Retardador 120 (of 1721 )

Training

cbtd 98-01 53.2659.10

Aftersales Service Manual VOITH Retarder 120 with Digiprop Control

Content

Table of Contents

1.

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

2.

General....................................................................................................2/1 2.1 Assembly Overview ..........................................................................2.1/1 2.2 Function and Operation Scheme .........................................................2.2/1 2.3 Retarder Data ..................................................................................2.3/1

3.

Maintenance............................................................................................3/1 3.1 Maintenance Work .............................................................................3.1/1 3.2 Oil Change .......................................................................................3.2/1 With Stainless-Steel Heat Exchanger ....................................................3.2/1 With Aluminium Heat Exchanger ..........................................................3.2/5 3.3 Checking Oil Level .............................................................................3.3/1 3.4 Cleaning Line Filter (Optional extra) ......................................................3.4/1

4.

Diagnosis/Troubleshooting......................................................................4/1 4.1 Troubleshooting Diagram ....................................................................4.1/1 Elektrical Connections Diagram ...........................................................4.1/2 4.2 Troubleshooting and Remedies ............................................................4.2/1 4.3 Checking Pump Pressure ...................................................................4.3/1 4.4 Checking Control System ....................................................................4.4/1 4.5 Operational Check .............................................................................4.5/1

5.

Removing, Installing Retarder .................................................................5/1 5.1 Removing, Installing Retarder (Free Mount Installation)............................5.1/1 5.2 Removing, Installing Retarder (Gearbox Attachment) ...............................5.2/1

cbtd 98-01 53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop Page IHV/1

Content

6.

Table of Contents (Continue)

Retarder Basic Group Repair (Gearbox Attachment)..............................6/1 6.1 Assembly Overview ...........................................................................6.1/1 6.2 Removing, Checking and Installing Casing Ventilation .............................6.2/1 6.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......6.3/1 6.4 Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger) .........................................................6.4/1 6.5 Removing, Cleaning and Installing Silencer ............................................6.5/1 6.6 Removing and Installing Bottom Cover ..................................................6.6/1 6.7 Checking, Removing and Installing Closing Cover of Retarder Housing ......6.7/1 6.8 Removing and Installing Labyrinth Ring (Output Side), Renewing Radial Shaft Sealing Ring .....................................................6.8/1 6.9 Removing and Installing Centering Cover (Input Side), Renewing Radial Shaft Sealing Ring .....................................................6.9/1

7.

Retarder Basic Group Repair (Free Mount Installation) ..........................7/1 7.1 Assembly Overview ...........................................................................7.1/1 7.2 Removing, Checking and Installing Casing Ventilation .............................7.2/1 7.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......7.3/1 7.4 Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger) .........................................................7.4/1

cbtd 98-01 53.2659.10


Content

Table of Contents (Continue)

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

8.

Removing, Checking and Installing Heat Exchanger ..............................8/1 8.1 Stainless-steel Heat Exchanger ...........................................................8.1/1 8.2 Aluminium Heat Exchanger .................................................................8.2/1

9.

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

10.

Annex ....................................................................................................10/1 Data Sheet Miscellaneous Conversions

cbtd 98-01 53.2659.10


Preface

1

Preface

The present service manual serves as training material of the basics course. The information and instructions which is given to you furthermore provide the basis for appropriate and professional maintenance and repair at the VOITH Retarder 120 with Digiprop control. We ask you firmly to notice the safety and warning notes which you will find in these instructions.

Caution! is associated for safety instructions and for warning notes at dangerous situations for persons, at reduction of quality of workmanship and the possibility of damage to property. Notice is associated for general notices for a better handling during maintenance of the retarder.

cbtd 98-01 53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop Page 1/1

Preface

1

Preface (Continue)

Caution! The switched-on retarder will not secure the parked vehicle. At a failure of the retarder, or while the temperature limitation is effective the vehicle speed must be settled with the service brake. Notice Only genuine spare parts may be used for repairs. For inquiries and orders, please provide the following information (see also Section 2.3): • •

Serial-Number Code-Number Notice

The used three- or four-digit item numbers in these instructions are corresponding to the item numbers in the spare part lists in the annex. Items or components shown with an oblique-number are not available. Items or components with two-digit item numbers are no spare parts and therefore not available in the spare part lists.

cbtd 98-01 53.2659.10


Preface

1

Preface (Continue)

Caution! Pay attention to absolute cleanliness in maintenance work. Dirt on bearing and sealing surfaces and electrical contacts may cause considerable damage or operational malfunctions. Notice To observe environmental protection you should dispose of drained fuels, coolants and lubricants professionally. Notice Shield retarder proportional valve from direct jet of high-pressure cleaner (steam jet cleaner)! Notice In troubleshooting you must not replace parts on suspicion. Warranty work or goodwill work can only be offered, if the parts involved are demonstrably defective.

To exclude injuries and to avoid impairment of the operational reliability of the retarder or damage to the retarder as a result of inexpert workmanship, the information and instructions must be read carefully and complied with in their entirety.

cbtd 98-01 53.2659.10


1

Preface

Preface (Continue)

Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situations which might entail the risk of injury for the person carrying out the work. It is therefore imperative that any person carrying out repair work on VOITH retarders uses his professional knowledge to make sure that his own safety is not endangered and that the retarder suffers no negative effects, in particular safety-wise, through the chosen working procedure. For these reasons, no liability can be assumed for damage incurred. It is therefore expressly pointed out that all working procedures described must be carried out only in compliance with the valid general directions and regulations of the locally responsible authorities, of the health protection, accident prevention and environmental protection organisations. The technical status of the present instructions can be seen from the updating index. There may be discrepancies between the actual technical status of the retarders and the descriptions owing to continuous development and improvement of the retarders. VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and without prior notification. Should you have queries about the descriptions, please contact the responsible person in the appropriate organisation of the country involved or: VOITH TURBO GmbH & Co. KG D-74564 Crailsheim Department cb; Voithstraße 1 Telephone (07951) 32-0 Telefax (07951) 32-756 Extensions: Customer telephone and Spare Parts Service 32-401 / 32-422

cbtd 98-01 53.2659.10


General

2

General

2.1

Assembly Overview ....................................................................................2.1/1 With Stainless-Steel Heat Exchanger .................................................................2.1/1 With Aluminium Heat Exchanger .......................................................................2.1/3

2.2

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

2.3

Retarder Data.............................................................................................2.3/1

cbtd 98-01 53.2659.10


General

2.1

Assembly Overview

Illustration VOITH Retarder R 120 with Digiprop control system basic group with stainless-steel heat exchanger 100/1 100/2 100/3 1000 1900

100/3

Retarder data Constant-air pressure connection p y „A“ Ventilation connection „R“ Heat exchanger Oil filler/check plug (M 30 x 1,5)

100/2

100/1 1900

1000 16001

cbtd 98-01 53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.1/1

General

2.1

Assembly Overview (Continue)

Illustration VOITH Retarder R 120 with Digiprop control system basic group with stainless-steel heat exchanger (Continue) 1000 1000/1 1000/5 1700

Heat exchanger Leakage oil drain plug (M 14 x 1,5) Cooling water drain plug (M 18 x 1,5) Retarder oil drain plug (M 22 x 1,5)

1700

1000/1

1000/5

1000 16002

cbtd 98-01 53.2659.10


General

2.1


Illustration VOITH Retarder R 120 with Digiprop control system basic group with aluminium heat exchanger 100/1 100/2 100/3 1000 1000/5 1900

100/3

Retarder data Constant-air pressure connection p y „A“ Ventilation connection „R“ Heat exchanger Cooling water drain plug (M 12 x 1,5) Oil filler/check plug (M 30 x 1,5)

100/2

1900 100/1

1000 1000/5

cbtd 98-01 53.2659.10


16003

General

2.1


Illustration VOITH Retarder R 120 with Digiprop control system basic group with aluminium heat exchanger (Continue) 1000 1000/1 1000/3 1000/5 1700

Heat exchanger Leakage oil drain plug (M 10 x 1) Heat exchanger oil drain plug (M 12 x 1,5) Cooling water drain plug (M 12 x 1,5) Retarder oil drain plug (M 22 x 1,5)

1700

1000/3

1000/1

1000/5

1000 16004

cbtd 98-01 53.2659.10


2.2

General

Function and Operation Scheme

Illustration of VOITH Retarder 120 with Digiprop control system

25

21 44

12

50

A R

67

46

4

16

P

26

37

5

8

69

7

23

52

20 2

19

45

18

53

43

56

66

4

7

17

15

47

70

1 Oil sump

Coolant (water)

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

Pump pressure p P

16005e

Notice The reference numbers indicated in Section 2.2 are not identical with the reference numbers of the spare parts lists.

1 2 4 5 7 8 12 15 16 17 18 19 20 21 23 25 26 37

cbtd 98-01 53.2659.10

Heat exchanger Control unit Connection terminal 15 Connection terminal 30 Fuses (5A) Connection ground Pump pressure test connection ABS-Signal Retarder stage switch Retarder pilot light Stop light relay Temperature pick-up cooling water Oil temperature pick-up Proportional valve Casing ventilation Constant-air pressure line p y „A“ Supply-air pressure line p v „P“ Ventilation line „ R“

43 44 45 46 47 50 52 53 56 66 67 69 70

Oil sump Stator Stator pin Rotor Speedometer signal Output restrictor D1 Filling restrictor D2 Filling duct Leakage oil return line Check valve (stainless-steel heat exchanger) Check valve (casing ventilation cover) ISO interface plug Extra operations plug


General

2.2

Function and Control System (Continue)

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

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


General

2.2


Description of operation of retarder R 120 with digiprop control system As a special version, the control system is available with push button operation for constant speed. The retarder is operated in this case by a 4-stage retarder stage switch. When the push button is pushed in any position of the retarder stage switch, the momentary speed is transferred to memory. In the 0 braking stage, this transfer to memory takes effect and the retarder holds the vehicle speed downhill constant within the limits of the maximum braking torque. Another push on the push button in any switch position will delete the speed data.

c

a

b

On a downhill run with „constant speed“ operation, the vehicle can be slowed down within the limits of the maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting to braking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle accelerates to the speed previously transferred to memory. The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank for auxiliary equipment on the vehicle. When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2). From this input signal, the control unit (2) provides a control current which flows to the proportional valve (21). The proportional valve (21), depending on the magnitude of the control current, provides a constant-air pressure p y on the oil sump (43).

16006

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

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

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


General

2.2


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

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


General

2.2


Temperatur pick-ups, water (19), oil (20) The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from the retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and oil temperature to the control unit (2). To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarder braking torque is limited to protect the vehicle cooling system and the retarder. The constant-air pressure p y is limited. The braking torque and consequently the heat generated are reduced until a balance is obtained between the braking energy of the retarder and the amount of heat which can be dissipated by the vehicle cooling system. If the cooling water temperature rises into the temperature limit range, the consequence is a limitation of the retarder braking torque to protect the vehicle cooling system. If the temperature rises above the temperature limit range, there is no more braking torque output. While the temperature limit is effective or if there is a retarder failure, the service brake must be used to control the vehicle. The control unit (2) also cuts back braking torque if oil temperature rises too rapidly, irrespective of actual oil temperature.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


General

2.2


Casing ventilation (23) During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) and the ventilation system (22) out of the retarder. Once the working circuit is free of air, a float rises and closes the casing ventilation. Stator pins (45) When the working chamber is empty, the rotor (46) sets up in it an air flow, which is retarded by the stator (44). To minimize this loss, automatically operating stator pins have been installed in the outer zone of the stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent the build-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back on their seats against the force of the spring and the full space between the blades is available. Check valve (66) stainless-steel heat exchanger The check valve (66) prevents the airflow emptying the heat exchanger insert of oil when idling.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


General

2.3

Retarder Data

The retarder data (arrow) are punched on the left side on the retarder housing. The retarder data plate (2) provides the following information: 1.

