Transmissão Voith Retarder 115 E 147 Pag.

Aftersales Service Manual Voith Retarder 115 E

Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11

Table of Content

1.

Preface.................................................................................. 4

2.

General ................................................................................. 9 2.1 2.2 2.3 2.4

3.

Assembly Overview ....................................................................................10 Retarder Data Plate ....................................................................................12 Data Plate of Retarder-Control Unit ............................................................13 Function- and Operation Scheme ...............................................................15

Maintenance ....................................................................... 19 3.1 Maintenance Work / Oil Change Intervals ..................................................20 3.2 Inspection of Oil Level.................................................................................23 3.3 Oil Change ..................................................................................................26

4.

Diagnosis / Troubleshooting ............................................... 32 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10

Electrical Connections Diagram..................................................................33 Overview of Control Parts ...........................................................................37 Troubleshooting Diagram............................................................................38 Troubleshooting and Remedies ..................................................................41 Checking Supply-Air Pressure (pv) .............................................................77 Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) ...............78 Checking Control Current of Proportional Valve .........................................86 Checking Pressure Sensor .........................................................................88 Checking Temperature Adaption ................................................................90 Table of Measurements ..............................................................................93


Table of Content Page 2

Table of Content

5.

Removing, Installing Retarder............................................. 99

6.

Repair Retarder ................................................................ 110 6.1 6.2 6.3 6.4 6.5 6.6 6.7

7.

Control Parts ..................................................................... 139 7.1 7.2 7.3 7.4

8.

Overall Illustration of Main Components ...................................................111 Removing, Checking and Installing Casing Ventlation .............................112 Removing, Cleaning and Installing Silencer .............................................122 Removing and Installing Water Neck........................................................123 Removing, Checking, Installing Heat Exchanger......................................124 Removing, Installing Oil Tank Cover.........................................................133 Removing, Installing Non-Return Valve Outlet .........................................136

Removing, Installing Proportional Valve and Damping Plate....................140 Removing, Installing Temperature Sensor Cooling Water........................141 Removing, Installing Temperature Sensor Oil ..........................................142 Removing, Installing Pressure Sensor......................................................143

Appendix ........................................................................... 144 8.1 Retarder Data Sheet .................................................................................145 8.2 Tightening Torques ...................................................................................146


Table of Content Page 3

Preface

1.

Preface This Aftersales Service Manual provides information and instructions on maintenance and repair of the Voith Retarder 115 E. These instructions present the basis for performing appropriate and expert maintenance and repair. It is indispensable that you observe the safety instructions and warning notes in this manual. Nevertheless, the user is obliged to exercise pertinent and professional care when handling machines, aggregates and hot media such as for example oil or water.

Attention! ... points out safety instructions and warning notes where persons are endangered, quality of workmanship is reduced or property damage may occur.

Notice ... points out information on improved handling of work at the retarder.


Preface Page 4

Preface

Attention! •

Maintenance and repair work may only be carried out by accordingly qualified personnel.

•

Make sure that the retarder is fully functional during all vehicle manoeuvres! Non-observance may inflict damages to the retarder!

•

When towing the vehicle, the following restrictions apply for the retarder: - tow distance: up to 100 km - towing speed: max 40 km/h.

•

The activated retarded may not be used as parking brake!

•

During failure of the retarder, or while temperature adaptation is active, use the service brake to slow down the vehicle and switch into the lowest possible gear (target: high engine speed). This vehicle state must be maintained until the retarder resumes full operation.

•

Unauthorized changes to the retarder, the use of spare parts, accessories, attachments and special features not tested and released by Voith may negatively affect the security of the entire vehicle. Voith does not assume any liability for damages arising as a result.


Preface Page 5

Preface

Attention! •

The retarder is constructed according to the state of the art in technology and acknowledged safety regulations. Nevertheless, hazardous situations and property damages may occur during improper use, maintenance and repair.

•

Therefore, Voith is not capable of warning the user in this Aftersales Service Manual about any situation conceivable in which he may suffer injuries and/or cause damage to the retarder. As a consequence, it is indispensable that any person engaged in operation, servicing, maintenance and repair of the retarder does not endanger his or her personal safety with the work and that the retarder is not affected adversely, particularly with regard to the safety regulations. Voith assumes no liability for personal and/or property damage caused by improper and unprofessional work.

•

Absolute cleanliness is essential during all stages of the work process. The presence of dirt due to improper handling may cause considerable material damages or malfunctions.

•

Be careful when handling hot media! Risk of burning and scalding!


Preface Page 6

Preface

Notice •

The item numbers used in this documentation are the same as the item numbers in the spare parts lists. Exception: Items and components with one- or two-digit item numbers are no spare parts and therefore are not included in the spare parts lists. Also items and components with dash numbers are no spare parts and therefore not included in the spare parts lists.

•

The relevant regulations for prevention of accidents, other generally acknowledged safety regulations and occupational health rules as well as the Motor Vehicle Regulations must be observed. Voith assumes no liability for damages resulting from non-observance of these regulations.

•

When handling oil, grease and other chemical substances, the pertinent safety regulations for these products must be heeded!

•

For the sake of environmental protection, drained fuels and fluids must be disposed of according to the relevant statutory regulations.

•

Information on the safe, technically correct and economical operation of the Voith Retarder 115 E are given in the operating instructions.

•

The valves and the pressure sensor of the retarder must be protected from the direct jet of a highpressure cleaner (steam-jet device).

•

When troubleshooting, do not replace parts on mere speculation. Warranty or goodwill service will only be rendered if there is proof that the parts in question are really defective.


Preface Seite 7

Preface If you have any questions or if you are uncertain about work steps, which are not described in this documentation, please ask your contact person responsible for your country or contact: Voith Turbo GmbH & Co. KG Department Retarder PO box 1555 D-74555 Crailsheim Phone: ++49 +7951 / 32-0 Fax: ++49 +7951 / 32-756 E-mail: [email protected] Direct dials: Customer service line and spare parts: 32-401 32-422 32-1860


Preface Seite 8

General

2.

General 2.1 2.2 2.3 2.4

Assembly Overview ....................................................................................10 Retarder Data Plate ....................................................................................12 Data Plate of Retarder-Control Unit ............................................................13 Function- and Operation Scheme ...............................................................15


General Page 9

General – Assembly Overview 2.1

Assembly Overview

3700 4100

Basic Group with Heat Exchanger 100 Retarder housing 3700 Proportional valve 4100 Oil filler plug M 30 x 1,5 6400 Heat exchanger

6400 100

11001

Illustration: Voith Retarder R115 E


General – Assembly Overview Page 10

General – Assembly Overview Basic Group with Heat Exchanger

5500/1 103 Screw plug M 12 x 1,5

3700

107 Oil drain plug M 24 x 1,5 3500 Screw plug with sieve M 30 x 1,5 3700 Proportional valve 4200 Oil drain plug M 24 x 1,5 5500/1 Ventilation 6400 Heat exchanger

3500 103 6400

107 4200 11002

Illustration: Voith Retarder 115 E


General – Assembly Overview Page 11

General – Retarder Data Plate 2.2

Retarder Data Plate The data plate is mounted on the left below of the retarder housing in right direction of travelling. The following details are on the data plate: a) Type of Retarder

a

b) Serial number 6-digit number

b

c) Year of manufacturing d) Retarder ratio (iRet) e) Customer-item number Type R 115 E

f) Voith-item number 8-digit number

Serial No

c d

Year of Man.

Cust. item No

Notice

Nr. hac Nr. -S hac -S

Voith-item-No

Kd.

th Voi

Please, always quote the retarder data when submitting queries or ordering spare parts. In this case a quick and working is possible.

e

f

11003e

Illustration: Retarder Data Plate


General – Retarder Data Plate Page 12

General – Data Plate of Retarder-Control 2.3

Data Plate of Retarder-Control Unit Digiprop The data plate of the Digiprop-control unit is mounted on the control unit and contains following information: 1. Basic-number 8-digit number The last two digits show the software version. Example: .12 = version 1.2

Ba s Co is-N Se de-N r.: rie r.: VO nIT Nr. H :

2. Code-number 3-digit number (Adjusting of control unit)

53 . xx xxxx x .12 xx xx /

3. Serial-number 5-digit number with date of coding 4. Voith precast unit number as well as customer number, if necessary

Notice Please, always quote the retarder data and retarder control unit data when submitting queries or ordering spare parts. In this case a quick and working is possible.

Basic-No.: Code-No.: Serial-No.: VOITH 11004e

Illustration: Data Plate of Retarder Control Unit Digiprop


General – Data Plate of Retarder-Control Page 13

General – Data Plate of Retarder-Control Data Plate of Retarder-Control Unit VERA

1. Serial-number 4-digit number / date

e1

3

X

VO

H IT

T

UR

BO

2. Spare-part-number 8-digit number

2 *7

TD .S RA 1 0 E V 08 it 2U n 200 l ro / 2 0 t 2 n X 3. X Co XX 76 X .2 7 er . r d No 6 t a ia l- o . . 1 e X R e r rt -N - N o S a M P E O

/2

45

*9

5/

* 54

20

84

*0

0

The data plate of the VERA-control unit is mounted on the control unit and contains following information:

3. OEM-number

Notice

Retarder Control Unit VE RA.STD Serial-No. XXXX / 2002-08-01 Part-No. 67.2763.20 OEM-No.

X1

X2

X3

e1*72/245*95/54*2084*00

VOITH T URBO

Please, always quote the retarder data and retarder control unit data when submitting queries or ordering spare parts. In this case a quick and working is possible.

11005

Illustration: Data Plate of Retarder Control Unit VERA


General – Data Plate of Retarder-Control Page 14

General – Function- and Operation Scheme 2.4

Function- and Operation Scheme

26

42

23

21

72

A R

36

25 20 1/1

1

1/2

63

Vehicle electronic

19

46 22 44 62 64 43 55

41

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

Coolant (water) Pump pressure p P

11006e

Illustration: Functional Drawing Retarder 115 E Digiprop

Notice Example of application hand control Digiprop. Further OEM-specific versions are possible. The given position numbers aren't identical with the position numbers of the spare part lists. 1

Heat exchanger complete

41

Filling duct

1/1

Retarder-oil cooling circuit

42

Oil tank

1/2

Gearbox-oil cooling circuit

43

Oil sump

19

Temperature sensor cooling water

44

Stator

20

Temperature sensor oil

46

Rotor

21

Proportional valve

55

Oil drain plugs

22

Ventilation

62

Pressure regulating valve

23

Casing ventilation

63

Non-return valve (inlet)

25

Air-pressure line „A“ constant-air pressure (py)

64

Non-return valve (outlet)

26

Air-pressure line supply-air pressure (pv)

72

Pressure sensor (OEM-specific)

36

Exhaust line „R“


General - Function- and Operation Scheme Page 15

General – Function- and Operation Scheme Functional Description The Voith Retarder 115 E is a powerful, hydrodynamic continous brake of compact design. The retarder is driven and braking torque is transmitted by pinions in the gearbox. The transmission ratio enables the retarder to achieve high braking torques right down to low r.p.m. ranges with the compactest configuration (small rotor/stator). Retarder braking torque is sustained even when gear changes are made. Do not use the switched-on retarder as handbrake while vehicle is in still-stand! During a failure of the retarder, or while the temperature-adaptation is effective, the vehicle-speed must be settled by using the service-brake and the lowest possible gear.


