retarder: SAE 10W, 20W 20, 30 Type of oil

Synth./part-synth. oil for use in retarder: SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40 Supplier

Type of oil

Supplier

Wintershall Rekord 20W-20 SRS

Agip Diesel Sigma TFE

Agip

Wintershall Rekord 30

SRS

Agip Sigma Super TFE

Agip

Havoline Motor Oil

Texaco

Agip Sigma Ultra TFE

Agip

Ursa Super LA

Texaco

Amsoil 10W30

Amsoil

Total rubia S

Total

Antar Maxolia 10W40

Antar

Unocal Firebird HD Motor Oil

Unocal

Aral Extra Turboral SAE 10W40

Aral

Aral High Turboral SAE 10W40

Aral

Aral Super Turboral SAE 5W30

Aral

Aral Mega Turboral SAE 10W40

Aral

Avia Synth 5W40

Avia

Avia Multi CFE 10W40

Avia

Avia Multi CFE Plus 10W40 Avia


Avia Turbosynth CFE 10W40

Avia

Avia Turbosynth HT-E 10W40

Avia

BP Vanellus FE 10W40

BP Oil


9RLWK7XUER*PE+ &R.*

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Annex


Synth./part-synth. oil for use in retarder: SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40 Type of oil

Supplier

Elf Performance Experty 10W40

Elf

Elf Performance Experty FE 5W40

Elf

BP Vanellus FE Extra 10W40

BP Oil

Esso Ultra

Esso

BP Vanellus HT 10W40

BP Oil

Esso Ultron

Esso

BP Vanellus HT Extra 10W40

BP Oil

Esso Ultra Diesel

Esso

Essolube XTS 301

Esso

Castrol Syntruck SAE 5W40

Castrol Commercial

Essolube XTS 501

Esso

Castrol Dynamax SAE 10W40

Castrol Commercial

Fina Kappa First SAE 15W40

Fina

Castrol Transmax Z

Castrol Commercial

Fina Kappa Ultra SAE 10W40

Fina

DEA Cronos Synth SAE 5W40

DEA

Fina First 5W40

Fina

DEA Cronos Premium HC SAE 10W40

DEA

Titan Unic MC SAE 10W40 Fuchs Fuchs

DEA Cronos Premium XL SAE 10W40

DEA

Titan Unic Plus MC SAE 10W40

Fuchs

DEA Cronos Premium FX SAE 10W40

DEA

Titan Cargo MC SAE 10W40 Emgard MTF 4200

Henkel

DEA Cronos Premium LD 10W40

DEA

HRD Maxima LD 10W40

Huiles Renault Diesel

Elf Ecomax FE 10W40

Elf

Klübersynth GEM 4-68

Klüber

Mogul Diesel DTT Plus 10W40

Koramo

Elf Ecomax FE plus 10W40 Elf



9RLWK7XUER*PE+ &R.*

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Annex


Synth./part-synth. oil for use in retarder: SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40 Type of oil