Serial number: Six-digit number

2.

Code number: Eight-digit number Notice

Please, always quote the retarder serial-No. and code-No. when submitting queries or ordering spare parts.

cbtd 98-01 53.2659.10


16007

Maintenance

3

Maintenance

3.1

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

3.2

Oil Change .................................................................................................3.2/1 Stainless-steel Heat Exchanger ........................................................................3.2/1 Aluminium Heat Exchanger ..............................................................................3.2/5

3.3

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

3.4

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

cbtd 98-01 53.2659.10


Maintenance

3.1

Maintenance Work

Overview of maintenance work Carry out the following maintenance work at each oil change: l

Clean the cleaning line filter (optional extra)

l

Carry out visual inspection on leaks at the complete retarder

l

Check hex.-head screws of prop shaft on correct fitment, or tighten. Observe guidelines and instructions!

l

Tighten all screw plugs of the retarder basic groups and the heat exchanger with the appropriate torque (see Annex) except all fastening nuts of the heat exchanger (see Annex).

Caution! Tighten fastening nuts of heat exchanger only in case of leakage. Tightening torque: 23 Nm

The oil change intervals and operating specifications have to be taken from the annex!

cbtd 98-01 53.2659.10


Maintenance

3.2

Oil Change

Illustration oil change R 120 with stainless-steel heat exchanger 1000/1 1000/2 1000/5 1000/6 1600 1700 1800 1900

Leakage oil drain plug (M 10 x 1), 13 Nm Sealing ring (A 10 x 13,5), renew Cooling water drain plug (M12 x 1,5), 25 Nm Sealing ring (A12 x 18), renew Sealing ring (A 22 x 29), renew Retarder oil drain plug (M 22 x 1,5), 66 Nm Sealing ring (A 30 x 36), renew Oil filler/check plug (M 30 x 1,5), 150 Nm

1900

1800

1000/6 1000/5

1000/2 1000/1 1600 1700

16008

cbtd 98-01 53.2659.10


Maintenance

3.2

Oil Change (Continue)

Notice

For satisfactory retarder operation, it is important to adhere to the specified service filling (see table below) and to use only oils specified in the operating specifications (see Annex) for operating the retarder in the relevant application.

Heat exchanger

Service filling

Stainless-steel heat exchanger (L+R)

4,5 l

After complete After exchange of taking apart and cle- heat exchanger aning, as well as emptied heat exchanger 5,8 l

6,5 l

The retarder oil temperature must be higher than 60 o C (operating temperature) for the oil to be drained. Caution! While the oil is being changed, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off!

cbtd 98-01 53.2659.10


Maintenance

3.2


Job scope 1.

Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch it off after approx. 5 sec. Repeat this procedure twice. Switch off the retarder and ignition and wait 5 minutes (control function). Caution! Risk of injury!

The oil filler/check plug is heated up (oil temperature)! 2.

Push an oil collecting pan under retarder.

3.

Screw out the oil check plug (1900) and remove sealing ring (1800). Caution! Risk of injury!

The retarder oil drain plug is heated up (oil temperature)! 4.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10

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


Maintenance

5.

3.2


Screw out the leakage oil drain plug (1000/1) and remove sealing ring (1000/2) and drain the accumulated oil. Notice

If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening the leakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with the vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two radial shaft sealing rings at the Retarder and renew those, if necessary (see Section 6.8, 6.9, 7.9, 7.10). If it is necessary to drain the cooling water during the service, remove and empty the retarder on oil side completely (see Section 8.1, 8.2). This process also must be enforced with strongly spent oil. 6.

Screw the oil drain plugs (1700 and 1000/1) tight with new sealing rings (1600 and 1000/2). Retarder oil drain plug (1700): Leakage oil drain plug (1000/1):

Tightening torque 66 Nm Tightening torque 13 Nm

7.

Fill in slowly, in the hole of the oil filler/check plug (1900), the quantity of oil specified (see page 3.2/2) in accordance with the operating specifications (see Annex).

8.

Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm

9.

Check the oil level (see Section 3.3).


cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Maintenance

3.2


Illustration oil change R 120 with aluminium heat exchanger 1000/1 1000/2 1000/3 1000/4 1600 1700 1800 1900

Leakage oil drain plug (M 10 x 1), 13 Nm Sealing ring (A 10 x 13,5), renew Heat exchanger oil drain plug (M 12 x 1,5), 25 Nm Sealing ring (A 12 x 15,5), renew Sealing ring (A 22 x 29), renew Retarder oil drain plug (M 22 x 1,5), 66 Nm Sealing ring (A 30 x 36), renew Oil filler/check plug (M 30 x 1,5), 150 Nm

1900

1000/4 1000/3 1800 1000/2 1000/1 1600

1700

16009

cbtd 98-01 53.2659.10


Maintenance

3.2


Notice

For satisfactory retarder operation, it is important to adhere to the specified service filling (see table below) and to use only oils specified in the operating specifications (see Annex) for operating the retarder in the relevant application.

Heat exchanger

Service filling

New filling

Aluminium heat exchanger (AKG)

5,5 l

6,0 l

The retarder oil temperature must be higher than 60 o C (operating temperature) for the oil to be drained.

Caution! While the oil is being changed, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off!

cbtd 98-01 53.2659.10


Maintenance

3.2


Job scope 1.

Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch it off after approx. 5 sec. Repeat this procedure twice. Switch off the retarder and ignition and wait 5 minutes (control function). Caution! Risk of injury!

The oil filler/check plug is heated up (oil temperature)! 2.

Push an oil collecting pan under retarder.

3.

Screw out the oil filler/check plug (1900) and remove sealing ring (1800). Caution! Risk of injury!

The retarder oil drain plug is heated up (oil temperature)! 4.

Screw out the retarder oil drain plug (1700) and the heat exchanger oil drain plug (1000/3) and remove the sealing rings (1600 and 1000/4) and drain oil.

5.

Screw out the leakage oil drain plug (1000/1) and drain the accumulated oil.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Maintenance

3.2


Notice If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening the leakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with the vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two radial shaft sealing rings at the Retarder and renew those, if necessary (see Section 6.8, 6.9, 7.9, 7.10).

6.

Screw the oil drain plugs (1700, 1000/3 and 1000/1) tight with new sealing rings (1600, 1000/2 and 1000/4). Retarder oil drain plug (1700): Heat exchanger oil drain plug (1000/3): Leakage oil drain plug (1000/1):

Tightening torque 66 Nm Tightening torque 25 Nm Tightening torque 13 Nm

7.

Fill in slowly, in the hole of the oil filler/check plug (1900), the quantity of oil specified (see page 3.2/2) in accordance with the operating specifications (see Annex).

8.

Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm

9.

Check the oil level (see Section 3.3).


cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Maintenance

3.3

Checking Oil Level

Illustration checking oil level

1900

Notice The oil change intervals and operating specifications have to be taken from the annex. 1800 1900

1800

Sealing ring (A 30 x 36), renew Oil filler/check plug (M 30 x 1,5), 150 Nm

Notice The illustration shows a retarder 120 with stainless-steel heat exchanger. A version with aluminium heat exchanger is possible.

16010

cbtd 98-01 53.2659.10


Maintenance

3.3

Checking Oil Level (Continue)

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

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Maintenance

3.3


Notice For the oil level check, the temperature of the retarder oil must be higher than 60°C (operating temperature). The oil level check must be carried out with the vehicle in a horizontal position. Difference between min. and max. mark on oil filler/check plug is approx. 0,5 l. Job scope 1.

Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch it off after approx. 5 sec. Repeat this procedure twice. Caution!

While the oil level is being checked, make sure that retarder and ignition system must have been switched off! Risk of injury exists at nonobservance, by hot leaving oil when screw out oil filler/check plug!

2.

Switch off the retarder and wait 5 minutes (control function). Caution! Risk of injury!

The oil filler/check plug (1900) is heated up (oil temperature)! 3.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10

Screw out the oil filler/check plug (1900) and remove sealing ring (1800). Wipe off oil of the oil filler/check plug.


Maintenance

3.3


4.

Position oil filler/check plug (1900) plane at the thread. Do not screw in the oil filler/check plug!

5.

Pull out again the oil filler/check plug (1900). Oil level is correct bewteen min. and max. mark of the oil filler/check plug.

6.

Top up slowly any lacking oil through the hole for the oil filler/check plug.

7.

Screw the oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm

1900 Max Min

16011

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Maintenance

3.4

Cleaning Line Filter (Optional Extra)

Illustration line filter Complete line filter Pressure spring Intermediate plate Cover Holding plate Pressure spring Filter housing Filter insert O-ring (36,2 x 3), renew, coat with silicone-free and non-corossive grease for installation

12000/1

12000/6 12111

12000/2 12000

12000 12000/1 12000/2 12000/3 12000/4 12000/5 12000/6 12111 12112

12000/5 Lubricants O-ring

12112

Silicone-free and non-corossive grease

12000/3

12000/4

16012

cbtd 98-01 53.2659.10


Maintenance

3.4

Cleaning Line Filter (Continue)

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

Caution! Risk of injury! Observe fall in pressure in the compressed air circuit for auxiliary equipment (e.g. air springs)! 1.

Disconnect constant-air pressure line at the line filter for air tank of auxiliary equipment .

2.

Press in the cover (12000/3) and pull out the holding plate (12000/4).

3.

Pull out of the filter housing (12000/6) the cover (12000/3) with O-ring (12112), the pressure spring (12000/5), the intermediate plate (12000/2), the filter insert (12111) and the pressure spring (12000/1) .

4.

Blow out the filter insert (12111) with compressed air from inside out. Check filter insert for damages and renew if necessary.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Maintenance

3.4

Cleaning Line Filter (Continue)

5.

Insert the pressure spring (12000/1), the filter insert (12111), the intermediate plate (12000/2) and the pressure spring (12000/5) in filter housing (12000/6).

6.

Coat new O-ring (12112) with silicone-free and non-corossive grease. Pull the new O-ring on to the cover (12000/3).

7.

Press in the cover (12000/3) into the filter housing (12000/6) and put in the holding plate (12000/4). Notice

If complete filter (12000) has to be removed, observe the correct installing position.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Diagnosis / Troubleshooting

4


4.1

Troubleshooting Diagram ...........................................................................4.1/1 Electrical Connections Diagram ........................................................................4.1/2

4.2

Troubleshooting and Remedies .................................................................4.2/1

4.3

Checking Pump Pressure...........................................................................4.3/1

4.4

Checking Control System...........................................................................4.4/1

4.5

Operational Check......................................................................................4.5/1

cbtd 98-01 53.2659.10


4.1

Diagnosis /

Troubleshooting Diagram

Troubleshooting Illustration troubleshooting diagram

Notice Before starting troubleshooting the oil level of the retarder must be checked and corrected (see chapter 3.3 ‘‘Checking oil level‘‘). It is important that the specific service filling is kept for a trouble-free operation of the retarder (see chapter 3.2 ‘‘Oil change‘‘ and annex).

Renew non-return valve

NOK

Contact VOITH

OK

Check non-return valve in cover of casing ventilation (Chapter 6.3)

Renew casing ventilation

NOK

OK Correct oil level of retarder (*)

see chapter6.4

Check casing ventilation (Chapter6.2)

Check cooling system: Check heat exchanger NO

YES

YES OK

Water in the oil? (emulsion)

NOK

-coolant level -thermostat -coolant pump -radiator fan -radiator grill for dirtiness

NO


Check oil level of retarder

Retarder: Check Temp.-Sens. (oil/water)

Driver instruction!