General – Function- and Operation Scheme Page 16

General – Function- and Operation Scheme Temperature Sensor Cooling Water (19), Oil (20) The temperature sensors are installed in the cooling system of the vehicle (cooling-return circle from the retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and oil temperature to the control unit (2).To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarder braking torque is adapted to protect the vehicle cooling system and the retarder. The braking torque and consequently the heat generated are reduced until a balance is obtained between the braking energy of the retarder and the amount of heat which can be dissipated by the vehicle cooling system. If the cooling water temperature rises into the temperature adaption range, the consequence is an adaption of the retarder braking torque to protect the vehicle cooling system. If the temperature rises above the temperature adaption range, there is no more braking torque output. While the temperature adaption is effective or if there is a retarder failure, the service brake must be used to control the vehicle. Additionally the control unit cuts back braking torque if oil temperature rises too rapidly - irrespective of actual oil temperature. Pressure regulating valve (62) The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder.



General – Function- and Operation Scheme Pressure sensor (72) The pressure sensor (72) observes the pneumatic constant-air pressure. At deviation of the permissible pressure tolerance an error is stored from the control unit displayed in the vehicle display in dependence of the OEM equipment. Casing ventilation (23) During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) and the ventilation system (22) out of the retarder. Once the working circuit is free of air, a float rises and closes the casing ventilation. Non-return valve (63) inlet When the retarder is switched on, the oil sump is pressurized, causing the check valve (63) to open and the oil to enter the working space. Non-return valve (64) outlet The oil pressure in the working space opens the check valve (64), causing the oil to enter the heat exchanger (1), to be cooled and to be returned to the working circuit. Proportional valve (21) Depending on the size of the electrical input signal a pneumatic constant-air pressure gets controlled from the proportional valve to the oil tank of the retarder.



Maintenance

3.

Maintenance 3.1 Maintenance Work / Oil Change Intervals ..................................................20 3.2 Inspection of Oil Level.................................................................................23 3.3 Oil Change ..................................................................................................26


Maintenance Page 19

Maintenance – Maintenance Work / Oil Change Intervals 3.1

Maintenance Work / Oil Change Intervals Maintenance work At each oil change: - Clean sieve of pressure regulating valve - Check fastening screws of the retarder heat exchanger - Check all screw plugs on leak and correct fitment - Carry out visual inspection on possible leak and existing damages

Please note the following data into the service overview of the Operation Manual „Gearbox-Retarder-System / GO170 - GO210 with R 115 E”: - maintenance work been carried out - the oil grade used for the oil change


Maintenance – Maintenance Work / Oil Change Intervals Page 20

Maintenance – Maintenance Work / Oil Change Intervals Oil change intervals, operating specification Synthetic oil 1)

Single grade-mineral oil

Synth. / part synth. oil

1)

1)

Normal duty

135.000 km 2)

180.000 km 3)

300.000 km 3)

Heavy duty

60.000 km 2)

90.000 km 3)

300.000 km 3)

Classification letter to DIN 51502

HD

HC

HC

Class of viscosity to DIN 51511

SAE 10W SAE 20W20 SAE 30

SAE SAE SAE SAE SAE SAE

0W40 5W30 5W40 5W50 10W30 10W40

SAE 75W80

Performance category

API - CC/SF and higher

API - CC/SF and higher

Emgard MTF,Henkel

1) according operating specification 2) carry out change oil at the latest after 1 year, if fewer kilometres are travelled 3) carry out change oil at the latest after 2 year, if fewer kilometres are travelled

Please take into account the oil recommendation list (Voith code number 67.2246.11).



Maintenance – Maintenance Work / Oil Change Intervals 1.

„Normal duty“ Example: • Long distance traffic

2.

„Heavy duty“ Subject to more than normal stress. Examples: • Use in regions with high ambient temperature (e.g. Saudi-Arabia) • High max. permissible weight with low rated engine power (< 6 kW / metric ton) • Streches with lots of hills and valleys • Extreme short-distance traffic with lots of gradients

The given maximum specified figures can be lowered, if overall maintenance cycles for the vehicle are improved. With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as other factors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervals between oil changes in individual cases. For use in extremely cold zones, oils in an appropriately lower viscosity class must be used. In doubts please contact our customer service.



Maintenance – Inspection of Oil Level 3.2

Inspection of Oil Level Notice For satisfactory retarder operation it is important to adhere to the specified service filling of 7,0 litres and to use only oils specified in the operating specifications for operating the retarder in the relevant application. The oil level check must be carried out with the vehicle in a horizontal position. For the inspection of oil level, temperature of retarder oil must have reached the operating temperature.

Caution! Two version of the screw plugs (107, 4100, 4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the inspection of oil level; replace completely if necessary.

B) Version with loose inserted copper-sealing ring. In this Aftersales Workshop Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings have to be renewed in general.


Maintenance – Inspection of Oil Level Page 23

Maintenance – Inspection of Oil Level 107 Oil drain plug M 24 x 1,5 Inhex-head w.a.f. 12, 47 Nm (80 Nm) 4200 Oil drain plug M 24 x 1,5 Inhex.head w.a.f. 12, 47 Nm (80 Nm)

Work scope 1.

Push a clean vessel under retarder.

107 4200

11007

Caution! Risk of injury! The oil drain plugs (107, 4200) and oil filler plug (4100) are hot (oil temperature)! The retarder must be switched-off during the inspection of oil level! If the retarder is switched-on during working step 2 and screwed out oil drain plugs and/or oil filler plug, high risk of injury exist by hot leaving oil (increased pressure)! 2.

Screw out oil drain plugs and drain oil in clean vessel.

3.

Check sealing rings of oil drain plugs for damages, renew oil drain plugs if necessary.

4.

Screw in oil drain plugs and screw them tight. Tightening torque oil drain plugs (107, 4200): 47 Nm (80 Nm)

5.

Measure drained oil.

6.

Top up any lacking oil according to the operating specifications, page 29.



Maintenance – Inspection of Oil Level

Caution! The retarder must only be filled with oil via the bore of the oil filler plug (4100)! 7.

Fill in slowly over a time period longer than 3 minutes the quantity of oil specified, in the bore of the oil filler plug (4100).

Notice With determined lacking oil quantity check retarder for possible outer leak. 8.

Check sealing ring of oil filler plug for possible damages, renew oil filler plug if necessary.

9.

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

Hinweis The following work step is required to the correct ventilation of the retarder system. Nonobservance can cause oil leak via the ventilation. If available, the foot control of the retarder must be switched off and switched on first after the described work process again. 10. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 times for respectively approx. 5 seconds in position 2 at the retarder stage switch or brake stage 1. Take the OEM specific using variants into account to this. The vehicle must not go slower than 20 km/h at this.



Maintenance – Oil Change 3.3

Oil Change Notice The gearbox- and retarder oil tanks are seperated from each other at the gearbox-retarder-system. Both oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder - without limited compromizes. For satisfacory retarder operation, it is important to adhere to the specified service filling (see table page 29) and to use only oils specified in the operating specifications page 21 for operating the retarder in the relevant application. For draining the oil the temperature of the retarder oil must have reached the operating temperature. Ensure that during the entire oil change no constant-air pressure acts on the retarder, that means the retarder must be switched off!


Maintenance – Oil Change Page 26

Maintenance – Oil Change

Attention! Two versions of screw plugs (107, 3500, 4100, 4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the inspection of oil level; replace completely if necessary.




Maintenance – Oil Change 107 Oil drain plug M 24 x 1,5 Inhex-head w.a.f. 12 47 Nm (80 Nm)

4100

3500 Screw plug with sieve M 30 x 1,5 Inhex-head w.a.f. 17 100 Nm (100 Nm) Clean sieve with appropriate cleaning agent and blow out with compressed-air 4100 Oil filler plug M 30 x 1,5 Inhex-head w.a.f. 17 100 Nm (100 Nm) 4200 Oil drain plug oil tank M24x1,5 Inhex-head w.a.f. 12 47 Nm (80 Nm) Lubricants and cleaning agents . Nr h. ac Nr .-S hKd ac -S ith

Vo

Sieve in screw plug

Benzine

107

3500

4200

4200

11008

Illustration: Oil change Retarder R 115 E



Maintenance – Oil Change

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

7,0 l

After exchange of heat exchanger

7,5 l

Work scope 1.

Push an oil collecting pan under the retarder.

Attention! Risk of injury! The oil drain plugs (107, 4200) are hot! Oil temperature! 2.

Screw out the oil drain plugs (107 and 4200) and drain the oil.

3.

Check integrated sealing rings of oil drain plugs on possible damages, renew oil drain plugs if necessary.

4.

Screw in the oil drain plugs tight. Tightening torque oil drain plugs (107, 4200): 47 Nm (80 Nm)

107

4200

4200 11009



Maintenance – Oil Change 5.

Screw screw plug with sieve (3500) out of the retarder.

6.

Clean sieve in screw plug with appropriate cleaning agent (Benzine) and blow it out with compressed-air.

7.

Check integrated sealing ring of screw plug with sieve on possible damages, renew screw plug if necessary.

8.

Screw in screw plug with sieve hand-tight then tighten it. Tightening torque screw plug (3500): 100 Nm (100 Nm)

Nr. hac Nr. -S hKd. ac th-S

Voi

3500

11010

9.

Screw out oil filler plug (4100).

4100 Attention! The retarder must only be filled with oil via the bore of the oil filler plug (4100)! 10. Fill in slowly over a time period longer than 3 minutes the quantity of oil, via the bore of the oil filler plug, specified in accordance to the service filling (see table page 29). This work step is required to the correct ventilation of the retarder system. 11011



Maintenance – Oil Change 11. Check integrated sealing ring of oil filler plug on possible damages, renew oil filler plug if necessary. 12. Fit oil filler plug and screw it tight. Tightening torque oil filler plug (4100): 100 Nm (100 Nm)

Achtung! The following work step is required to the correct ventilation of the retarder system. Nonobservance can cause oil leak via the ventilation. If available, the foot control of the retarder must be switched off and switched on first after the described work process again. 13. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 times for respectively approx. 5 seconds in position 2 at the retarder stage switch or brake stage 1. Take the OEM specific using variants into account to this. The vehicle must not go slower than 20 km/h at this.



Diagnosis / Troubleshooting

4.