Supplier

Sintetic 10W40 Gasolina

Krafft

Sintetic 10W40 Diesel

Krafft

Mobil Delvac XHP 10W40

Mobil Oil

Mobil Delvac XHP Extra 10W40

Mobil Oil

Oest gigant Turbo FE 10W40

Oest

Trysk Top Tir - Fe 10W40

Paramo

Repsol Competicion 5W40 Repsol Repsol Sintetico Gasolina 10W40

Repsol

Repsol Sintetico Diesel 10W40

Repsol

Shell Myrina TX 5W30

Shell

Mobil Delvac 1 SHC 5W40 Mobil Oil

Shell Myrina TX 10W40

Shell

Carrier Diesel Sint 10W40

Mol

Glap Synth D 1040

Sofomil

MC Power 3 SAE 10W40

Motorex

Wintershall TFX

SRS

MC plus SAE 10W40

Motorex

Wintershall TFE

SRS

Star-Synt SAE 5W50

Motorex

Wintershall TFG

SRS

Multimiles MM-1 Bioil chem. 0W30/40

Multimiles

Ursa Super TDX 10W40

Texaco

Total rubia TIR 8600

Total

Multimiles Fut. 3 MM-23 D-2 10W40

Multimiles

Wameco Green Rallenter Fluid N

Wameco

Multimiles Fut. 2 MM-23 F-H 10W40

Multimiles

Wameco Red Rallenter Fluid N

Wameco

Multimiles Fut. 2 MM-23 F-HP 10W40

Multimiles

Multimiles Fut. 2 MM-23 F-P 5W50

Multimiles



9RLWK7XUER*PE+ &R.*

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Annex


Synthetic oil for use in retarder: SAE 75W-80W Type of oil Emgard MTF


Supplier Henkel


9RLWK7XUER*PE+ &R.*

3URGXFWXQLWUHWDUGHU

Annex


Cooling water quality

Caution! Risk of poisoning! Fuels are harmful to health! If a fuel was swallowed, visit immediately a doctor! Keep fuels away of children! The coolant may not be discharged into the sewage system. It must be brought to the recycling as well as to the waste disposal. The legal regulations as well as regulations for sewage can deviate country-specific and are to be heeded with the waste disposal of used coolants. Before use of the coolants, the safety-data-sheets and product-information of the respective manufacturer are to be heeded and to keep. The coolant is a mixture of water and corrosion-/anti-freeze agent.From reasons of the corrosion-protection and to the increase of the boiling point, the coolant must remain non-seasonal in the cooling system. Coolants have to be renewed after three years, because the corrosion-protection will reduce itself. Water Water itself is not allowable as coolant, even if anti-freeze-qualities are not necessary. The water of the coolant must fulfil defined requests, that frequently, however not always meet the drinking water quality. If the water-quality is not sufficient, the water must be purified. Information about this can be ordered from us.



9RLWK7XUER*PE+ &R.*

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Annex


Corrosion-/anti-freeze agent To avoid damages in the retarder cooling-system: •

Use only a released corrosion-/antifreeze agent, that is released expressly for aluminium by the manufacturer. The use of purely glycol is not allowed.

•

With refills (after coolant-loss) a proportion of corrosion-/antifreeze agent of 50 vol.-% in the coolant (antifreeze to -37 °C) must be secured.

• •

Do not use more than 55 vol. -% (= maximum antifreeze) corrosion-/antifreeze agent. The feature of antifreeze will be reduced and the heat rejection poor.

Ratio for coolant Antifreeze to °C

Water Vol.-%

Corrosion-/ antifreeze agent vol.-%

-37

50

50

approx. -45

45

max. 55

In exceptions, if no corrosion-/antifreeze agent is available and no antifreeze is required (for example tropics), 1 vol. -% = 10 cm3/litre refining agent must be used. In this case, the coolant is to be renewed annually. Continuing information can be taken from the Voith cooling-water list. This can be ordered from Voith Turbo with the Voith item-number 67.2224.10.



9RLWK7XUER*PE+ &R.*

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Annex

6SDUH3DUWV/LVWV

Remark: Terms of items from DaimlerChrysler-EPC-documentation

Gearbox spare part recommendation list 26/350/083

26/350/080

26/100/056

26/250/047 26/100/206

26/100/053 26/350/101

26/100/059

26/860/026

26/100/032 26/860/017 26/860/014

25/250/020 26/100/038

26/860/026

26/100/014 26/100/008

26/100/197 26/100/200

26/100/203

26/100/194

26/100/023 26/100/029

26/100/128

26/400/083

26/100/128

26/400/089 26/100/122

26/100/128

26/100/125

26/100/125 25/250/113

25/250/008

26/350/071

26/250/068

26/100/113 26/100/116 26/100/107 26/100/119

26/350/ 25/250/068 26/350/065 25/250/110



9RLWK7XUER*PE+ &R.*

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Annex

6SDUH3DUWV/LVWV (Continue) 6101 3300

Retarder spare part recommendation list

3300 2800/1

4100

6100 6101 9000 3850 3850 3800

3100 2000/1 3900 8000

6600 6700 3700 2900

2300

7500

2301

25000

4000 5400 5500 5600

109 850 6400 7300

20100 20000 20300

7600

5200 5300

20200

7500 103

2600

7300

20300

3500

5200 5300

2500/1 3100 4200

20100

4100 4200

107

6700 6600 20000 20200

6700 6600

20300 M+P-07A-1504b



9RLWK7XUER*PE+ &R.*

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Annex

6SDUH3DUWV/LVWV (Continue)

Digiprop Control Unit

Vo it Co h-N r. Se de-N : ri Ku en-Nr.: nd en r.: -N r.:

53 .x xx xxx x .12 xx xx /D atu m

M+P-07A-1617a

Retarder stage switch



9RLWK7XUER*PE+ &R.*

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Ersatzteil-Katalog - Stand: 2000-04-13 Gruppe

Katalog

Benennung

Typ

Zeichnung-/ET-Katalog-Nr.