Oil leak by ventilation OK flashes

If the retarder is still leaking, or the chamber of leakage oil is filled again with oil after 1000 km, renew radial shaft seal

Empty chamber of return of leakage oil (at heat exchanger) (Chapter3.3)

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

Complaint Oil leak input side or output side

NOK

Temperature limit!

Retarder pilot light

R 120 Digiprop

Permanent lighting No respectively too insufficient retarder braking effect

Activate flash code and read out trouble code (Chapter4.2)

Clear faults and delete fault memory (Chapter4.2)

Check oil level of retarder Water in the oil? (emulsion) NO

OK

YES

YES

NO

Check heat exchanger

Check yp(static) (Chapterl 4.4 ) OK


NOK

see chapter

Correct oil level of retarder

6.4

NOK

Check p (dynamic) (Kapitel4.3) OK

NOK

Check voltage of proportional valve (Chapter4.4) OK

Contact VOITH

NOK

Contact VOITH Check control unit (Chapter4.4) OK

Contact VOITH

Check compressed-air supply (Chapter 4.4) OK

NOK

Contact VOITH

NOK

Check vehicle compressed-air supply

Mechanical fault of proportional valve

OK

Contact VOITH

* If you get oil leakage after a trail run again: continue at ´Ćhecking casing ventilation´´

NOK

Contact vehicle manufacturer

FD 1601

cbtd 98-01 53.2659.10


4.1


Troubleshooting Diagram (Continue)

Electrical Diagram Version 1

Connecting plug 4 pins "ISO Interface" 3 1 2 4

Digiprop

X1. 18pins

X2. 9pins

X3. 12pins

3 2 1 6 5 4 9 8 7

CAN-high CAN-Ground CAN-low Position 1 Position 2 Position 3 Position 4 Position 5 T 15 (Ignition lock)

Lead E-Box

T 30 (Battery) Output / high side 1 `HS 1` Output / low side 1 `LS 1` Output / high side `HS 2`

pink blue orange white weiß grey red red blue/white orange/white purple purple brown brown black beige yellow/green black/white

Prop valve `+` Prop valve `-` Changeover valve `+` Changeover valve `-` Water temp.`+` Water temp.`-` Oil temp.`+` Oil temp.`-`

pink grey orange beige yellow/green blue purple white

12 11 10

ISO K ISO L Retarder Stage Switch`+`

15 14 13 18 17 16

T 31 (Ground)

3 2 1 6 5 4 9 8 7

Connecting plug 8 pins "Retarder Stage Switch"

3 2 1 6 5 4 9 8 7 12

ABS Speedometer signal Input / pull-up `DIU 1` Input / pull-up `DIU 2` Input / pull-down `DID 1` Input / pull-down `DID 2` Input / pull-down `DID 3 ` Retarder pilot light Input / (m 0...5V ) ÌNA-U ` Input / p.-down / PWM-in `DID 4 `

11 10

Stop light relay Input / (0...20mA ) ÌNA-I ´

7 6 5 3 2 8 4

Position 1 Position 2 Position 3 Position 4 Position 5 Retarder Stage Switch`+`

T 15 (Ignition lock) T 31 (Ground) T 30 (Battery)

+ +

Lead Retarder Pin 1 2 3 4


black/white blue white pink blue/white brown/white orange/white yellow/green grey/black grey grey orange red/white

ABS Speedometer signal

+


Stop light relay

1 9 5 8 4 3 2 7 6 1112101314 Connecting plug 14 ins "Additional Functions"

16014e

Electrical Diagram Version 2

"ISO Interface" 3 1 2 4

Digiprop

X1. 18pins

X2. 9pins

X3. 12pins

3 2 1 6 5 4 9 8 7

CAN-high CAN-Ground CAN-low Position 1 Position 2 Position 3 Position 4 Position 5 T 15 (Ignition lock)

Lead E-Box

T 30 (Battery) Output / high side 1 `HS 1` Output / low side 1 `LS 1` Output / high side `HS 2`

pink blue orange white weiß grey red red blue/white orange/white purple purple brown brown black beige yellow/green black/white


pink grey orange beige yellow/green blue purple white

12 11 10

ISO K ISO L Retarder Stage Switch`+`

15 14 13 18 17 16

T 31 (Ground)

3 2 1 6 5 4 9 8 7

Connecting plug 8 pins "Retarder Stage Switch"

3 2 1 6 5 4 9 8 7 12

ABS Speedometer signal Input / pull-up `DIU 1` Input / pull-up `DIU 2` Input / pull-down `DID 1` Input / pull-down `DID 2` Input / pull-down `DID 3 ` Retarder pilot light Input / (m 0...5V ) ÌNA-U ` Input / p.-down / PWM-in `DID 4 `

11 10

Stop light relay Input / (0...20mA ) ÌNA-I ´

7 6 5 3 2 8 4

Position 1 Position 2 Position 3 Position 4 Position 5 Retarder Stage Switch`+`

T 15 (Ignition lock) T 31 (Ground) T 30 (Battery)

+ +

Lead Retarder Pin 1 2 3 4 Pin 1 2 3 4

black/white blue white pink blue/white brown/white orange/white yellow/green grey/black grey grey orange red/white


ABS Speedometer signal


+

Stop light relay

1 9 5 8 4 3 2 7 6 1112101314 Connecting plug 14 pins "Additional Functions"

cbtd 98-01 53.2659.10


16015e


4.2

Troubleshooting and Remedies

Troubleshooting and remedies Check requirements • • • • 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) must be connected terminal 15 and at pin 13 (terminal X1) terminal 30.

Notice Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary (see Section 3.3 „Checking Oil Level“). For trouble-free retarder operation, it is important that the filling quantity specified is adhered to (see table, Section 3.2, page 3.2/2).

cbtd 98-01 53.2659.10



4.2

Troubleshooting and Remedies (Continue)

Notice

R

The retarder pilot light (arrow) has additionally the function of a fault code: - slight fault Permanent lighting in position 0 - 5 of retarder stage switch, braking is still possible to limited extent. - serious fault Permanent lighting in position 0 - 5 of retarder stage switch, braking no longer possible - retarder is switched off. 16016

Notice If the ignition is switched off and on, the retarder is in operation again and the retarder pilot light goes off. If a serious fault remains present or reoccurs, the retarder switches off again and the retarder pilot light comes on permanently in position 0 to 5 of the retarder stage switch.

cbtd 98-01 53.2659.10



4.2


Connector arrangement and pin assignment

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

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

cbtd 98-01 53.2659.10

Not in use Not in use Not in use Retarder stage switch, position 3 -(or) Retarder stage switch, position 2 -(bl) Retarder stage switch, position 1 -(pi) Terminal 15 (rd) Retarder stage switch, position 5 -(gr) Retarder stage switch, position 4 -(wh) Retarder stage switch + (vi) ISO-interface, L-lead (or/wh) ISO-interface, K-lead (bl/wh) Terminal 30 (bl) Not in use Terminal 31 (br) Output / high side 2 „HS2“ (bl/wh) Output / low side 1 „LS1“ (ye/gr) Output / high side 1 „HS1“ (be)

16

13

10

7

4

1

17

14

11

8

5

2

18

15

12

9

6

3

16017



4.2


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

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

7

4

1

8

5

2

9

6

3

16018

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

cbtd 98-01 53.2659.10

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


10

7

4

1

11

8

5

2

12

9

6

3

16019


4.2


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

Retarder stage switch + (vi) Input / pull down „DID 1“ (bl/wh) Input / pull down „DID 2“ (br/wh) Input / pull down „DID 3“ (or/wh) Input / pull down / PWM -in „DID 4“ (gr) Input / pull up „DIU 1“ (wh) Input / pull up „DIU 2“ (pi) Input / (0...5V) „INA-U“ (gr/bl) Input / (0...20 mA) „INA-I“ (rd/wh) Output / high side 1 „HS1“ (be) Output / high side 2 „HS2“ (bl/wh) Output / low side 1 „LS1“ (ye/gr) Terminal 15 (rd) Terminal 31 (br)

2

4

6

8

10

12

14

1

3

5

7

9

11

13

16020

ISO-Interface plug 1 2 3 4

K-lead (bl/wh) K-lead (or/wh) Terminal 15 (rd) Terminal 31 (br)

4

3

2

1

16021

cbtd 98-01 53.2659.10



4.2


Cooling water temperature pick-up plug Oil temperature pick-up plug

16022

Proportional valve plug 1 2 3 4

Proportional valve + (pi) Proportional valve + (gr) Not operational (or) Not operational (be)

4 1

2 3

16023

cbtd 98-01 53.2659.10



4.2


Retarder stage switch plug 1 2 3 4 5 6 7 8

Not in use Position 5 - (gr) Position 4 - (wh) Retarder stage switch + (vi) Position 3 - (or) Position 2 - (bl) Position 1 - (pi) Bridge to pin 4

5

6

7

8

1

2

3

4

16024

cbtd 98-01 53.2659.10



4.2


A. With fault code Special tool

53.8224.10

Commercially available tool Multimeter

recommended: Fluke 87

Notice The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-out from the fault memory. Furthermore a diagnosis with the PC „DigiDia“ software is possible. In this case please contact VOITH TURBO or a responsible contracting party.

cbtd 98-01 53.2659.10



4.2


Fault memory read-out via retarder pilot light blinking code

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

Fault memory read-out with service cable (Digiprop-Version 0.2) Requirements -

1.

Retarder stage switch in position 0 Vehicle in parking position, Ignition ON Service interface L-lead connected to ground for ≥ 2 s. For this purpose, press push-button of service cable switch.

2.

First fault as blinking code output.

3.

Repeat from step 2 and 3 for more blinking code outputs.

Meaning -

cbtd 98-01 53.2659.10

long blinking signals (2 sec.) tens unit. short blinking signals (0,5 sec.) single unit.



4.2


Digiprop-Version 1.0 The blinking code can be triggered analogous to V 0.2, the conditions are the same. Additionally the blinking code can be triggered with the help of the retarder stage switch during the service function: 1. 2. 3. 4. 5.

Shift RSS-Position 0 Shift RSS-Position 1 ( ≥ 2 Seconds) Shift RSS-Position 0 Blinking code of first fault is indicated Repeat from step 2 to 3 for more blinking code outputs

Addition for versions as of V 1.1 There is a break of 3 seconds before and after each blinking code output, during this time the retarder pilot light is switched off.

16025

Display example: Fault code 23

Display example for fault code 23: The number of tens will be indicated first as long ON-time: The number of singles afterwards will be indicated as short ON-time: Breaks between each ON-time:

each 2 seconds each 0,5 seconds each 1 second

E A t

If a relevant fault is indicated, the retarder pilot light is ON before triggering of the blinking code, the retarder pilot light switches to permanent lighting again after the blinking code. If there is only one fault in the memory, the retarder pilot light stays OFF after the output.

cbtd 98-01 53.2659.10


Retarder stage switch on Retarder stage switch off Time


4.2


Delete fault memory No marginal conditions in accordance with read-out of fault memory. 1.

Ignition: OFF

2.

Service interface L-lead connected to ground. For this purpose, press push-button of service cable switch.

3.

Ignition: ON

4.