Diagnosis / Troubleshooting 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10

Electrical Connections Diagram..................................................................33 Overview of Control Parts ...........................................................................37 Troubleshooting Diagram............................................................................38 Troubleshooting and Remedies ..................................................................41 Checking Supply-Air Pressure (pv) .............................................................77 Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) ...............78 Checking Control Current of Proportional Valve .........................................86 Checking Pressure Sensor .........................................................................88 Checking Temperature Adaption ................................................................90 Table of Measurements ..............................................................................93


Diagnosis / Troubleshooting Page 32

Diagnosis / Troubleshooting – Elektrical Connections Diagram Elektrical Connections Diagram (Voith-Wiringharness Digiprop without CAN)

P 1

U 2

72

4

70

14 13 11 12 10 1

9

5

47 15 8 4

3

2

7

21

19

20

6

18

.

87 87a 30

4.1

2 Control unit

.

4 Connection terminal 15

-

+ +

-

+

-

.

15 ABS-signal 16 Retarder stage switch 17 Retarder pilot light 18 Brake light relay

17

X3

.4

8 11 10 12 7

9

4

5

6

1

2

X2

3

2

3

1 6

5

4

9

8

7

2

19 Temperature sensor cooling water

18 17 16 6

5

4

9

8 10 11 12 13 14 15 7

3 2

1

X1

20 Temperature sensor oil 21 Proportional valve 47 Speedometer signal 69 Plug ISO-interface

7

6

5

2

8

4

4 3

2

1

4

69

70 Plug optional function 72 Pressure sensor (OEM-specific)

3

16 11012


Diagnosis / Troubleshooting – Elektrical Connections Diagram Page 33

Diagnosis / Troubleshooting – Elektrical Connections Diagram Digiprop with CAN

P

2 Control unit

1

U 2

72

21

19

20

4

4 Connection terminal 15 16 Retarder stage switch

-

+

+

-

+

-

17 Retarder pilot light 19 Temperature sensor cooling water 20 Temperature sensor oil 21 Proportional valve 72 Pressure sensor (OEM-specific)

17

X3

.4

12 8 11 10 7

9

4

5

6

1

2

X2

3

2

3

1 6

5

4

9

8

7

2 18 17 16 6

5

4

9

8 10 11 12 13 14 15 7

3 2

1

CAN

X1

4

16 11013



Diagnosis / Troubleshooting – Elektrical Connections Diagram VERA „general“ P

2 Control unit

1

U 2

72

80

21

20

19

81 82

4

4 Connection terminal 15 15 ABS-signal +

16 Retarder stage switch

-

+

-

+

-

+

-

18 87 87a 30

17 Retarder pilot light 18 Brake light relais 19 Temperature sensor cooling water

X3

20 Temperature sensor oil 9

21 Proportional valve 47 Speedometer signal 72 Pressure sensor (OEM-specific)

17

7

8 10 11 12 3 4

5

6

2

X2 8

1

7

6 4

5 9

3

2

1

2

.4

16 15 4 5

6 8

9 18 10 17 11 12 13 14

7

3 2

1

X1

80 On/off valve 81 Input (3 times)

CAN

82 Output (3 times)

4

83 ISO-diagnosis 83 16

47

15 11014



Diagnosis / Troubleshooting – Elektrical Connections Diagram VERA „DAFBUS“

21

72 P

2 Control unit 4 Connection terminal 15

1

2

19

94

90

91

96

4

16 Retarder stage switch

+

18 Brake light relais

20

U

-

+

-

+

-

18 87 87a 30

19 Temperature sensor cooling water 20 Temperature sensor oil 21 Proportional valve

X3

72 Pressure sensor (OEM-specific)

9

7 8 10 11 12 3 4

5

6

2

X2 8

1

7

6 1

90 Fan relais 91 Brake valve 92 Diagnosis K-Lead

93

9

2

3 4

5

2

.4

16 15 4 5

6 8

9 10 18 17 11 12 13 14

7

3 2

1

95

X1

93 Fault light 94 Operating light

CAN

95 Foot Off/On

4

96 Indication light

92 16 11015



Diagnosis / Troubleshooting – Overview of Control Parts 4.2

Overview of Control Parts 11

Notice

33

71 32

The given position-numbers are not identical with position-numbers of spare parts lists.

R

P

36 25

61

26

A

1 Heat exchanger

21

31

2 Control unit (e.g. Digiprop/ VERA)

35

34

11 Connection control current of proportional valve 19 Temperature sensor cooling water

40

20 Temperature sensor oil 21 Proportional valve 25 Compressed-air pressure line constant-air pressure (py)

2

20

39 19

26 Compressed-air pressure line suppla-air pressure (pv) 31 Compressed-air pressure line (pressure regulator - fourcircuit protection valve) 32 Compressed-air pressure line (four-circuit protection valve air tank for auxiliary equipment) with with test connection 33 Compressed-air pressure line (brake circuit 1)

72 1

11016

34 Compressed-air pressure line (brake circuit 2) 35 Compressed-air pressure line (parking brake) 36 Ventilation line connection „R“ 39 Electrical lead (temperature sensor cooling water) to control unit, 2 wires) 40 Electrical lead (temperature sensor oil) to control unit, 2 wires) 61 Four-circuit protection valve 71 Air tank for auxiliary equipment 72 Pressure sensor (OEM-specific)


Diagnosis / Troubleshooting – Overview of Control Parts Page 37

Diagnosis / Troubleshooting – Troubleshooting Diagram 4.3

Troubleshooting Diagram

A * Retarder Pilot Light (Standard version)

Complaint Retarder R 115 E

* Notice: OEM-specific is an on-board-diagnosis possible (display). Notice the information from the vehicle manufacturer to it.

Oil leak via ventilation and / or non or too low braking efficiency

B

11017e


Diagnosis / Troubleshooting – Troubleshooting Diagram Seite 38

Diagnosis / Troubleshooting – Troubleshooting Diagram

A * Retarder Pilot L ight (Standard version)

Permanent light in position 0 after lamp test?

Activate flash code and read out fault code *

* OE M-specific is an on-board-diagnosis possible (display). Notice the information from the vehicle manufacturer to it.

no function?

flashes?

Check fuse

Temperature adaption

ABS or idle switch active? Clear fault and erase fault memory *

Check operation (during Retarder braking most possible engine nominal speed)

Check pilot light and renew, if necessary

OK

NOK

* Notice the information of the vehicle manufacturer Check temp.-sensors (oil / water) (page 90 ff)

OK

Check vehicle cooling system: - coolant level - Thermostat - Coolant pump - Radiator fan - Radiator on pollution

Instruct driver!

NOK

Replace temp.-sensos (page 141, 142)

11018e

Illustration: Complaint main group A


Diagnosis / Troubleshooting – Troubleshooting Diagram Page 39

Diagnosis / Troubleshooting – Troubleshooting Diagram Prior work •

Check retarder system on outer leaks (apart from ventilation)

•

Check whether running in instruction was carried out after oil change, carry out if necessary

B Oil leak via ventilation and / or non or too low brake efficiency

Outer Leak (apart ventilation)

No

At complaint "non or too low braking efficiency": Consultation Voith

Check retarder oil level (page 23 ff)

Check p (dynam.) and py (statisch) (page 78 ff)

check py (static) (page 78 ff)

For examination the retarder oil level must be correct!

For examination the retarder oil level must be correct!

OK

At complaint "Oil leak via ventilation": continue with checking casing ventilation

Repair Retarder

Yes

NOK

OK

OK

NOK

Water in oil (emulsion)

Check heat exchanger (page 124 ff)

NOK

Yes

Check retarder oil level

too low

Check gear box oil level p (dynamic) NOK

Check casing ventilation (page 112 ff)

NOK

Check gear box oil level

Replace casing ventilation (page 112 ff)

NOK OK

Check control current of prop. valve as well as leads und plug connections (page 86 ff)

OK Replace proportinal valve (page 140)

OK

NOK

too high

Correct retarder- and gearbox oil level If problem occours again: Consultation Voith

too low Check gearbox oil level

Correct retarder- and gearbox oil level

NOK

OK

Outlet valve .11 and higher?

Yes

No

Check gearbox oil level

If problem occours again: Consultation Voith

Check supplyair pressure (page 77)

Check temperature adaption or temp.-sensors (oil/water) and pressure sensor or leads (page 88 ff)

OK NOK Replace outlet valve (page 136 ff) If problem occours again: Replace proportional valve.

too high

py (static) NOK

OK NOK

Check proportional valve (page 86 ff)

No

Proportional valve or damping plate mechanically defect

Check vehicle compressed-air system

OK

NOK

too high

Correct retarder- and gearbox oil level

Compressed-air pressure line to prop. valve interrupted or leaking

Consultation Voith Contact vehicle manufacturer

too low

Check gearbox ventilation

NOK

OK NOK Replace temperature sensors or leads (page 141, 142)

Correct retarder oil level

OK

Repair gearbox ventilation; correct retarder- and gearbox oil level

Correct retarderand gearbox oil level

If problem occours again: Consultation Voith

11019e

Illustration: Complaint main group B


Diagnosis / Troubleshooting – Troubleshooting Diagram Seite 40

Diagnosis / Troubleshooting – Troubleshooting and remedies 4.4

Troubleshooting and remedies Requirements for check •

Battery voltage 18 - 32 V

•

Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory.

•

Fuse for retarder control unit checked and found satisfactory.

•

Compressed-air pressure 6 - 11 bar

•

Version Digiprop with and without CAN: for check with multimeter must be at the control unit pin 15 (plug X1) Ground (terminal 31), at pin 7 and pin 13 (plug X1) must be connected terminal 15

•

Version VERA: for check with multimeter must be at the control unit pin 14 (plug X1) Ground (terminal 31), at pin 7 (plug X1) must be connected terminal 15

Note Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary (see page 29).


Diagnosis / Troubleshooting – Troubleshooting and remedies Page 41

Diagnosis / Troubleshooting – Troubleshooting and remedies

Note The retarder pilot light additionally has the function of a fault code. An on-board-diagnosis (display) is OEM-specific possible. Heed herefore the statements of the vehicle manufacturer: •

slight fault Permanent light in position 0 - 5 of retarder stage switch, braking is still possible to limited extent.

•

serious fault Permanent light in position 0 - 5 of retarder stage switch,, braking is no longer possible the retarder is switched off.