Blatt Nr.

Group

Identification No

Designation

Type

Drawing-/SP-Catalog-No.

Sheet No.

ET-VORSCHLAGSLISTE

RET. 115 E

01 53.2654.90

1

ZPOSNR

Sachnummer

Benennung

Abmessung

Norm-Nr.

Draw.it.No

Identification No

Designation

Dimensions

Standard No.

GR

BTA

ET-KZ

Menge Quantity

Revisions-Nr.: Bemerkung.:

ET - Vorschlagsliste

AZ-Nummer: Typ:

Retarder 115 E

Kennwort:

Schulungsmappe

Betriebsanl.Nr.: Werkstatthandb.: 137975

Kunden-Nr.: Kunden-Code:

53.2993.00

01

RETARDER 115

1

SP.PARTS CATALOGUE

103

01 . 0907 . 86

VERSCHLUSSSCHRAUBE

VS M12X1,5

VN 1638

1

M24X1,5

OHNE ZCHN

1

M24X1,5

OHNE ZCHN

1

M802011AP

OHNE ZCHN

1

D30X38 DRUCKG.

53.1332.11

1

55X3

VN 3014

1

67.1491.10

1

PE-DECKEL

67.1497.10

1

M 8 X 30

53.9451.20

22

M 8 X 80

53.9451.20

11

MIT SIEB

67.2418.10

1

SCREW PLUG Kunden-Sachnr.: A 000 997 68 32

107

91 . 2769 . 10

VERSCHLUSSSCHRAUBE SCREW PLUG Kunden-Sachnr.: A 000 997 69 32

109

91 . 2769 . 10


850

91 . 2493 . 10

AUSSENRING OUTER RING Kunden-Sachnr.: A 000 438 01 12

2300

53 . 1332 . 11

PROFILENTLUEFT.BGR. HOUSING VENTILATION Kunden-Sachnr.: A 003 430 58 81 beinhaltet Pos. 2301 INCLUDES POS. 2301

2301

01 . 0647 . 56

RUNDDICHTRING O-RING Kunden-Sachnr.: A 006 997 56 48

2600

67 . 1491 . 10

DICHTUNG UNTEN SEAL Kunden-Sachnr.: A 000 438 13 80

2900

67 . 1497 . 10

DICHTUNG SEAL Kunden-Sachnr.: A 000 438 14 80

3100

53 . 9454 . 20

KOMBI-6KT.SCHRAUBE HEXAGON BOLT Kunden-Sachnr.: A 000 438 27 71

3300

53 . 9457 . 20


3500

67 . 2418 . 10

VERSCHLUSSCHRAUBE SCREW PLUG Kunden-Sachnr.: A 000 997 70 32


Katalog

Benennung

Typ


Blatt Nr.

Group

Identification No

Designation

Type


Sheet No.

ET-VORSCHLAGSLISTE

RET. 115 E

01 53.2654.90

2

ZPOSNR

Sachnummer

Benennung

Abmessung

Norm-Nr.

Draw.it.No

Identification No

Designation

Dimensions

Standard No.

Quantity

PROPORTIONAL-VENTIL

DIGIPROP

67.1098.22

1

160X70X22

67.1703.10

1

16X3

VN 3014

4

M 8 X 20

53.9451.11

4

M8

DIN 6927

4

M30X1,5

OHNE ZCHN

2

M24X1,5

OHNE ZCHN

2

M14X1,5/SW21

67.0150.22

2

A14X20

DIN 7603

2

SSB-0118

OHNE ZCHN

2

D30X4

53.3467.10

2

JL 30X1,2

90.9270.10

2

M. RDR / LUFT

67.1947.10

1

15,3X2,4

VN 3014

2

3700

53 . 9490 . 22

GR

BTA

ET-KZ

Menge

PROPORTIONAL VALVE Kunden-Sachnr.: A 000 438 17 81

3800

67 . 1703 . 10

DAEMPFUNGSPLATTE DAMPING PLATE

Bei Sandgussventil 67.1091.10 ist der Reparatursatz 53.2672.10 zuverwenden.