Disconnect after ≥ 2 seconds the L-lead of ground.

cbtd 98-01 53.2659.10



4.2


Notice Meaning of entries in „Measurement/test connection“ column: X 1/15 W X 3/11 Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3 Table 1: Fault

Code 01

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ test connection1 )

Result/ Set point

Cause/ Remedy 2)

Stop light relay/

slight

1s

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

X 3/11 W X 1/15

Relay is installed: 250 - 350 W

Check lead, plugs and relay or consumers

slight

400 ms

- Ignition: OFF - Pull plug X1 out of control unit - Disconnect plug for extra operation (e.g. lamp or relay) - Ignition: ON

X 1/17 V X 1/15

0V


(Check)

Short circuit to ground 02

LS 1 output Short circuit to battery

1) 2)

cbtd 98-01 53.2659.10

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



4.2


Table 2: Fault text Fault Code 03

Fault class

Trigger time

slight

1s

Measurement/ test connection

Result/ Set point

Cause/ Remedy


X 1/18

W X 1/ 15

With relay installed: 250 - 350 W


slight

1s


X 1/16 W X 1/15

With relay installed: 250 - 350 W


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)

Operation

(Check) HS 1 output Short circuit

04

HS 2 output Short circuit

05

Terminal 15 Undervoltage

06

Terminal 15 Overvoltage

cbtd 98-01 53.2659.10

Requirement /



4.2


Table 3: Fault text Fault Code 08 09

Fault class

Trigger time



Result/ Set point

(Check) 1s

Water temperature sensor Discontinuity / Short circuit to battery

serious/ slight *


X 2/5 W X 2/4 20°C ± 10 °C = 1039 - 1117W 60°C ± 10 °C = 1099 - 1271W 80°C ± 10 °C = 1271 - 1347W Notice: The measuring in one temperature range normally is sufficient.

*

cbtd 98-01 53.2659.10

Cause/ Remedy

Fault is in serious class, if temperature sensor for oil and water are defective at the same time.


Check lead and sensor


4.2


Table 4: Fault text Fault Code 11 12

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

X 2/9 W X 2/8

20°C ± 10 °C = 1039 - 1117W

Check lead and sensor

(Check) Oil temperature sensor

1s serious/ slight *


60°C ± 10 °C = 1099 - 1271W

Discontinuity / Short circuit to battery

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

cbtd 98-01 53.2659.10

Fault is in serious class, if temperature sensor for oil and water are defective at the same time.



4.2


Table 5: Fault text Fault Code

(Check)

13

1

13

13

2

3

Retarder stage switch Undefined switch state

Fault class

Trigger time

serious

100 ms

Requirement /


Result/ Set point

Cause/ Remedy

- Ignition: ON - Retarder stage switch: Position 0

X 1/10 V X 1/15

≥ 17,5 V

Check lead, plug and retarder stage switch


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

Operation


X 1/6 X 1/5 X 1/4 X 1/9 X 1/8

X 1/5 X 1/4 X 1/9 X 1/8

V V V V

X 1/15 X 1/15 X 1/15 X 1/15 X 1/15

X 1/15 X 1/15 X 1/15 X 1/15

X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 X 1/9 X 1/8

cbtd 98-01 53.2659.10

V V V V V

V X 1/15 V X 1/15 V X 1/15


0V 0V 0V 0V 0V ≥ 17,5 V ≥ 17,5 V


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



4.2



(Check)

13

4

Fault class

Trigger time



Result/ Set point

Cause/ Remedy


X 1/10 V X 1/6 V X 1/5 V X 1/4 V

≥ ≥ ≥ ≥


X 1/15 X 1/15 X 1/15 X 1/15

X 1/9 V X 1/15 X 1/8 V X 1/15 13

5


X X X X X

1/10 V 1/6 V 1/5 V 1/4 V 1/9 V

X X X X X

1/15 1/15 1/15 1/15 1/15

X 1/8 V X 1/15 13

cbtd 98-01 53.2659.10

6


X 1/10 X 1/6 X 1/5 X 1/4 X 1/9 X 1/8

V V V V V V

X X X X X X

1/15 1/15 1/15 1/15 1/15 1/15


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

0V 0V ≥ ≥ ≥ ≥ ≥

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


0V ≥ ≥ ≥ ≥ ≥ ≥

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



4.2



Fault class

Trigger time



Result/ Set point

Cause/ Remedy

(Check)

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 W X 1/15

Resistor infinite

Single check of stages for short circuit

cbtd 98-01 53.2659.10



4.2


Table 8: Fault text Fault Code 16

Fault class

Trigger time

serious



Result/ Set point

Cause/ Remedy

2s

- Ignition: ON

X 3/2 V X 1/15

≤==1 V

Check lead and speedometer

serious

2s


X 3/2 V X 1/15

≤==9 V

Check lead and speedometer

serious

60 s

- Ignition: ON

X 3/3 V X 1/15

≥ 3,5 V

Check lead, relay and ABS-control unit

(Check) Speedometer signal Discontinuity

18

Speedometer signal Short circuit to battery

19

cbtd 98-01 53.2659.10

ABS Short circuit to ground



4.2



Fault class

Trigger time



Result/ Set point

Cause/ Remedy

X 3/3 V X 1/15

≥ 16,5 V

Check lead, relay and ABScontrol unit

−

Replace control unit

≤==10 V

Check lead

(Check)

21

ABS-Signal undefined

serious

60 s

- Ignition: ON

22

Internal fault ABS-current path

serious

1s

-

23

Proportional valve Fault No. 1: Short circuit to battery

serious

1s


cbtd 98-01 53.2659.10

X 2/3 V X 1/15



4.2



(Check)

24

1

24

2

cbtd 98-01 53.2659.10

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

Fault class

Trigger time

serious

1s

Requirement /


Result/ Set point

Cause/ Remedy

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

X 2/2 W X 2/3

18-25 W

Check lead and proportional valve (valve block)


X 2/3 W X 1/15

Resistor infinite


Operation



4.2



(Check)

24

3

Fault class

Trigger time




Result/ Set point

Cause/ Remedy

X 2/2 W X 1/15

Resistor infinite


25

Proportional valve Fault No. 3: defective control unit

serious

10 s


27

Proportional valve Fault No. 5: defective control unit

serious

2s


28

Terminal 30

serious

60 s

Undervoltage

cbtd 98-01 53.2659.10


X 1/13 V X 1/15


≥ 17,5 V

Check lead, plug and fuse


4.2



Fault class

Trigger time



Result/ Set point

Cause/ Remedy

(Check)

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

≤==2 V

Check lead and retarder pilot light

cbtd 98-01 53.2659.10



4.2



Fault class

Trigger time



Result/ Set point

Cause/ Remedy

(Check)

35

Fault control unit

serious

500 ms / 123 s


37

Fault pedal operation

slight

100 ms / 1 s

Check installation relating to OEMrespectively VOITHinstructions

cbtd 98-01 53.2659.10



4.2


B. Without fault code Notice Retarder faults without fault code are not recognized electronically.

cbtd 98-01 53.2659.10



4.3

Checking Pump Pressure

Illustration checking pump pressure Preconditions for checking • •

Ignition OFF Retarder stage switch in position 0 101 Hex.-head screw (M 12 x 1,5), (Pump pressure measuring point) 25 Nm 102 Sealing ring (A 12 x 15,5), renew

101 102

Notice The pump-pressure check provides information on the mechanical condition of rotating parts, on internal leaks and on the operation of the retarder. Special tool

53.4788.10 16026

Pressure gauge 0 - 25 bar cbtd 98-01 53.2659.10



4.3

Checking Pump Pressure (Continue) 99/1

Caution! Risk of injury! The screw plug is heated up! Job scope 1.

Screw out screw plug (101) with sealing ring (102) at the retarder housing.

2.

Connect up pressure gauge (99/1) to retarder housing.

3.

Shift retarder stage switch (16) to the highest braking stage with the vehicle in parking position and read-off after 30 sec. the pump pressure from the pressure gauge (99/1).

4.

Compare read-off pump pressure with the setpoint of the static pump pressure (see following table page 4.3/3).

16027

99/1 Pressure gauge 53.4788.10

Caution! If the measurement of the static pump pressure falls short of the setpoint, either the retarder is leaking or the control system is defective (see troubleshooting diagram).

cbtd 98-01 53.2659.10



Setting [Nm]

4.3

Code Number

3)

Checking Pump Pressure (Continue)

Pump pressure static Setpoint [bar]

Pump pressure dynamic 1 ) v p s = 1000 r.p.m. Minimum value [bar]

1) 2) 3)

1000

027

1,15 – 1,45

7

1250

028

1,45 – 1,75

9

1500

029

1,75 – 2,05

12

1750

030

2,05 – 2,35

14

2000

031

2,35 – 2,65

16

Retarder stage switch in highest position Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure) The code number is to be found at the control unit Notice

The data represent the state of the art at the time of going to print. Control units with different values are still in circulation. The manufacturer reserves the right to make further modifications.

cbtd 98-01 53.2659.10



4.3

Checking Pump Pressure (Continue)

Job scope dynamic 1.

Drive the vehicle with a prop-shaft speed of v p s = 1000 r.p.m.

2.

Shift the retarder stage switch (16) to position 5 while on the move at vps = 1000 r.p.m. and read-off pump pressure at pressure gauge (99/1).

3.

Compare read-off pump pressure with the value of dynamic pump pressure (see table page 4.3/3). Caution!

If the setpoint is obtained in the check at parking position but the minimum value is not reached in the dynamic check, please contact VOITH TURBO!

Caution! Risk of injury! The screw of the pressure gauge and the retarder are heated up! 4.

cbtd 98-01 53.2659.10

Disconnect the pressure gauge (99/1). Screw in screw plug (101) with new sealing ring. Tightening torque 25 Nm


4.4

Diagnosis /

Checking Control System

Troubleshooting Illustration checking control system

25

Notice The reference numbers indicated in Section 4.4 are not identical with the reference numbers of the spare parts lists.

33

71 32

21

61

A R P

37 1 2 11 19

20 21 25 26 31

32

33 34 35 37 39

40 61 71

cbtd 98-01 53.2659.10

Heat exchanger Control unit Proportional valve current connection Temperatur pick-up cooling water alternative: positions 19 and 20 joining in the central-plug (see electrical diagram Version 2) Temperature pick-up oil Proportional valve Constant-air pressure line p y (Connection A) Supply-air pressure line p v (Connection P) Compressed air line (pressure regulator - four-circuit protection valve) Compressed-air pressure line (four-circuit protection valve air tank for auxiliary equipment with test connection Compressed-air line (brake circuit No. 1) Compressed-air line (brake circuit No. 2) Compressed-air line (parking brake) Ventilation line „R“ Electrical lead (cooling-water temperature pick-up to control unit, 2 wires) Electrical lead (oil temperature pick-up to control unit, 2 wires) Four-circuit protection valve Air tank for auxiliary equipment

31

1 35

26

34

40 2


20

39 19

1

16028

4.4


Checking Control System (Continue)

Check requirements • • • • •

Battery voltage 18 - 32 V 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. Retarder stage switch in Position 0 Ignition OFF

Special tools

Wasser

53.4788.10

Öl

53.8207.10

53.8279.10

53.8198.10

Pressure gauge 0 -25 bar The adapter lead 53.8279.10 (98/5) has to be used only to connect the temperature simulator 53.8207.10 (99/2), if the temperature sensor for oil and water are using one central plug. Commercially available tool Multimeter

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10

recommended: Fluke 87



4.4


Checking supply-air pressure pv 1.

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

6 bar

Maximum pressure:

11 bar

Notice If the pressure is not within the specified range, the service brake must be checked to the manufacturer´s data.

32 16029

Pressure gauge 53.1403.10

Test set-up job scope 1.

57

98/5

Connect temperature simulator (99/2) with the adapter lead (98/5) at the temperature pick-up (57).

99/2

Notice Pay attention to the correct connection of the plugs for cooling water and oil.

16030

99/2 Temperature simulator 53.8207.10

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10



2.

4.4


Screw out oil filler/check plug (1900) with sealing ring (1800).

1900

1800

16031

3.

Connect pressure gauge (99/7) to retarder housing.

99/7

16032

99/7 Pressure gauge 53.1403.10

cbtd 98-01 53.2659.10



4.4


4.