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



Diagnosis / Troubleshooting – Troubleshooting and remedies Connector arrangement and pin assignment

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

Plug X1 control unit (Digiprop) 1 Not in use or CAN-LOW 2 Not in use or CAN-GROUND 3 Not in use or CAN-HIGH 16

13

10

7

4

1

5 Retarder stage switch, Position 2

17

14

11

8

5

2


18

15

12

9

6

3


7 Terminal 15 8 Retarder stage switch, Position 5

11020

9 Retarder stage switch, Position 4 10 Retarder stage switch + 11 ISO-interface, L-lead 12 ISO-interface, K-lead 13 Connected with terminal 15 14 Not in use 15 Terminal 31 16 Output / high side 2 „HS2“ 17 Not in use 18 Output / high side 1 „HS1“



Diagnosis / Troubleshooting – Troubleshooting and remedies Plug X2 control unit (Digiprop) 1 Not operational 2 Proportional valve 3 Proportional valve + 4 Cooling-water temperature-sensor -

7

4

1

5 Cooling-water temperature-sensor +

8

5

2

9

6

3

6 Not operational 7 Not in use 8 Oil-temperature sensor -

11021

9 Oil-temperature sensor +

Plug X3 control unit (Digiprop) 1 Input / pull up „DIU 1“ 2 Speedometer signal 3 ABS-signal 4 Input / pull down „DID 2“

10

7

4

1

5 Input / pull down „DID 1“

11

8

5

2

6 Pressure-sensor ground

12

9

6

3

7 Pressure-sensor signal voltage 8 Retarder pilot light

11022

9 Input / pull down „DID 3“ 10 Pressure-sensor supply voltage 11 Stop light relais 12 Input / pull down / PWM-in „DID4“



Diagnosis / Troubleshooting – Troubleshooting and remedies Plug optional functions (cable Digiprop) 1 Retarder stage switch + 2 Input / pull down „DID 1“ 3 Input / pull down „DID 2“

2

4

6

8

10

12

14

1

3

5

7

9

11

13

4 Input / pull down „DID 3“ 5 Input / pull down / PWM -in „DID 4“ 6 Input / pull up „DIU 1“ 7 Pressure-sensor Ground 8 Pressure-sensor signal voltage

11023

9 Pressure-sensor supply voltage 10 Output / high side „HS1“ 11 Output / high side 2 „HS2“ 12 Not operational 13 Terminal 15 14 Terminal 31

Plug ISO-interface (cable Digiprop) 1 K-lead 2 L-lead 3 Terminal 15 4 Terminal 31

4

3

2

1

11024



Diagnosis / Troubleshooting – Troubleshooting and remedies Connector arrangement and pin assignment

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

Plug X1 control unit (VERA) 1 CAN-LOW 2 CAN-GROUND 3 CAN-HIGH 4 Retarder stage switch, Position 0

16

13

10

7

4

1


17

14

11

8

5

2


18

15

12

9

6

3

7 Terminal 15 = battery voltage 8 Retarder stage switch, Position 3

11025

9 Retarder stage switch, Position 4 10 Retarder stage switch + 11 Speedometer signal 12 ISO-interface, K-lead 13 ABS-signal 14 Terminal 31 = Ground 15 Retarder pilot light 16 Brake light relais 17 Engine speed 18 Retarder stage switch, Position 5



Diagnosis / Troubleshooting – Troubleshooting and remedies Plug X2 control unit (VERA) 1 Output / highside „OUT 1“ 2 Output / highside „OUT 2“ 3 Output / highside „OUT 3“ 4 Input / analog „IN 3“

7

4

1

5 Input / analog „IN 1“

8

5

2

9

6

3

6 Not in use (boot 1) 7 Not in use (boot 2) 8 Not in use (boot 3)

11026

9 Input / digital „IN 2“

Plug X3 control unit (VERA) 1 Cooling-water temperature-sensor 2 Cooling-water temperature-sensor + 3 Proportional valve + 4 Proportional valve -

10

7

4

1

5 Oil-temperature sensor +

11

8

5

2

6 Oil-temperature sensor -

12

9

6

3

7 Pressure-sensor signal voltage 8 Pressure-sensor Ground

11027

9 Pressure-sensor supply voltage 10 Not in use (switch valve +) 11 Not in use (switch valve -) 12 Not in use



Diagnosis / Troubleshooting – Troubleshooting and remedies Plug cooling-water temperature pick-up Plug oil temperature pick-up

11028

Plug proportional valve 1 Proportional valve + 2 Proportional valve – 3 Not in use

4 1

2 3

4 Not in use

11029



Diagnosis / Troubleshooting – Troubleshooting and remedies Plug retarder stage switch 1 Not in use 2 Position 5 3 Position 4 4 Retarder stage switch +

5

6

7

8

5 Position 3

1

2

3

4

6 Position 2 7 Position 1 8 Bridge to pin 4


11030


Diagnosis / Troubleshooting – Troubleshooting and remedies A. With fault code, e.g. retarder control unit reports fault Special tool

53.8224.10

Service cable (only Digiprop) Commercially available tool Multimeter

recommended: Fluke 87

Note The fault memory can be read-out from blinking code of retarder pilot light via service-cable (53.8224.10 only Digiprop), if this function is realised. An on-board-diagnosis (display) is OEM-specific possible. Heed herefore the statements of the vehicle manufacturer.



Diagnosis / Troubleshooting – Troubleshooting and remedies Fault memory readout via retarder pilot light blinking code

Note If sveral faults have been stored in the memory, they are output in the sequence of their occurence, but always only one fault per triggering. Exception: The fault „Coding Fault“ is not held in the memory but is output via the blinking code. The blinking code can be read-out of control unit by using the service cable (only Digiprop) or retarder stage switch.

Fault memory readout with service cable (only Digiprop) Requirements •

Retarder stage switch in position O.

•

Vehicle at standstill, ignition ON 1. L-lead of service interface connected to ground ≥ 2s. For this pupose, press „L - pushbutton“ on service cable 2. First fault as blinking code output. 3. Item 2 and 3 repeated for more blinking code outputs.

Meaning •

Long blinking signals (2 sec.) tens unit.

•

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



Diagnosis / Troubleshooting – Troubleshooting and remedies Fault memory read out with retarder stage switch The blinking code can be triggered with the retarder stage switch during the service function (vehicle ignition system ON and v = 0): 1.

Retarder stage switch in position 0

2.


3.


4.

First fault as blinking code

5.

Items from ...3 for more blinking code outputs

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

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

1 sec

0,5 sec

1 sec

each 1 second

0,5 sec

Breaks between each ON time:

1 sec

each 0,5 seconds

0,5 sec

The number of single unit then is indicated as short ON time:

2 sec

each 2 seconds 1 sec

The number of tens units first indicated as long ON time:

2 sec

Display example for fault code 23 (Digiprop):

11031

Display example for fault code 23 (Digiprop) E Retarder pilot light ON A Retarder pilot light OFF t Time



Diagnosis / Troubleshooting – Troubleshooting and remedies Display example for fault code 20 (only for VERA): The number of tens units first indicated as long ON time:

each 2 seconds

2 sec

each 1 second

1 sec

Breaks between each ON time:

2 sec

Then blinking code goes off, no single unit in this method

11032

Display example for fault code 23 (VERA) E Retarder pilot light ON A Retarder pilot light OFF t Time



Diagnosis / Troubleshooting – Troubleshooting and remedies Delete fault memory (only for Digiprop) No marginal notes in accordance with fault memory read out. 1.

Vehicle ignition system: OFF

2.

Servcie interface L-lead connected to ground. For this purpose, press „L-pushbutton“ of service cable.

3.

Vehicle ignition system: ON

4.

Release L-lead from ground after ≥ 2 sec.

Delete fault memory (only for VERA) It is only possible to delete fault memory via WinDia.



Diagnosis / Troubleshooting – Troubleshooting and remedies Version Digiprop

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

Fault

Code

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection1)

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

X 3/11 Ω X 1/15

Result/ Set point

Cause/ Remedy 2)

Test step

01

Stop light relay/

slight

Short circuit to ground 1) 2)

1s

Relay is installed: 250-350 Ω

Check lead, plugs and relay or consumers

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




Fault Code

Fault text

Fault class

Trigger time


Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Test step

03

HS 1 output Short circuit

slight

1s


X 1/18 Ω X 1/15



04

HS 2 output Short circuit

slight

1s


X 1/16 Ω X 1/15



05

Terminal 15 Undervoltage

serious

60 s

- Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON

X 1/7 V X 1/15

≥ 17,5 V

Check lead, plugs and fuses

06

Terminal 15 Overvoltage

serious

10 s

- Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Start engine (idle speed)

X 1/7 V X 1/15

≤ 32,5 V

Checking electrical installation of vehicle (see manufacturer instructions)




Fault Code

Fault text

Fault class

Trigger time



Result/ Set point


X 2/5 Ω X 2/4

20°C ± 10°C = 1039 - 1117Ω

Cause/ Remedy

Test step

08 09

Cooling-water temperature sensor Discontinuity / Short circuit to battery

1s serious/ slight *

Check lead and sensor

60°C ± 10°C = 1194 - 1271Ω 80°C ± 10°C = 1271 - 1347Ω Notice: The measuring in one temperature range normally is sufficient.

*

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




Fault Code

Fault text

Fault class

Trigger time



Result/ Set point


X 2/9 Ω X 2/8

20°C ± 10°C = 1039 - 1117Ω

Cause/ Remedy

Test step

11 12

Oil temperature sensor Discontinuity / Short circuit to battery

1s serious/ slight *

Check lead and sensor

60°C ± 10°C = 1194 - 1271Ω 80°C ± 10°C = 1271 - 1347Ω Notice: The measuring in one temperature range normally is sufficient.

*

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




Fault Code 13

13

13

Fault text

Fault class

Retarder stage switch Undefined switch state

serious

Trigger time



Result/ Set point

Cause/ Remedy

Test step 1

2

3


1s

- Ignition: ON - Retarder stage switch: Position 0

X 1/10 V X 1/15

≥ 17,5 V

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

0V 0V 0V 0V 0V


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

≥ 17,5 V ≥ 17,5 V

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

0V 0V 0V 0V


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

≥ 17,5 V ≥ 17,5 V ≥ 17,5 V

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

0V 0V 0V

Check lead, plug and retarder stage switch





Fault Code 13

13

13

Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step 4

5

6





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

≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V

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

0V 0V

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

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

X 1/8 V X 1/15

0V

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

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






Fault

Code

Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step

14

Retarder stage switch Short circuit to battery

serious

10 s

- Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Retarder stage switch: Position 0

X 1/10 V X 1/15

0V

Check lead and plug

15

Retarder stage switch Short circuit to battery

serious

1s

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

X 1/10 Ω X 1/15

Resistor endless

Single check of stages for short circuit

16

Speedometer signal Discontinuity

serious

2s

- Ignition: ON

≤ 1V

Check lead and speedometer


X 3/2 V X 1/15



Fault Code

Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step

18

Speedometer signal Short circuit to battery undefined signal

serious

2s


X 3/2 V X 1/15

≤ 9V

Check lead and speedometer

19

ABS Short circuit to ground

serious

60 s

- Ignition: ON

X 3/3 V X 1/15

≥ 3,5 V

Check lead, relay and ABS-control unit

21

ABS-Signal undefined

serious

1s

- Ignition: ON

X 3/3 V X 1/15

≥ 16,5 V

Check lead, relay and ABS-control unit

22

Internal fault ABS-current path

serious

1s

-

23

Proportional valve Fault No. 1: Short circuit to battery

serious

1s



X 2/3 V X 1/15

≤ 10 V

Replace control unit Check lead



Fault



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

X 2/2 Ω X 2/3

18-25 Ω

Check lead and proportional valve (valve block)