3850

01 . 0041 . 83


3900

53 . 9452 . 11

KOMBI-6KT.SCHRAUBE HEXAGON BOLT

nur noch fuer Befestigung der Dõmpfungsplatte fuer andere Anwendungen ==> Ersatz 53.9452.20 ONLY FOR MOUNTING OF DAMPING PLATE, FOR OTHER USES REPLACED BY 53.9452.20

4000

01 . 0837 . 09

SECHSKANTMUTTER HEXAGON NUT

4100

91 . 2770 . 10


4200

91 . 2769 . 10


5200

67 . 0150 . 22

TEMPERATURGEBER THERMOCOUPLE Kunden-Sachnr.: A 001 540 52 17

5300

01 . 0044 . 47

DICHTRING SEAL RING Kunden-Sachnr.: N 007603 014106

5400

91 . 2474 . 10

WELLENFEDER UNDULATED WASHER Kunden-Sachnr.: A 000 438 00 93

5500

53 . 3467 . 10

SCHEIBE (DAEMPFER) WASHER Kunden-Sachnr.: A 000 438 04 67

5600

90 . 9270 . 10

SICHERUNGSRING CIRCLIP Kunden-Sachnr.: A 000 438 06 73

6100

67 . 1947 . 10

ROHR PIPE Kunden-Sachnr.: A 000 438 02 29 beinhaltet Pos. 6101 INCLUDES POS. 6101

6101

01 . 0041 . 78



Katalog

Benennung

Typ


Blatt Nr.

Group

Identification No

Designation

Type


Sheet No.

ET-VORSCHLAGSLISTE

RET. 115 E

01 53.2654.90

3

ZPOSNR

Sachnummer

Benennung

Abmessung

Norm-Nr.

Draw.it.No

Identification No

Designation

Dimensions

Standard No.

Quantity

67.2378.13

1

M14 X 40

53.9458.11

4

15X4

VN 3014

3

45X5

VN 3014

2

25X4

VN 3014

1

196X144X2

67.2043.10

1

0-4 BAR

53.8258.10

1

AD 52

67.2069.20

2

WASSERSTUTZEN 67.2178.10

2

M 8 X 80

53.9451.20

6

R115 AN GO4

O.Z.

1

D 14 X 4

O.Z.

2

M10X70

O.Z.

5

M10X60

O.Z.

17

6400

67 . 2378 . 13

WAERMETAUSCHER

GR

BTA

ET-KZ

Menge

HEAT EXCHANGER

6600

53 . 9461 . 10

6KT.SCHRAUBE M.FL. HEXAGON BOLT Kunden-Sachnr.: A 000 438 22 71

7300

01 . 0759 . 56


7500

01 . 0759 . 32


7600

01 . 0759 . 63


8000

67 . 2043 . 10

ZWISCHENPLATTE INTERMEDIATE PLATE Kunden-Sachnr.: A 000 438 01 84

9000

53 . 8258 . 10

DRUCKSENSOR PRESSURE SENSOR Kunden-Sachnr.: A 002 542 64 18

20000

67 . 2069 . 20

WASSERSTUTZEN WATER SOCKET Kunden-Sachnr.: A 656 997 00 72

20100

67 . 2178 . 10

DICHTUNG SEAL Kunden-Sachnr.: A 656 997 00 49

20200

53 . 9457 . 20


25000

67 . 2674 . 10

AUSGLEICHSCH.(AUSW) SET OF SHIMS

bestehend aus A 629 261 01 52 bis A 629 261 33 52

25100

67 . 2683 . 10

O-RING O RING Kunden-Sachnr.: A 019 997 83 48

25200

67 . 2676 . 10

SCHRAUBE BOLT Kunden-Sachnr.: A 914 26 01 00 37

25300

67 . 2675 . 10

SCHRAUBE BOLT

Kunden-Sachnr.: A 914 126 01 00 51

050399_r

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