Connect up „Propstrom“ measuring adapter (99/3).

•

Disconnect plug from proportional valve (21) and connect it up to „Propstrom“ measuring adapter (99/3).

21

•

Connect plug of „Propstrom“ measuring adapter (99/3) to proportional valve (21).

•

Connect up multimeter (98/8) to measure mA.

•

Set switch „Propvalve“ on „Propstrom“ measuring adapter (99/3) to position „I“.

98/8

99/3 16033

99/3 „Propstrom“ measuring adapter 53.8198.10 99/8 Multimeter

cbtd 98-01 53.2659.10



4.4


Job scope test •

57

98/5

Preconditions for checking Ignition ON

1.

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 stage. The constant-air pressure p y and the control current must reach the values given in table on the next page (page 4.4/7).

2.

Set the rotary switch of the temperature simulator (99/2) to 105 oC cooling water temperature. The constant-air pressure p y must drop to at approx. 7% bar below the set maximum pressure. Set rotary switch of the temperature simulator (99/2) to 125 oC cooling water temperature. There must be no more output of constant-air pressure p y . Set rotary switch of temperature simulator (99/2) again to 95o C cooling water temperature.

16030

99/2 Temperature simulator 53.8207.10

o

3.

Set the rotary switch of the temperature simulator (99/2) to 185 C oil temperature. The constant-air pressure must drop to at approx. 4% below the set maximum pressure. Set the rotary switch of the temperature simulator (99/2) to 225 oC oil temperature. There must be no more output of constant-air pressure p y .

4.

Carry out measurements for current and constant-air pressure regarding the following table (see page 4.4/7).

5.

Screw oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm

6.

Reconnect electrical lead (57) for cooling water and oil to temperature pick-ups for cooling water and oil.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10

99/2



4.4


Notice If the control current is reached but the constant-air pressure is not, either the retarder is leaking or the proportional valve is defective and must be renewed. If both values are not reached, please see Section 4.2 „Troubleshooting and Remedies“. Setting [Nm]

1) 2)

3)

cbtd 98-01 53.2659.10

Code Number1 )

Control current [mA] 2 )

Constant-air pressure p y [bar] 3 )

1000

027

429 – 441

1,15 – 1,45

1250

028

449 – 461

1,45 – 1,75

1500

029

470 – 482

1,75 – 2,05

1750

030

490 – 502

2,05 – 2,35

2000

031

510 – 522

2,35 – 2,65

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



4.5

Operational Check

Requirements for check • • • •

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

R

The following operational states are indicated by the retarder pilot light (arrow):

16016

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

slight fault The retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch, braking operations are possible (the retarder operates with limited braking torque).

-

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

cbtd 98-01 53.2659.10



4.5

Operational Check (Continue)

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

cbtd 98-01 53.2659.10

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



4.5

Operational Check (Continue)

Troubleshooting Test step 1

2

cbtd 98-01 53.2659.10

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 4.1/1

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

Retarder operates trouble-free.

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

Troubleshooting as on page 4.1/1


Retarder Removing, Installing

5

Removing, Installing Retarder

5.1

Removing, Installing Retarder (Free Mount Installation) ............................5.1/1

5.2

Removing, Installing Retarder (Gearbox Attachment)................................5.2/1

cbtd 98-01 53.2659.10



5.1

Removing, Installing Retarder (Free Mount Installation)

Illustration Retarder (Free mount installation)

1300 1300 1400 1400

1200

1200

94

92

95

36

92

25 1100 96

93 97

1000 96

57 1000/6 1200 1000-5 1200/1 1500 16034

Preconditions for job • • • • •

Drain oil from retarder (see Section 3.2) Drain oil from heat exchanger (see Section 8.1 and 8.2) Drain cooling water Retarder stage switch in switch position 0 Ignition OFF Notice

When stainless-steel heat exchanger is installed, oil can not be drained from the heat exchanger. 25 36 57 92 93 94 95 96 97 1000

Constant-air pressure line p y „A“ Ventilation line „R“ Plug temperature pick-up Prop-shaft Hex.-head screw Spring washer Hex.-head screw Hose clamp Hose connection Heat exchanger

1000/5 1000/6 1100 1200 1200/1 1300 1400 1500

Drain plug cooling water (M 18 x 1,5), 50 Nm Sealing ring (A 18 x 22), renew Suspension complete Megi-pads, check, renew if necessary Spacer tube Hex.-head screw (M 16 x 90) Washer (B 16) Hex.-head nut (M 16) self-locking, renew, 110 Nm

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

cbtd 98-01 53.2659.10



5.2

Removing, Installing Retarder (Gearbox Attachment)

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

cbtd 98-01 53.2659.10


Repair Gearbox Attachment

6

Repair (Gearbox Attachment)

6.1

Assembly Overview ....................................................................................6.1/1

6.2

Removing, Checking and Installing Casing Ventilation ..............................6.2/1

6.3

Removing, Installing Non-Return Valve (Casing Ventilation) .....................6.3/1

6.4

Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger) ..............................................................6.4/1

6.5

Removing, Checking and Installing Silencer ..............................................6.5/1

6.6

Removing and Installing Bottom Cover ......................................................6.6/1

6.7

Checking, Removing and Installing Closing Cover of Retarder Housing ...6.7.1

6.8

Removing and Installing Labyrinth Cover (output side) Renewing Radial Shaft Sealing Ring .........................................................6.8/1

6.9

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

cbtd 98-01 53.2659.10


6.1

Repair Gearbox

Assembly Overview

Attachment Illustration assembly overview (retarder basic group)

3200 3100

2800 2700

2900

2500 2902 2901 2903

4600 4400 4500

2600 2300/1

3000

2301

4300

101

2300 2300/2

102

2300/3 2400

1900 1800 700

850 800 900

104 103 103 104

1200 1300

1100

1400

1600

1500

1000

1700 16035

101 102 103 104 700 800 850 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2300 2300/1 2300/2 2300/3

cbtd 98-01 53.2659.10

Hex.-head screw (M 12 x 1,5) Sealing ring (A 12 x 15,5) Silencer-ventilation (30 x 4) Circlip (JL 30 x 1,2) Raduial shaft sealing ring (80 x 100 x 10) Labyrinth cover O-ring (125 x 2,5) Hex.-head screw (M 8 x 25) Cover O-ring (82 x 4) Gasket Bottom cover Washer (B 8,4) Cap screw (M 6 x 20) Sealing ring (A 22 x 29) Screw plug (M 22 x 1,5) Sealing ring (A 30 x 36) Oil filler/check plug (M 30 x 1,5) Casing ventilation (D 30 x 38) contents Position 2301 Valve insert Float Float cage

2301 2400 2500 2600 2700 2800 2900 2901 2902 2903 3000 3100 3200 4300 4400 4500 4600

O-ring (55 x 3) Sieve (D 60 x 23) Cover sheet metal Spacer (D 50/42 x 15,5) Washer (B 6,4) Cap screw (M 6 x 12) Top cover with 7 threads for M 6 Valve internal part Spring Connector Gasket for 7 fixing screws M 6 Washer (B 6,4) Cap screw (M 6 x 30) Radial shaft sealing ring (85 x 105 x 13) Centering cover (D 180 x 70) O-ring (130 x 4) Hex.-head screw (M 8 x 20)



6.2

Removing, Checking and Installing Casing Ventilation

Illustration casing ventilation Preconditions for job • • •

Retarder removed (see Section 5.1). Retarder stage switch in position 0 Ignition OFF

2800 2700

3200

2500

3100

2600 2300 2300/1 2300/2 2300/3 2301

2400 2500 2600 2700 2800 2900 3000 3100 3200

Casing ventilation Valve insert Float checking, renew if necessary Float cage O-ring (55 x 3), renew, coat of silicone-free and noncorrosive grease for installation Mesh strainer clean with benzine Cover plate Spacer Washer (B 6,4) Hex.-head screw (M 6 x 12), 10 Nm Cover Gasket, renew Washer (B 6,4) Cap screw (M 6 x 30), 10 Nm

2900 2300/1 2300

3000

2301 2300/2 2300/3

2400

16036

cbtd 98-01 53.2659.10


6.2


Removing, Checking and Installing Casing Ventilation (Continue)

Lubricants and cleaning agents Mesh strainer

Benzine

O-ring

Silicone-free and non-corrosive grease

Float

Methylated Spirit

Special tools

53.7712.10

53.9428.10

To remove 1.

Screw out hex.-head screws (3200).

2.

Remove washer (3100).

cbtd 98-01 53.2659.10



6.2


3.

Remove the cover (2900) from the retarder housing.

4.

Remove gasket (3000) and clean the sealing surface.

5.

Screw out hex.-head screws (2800) and remove Washer (2700).

98/7

6.

Remove cover plate (2500).

2300

7.

Remove spacer (2600).

8.

Use the impact tool (99/5) and adapter (98/9) to extract the casing ventilation (2300).

99/5

16037

98/7 Adapter 53.9428.10 99/5 Impact tool 53.7712.10 9.

Extract the valve insert (2300/1) from float cage (2300/3).

10.

Lever O-ring (2301) out of the groove of the valve insert (2300/1).

11.

Remove the mesh strainer (2400), check and wash with benzine, if necessary.

2300/1 2301

2300/3 16038

cbtd 98-01 53.2659.10



6.2


To check 1.

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

2.

Weight the float (2300/2). Specified weight 11g ± 1 Gramm. If the weight is more than the specified weight, renew the complete casing ventilation. 2300/2 Notice

Oil has penetrated into the float, the retarder is impaired in its operation. 16039

3.

Check sealing edge of shaft sealing ring (arrow) in valve insert (2300/1). Set the valve insert (2300/1) down on the float (2300/2) and fill up the cavity between float (2300/2) and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not damaged, the fluid level must not change within 1 minute. If necessary, renew the complete casing ventilation.

2300/2

2300/1

16040

cbtd 98-01 53.2659.10



6.2


To install 1.

Install the mesh strainer (2400).

2.

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

3.

Fit the float (2300/2) into float cage (2300/3).

2300/1

2301

Notice If the float only has one polished surface fit float with this surface on top.

16041

4.

Fit the float cage (2300/3) into the valve insert (2300/1).

5.

Fit the casing ventilation (2300) into the retarder housing.

6.

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

cbtd 98-01 53.2659.10



6.2


7.

Place the spacer (2600) on the casing ventilation (2300)

8.

Position cover plate (2500).

9.

Screw new hex.-head screws (2800) with washer (2700) tight. Tightening torque 10 Nm

10.

Position new gasket (3000) and the cover (2900) at the retarder housing.

Caution! Make sure the gasket (3000) is properly located.