2


X 2/3 Ω X 1/15

Resistor endless

Check lead and proportional valve (valve block)

3


X 2/2 Ω X 1/15

Resistor endless

Check lead and valve block

Code 24

Fault text

Fault class

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

serious

Trigger time

Result/ Set point

Cause/ Remedy

Test step 1


1s



Fault Code

Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step

25

Valve block Fault No. 3: defective control unit

serious

10 s

Replace control unit

27

Valve block Fault No. 5: defective control unit

serious

2s


28

Terminal 30 Undervoltage

serious

60 s

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 1/13 V X 1/15

X 3/8 V X 1/15

≥ 17,5 V

≥ 17,5 V

Check lead, plug and fuse

Check lead, retarder pilot light and fuse



Fault Code

Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step Retarder pilot light: Short circuit to battery

serious

3s

35

Fault control unit

serious

500 ms / 123 s


37

Fault foot operation

slight

100 ms / 1 s

Check installation in accordance with OEM - as well as Voith requirements

Fault constant-air pressure

slight

1 s to 10 s

38

1

2



Ignition: ON Position 0

X 3/8 V X 1/15

≤ 2V

33

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

0,3-0,7 V 4,75-5,25 V

Check lead and retarder pilot light

Pressure sensor wiring harness If deviation: step 2 Troubleshooting in wiring harness, pressure sensor, proportional valve, supply-air pressure, ECU (Contact Voith)


Diagnosis / Troubleshooting – Troubleshooting and remedies Version VERA

Note - X1 / 14 = Ground control unit - replace control unit first, if complete check of periphery did not yield any faults - Project specifically is normally only a part of the listed pins used (e.g.: ABS not via pin X1/13, but via CAN)

Fault BlinkCode

Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step

1

1

Data set fault

heavy

immediately after ignition ON

Parameter setting fault, new parameter setting

2

1

EEprom fault

heavy

immediately after ignition ON


3

1

ROM fault

heavy

approx. 10s after ignition ON


4

1

SIBA fault

heavy

60 ms


5

1

Proportionalvalve chasssis ground end, interruption, short circuit, connecting lead

heavy

1s


-

Ignition: OFF disconnect plug X3

X 3/3

Ω X 3/4

18 ... 25 Ω

Check electrical lead and proportional valve


Diagnosis / Troubleshooting – Troubleshooting and remedies Fault BlinkCode

Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step

5

2

X 3/3

Ω X 1/14

Resistor endless


5

3

X 3/3

Ω X 1/14

Resistor endless


6

1

X 3/3

V X 1/14

≤10 V

Check electrical lead and plug

Proportionalvalve battery short circuit

heavy

1s

-

Ignition: OFF Pull off plug X1, X3 Ignition: ON

8

1

Proportionalvalve-control, int. fault at control unit

heavy

3s


9

1

Terminal 15 undervoltage

heavy

60s

-

Ignition: OFF Pull off plug X1 Ignition: ON

X 1/7

V X 1/14

≥ 17,5 V

Check electrical lead, fuse and plug

10

1

Terminal 15 overvoltage

heavy

10s

-

Ignition: OFF Pull off plug X1, X3 Ignition: ON

X 1/7

V X 1/14

≤ 32,5 V

Check electrical unit of vehicle (see manufacturer´s instructions)

-



Diagnosis / Troubleshooting – Troubleshooting and remedies Fault BlinkCode 11

Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step - Ignition: ON - Retarder stage switch: position 0

X 1/10 X 1/5 X 1/6 X 1/8 X 1/9 X 1/18

V V V V V V

X 1/14 X 1/14 X 1/14 X 1/14 X 1/14 X 1/14

≥ 17,5 V 0V 0V 0V 0V 0V

Check electrical lead, plug and retarder stage switch

2

- Ignition: ON - Retarder stage switch: position 1

X 1/10 X 1/5 X 1/6 X 1/8 X 1/9 X 1/18

V V V V V V

X 1/14 X 1/14 X 1/14 X 1/14 X 1/14 X 1/14

≥ 17,5 V ≥ 17,5 V 0V 0V 0V 0V


3


X 1/10 X 1/5 X 1/6 X 1/8 X 1/9 X 1/18

V V V V V V

X 1/14 X 1/14 X 1/14 X 1/14 X 1/14 X 1/14

≥ 17,5 V ≥ 17,5 V ≥ 17,5 V 0V 0V 0V


4


X 1/10 X 1/5 X 1/6 X 1/8 X 1/9 X 1/18

V V V V V V

X 1/14 X 1/14 X 1/14 X 1/14 X 1/14 X 1/14

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


1

Retarder stage switch undefined condition

heavy


2s



Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step 5


X 1/10 X 1/5 X 1/6 X 1/8 X 1/9 X 1/18

V V V V V V

X 1/14 X 1/14 X 1/14 X 1/14 X 1/14 X 1/14

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


6


X 1/10 X 1/5 X 1/6 X 1/8 X 1/9 X 1/18

V V V V V V

X 1/14 X 1/14 X 1/14 X 1/14 X 1/14 X 1/14

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


12

1

Retarder stage switch chasssis ground end

heavy

1s

- Ignition: OFF - Pull off plug X1 - Retarder stage switch: position 5

X 1/10 Ω X 1/14

Resistor endless

Check each stage on chsssis ground end

13

1

Retarder stage switch battery shortcircuit

heavy

10s

- Ignition: OFF - Pull off plug X1 - Retarder stage switch: position 0

X 1/10 V X 1/14

0V





Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step

16

1

Temperaturesensors (both sensors defect)

heavy

1s

17

1

Cooling-water temperature sensor interruption

light

1s

See blinking code 17 to 20

- Ignition: OFF - Pull off plug X3

X 3/1

Ω X 3/2

20°C ± 10 °C = 1039 - 1117Ω

Check electrical lead, sensor and plug

60°C ± 10 °C = 1194 - 1271Ω 80°C ± 10 °C = 1271 - 1347Ω Note: The measuring in one temperature range normally is sufficient.

18

1

Cooling-water temperature sensor chasssis ground end

light


1s

-

Ignition: OFF Pull off plug X1, X3

X 3/2

Ω X 1/14

Resistor endless

Check electrical lead



Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step 1

Oil-temperature sensor interruption

light

1s

-

Ignition: OFF Pull off plug X3

X 3/5

Ω X 3/6

20°C ± 10 °C = 1039 - 1117Ω


60°C ± 10 °C = 1194 - 1271Ω 80°C ± 10 °C = 1271 - 1347Ω Note: The measuring in one temperature range normally is sufficient.

20

1

Oil-temperature sensor chasssis ground end

light

1s

- Ignition: OFF - Pull off plug X1, X3

X 3/5

21

1

Speedometer signal interruption

heavy

2s

-

Ignition: ON

22

1

Speedometer signal battery shortcircuit

heavy

2s

-



Ω X 1/14

Resistor endless


X 1/11 V X 1/14

≤1V

Check electrical lead and speedometer

X 1/11 V X 1/14

≤9V

Check electrical lead and speedometer



Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step

23

1

Retarder pilot light interruption, chasssis ground end

heavy

1s

-


X 1/15 V X 1/14

≥ 17,5 V

Check electrical lead and fuse

24

1

Retarder pilot light interruption, battery shortcircuit

heavy

3s


X 1/15 V X 1/14

≤2V

Check electrical lead and retarder pilot light

25

1

Pressure sensor fault (supply)

light

0,5s

-

Ignition: ON

X 3/8

V X 3/9

4,75 ... 5,25 V

Check electrical lead

26

1

Pressure sensor interruption, chasssis ground end

light

1s

-

Ignition: OFF Pull off plug X1, X3

X 3/7

Ω X 1/14

Resistor endless

Check electrical lead and pressure-sensor

27

1

Pressure sensor battery shortcircuit

light

1s

-

Ignition: ON

X 3/9

V X 3/8

4,75 ... 5,25 V


28

1

Pressure sensor unplausible signal

light

10s


X 3/7

V X 3/8

0,3 ... 0,7 V





Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step

29

1

ABS chasssis ground end

heavy

60s

-

Ignition: ON

X 1/13 V X 1/14

≥ 3,5 V

Check electrical lead, relay and ABS-control unit

30

1

ABS undefined condition

heavy

5s

-

Ignition: ON

X 1/13 V X 1/14

≥ 16,5 V

Check electrical lead, relay and ABS-control unit

31

1

ABS int. fault at control unit

heavy

1s

33

1

Brake light relay chasssis ground end

light

1s

-


X 1/16 Ω X 1/14

At installed relay 250-350 Ω

Check electrical lead plug and relay or consumer

34

1

Brake light relay interruption, battery shortcircuit

light

1s

-


X 1/16 Ω X 1/14

< 1,5kΩ


-


X 1/16 V X 1/14

0V


-


X 2/1

At installed consumer > 150Ω


2

35

1

Output 1 (OUT-1) chasssis ground end

light


1s


Ω X 1/14



Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step 1

Output 1 (OUT-1) interruption, battery short circuit

light

1s

2

X 2/1

Ω X 1/14

< 3kΩ


- Ignition: OFF - Pull off plug X2 - Ignition: ON

X 2/1

V X 1/14

0V


-


37

1


light

1s

-


X 2/2

Ω X 1/14

At installed consumer > 150 Ω


38

1

Output 2 (OUT-2) interruption, battery shortcircuit

light

1s

-


X 2/2

Ω X 1/14

< 3kΩ


-


X 2/2

V X 1/14

0V


-


X 2/3

Ω X 1/14

At installed consumer > 150Ω


2

39

1


light


1s



Fault text

Fault class

Trigger time



Result/ Set point

Cause/ Remedy

Test step 1

Output 3 (OUT-3) interruption, battery shortcircuit

light

1s

2

-


- Ignition: OFF - Pull off plug X2 - Ignition: ON

X 2/3

Ω X 1/14

< 3kΩ


X 2/3

V X 1/14

0V


41

1

CAN-fault messages failing to appear, interruption

heavy

1s

Check electrical connections and leads of vehicle CAN-Bus

42

1

CAN BusOff

heavy

200ms

Check electrical connections and leads of vehicle CAN-Bus

46

1

Retarder footswitch chasssis ground end (IN-3)

light

500ms


-

Ignition: ON

X 2/4

V X 1/14

> 0,4 V

Check analoge footpedal, electrical lead and plug


Diagnosis / Troubleshooting – Troubleshooting and remedies B. Without fault code Hinweis Retarder faults without fault code are not recognized electronically.



Diagnosis / Troubleshooting – Checking Supply-Air Pressure (pv) 4.5

Checking Supply-Air Pressure (pv) Work scope test 1.

Connect appropriate test pressure gauge to test connection of compressed-air line (32) at four-circuit protection valve - air tank for auxiliary equipment and check supply-air pressure (pv). • Minimum pressure: 6 bar • Maximum pressure: 11 bar

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


32

Diagnosis / Troubleshooting – Checking Supply-Air Pressure (pv) Page 77

11033

Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) 4.6

Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Requirements for check •


•

Vehicle ignition OFF

4100 103

K

d.

-S

V

ac

oi

th

h-

N

-S

r.

ac

h-

N

r.

103 Screw plug (test connection pump pressure) M12x1,5 Inhex-head w.a.f. 6 13 Nm (20 Nm) 4100 Oil filler plug M30x1,5 Inhex-head, w.a.f. 17 100 Nm (100 Nm)

Notice The pump pressure check provides e.g. information on internal leaks and on the correct operation of the retarder. 11034


Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 78

Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Requirements for check •


•


•

Vehicle electrical system (e.g. battery voltage, fuse etc.) checked in accordance with the Owner´s Manual for the vehicle and found satisfactory

•

Compressed-air pressure 6 - 11 bar

Special tools:

H53.478810

Compressed-air pressure gauge 0 - 6 bar 99/7

Oil-pressure gauge 0 - 25 bar 99/1



Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)

Attention! Two version of the screw plugs (107, 3500, 4100, 4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the inspection of oil level; replace completely if necessary.




Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Work scope check

4100

Attention! Risk of injury! The oil filler plug (4100) and the retarder are hot! oil temperature!

1.

Screw out oil filler plug (4100).

11035

2.

Connect air-pressure gauge (99/7) to bore of oil filler plug (4100).

99/7

11036

99/7 Air-pressure gauge 53.1403.10




Attention! Risk of injury! The screw plug (103) and the oil are hot! Oil temperature! 3.

Screw out screw plug (103).

103

11037

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

99/1 4.

Connect oil-pressure gauge (99/1) to bore of screw plug (103).

11038

99/1 Oil-pressure gauge 53.4788.10



Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) 5.

Drive the vehicle with a prop shaft speed of vps = 1000 r.p.m.

Notice Shift into direct gear (ratio 1:1). The engine speed 1000 r.p.m. corresponds to prop shaft speed of 1000 r.p.m.. 6.

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

7.

Compare read-off pump pressure with the minimum value of dynamic pump pressure (pdyn) according to the table see pages 93 ff.

8.

Compare read-off constant-air pressure (py) with determined value of constant-air pressure (py) according tables on pages 93 ff.

Attention! If the nominal value of the constant-air pressure (py) is obtained, however the pump pressure is below, the retarder is inside defect. If the respectively required set point is fallen at the measuring of the constant-air pressure (py), either a leak of the retarder or a defect is due to the control (see troubleshooting diagram). The constant-air pressure (py) must not change during the drive.




Attention! Risk of injury! Screwing of oil-pressure gauge and retarder are hot! When screwing out oil-pressure gauge (99/1) hot oil can flow out! 9.

Disconnect oil-pressure gauge (99/1).

99/1

11039

99/1 Oil-pressure gauge 53.4788.10

103 Notice Check sealing ring of screw plug (103) for a possible damage, replace screw plug (103) if necessary. 10. Screw tight screw plug (103). Tightening torque screw plug (103): 13 Nm (20 Nm)

11040




Attention! Risk of injury! The screwing of the air-pressure gauge and the retarder are hot! 11. Disconnect air-pressure gauge (99/7).

99/7

11041

99/7 Air-pressure gauge 53.1403.10

4100 Notice Check sealing ring of oil filler plug (4100) for a possible damage, replace oil filler plug (4100), if necessary. 12. Screw tight oil filler plug (4100). Tightening torque oil filler plug (4100): 100 Nm (100 Nm)

11042



Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve 4.7

Checking Control Current of Proportional Valve Requirements for check •

Battery voltag 24 - 28 V

•

Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory

•

Fuse for retarder control unit checked and found satisfactory

•

Plug at proportional valve and socket checked for damage as well as wear (notch scratches)

•

Electrical lead and plug-in connection checked (visual examination) and found satisfactory

Special tool:

Measuring adapter 99/3

Commercially available tool Multimeter

Fluke 87 or 79 (otherwise possible differing in measurements!)


Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve Page 86

Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve Work scop check 1.

Disconnect plug at proportional valve (21) and connect with measuring adapter (99/3).

2.

Connect plug of measuring adapter (99/3) with the proportional valve (21).

3.

Connect the Multimeter (98/8). Switch position: mA.

4.

Turn switch „Propvalve“ at measuring adapter (99/3) in position „I“.

5.

Shift the retarder stage switch in position 5 and compare the read-off value with the given values of the control current of the proportional valve in accordance with the tables see page 93 ff.

6.

Disconnect plug of measuring adapter (99/3) and connect to the proportional valve (21) again.

21 98/8

99/3 11043

98/8 Multimeter 99/3 Measuring adapter 53.8198.10


Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve Page 87

Diagnosis / Troubleshooting – Checking Pressure Sensor 4.8

Checking Pressure Sensor Requirements for check •


•

Connected pressure gauge constant-air pressure

•


•


Special tool:

Measuring adapter 99/3

Commercially available tool Multimeter

recommended: Fluke 87


Diagnosis / Troubleshooting – Checking Pressure Sensor Page 88

Diagnosis / Troubleshooting – Checking Pressure Sensor Work scope check 1.

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

2.

Connect plug of measuring adapter (99/3) to pressure sensor (38).

3.

Connect electrical lead ground of multimeter (98/8) to measuring socket 4 (ground) of adapter.

4.

Turn switch „Propvalve“ at measuring adapter (99/3) in position „Propventil“.

5.

Now, switch on vehicle ignition!

6.

Connect electrical lead positive of Multimeter (98/8) to measuring socket 1 (positive).

7.

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

98/8

38

99/3

11044

Notice If there is an error (wire or sensor), the supply voltage is switched off by the control unit. Check the wire or the sensor and replace the defect part, if necessary. 8.

Connect electrical lead positive of Multimeter (98/8) to measuring socket 2 (output).

9.

Compare measured voltage in conjunction of constant-air pressure with values on page 93 ff. For the purpose of comparison a manometer "py" must be parallelly installed (unless for pressure = 0 / Retarder OFF) see page 78 ff.

98/8 Multimeter 99/3 Measuring adapter 53.8198.10

10. Switch-off vehicle ignition after measurements! 11. Reconnect after removing measuring adapter (99/3) the electrical lead to the pressure sensor.


Diagnosis / Troubleshooting – Checking Pressure Sensor Page 89

Diagnosis / Troubleshooting – Checking Temperature Adaption 4.9

Checking Temperature Adaption Requirements for check •

Battery voltage 24 - 28 V

•


•

Pressure gauge constant-air pressure connected

•

Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory

•

Fuse for retarder control unit checked and found satisfactory

•


Special tool:

Temperature simulator 99/2


Diagnosis / Troubleshooting – Checking Temperature Adaption Page 90

Diagnosis / Troubleshooting – Checking Temperature Adaption Work scope check 1.

Disconnect electrical lead cooling water (39) and electrical lead oil (40) to cooling-water temperature-sensors (19) and oil (20) and connect these to the temperature simulator (99/2).

40

39

99/2 Notice Pay attention to the correct connection of the plugs for water and oil. If the two sensors are too far away from each other, then these have to be checked separated. Wasser

Öl

11045

99/2 Temperature simulator 53.8207.10 2.

Set rotary switch of temperature simulator (99/2) to 95°C cooling water temperature and 165°C oil temperature.

3.

Switch-on vehicle ignition!

4.

Operate retarder at highest braking stage. Constant-air pressure (py) control current must reach values given on table on pages 93 ff.

5.

Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. The constant-air pressure py must drop below the set maximum pressure. Set rotary switch of temperature simulator (99/2) to 125oC cooling water temperature. There must be no more output of constant-air pressure py.

6.

Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature.



Diagnosis / Troubleshooting – Checking Temperature Adaption 7.

Set rotary switch of temperature simulator (99/2) to 185oC oil temperature. The constant-air pressure must drop below the set maximum pressure.

8.

Set rotary switch of temperature simulator (99/2) to 225oC oil temperature. There must be no more output of constant-air pressure py.

9.

Take measurement for resistance on both temperature sensors according table on page 93 ff.

10. Switch-off vehicle ignition! 11. Reconnect electrical connection lead cooling water (39) and electrical connection lead oil (40) to temperature sensors cooling water (19) and oil (20).



Diagnosis / Troubleshooting – Table of Measurements 4.10 Table of Measurements Digiprop without CAN With pressure sensor Code-Number 2) OLD

1) 2) 3) 4) 5)

NEW

Amperage control current mA1) 3) 5)

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

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

038

138

396 - 596

2,05 - 2,35

18

050

150

365 - 565

1,60 - 1,90

13,5

051

151

379 - 579

1,80 - 2,10

15

052

152

396 - 596

2,05 - 2,35

17

053

153

423 - 623

2,45 - 2,75

20

055

155

396 - 596

2,05 - 2,35

17

057

157

409 - 609

2,25 - 2,55

18,5

058

158

409 - 609

2,25 - 2,55

18,5

079

179

440 - 640

2,70 - 3,00

22

080

180

440 - 640

2,70 - 3,00

22

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

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


Diagnosis / Troubleshooting – Table of Measurements Page 93

Diagnosis / Troubleshooting – Table of Measurements Digiprop with CAN With pressure sensor

1) 2) 3) 4) 5)

Code-Number 2)




502

440 - 640

2,70 - 3,00

22

504

440 - 640

2,70 - 3,00

22

508

440 - 640

2,70 - 3,00

22

510

430 - 630

2,55 - 2,85

21

512

440 - 640

2,70 - 3,00

22

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




Diagnosis / Troubleshooting – Table of Measurements Without pressure sensor / without CAN Code-Number 2) OLD

NEW

059 1) 2) 3) 4) 5)




534 - 546

2,60 - 3,10

22

159

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




Diagnosis / Troubleshooting – Table of Measurements VERA DAFBUS

1) 2) 3) 4)

Serial-Number




H67.276320

440 - 640

2,70 - 3,00

22

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




Diagnosis / Troubleshooting – Table of Measurements Voltage measurement at the pressure sensor

5 4,5 4 3,5 3 [ V ] 2,5 2 1,5 1 0,5 0 0

0,5

1

1,5

2

2,5

3

3,5

4

[ BAR ] 11046




Diagnosis / Troubleshooting – Table of Measurements Resistance measuring at the temperature sensor Temperature

Resistor

20°C ± 10 °C

1039 - 1117 Ω

60°C ± 10 °C

1194 - 1271 Ω

80°C ± 10 °C

1271 - 1347 Ω

Notice The measuring in one temperature area normally is sufficient. These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.