11.

cbtd 98-01 53.2659.10

Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm



6.3

Removing and Installing Non-Return Valve (Casing Ventilation)

Illustration non-return valve (casing ventilation) 2901

2902

2903

2902

Valve internal components, check for damage, renew complete non-return valve, if necessary Spring, check for damage, renew complete non-return valve, if necessary Connector, install with Loctite 270 locking agent, 100 Nm check valve seat, renew complete non-return valve, if necessary

2901

2903

Locking agent Connector

Loctite 270

16042

cbtd 98-01 53.2659.10



6.4

Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger

Illustration non-return valve (stainless-steel heat exchanger) 1400 1200 1200/1 1200/2 1200/3

1200/4

1200/5

1300 1400

Non-return valve (stainless-steel heat exchanger) Valve cover Valve housing O-ring , renew, coat of silicone-free and noncorrosive grease for installation Spring, check for fatigue, renew complete non-return valve (1200), if necessary Valve piston, check valve seat in heat exchanger and vulcanization, renew complete non-return valve (1200), if necessary. Spring washer, renew Cap screw (M 8 x 20), 25 Nm

1300 1200/1 1200/2 1200/3 1200 1200/4

1200/5

Lubricants O-ring

Silicone-free and non-corrosive grease 16043

cbtd 98-01 53.2659.10


6.5


Removing, Checking and Installing Silencer

Illustration Silencer Preconditions for job • •

Retarder stage switch in position 0 Ignition OFF Notice

This step can be performed with the retarder removed or installed. 103

104

Silencer (30 x 4) clean with Benzine and blow out with compresse-air Circlip (JL 30 x 1,2), concave side must face silencer

104

103

Cleaning agents Silencer

Benzine 103 104 16044

cbtd 98-01 53.2659.10



6.6

Removing and Installing Bottom Cover

Illustration bottom cover Preconditions for job • • •

Oil drained from retarder (see Section 3.2) Retarder stage switch in position 0 Ignition OFF 1200 1300 1400 1500

Gasket, renew Bottom cover Washer (B 6,4) Cap screw (M 6 x 20), 10 Nm 1200

1300

1400 1500

16045

cbtd 98-01 53.2659.10



6.7

Checking, Removing and Installing Closing Cover of Retarder Housing

Special tool

1000

53.7712.10

99/5

To check 1.

1100 1000

Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.

99/5 Impact tool 53.7712.10

To remove 1.

Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).

To install 1.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10

Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease and install together with closing covers (1000).


16046


6.8

Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring

Illustration labyrinth cover (output side) Prior jobs • • • •

Prop shaft removed from flange (see vehicle manufacturer instructions) Prop shaft flange removed (see VOITH-installation schemes) Retarder stage switch in position 0 Ignition OFF

700

850 800

Notice

900

This job can be performed with the retarder removed or installed. 700

800

850

900

cbtd 98-01 53.2659.10

Radial shaft sealing ring (80 x 100 x 10), renew, coat with silicone-free and non-corossive grease for installation Labyrinth cover, coat with Hylomar sealant around leakage oil return bore O-ring (125 x 2,5), renew, coat with silicone-free and non-corossive grease for installation Hex.-head screw (M 8 x 25) self-locking, renew, 23 Nm

16047



6.8

Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring (Cont.)

Sealants and locking agents Housing sealing surfaces O-ring

Hylomar Silicone-free and non-corossive grease

Special tool

53.0742.10

Job scope 1.

Screw out hex.-head screw (900).

2.

Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the rotor housing.

800

16048

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10



6.8


3.

Place the labyrinth cover (800) on a piece of pipe.

4.

Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes (arrows) out of the labyrinth cover (800). Notice

Check race of radial shaft sealing ring for scores and uneven surface. If a sealing function is no longer guaranteed, please contact VOITH TURBO. 5.

800

700

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (700). 16049

6.

Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into the labyrinth cover (800). Position for installation: Sealing lip at top.

94/4

700

800

16050

94/4 Press-in equipment 53.0742.10 cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10



6.8


7.

Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in the labyrinth cover.

8.

Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800). Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow) are in alignment.

9.

Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm

850 800

16051

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10



6.9

Removing and Installing Centering Cover (Input Side), Renewing Radial Shaft Sealing Ring

Illustration centering cover (input side) Prior job •

Retarder removed (see Section 5) 4300

4400 4500

4600

Radial shaft sealing ring (85 x 105 x 13), renew, coat with silicone-free and non-corossive grease for installation Centering cover O-ring (130 x 4), renew, coat with silicone-free and non-corossive grease for installation Hex.-head screw (M 8 x 20), self-locking, renew, 23 Nm

4600

Lubricants O-ring


4500

4300

4400 16052

cbtd 98-01 53.2659.10



6.9

Removing and Installing Centering Cover (Input Side), Renewing Radial Shaft Sealing Ring (Cont.)

Special tool

53.0742.10

Job scope 1.


2.

Use two hex.-head screws (M 8 x 30) (arrows) to press centering cover (4400) off retarder housing.

3.

Remove O-ring (4500) of centering cover (4400).

4.

Use an appropriate punch to knock the radial shaft sealing ring (4300) out of the centering cover (4400). Notice

4400

4400

Check race of radial shaft sealing ring for scores and uneven surface. If a sealing function is no longer guaranteed, please contact VOITH TURBO.

cbtd 98-01 53.2659.10

4500


16053


5.

6.9

Removing and Installing Centering Cover (Input Side), Renewing Radial Shaft Sealing Ring (Cont.)

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (4300). 94/4

6.

Use a press-in equipment (94/4) to press the radial shaft sealing ring (4300) as far as it will go into the centering cover (4400). Position for installation: Sealing lip at top.

4300

4400 16054

94/4 Press-in equipment 53.0742.10

7.

Apply thin coat of silicone-free and non-corossive grease to new O-ring (4500) and fit in the centering cover.

8.

Apply thin coat of Hylomar sealant around leakage-oil return bore in centering cover (4400). Install so that the leakage-oil return bores in the rotor housing and in the centering cover (arrow) are in alignment.

9.

4600

4500

Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm 4400 16055

cbtd 98-01 53.2659.10


Repair Free Mount Installation

7

Repair (Free Mount Installation)

7.1

Assembly Overview ....................................................................................7.1/1

7.2

Removing, Checking and Installation Casing Ventilation ...........................7.2/1

7.3

Removing, Installing Non-Return Valve (Casing Ventilation) .....................7.3/1

7.4

Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger) ..............................................................7.4/1

7.5

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

7.6

Removing and Installing Bottom Cover ......................................................7.6/1

7.7

Removing and Installing Prop Shaft Flanges ............................................7.7/1

7.8

Checking, Removing and Installing Closing Cover of Retarder Housing ...7.8/1

7.9

Removing and Installing Labyrinth Cover (output side) Renewing Radial Shaft Sealing Ring .........................................................7.9/1

7.10

Removing and Installing Labyrinth Cover (input side) Renewing Radial Shaft Sealing Ring .........................................................7.10/1

cbtd 98-01 53.2659.10


Repair Free Mount Installation

7.1

Assembly Overview

Illustration assembly overview (retarder basic group) 3200

2800 2700

2900

3100 2500 4700

2902 2901 2903

800 3000

850

700

2600 2300/1 2301

2300

101 102

2300/2 2300/3

5400 5500

2400

1900 1800 5500 5400

700

850 800

104 900

103 103 104

1200 1300 1400 1500

1100 1600

1000

1700 16056

101 102 103 104 700 800 850 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2300 2300/1 2300/2 2300/3

cbtd 98-01 53.2659.10

Hex.-head screw (M 12 x 1,5) Sealing ring (A 12 x 15,5) Silencer-ventilation (30 x 4) Circlip (JL 30 x 1,2) Raduial shaft sealing ring (80 x 100 x 10) Labyrinth cover O-ring (125 x 2,5) Hex.-head screw (M 8 x 25) Cover O-ring (82 x 4) Gasket Bottom cover Washer (B 8,4) Cap screw (M 6 x 20) Sealing ring (A 22 x 29) Screw plug (M 22 x 1,5) Sealing ring (A 30 x 36) Oil filler/check plug (M 30 x 1,5) Casing ventilation (D 30 x 38) contents Position 2301 Valve insert Float Float cage

2301 2400 2500 2600 2700 2800 2900 2901 2902 2903 3000 3100 3200 4300 4700 5400 5500 5600

O-ring (55 x 3) Sieve (D 60 x 23) Cover sheet metal Spacer (D 50/42 x 15,5) Washer (B 6,4) Cap screw (M 6 x 12) Top cover with 7 threads for M 6 Valve internal part Spring Connector Gasket for 7 fixing screws M 6 Washer (B 6,4) Cap screw (M 6 x 30) Radial shaft sealing ring (95 x 115 x 10) Hex.-head screw (M 8 x 30), self-locking Race O-ring (80 x 3) O-ring (125 x 2,5)


Repair Free Mount7.2 Installation

Removing, Checking and Installing Casing Ventilation

Illustration casing ventilation

2800

3200

2700

Preconditions for job The job in this section can be performed with the retarder removed or installed. • Retarder stage switch in position 0 • Ignition OFF 2300 2300/1 2300/2 2300/3 2301

2400 2500 2600 2700 2800 2900 3000 3100 3200

Casing ventilation Valve insert Float checking, renew if necessary Float cage O-ring (55 x 3), renew, coat of silicone-free and noncorrosive grease for installation Mesh strainer clean with benzine Cover plate Spacer Washer (B 6,4) Hex.-head screw (M 6 x 12), 10 Nm Cover Gasket, renew Washer (B 6,4) Hex.-head screw (M 6 x 30), 10 Nm

3100

2500 2600

2900

2300/1 2300

3000

2301 2300/2 2300/3 2400

16057

cbtd 98-01 53.2659.10


Repair Free Mount 7.2 Installation


Lubricants and cleaning agents Mesh strainer

Benzine

O-ring


Float

Methylated Spirit

Special tools

53.7712.10

53.9428.10

To remove 1.


2.

Remove washer (3100).

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10




3.

Remove the cover (2900) from the retarder housing.

4.

Remove gasket (3000) and clean the sealing surface.

5.

Screw out hex.-head screws (2800) and remove Washer (2700).

99/5

99/9 6.

Remove cover plate (2500).

7.

Remove spacer (2600).

8.

Use the impact tool (99/5) and adapter (98/9) to extract the casing ventilation (2300).

16058

99/9 Adapter 53.9428.10 99/5 Impact tool 53.7712.10 9.

Extract the valve insert (2300/1) from float cage (2300/3).

10.

Lever O-ring (2301) out of the groove of the valve insert (2300/1).

11.

Remove the mesh strainer (2400), check and wash with benzine, if necessary.

2300/1 2301

2300/3 16038

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10




To check 1.

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

2.

Weight the float (2300/2). Specified weight 11g ± 1 Gramm. If the weight is more than the specified weight, renew the complete casing ventilation. 2300/2 Notice

Oil has penetrated into the float, the retarder is impaired in its operation. 16039

3.

Check sealing edge of shaft sealing ring (arrow) in valve insert (2300/1). Set the valve insert (2300/1) down on the float (2300/2) and fill up the cavity between float (2300/2) and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not damaged, the fluid level must not change within 1 minute. If necessary, renew the complete casing ventilation.

2300/2

2300/1

16040

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10




To install 1.

Install the mesh strainer (2400).

2.

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

3.

Fit the float (2300/2) into float cage (2300/3).

2300/1

2301

Notice If the float only has one polished surface fit float with this surface on top.

16041

4.

Fit the float cage (2300/3) into the valve insert (2300/1).

5.

Fit the casing ventilation (2300) into the retarder housing.

6.

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

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10




7.

Place the spacer (2600) on the casing ventilation (2300)

8.

Position cover plate (2500).

9.

Screw new hex.-head screws (2800) with washer (2700) tight. Tightening torque 10 Nm

10.

Position new gasket (3000) and the cover (2900) at the retarder housing.

Caution! Make sure the gasket (3000) is properly located.