Removing, Installing Retarder

5.



Removing, Installing Retarder Page 99

Removing, Installing Retarder Prior work •

Cooling water drained *

•

Oil drained of retarder (see page 26)

•

Propeller shaft at the gearing flange removed *

•

Oil drained of gearbox *

•

Waterneck removed (see page 123)

•

Speedometer sensor removed *

•

Output shaft-flange removed *

25300 25000

25300

850

25200

25100

4100

* Notice the information of the vehicle manufacturer

25200 Notice The shim must always be determined newly, if: •

taper roller bearing (800) is renewed

•

Retarder is installed at gearbox

•

Retarder was repaired

•

Gearbox was repaired

850/1 11047

Illustration: Removing, installing retarder

850/1 Taper roller bearing 850 Outer race Only removing, if the tapered roller bearing is replaced or a new shim enclosed 4100 Screw plug M 30 x 1,5 Inhex-head w.a.f. 17 100 Nm (100 Nm) 25000 Shim 25100 O-Ring, renewed coat with silicone-free and non-corrosive grease for installation 25200 Hex.-head screw M 10 x 70 Hex head w.a.f. 16 58 Nm 25300 Hex.-head screw M 10 x 60 Hex head w.a.f. 16 58 Nm



Removing, Installing Retarder Tool for local fabrication

FJ 6280 0 486 265

67.3224.10

67.3319.10

Measuring device

Drive in tool Bearing outer ring 98/3

98/1

67.3320.10 Puller Bearing outer ring 98/4

M10

Special tools:

15

80

Material: St37-2, DIN 17100 (1.80)

28028e

Threaded bolt

Sealants and lubricants O-Ring Retarder housing

Silicone-free and non-corrosive grease Omnifit FD 10-1042




Achtung! Two version of the screw plugs (4100) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the inspection of oil level; replace completely if necessary.


Removing 1.

Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove with appropiate lifting device retarder from gearbox.

25200

25300

4100

25200 11049



Removing, Installing Retarder 2.

Remove O-Ring (25100) from gearbox.

Notice

25000 850 98/4

00 628 FJ 265 486

Carry out following working step, if: - taper roller bearing (800) is renewed - Retarder is installed at gearbox - Retarder was repaired - Gearbox was repaired

25100

11050

3.

Pull off outer ring (850) with puller bearing outer ring (98/4) and remove shim (25000).


98/4 Puller bearing outer ring 67.3320.10


Removing, Installing Retarder Assembling 1.

Determine thickness of shim as follows:

Notice The shim must always be determined newly, if: •

taper roller bearing (800) is renewed

•

Retarder is installed at gearbox

•

Retarder was repaired Gearbox was repaired

Attention! The measurings described below may only carried out at ambient temperature and with the retarder in vertical position (see illustration)! 1.1 Measure the distance "B" between bearing surface on retarder side of the gearbox and the bearing surface of the shim and note value.

B

11051



Removing, Installing Retarder 1.2 Put the bearing outer ring (850) on the taper roller bearing (850/1).

850

850/1

11052

1.3 Put measuring device (98/1) on gearbox and tighten hex.-head screws handtight (3 Nm). 1.4 Put the lever from position 1 in position 2 to pressurize the drive shaft with a defined preload of approx. 400 N.

Pos.1

Pos. 2

1.5 Turn the pinion by hand 15 times clockwise and after that 15 times counterclockwise.

98/1

11053

98/1 Measuring device 67.3224.10



Removing, Installing Retarder 1.6 Set the vernier depth gauge on gearbox seperation area and zero vernier depth gauge.

11054

1.7 Put vernier depth gauge on the measuring area of the measuring plate. 1.8 Measure distance of measuring area of the measuring plate to seperation area of the retarder housing and note value "A". 1.9 Determine thickness of shim as follows: Thickness of shim = dimension B minus dimension A minus 0,02mm

11055




Notice The thicker shim must always be placed first in the gearbox housing.

2.

Put shim (25000) into the gearbox housing (if removed).

Notice

25000 850

If taper roller bearing was replaced, also replace the bearing outer ring (850). 98/3

Notice If necessary warm housing for the simpler assembly in the area of the bearing outer ring to approx. 80°C. 3.

11056

98/3 Drive in tool 67.3319.10

Insert bearing outer ring (850 if removed) into the gearbox housing and knock this with the drive in tool (98/3) in as far as possible.




Clean sealing surface of retarder housing (1).

1

11057

5.

Turn gearbox till the sealing surface points up (gearing stands vertically).

6.

Clean sealing surface of gearbox housing and coat with sealant Loctite 5203.

7.

Coat O-Ring (25100) with silicon free and non-corrosive grease and place in gearbox.

8.

Turn two threaded bolts M 10 x 80 (see arrows) into the gerarbox housing . The threaded bolts are needed so that the sealing surfaces (gearbox/retarder) can be assembled congruently.

25100

11058




Place retarder at gearbox and fix this with 5 hex.-head screws (25200). Tightening torque hex.-head screws (25200): 58 Nm

25200

25200

10. Screw out again the two threaded bolts M 10 x 80. 11. Insert the 17 hex.-head screws (25300) and tighten them. Tightening torque hex.-head screws (25300): 58 Nm

25200

25300 11059



Repair Retarder

6.

Repair Retarder 6.1 6.2 6.3 6.4 6.5 6.6 6.7

Overall Illustration of Main Components ...................................................111 Removing, Checking and Installing Casing Ventilation.............................112 Removing, Checking and Installing Silencer.............................................122 Removing and Installing Water Neck........................................................123 Removing, Checking and Installing Heat Exchanger................................124 Removing and Installing Oil Tank Cover...................................................133 Removing, Installing Non-Return Valve Outlet .........................................136


Repair Retarder Page 110

Repair Retarder – Overall Illustration of Main Components 6.1

Overall Illustration of Main Components 3300

6101

3300 2800

6100 9000 6101 2810 3850 3850 3900

2300

2000 8000

2301 2300/2

4000 3700 5400 5500 5600

2900

2300/3

3100

3800

2300/1

4100

6600 6700

7500 109 6400

6700 6600

7300 5300 5200

7600 20100 20000 20200

7500

100

7300

103 3500 4100

6700 6600

107

20100 20400 5200 20300 5300 20000 20200 20400 20300

2600 2500

2105 2106 1700 1600 3100

3100 4200 2100

11060

Illustration: Components Retarder 115 E 100 103 107 109 1600 1700 2000 2100 2105 2106 2300 2300/1 2300/2 2300/3 2301

Retarder housing Screw plug M12 x 1,5, inhex-head, w.a.f. 6 Oil drain plug Retarder M 24 x 1,5, inhex.-head, w.a.f. 12 Screw plug M 24 x 1,5, inhex.-head, w.a.f. 12 Valve cover O-Ring 60 x 3 Top cover Non-return valve outlet, complete O-Ring, 34 x 3 O-Ring, 54 x 3 Casing ventilation Valve insert Float Float cage O-Ring 55 x 3

2500 2600 2800 2810 2900 3100 3300 3500 3700 3800 3850 3900

4000 4100 4200


Bottom cover Bottom gasket Cover for casing ventilation Vent and air filter M 12 x 1,5, hex.-head, w.a.f. 17 Gasket Combined hex.-head screw M 8 x 30, hex.-head, w.a.f. 13 Combined hex.-head screw M 8 x 80, hex.-head, w.a.f. 13 Screw plug with sieve, M 30 x 1,5, inhex.-head, w.a.f. 17 Proportional valve Damping plate O-Ring 16 x 3 Combined hex.-head screw M 8 x 20, hex.-head, w.a.f. 13 Hex.-head nut M8, hex.-head, w.a.f. 13 Screw plug M 30 x 1,5, inhex.-head, w.a.f. 17 Screw plug M 24 x 1,5, inhex.-head, w.a.f. 12

5200 5300 5400 5500 5600 6100 6101 6400 6600

6700 7300 7500 7600 8000 9000 20000 20100 20200 20300 20400

Temperature sensor Sealing ring A 14 x 20 Corrugated spring Disc (silencer) D 30 x 4 Retaining ring JL 30 x 1,2 Pipe O-Ring 15,3 x 2,4 Heat exchanger Hex.-head screw M 14 x 45, hex.-head, w.a.f. 22 old: hex.-head screw with flange M 14 x 40, hex.-head, w.a.f. 19 Washer A15 O-Ring 15 x 4 O-Ring 45 x 5 O-Ring 25 x 4 Intermdiate plate 196 x 144 x 2 Pressure sensor 0 to 4 bar Water neck Gasket, renew Combined hex.-head screw M 8 x 80, hex.-head, w.a.f. 13 Screw plug M 14 x 1,5, hex.-head, w.a.f. 13 Sealing ring A 14 x20

Repair Retarder – Overall Illustration of Main Components Page 111

Repair Retarder – Removing, Checking and Installing Casing Ventilation 6.2

Removing, Checking and Installing Casing Ventilation

Notice This working step can be performed with retarder removed or installed. Prior jobs •

Vehicle ignition switched off

•

Retarder switched off

•

Proportional valve and damping plate removed (see page 140)

Attention! Risk of injury! Retarder housing is hot!


Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 112

Repair Retarder – Removing, Checking and Installing Casing Ventilation

2300 Casing ventilation

3300

2300/1 Valve insert 2300/2 Float desired weight 11g ± 1 g

6101

2300/3 Float cage 2301 O-Ring 55 x 3, renew, coat with silicon-free and noncorrosive grease for installation

2800

2800 Cover casing ventilation

2900

6100 6101

2900 Gasket casing ventilation, renew 3300 Combined hex.-head screw M 8 x 80, renew hex.-head, w.a.f. 13, 30 Nm 6100 Air-pipe coat with silicon-free and noncorrosive grease for installation 6101 O-Ring 15,2 x 2,4, erneuern coat with silicon-free and noncorrosive grease for installation

2300/1 2300

2301 2300/2 2300/3

sealant and lubricant O-Ring Float

silicon-free and non-corrosive grease Methylated spirit 11061

Illustration: Casing ventilation



Repair Retarder – Removing, Checking and Installing Casing Ventilation Tool for local fabrication

Ø 40,5 mm Ø 60 mm Material: St 37 Weight: 0,085 kg Impact puller 99/5

Adapter 98/7

7 mm

Special tools:

28049e

Test ring 99/7

Notice The test ring also can be ordered with Voith item-number 67.2757.10 at Voith Turbo GmbH&Co. KG.



Repair Retarder – Removing, Checking and Installing Casing Ventilation Removing 1.

Screw out combined hex.-head screws (3300).

3300

11063

2.

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

2800

2900

11064



Repair Retarder – Removing, Checking and Installing Casing Ventilation 3.

Remove air-pipe (6100) and O-Rings (6101).