11.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10

Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm



Removing and Installing Non-Return Valve (Casing Ventilation)

Illustration non-return valve (casing ventilation) 2901

2902

2903

2902

Valve internal components, check for damage, renew complete non-return valve if necessary Spring, check for damage, renew complete non-return valve if necessary Connector, install with Loctite 270 locking agent, 100 Nm check valve seat, renew complete non-return valve if necessary

2901

2903

Locking agent Connector

Loctite 270

16059

cbtd 98-01 53.2659.10



Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger

Illustration non-return valve (stainless-steel heat exchanger) 1400 1200 1200/1 1200/2 1200/3

1200/4

1200/5

1300 1400

Non-return valve (stainless-steel heat exchanger) Valve cover Valve housing O-ring , renew, coat of silicone-free and noncorrosive grease for installation Spring, check for fatigue, renew complete non-return valve (1200), if necessary Valve piston, check valve seat in heat exchanger and vulcanization, renew complete non-return valve (1200), if necessary. Spring washer, renew Cap screw (M 8 x 20), 25 Nm

1300 1200/1 1200/2 1200/3 1200 1200/4

1200/5

Lubricants O-ring

Silicone-free and non-corrosive grease 16043

cbtd 98-01 53.2659.10


Repair Free Mount 7.5

Removing, Checking and Installing Silencer

Installation Illustration Silencer Preconditions for job • •

Retarder stage switch in position 0 Ignition OFF Notice

This step can be performed with the retarder removed or installed. 103

104

Silencer (30 x 4) clean with Benzine and blow out with compressed-air Circlip (JL 30 x 1,2), concave side must face silencer

104

103

Cleaning agents Silencer

Benzine 103 104 16044

cbtd 98-01 53.2659.10



Removing and Installing Bottom Cover

Installation Illustration bottom cover Preconditions for job • • •

Oil drained from retarder (see Section 3.2) Retarder stage switch in position 0 Ignition OFF 1200 1300 1400 1500

Gasket, renew Bottom cover Washer (B 6,4) Cap screw (M 6 x 20), 10 Nm 1200

1300

1400 1500

16045

cbtd 98-01 53.2659.10



Removing and Installing Prop Shafts Flanges

Installation Illustration prop shafts flanges Prior jobs •

Prop shafts flanges removed (see vehicle manufacturer instructions) Notice

93/1

97/6

97/8

The jobs in this section can be performed with the retarder removed or installed. 93/1 95/2 97/6 97/7 97/8 97/9 98

98

97/9

Hex.-head screw (M 20 x 180) Hex.-head nut (M 20), 375 Nm Prop shaft flange (output side) Prop shaft screw, renew Guard ring (output side) Guard ring (input side) Prop shaft flange (input side)

95/2

97/7

16060

cbtd 98-01 53.2659.10



Removing and Installing Prop Shafts Flanges (Continue)

Removing and installing 1.

Screw out hex.-head screw (95/2). Note for installation Screw hex.-head nut (95/2) tight. Tightening torque 375 Nm

2.

Pull out hex.-head screw (93/1) on output side.

3.

Pull both prop shaft flanges (97/6, 98) out of the retarder housing.

4.

Remove guard rings (97/8, 97/9).

97/7

97/8 97/9

Note for installation Renew prop shaft screws (97/7). Align hole patterns of both prop shaft flanges prior to installation. Maximum permissible offset 5°. 5.

Install the prop shafts in accordance to the vehicle manufacturer instructions. 16061

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10



Checking, Removing and Installing Closing Cover of Retarder Housing

Special tool

99/5 1000 1100

53.7712.10

1000

To check 1.

16062

Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.

To remove 1.

Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).

To install 1.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10

Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease and install together with closing covers (1000).



Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring

Illustration labyrinth cover Prior jobs • • • •

Prop shaft removed from flange (see vehicle manufacturer instructions) Prop shaft flange removed (see VOITH-installation schemes) Retarder stage switch in position 0 Ignition OFF

5500

5400

700

850 800 900

Notice This job can be performed with the retarder removed or installed. 700

800

850

900 5400 5500

cbtd 98-01 53.2659.10

Radial shaft sealing ring (80 x 100 x 10), renew, coat with silicone-free and non-corossive grease for installation Labyrinth cover, coat with Hylomar sealant around leakage oil return bore O-ring (125 x 2,5), renew, coat with silicone-free and non-corossive grease for installation Hex.-head screw (M 8 x 25) self-locking, renew, 23 Nm Race O-ring (80 x 3), renew, coat with silicone-free and non-corossive grease for installation

16063




Sealants and locking agents Housing sealing surfaces O-ring

900

Hylomar Silicone-free and non-corossive grease

Special tool

16064

53.0742.10

Job scope 1.

Screw out hex.-head screw (900).

2.

Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the rotor housing.

800

16065

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10




3.


4.

Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes (arrows) out of the labyrinth cover (800).

5.

Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft.

6.

Remove O-ring (5500) of hollow shaft.

7.

Check race for scores and radial shaft sealing ring for uneven surface and renew race if necessary. Notice

800

700

16049

If a sealing function is no longer guaranteed, please contact VOITH TURBO. Recommendation: Always change radial shaft sealing ring and race together. 8.

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500) and pull-on to the hollow shaft.

9.

Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it will go.

10.

Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).

5400

16066

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Repair Free Mount 7.9 Installation 11.



94/4

700

800

94/4 Press-in equipment 53.0742.10 12.


13.


14.


850 800

16051

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10



Removing and Installing Labyrinth Cover (Input Side), Renewing Radial Shaft Sealing Ring

Illustration labyrinth cover Prior jobs • •

Prop shaft removed from flange (see vehicle manufacturer instructions) Prop shaft flange removed (see Section 7.7) 5500 Notice

5400

700

850 800

This job can be performed with the retarder removed or installed. 700

800

850

4700 5400 5500

cbtd 98-01 53.2659.10

Radial shaft sealing ring (95 x 115 x 10), renew, coat with silicone-free and non-corossive grease for installation Labyrinth cover, coat with Hylomar sealant around leakage oil return bore O-ring (125 x 2,5), renew, coat with silicone-free and non-corossive grease for installation Hex.-head screw (M 8 x 30) self-locking, renew, 25 Nm Race O-ring (80 x 3), renew, coat with silicone-free and non-corossive grease for installation

4700

16067



Removing and Installing Labyrinth Cover (Input Side), Renewing Radial Shaft Sealing Ring (Cont.)

Sealants and locking agents Housing sealing surfaces

Hylomar

O-ring


Special tool

53.0742.10

Job scope 1.


2.

Use two hex.-head screws (M 8 x 40) (arrows) to press labyrinth cover (4400) off retarder housing.

3.


800

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


16068



4.

Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes (arrows) out of the labyrinth cover (800).

5.

Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft.

6.

Remove O-ring (5500) of hollow shaft.

7.

Check race for scores and radial shaft sealing ring for uneven surface and renew race if necessary. 800

700

Notice If a sealing function is no longer guaranteed, please contact VOITH TURBO.

16049

Recommendation: Always change radial shaft sealing ring and race together. 8.

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500) and pull-on to the hollow shaft.

9.

Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it will go.

10.

Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).

16069

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Repair Free Mount 7.10 Installation 11.



94/4

700

800

16050

94/4 Press-in equipment 53.0742.10 12.


13.


14.


850 800

16051

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Repair Heat Exchanger

8

Removing, Checking and Installing Heat Exchanger

8.1

Removing, Checking and Installing Stainless-steel Heat Exchanger.........8.1/1

8.2

Removing, Checking and Installing Aluminium Heat Exchanger ...............8.2/1

cbtd 98-01 53.2659.10


8.1


Removing, Checking and Installing Stainless-steel Heat Exchanger

Illustration stainless-steel heat exchanger

1000/6 1000/5

9500 3000 2000

1000/2

8000

1000/1

15000 9000

17000

1800

4000

7000 1700 4000

16000

4000

17000

5000

13000 14000

97

5000 96 1000

17000 16000 12000

14000 16070

Prior jobs • Retarder removed (Section 5.1) This job sequence can also be performed with the retarder installed, if necesary. • Retarder stage switch on stage position 0 • Ignition OFF 96 97 1000 1000/1 1000/2 1000/5 1000/6 1600 1700 2000 3000 4000

Hose clamp Cooling water hose Heat exchanger Leaking oil drain plug (M 14 x 1,5), 32 Nm Sealing ring (A 14 x 18), renew Cooling water drain plug (M 18 x 1,5), 50 Nm Sealing ring (A 18 x 22), renew Sealing ring (A 22 x 29), renew Retarder oil drain plug (M 22 x 1,5), 66 Nm Throttle disc (outlet throttle) O-ring (36 x 4), renew, coat with silicone-free and non-corrosive grease Washer (B 8,4)

5000 7000 8000 9000 9500 12000 13000 14000 15000 16000 17000

Hex.-head nut M 8, self-locking, renew, 23 Nm Hex.-head screw (M 8 x 35), 23 Nm Pin screw (M 10 x 50) O-ring (45 x 4) renew, coat with silicone-free and non-corrosive grease O-ring (8 x 2) renew, coat with silicone-free and non-corrosive grease Connecting piece Connecting piece Sealing ring, renew Hex.-head screw (M 10 x 65), 46 Nm Hex.-head screw (M 10 x 35), 46 Nm Washer (B 10,6)

Data Pressure test (oil section) max.10 bar

Lubricants O-ring

cbtd 98-01 53.2659.10



Repair

8.1

Heat Exchanger

Removing, Checking and Installing Stainless-steel Heat Exchanger (Continue)

Notice If this job sequence will be performed with the retarder installed, the following prior jobs must be performed prior to removal of the heat exchanger. Caution! Risk of injury! The coolant drain plug is heated up! 1.

Screw out coolant drain plug (1000/5) with sealing ring (1000/6) and drain the cooling water from the heat exchanger. Remove the cooling water hoses (97) from the retarder.

2.

Push an oil collecting pan under retarder. Caution! Risk of injury!

The oil drain plugs are heated up (oil temperature)! 3.

Screw out the oil drain plugs (1700, 1000/1) and remove the sealing rings (1600, 1000/2). Drain the oil.

4.

Screw the coolant drain plug (1000/5) with new sealing ring (1000/6) and the oil drain plugs (1700, 1000/1) with new sealing rings (1600, 1000/2) tight.

cbtd 98-01 53.2659.10


Repair

8.1

Heat Exchanger


To remove 1.

Screw out the four hex.-head nuts (5000) and remove the washers (4000).

2.

Screw out the two hex.-head screws (7000) remove the washers (4000) and heat exchanger (1000).

3.

Remove the three O-rings (9000, 3000, 9500) and throttle disc (2000) from retarder housing. Notice

Do not remove insert (93/8) with the throttle disc. 4.

Check closing cover (1000) for leaks, renew O-ring (1100), if necessary (see Section 6.7 and 7.8 „Checking, removing and installing closing cover“).

Caution! Do not pressurize heat exchanger with pressure-test plate 53.4786.10. An appropriate variant on the stainless-steel heat exchanger is in preperation. Please, contact VOITH TURBO.

cbtd 98-01 53.2659.10



8.1


To install

Notice New heat exchangers are wetted with preserving oil in the cooling water section and in the oil section. Prior to installation of a new heat exchanger, drain any preserving oil which has collected and flush out the cooling water section with hot water. 1.

Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (9000, 3000, 9500). Fit them in the feed bores of the retarder housing.

2.

Apply thin coat of silicone-free and non-corrosive grease to the throttle disc (2000) and fit it in the right bore.

3.

Install the heat exchanger (1000) to the retarder housing and use new self-locking hex.-head nuts (5000) and washers (4000), hex.-head screws (7000) and washers (4000) to screw it tight on the retarder housing. Tightening torque 23 Nm

4.

Install retarder, if necessary (see Section 5.1).

5.

Fill in cooling water and bleed coolant circuit according to the vehicle instructor manual. Notice

Heed the statements of the vehicle-manufacturer respecting the cooling water-quality, as well as the VOITH cooling water-list in the appendix.

cbtd 98-01 53.2659.10


Repair

8.1

Heat Exchanger 6.


If the heat exchanger (1000) had been leaking in the oil section, splush the retarder: While flushing, brake lightly several times to avoid the retarder oil overheating. Caution! Risk of injury!

The oil drain plug is heated up (oil temperature)! Fill retarder with 4,5 litres engine oil or flushing oil. Flush the retarder system by braking several times and drain the oil through the oil drain plug (1700). Repeat the procedure two or three times until no more oil is visible in the water. Screw oil drain plug (1700) tight with new sealing ring. Tightening torque 66 Nm 7.

Fill in retarder oil in accordance with the operating specifications (see Section 3.2 „Oil change“ and annex). Notice

If retarder oil has entered the cooling-water system, the vehicle-cooling system must be cleaned in accordance with the instructions of the vehicle manufacturer. 8.

cbtd 98-01 53.2659.10

If heat exchanger (1000) had been leaking, deoil vehicle cooling and heating system in accordance with vehicle manufacturer´s data.


1700

16071

8.2


Removing, Checking and Installing Aluminium Heat Exchanger

Illustration aluminium heat exchanger

1000/4 9500

1000/3 1000/6

3000

1000/2

1000/5

2000 8000

1000/1 20

4000

93/9

4000

9000 7000 4000

1600 5000

1700

5000 1000 97 96

16072

Prior jobs • Retarder removed (Section 5.1) This job sequence van also be performed with the retarder installed, if necessary. • Retarder stage switch in stage position 0 • Ignition OFF

20 96 97 93/9 1000 1000/1 1000/2 1000/3 1000/4 1000/5 1000/6 1600

Oil temperature pick-up (M 14 x 1,5), 32 Nm Hose clamp Cooling water hose Sealing ring (A 14 x 20), renew Heat exchanger Leaking oil drain plug (M 14 x 1,5), 32 Nm Sealing ring (A14 x 18), renew Oil drain plug heat exchanger (M 12 x 1,5), 25 Nm Sealing ring (A 12 x 15,5), renew Cooling water drain plug (M 18 x 1,5), 50 Nm Sealing ring (A12 x 15,5), renew Sealing ring (A 22 x 29), renew

1700 2000 3000 4000 5000 7000 8000 9000 9500

Heat exchanger oil drain plug (M 22 x 1,5), 66 Nm Throttle disc (outlet throttle) O-ring (36 x 4), renew, coat with silicone-free and non-corrosive grease Washer (B 8,4) Hex.-head nut M 8, self-locking, renew, 23 Nm Hex.-head screw (M 8 x 35), 23 Nm Pin screw (M 10 x 50) O-ring (45 x 4), renew, coat with silicone-free and non-corrosive grease O-ring (8 x 2), renew, coat with silicone-free and non-corrosive grease

Data Pressure test (oil section) max.10 bar Special tool Lubricants O-ring


53.4786.10

cbtd 98-01 53.2659.10


Repair

8.2

Heat Exchanger

Removing, Checking and Installing Aluminium Heat Exchanger (Continue)

Notice If this job sequence will be performed with the retarder installed, the following prior jobs must be performed prior to removal of the heat exchanger. Caution! Risk of injury! The coolant drain plug is heated up!

1.

Screw out coolant drain plug (1000/5) with sealing ring (1000/6) and drain the cooling water from the heat exchanger. Remove the cooling water hoses (97) from the retarder.

2.

Push an oil collecting pan under retarder. Caution! Risk of injury!

The oil drain plugs are heated up (oil temperature)! 3.

Screw out the oil drain plugs (1700, 1000/1, 1000/3) and remove the sealing rings (1600, 1000/2, 1000/4). Drain the oil.

4.

Screw the coolant drain plug (1000/5) with new sealing ring (1000/6) and the oil drain plugs (1700, 1000/1, 1000/3) with new sealing rings (1600, 1000/2, 1000/4) tight.

cbtd 98-01 53.2659.10


Repair

8.2

Heat Exchanger


To remove 1.

Screw out the four hex.-head nuts (5000) and remove the washers (4000).

2.

Screw out the two hex.-head screws (7000) remove the washers (4000) and heat exchanger (1000).

3.

Remove the three O-rings (9000, 3000, 9500) and throttle disc (2000) from retarder housing. Notice

Do not remove insert (93/8) with the throttle disc. 4.

Check closing cover (1000) for leaks, renew O-ring (1100), if necessary (see Section 6.7 and 7.8 „Checking, removing and installing closing cover“).

To check 1.

Fit pressure-test plate (99/6) on heat exchanger (1000) and connect compressed-air line and pressure minimizer.

2.

Fill the heat exchanger (1000) in water section with hot water (approx. 70°C).

3.

Pressurize the heat exchanger (1000) slowly from 0 to max. 10 bar overpressure (oil section).

99/6

Notice If air bubbles form in the hot water, the heat exchanger is leaking and must be renewed.

1000 16073

99/6 Pressure-test plate 53.4786.10 cbtd 98-01 53.2659.10


Repair

8.2

Heat Exchanger 4.


Remove the pressure-test plate (99/6).

To install

Notice New heat exchangers are wetted with preserving oil in the cooling water section and in the oil section. Prior to installation of a new heat exchanger, drain any preserving oil which has collected and flush out the cooling water section with hot water.

1.

Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (9000, 3000, 9500). Fit them in the feed bores of the retarder housing.

2.

Apply thin coat of silicone-free and non-corrosive grease to the throttle disc (2000) and fit it in the right bore.

3.

Install the heat exchanger (1000) to the retarder housing and use new self-locking hex.-head nuts (5000) and washers (4000), hex.-head screws (7000) and washers (4000) to screw it tight on the retarder housing. Tightening torque 23 Nm

4.

Install retarder, if necessary (see Section 5.1).

5.

Fill in cooling water and bleed coolant circuit according to the vehicle instructor manual. Notice

Heed the statements of the vehicle-manufacturer respecting the cooling water-quality, as well as the VOITH cooling water-list in the appendix.

cbtd 98-01 53.2659.10


Repair

8.2

Heat Exchanger 6.


If the heat exchanger (1000) had been leaking in the oil section, splush the retarder: While flushing, brake lightly several times to avoid the retarder oil overheating. Caution! Risk of injury!

The oil drain plug is heated up (oil temperature)! Fill retarder with 5,5 litres engine oil or flushing oil. Flush the retarder system by braking several times and drain the oil through the oil drain plugs (1700, 1000/3). Repeat the procedure two or three times until no more oil is visible in the water. Screw oil drain plug (1700, 1000/3) tight with new sealing rings. Oil drain plug retarder (1700) 66 Nm Oil drain plug heat exchanger (1000/3) 25 Nm 7.

Screw out oil drain plug leakage oil (1000/1) and drain any leaking oil and water which has collected.

8.

Fill in retarder oil in accordance with the operating specifications (see Section 3.2 „Oil change“ and annex).

cbtd 98-01 53.2659.10


Control Parts

9.1

cbtd 98-01 53.2659.10

9

Control Parts

Proportional valve.................................................................. in preparation Cooling Water Temperature Pick-up ..................................................................9.1/1 Oil Temperature Pick-up ..................................................................................9.1/2


Control Parts

9.1

Control Parts

Removing and installing cooling water temperature pick-up

Caution! Risk of injury! The temperature pick-up is heated up (cooling water temperature)! Job scope 1.

2.

3.

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

38 19

Mount the temperature pick-up (19) in reverse sequence.

16074

cbtd 98-01 53.2659.10


Control Parts

9.1

Control Parts (Continue)

Removing and installing oil temperature pick-up

Caution! Risk of injury! The oil control plug is heated up (oil temperature)! Job scope 1.

Disconnect oil temperature pick-up (20). Tightening torque 28 Nm The electrical lead of the temperature pick-up is pured alternatively.

2.

Screw out temperature pick-up (20) and lock the opening immediately with one stuffing.

3.

Mount the temperature pick-up (20) in reverse sequence.

cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10


Annex

10

Annex

Data Sheet Miscellaneous Conversions Operating Specifications Spare Parts Lists Other Information

cbtd 98-01 53.2659.10

Aftersales Service Manual VOITH Retarder R 120 Digiprop Page 10/1

Data Sheet VOITH Retarder 120 Digiprop Max. braking torque at prop shaft M (Br) ma x

2000 Nm *

Max. retarder speed (= max. prop shaft speed v(m ax. )

4870 r.p.m. at vps = 2400 r.p.m.

with stainless-steel heat exchanger

v(m ax. ) = 3000 r.p.m.

with aluminium heat exchanger

v(m ax. ) = 2800 r.p.m.

Working medium

Oil grade given in Operating Specification

Service filling:

With AKG heat exchanger

-

service filling (Oil change, checking oil level)

5,5 Litre

4,5 Litre

-

after complete taking apart and cleaning

-

5,8 Litre **

-

new filling

6,0 Litre

6,5 Litre

Overall weight (with flange and heat exchanger, without oil filling)

*

Overall weight will depend on the retarder version.

**

Emptied heat exchanger

cbtd 98-01 53.2659.10

With heat exchanger L+R

approx. 70 kg *

Service-Handbuch VOITH Retarder R 120 Digiprop Seite 10/2

Miscellaneous Conversions Retarder 120 with Digiprop Control

cbtd 98-01 53.2659.10

D

GB

USA

D

GB

USA

10 oC

50 oF

50 o F

110 Nm

81 lbf-ft

81 lbf-ft

20 o C

68 oF

68 o F

150 Nm

111 lbf-ft

111 lbf-ft

60 o C

140 o F

140 oF

375 Nm

277 lbf-ft

277 lbf-ft

70 o C

158 o F

158 oF

1000 Nm

740 lbf-ft

740 lbf-ft

80 o C

176 o F

176 o F

1250 Nm

925 lbf-ft

925 lbf-ft

95 o C

203 oF

203 oF

1500 Nm

1110 lbf-ft

1110 lbf-ft

105 oC

221 o F

221 oF

1750 Nm

1295 lbf-ft

1295 lbf-ft

125 oC

257 oF

257 oF

2000 Nm

1480 lbf-ft

1480 lbf-ft

185 oC

365 oF

365 oF

1,15 - 1,45 bar

16,7 - 21,0 psi

16,7 - 21,0 psi

225 oC

437 oF

437 oF

1,45 - 1,75 bar

21,0 - 25,4 psi

21,0 - 25,4 psi

10 Nm

7 lbf-ft

7 lbf-ft

1,75 - 2,05 bar

25,4 - 29,7 psi

25,4 - 29,7 psi

13 Nm

10 lbf-ft

10 lbf-ft

2,05 - 2,35 bar

29,7 - 34,1 psi

29,7 - 34,1 psi

23 Nm

17 lbf-ft

17 lbf-ft

2,35 - 2,65 bar

34,1 - 38,4 psi

34,1 - 38,4 psi

25 Nm

18 lbf-ft

18 lbf-ft

7 bar

101,5 psi

101,5 psi

32 Nm

24 lbf-ft

24 lbf-ft

9 bar

130,5 psi

130,5 psi

50 Nm

37 lbf-ft

37 lbf-ft

12 bar

174 psi

174 psi

66 Nm

49 lbf-ft

49 lbf-ft

14 bar

203 psi

203 psi

100 Nm

74 lbf-ft

74 lbf-ft

16 bar

232 psi

232 psi


Miscellaneous Conversions Retarder 120 with Digiprop Control (Continue)

cbtd 98-01 53.2659.10

D

GB

USA

0 - 25 bar

0 - 362,5 psi

0 - 362,5 psi

0 - 10 bar

145 psi

145 psi

0,2 l

0,044 UK gal

0,053 US gal

0,5 l

0,110 UK gal

0,132 US gal

4,5 l

0,99 UK gal

1,188 US gal

5,5 l

1,210 UK gal

1,452 US gal

5,8 l

1,276 UK gal

1,531 US gal

6,0 l

1,320 UK gal

1,584 US gal

6,5 l

1,430 UK gal

1,716 US gal

1000 km

621,4 miles

621,4 miles


Retardador 120 (of 1721 )

Recommend Documents