6101 6100 6101

11065

4.

Use impact puller (99/5) and adapter (98/7) to extract valve insert of retarder housing (100).

99/5

100

98/7

11066

99/5 Impact puller 53.7712.10 98/7 Adapter 53.9428.10




Take float (2300/2) and float cage (2300/3) out of retarder housing (100).

2300/2 100

2300/3

11067

6.

Lever out O-Ring (2301) of groove of valve insert (2300/1) and remove this.

2300/1

2301 11068



Repair Retarder – Removing, Checking and Installing Casing Ventilation Checking 1.

Check float (2300/2) on damages of surfaces and sealing surfaces (arrow).

2.

Weigh float (2300/2). The desired weight is 11 g ± 1 g. If the weight is more than the desired weight renew complete casing ventilation.

2300/2

Notice 11069

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

3.

Check sealing edge of radial shaft sealing ring (arrow) in valve insert (2300/1). Put down valve insert (2300/1) on float (2300/2) than weigh down valve insert with test ring (99/7). Fill up the hollow space between float and upper edge of valve insert with methylated spirit. If the sealing edge is not damaged, the fluid level must not alter in the course of 1 minute. If necessary, renew complete casing ventilation.

99/7 2300/2

2300/1

11070

99/7 Test ring 67.2757.10



Repair Retarder – Removing, Checking and Installing Casing Ventilation Installing 1.

Coat new O-ring (2301) with silicon-free and non-corrosive grease and pull on valve insert (2300/1).

2300/1

2301

11071

2.

Insert float (2300/2) and float cage (2300/3) in valve insert (2300/1).

2300/1

2300/2

2300/3 11072




Coat bore of casingventilation in retarder housing (100) with silicon-free and non-corrosive grease.

4.

Insert casing ventilation in retarder housing (100).

5.

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

99/5 100

98/7

11073

99/5 Impact puller 53.7712.10 98/7 Adapter 53.9428.10 6.

Coat new O-rings (6101) with silicon-free and non-corrosive grease and pull over air-pipe (6100).

7.

Coat bore for air-pipe (6100) in cover (2000) with silicon-free and non-corrosive grease.

8.

Slip air-pipe (6100) in to the cover (2000).

2000 6100 6101

11074




Place new gasket (2900) on retarder housing.

2900

11075

10. Coat bore for air-pipe (6100) in cover (2800) with silicon-free and non-corrosive grease.

6100

11. Slip cover (2800) in air-pipe (6100) and place this at retarder housing. 12. Screw in combined hex.-head screws (3300) and screw them tight. Tightening torque combined hex.-head screw (3300): 30 Nm.

3300 2800

11076



Repair Retarder – Removing, Cleaning and Installing Silencer 6.3

Removing, Cleaning and Installing Silencer Notice

5400

This work step can be performed with retarder installed or removed.

5500 5600

5400 Corrugated spring 5500 Disc (silencer) D 30 x 4, clean with appropriate cleaning agent (Benzine) and blow out with compressed-air 5600 Circlip JL 30 x 1,2 dished side must face silencer

Cleaning agent Silencer

Nr. hac Nr. -S hKd. ac th-S Voi

Benzine

11077

Illustration: Silencer


Repair Retarder – Removing, Cleaning and Installing Silencer Page 122

Repair Retarder – Removing and Installing Water Neck 6.4

Removing and Installing Water Neck Prior jobs •


•


•

Cooling water drained

20100 20000 20200

20000 Water neck 20100 Gasket, renew 20200 Combined hex.-head screw M 8 x 80 hex.-head, w.a.f. 13, 30 Nm

20100 . Nr h. ac Nr .-S hKd ac -S ith Vo

20000 20200

11078

Illustration: Water neck


Repair Retarder – Removing and Installing Water Neck Page 123

Repair Retarder – Removing, Checking, Installing Heat Exchanger 6.5

Removing, Checking, Installing Heat Exchanger Notice If necessary, the heat exchanger can be removed also with mounted retarder. Prior jobs •


•

Retarder removed (see page 99)

With installed retarder: •

Oil drained from retarder (see page 26 ff)

•


•

Water neck removed (see page 123)

Attention! The heat exchanger must be secured before removing with appropriate parts!

Notice A throttle disk can be installed between heat exchanger and housing at retarder with ending number .10 in the type plate. This must be removed. In connection with this, the retarder control unit has to be progammed on the latest for this retarder valid code and the non-return valve (outlet) must be installed as of code number 67.2550.22.


Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 124

Repair Retarder – Removing, Checking, Installing Heat Exchanger 107 Oil drain plug retarder M 24 x 1,5, inhex.-head, w.a.f. 12, 47 Nm (80 Nm) 4200 Oil drain plug oil tank M 24 x 1,5, inhex.-head, w.a.f. 12, 47 Nm (80 Nm) 6400 Heat exchanger 6600 Hex.-head screw M 14 x 45, renew hex.-head, w.a.f. 22, Pre-torque: 50 Nm Final torque: 30° turning angle old version: hex.-head screw M14 x 40 with flange, hex.-head, w.a.f. 19 6700 Washer A15 7300 O-ring 15 x 4, renew coat with silicon-free and noncorrosive grease for installation 7500 O-ring 45 x 5, renew coat with silicon-free and noncorrosive grease for installation 7600 O-ring 25 x 4, renew coat with silicon-free and noncorrosive grease for installation

7500

6700

6600

7300 7600 6400 7500 7300 4200

6700 6600

4200

107

Lubricant 11079

O-rings

silicon-free and non-corrosive grease


Illustration: Removing heat exchanger


Repair Retarder – Removing, Checking, Installing Heat Exchanger

Attention! Two versions of screw plugs (107, 4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the installation of the heat exchanger; replace complete screw plug if necessary. B) Version with loose inserted copper-sealing ring. In this Aftersales Service Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings are generally to be renew.



Repair Retarder – Removing, Checking, Installing Heat Exchanger Special tool

67.1948.10

Pressure test plate 99/6

Commercially available tool Turning angle measuring tool 3/4“


e.g. Messrs Richard Abr. Herder Post box 10 08 67 D-42659 Solingen Tel. 0212/ 888-0 Ordering No. 8200-02


Repair Retarder – Removing, Checking, Installing Heat Exchanger

Notice If this work sequence is performed with the retarder in situ, the following prior jobs must be performed: 1.

Screw out oil-drain plugs (107 and 4200) as well as the oil filler plug (for quicker drain) and drain oil.

2.

Shut, if available, the stopcocks in the cooling-water circuit of the vehicle.

3.

Remove the cooling water hoses of the heat exchanger.

107

4200

4200 11080



Repair Retarder – Removing, Checking, Installing Heat Exchanger Removing 1.

Screw out hte four hex.-head screws (6600) and remove washers (6700).

2.

Remove heat exchanger (6400).

6400

6600 6700

6700 6600

3.

6700 6600 11081

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

7500 7300 7300 7600 7500 7300 11082



Repair Retarder – Removing, Checking, Installing Heat Exchanger Checking 1.

Install pressure test plate (99/6) with O-rings at heat exchanger (6400) and connect compressd-air pressure lines to bottom connection (arrow).

2.

Fill heat exchanger (6400) on water side with hot water (approx. 70oC).

3.

Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the heat exchanger).

99/6

6400

Notice If air bubbles form in the hot water the heat exchanger is leaking and must be exchanged. 11083

99/6 Pressure test plate 67.1948.10 4.

Connect compressed-air line to top connection (arrow).

5.

Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the heat exchanger).

99/6

6400

Notice If air bubbles form in the hot water the heat exchanger is leaking and must be exchanged. New heat exchanger are wetted with corrosion-inhibiting oil in the water- and oil section of the heat exchanger. Prior to installing a new heat exchanger, drain any corrosion-inhibiting oil which may have collected and flush it out with hot water in the water section of the heat exchanger.


11084

99/6 Pressure test plate 67.1948.10


Repair Retarder – Removing, Checking, Installing Heat Exchanger Installing 1.

Fit new O-rings (7300, 7500 and 7600) in the bores and coat them with silicon-free and non-corrosive grease.

7600 7500

7300 7300

7500 7300 11085

2.

Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) with washers (6700) tight. Initial torque:

50 Nm

Final torque:

30° turning angle

6400

6600 6700

6700 6600


6700 6600 11086


Repair Retarder – Removing, Checking, Installing Heat Exchanger 3.

Install retarder, if necessary (see page 99 ff).

4.

Fill in cooling-water and bleed cooling-water circuit. If available, open the check valves in the flow- and return pipe of the cooling-water section.

Attention! If the heat exchanger leaks, there is water present in the retarder. If the retarder is filled up, a mixture of oil and water is created, causing the oil in the retarder to foam and escape through the casing ventilation system to the atmosphere. For this reason, it is indispensible to flush out the retarder after repair! While flushing, apply the brake gently several times to prevent the retarder oil warming up excessively. 5.

Flush the retarder, if the heat exchanger has leaked as follows: To flush the retarder, fill it with 7,0 litres of engine- or flushing oil. Apply the brakes gently several times to flush out the retarder system and drain the oil through the oil drain plugs (107 and 4200). Repeat the procedure 2 or 3 times.

6.

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

7.

Screw oil-drain plug (107, 4200) tight Tightening torque oil-drain plug (107, 4200): 47 Nm (80 Nm)

107

8.

Fill in retarder oil (see page 29).

9.

If heat exchanger were leaking, deoil cooling- and heatingsystem of vehicle according manufacturer instructions.


4200

4200 11087


Repair Retarder - Removing, Installing Oil Tank Cover 6.6

Removing, Installing Oil Tank Cover

6101

A) Top Oil Tank Cover

3300

6100

9000

Prior jobs •

Vehicle ignition switched OFF

•


6101

3100

Notice This working step can be performed with retarder removed or installed..

2000

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

8000 2000 Top cover 3100 Combined hex.-head screw M 8 x 30, renew hex.-head, w.a.f. 13 30 Nm 3300 Combined hex.-head screw M 8 x 80, renew inhex.-head, w.a.f. 13 30 Nm 6100 Air-pipe 6101 O-Ring 15,3 x 2,4, renew coat with silicon-free and non-corrosive grease for installation

11088

Illustration: Top Oil Tank Cover

8000 Intermediate plate, renew 9000 Pressure sensor Lubricant O-ring

Silicon-free and non-corrosive grease


Repair Retarder – Removing, Installing Oil Tank Cover Page 133

Repair Retarder – Removing, Installing Oil Tank Cover B) Bottom Oil Tank Cover Prior jobs •

Vehicle ignition switched OFF

•


•

Retarder oil drained (see page 26 ff)

2500 Bottom cover 2600 Bottom gasket, renew 3100 Combined hex.-head screw M 8 x 30, renew, hex.-head, w.a.f. 13, Heed tightening sequence! 30 Nm 4200 Oil drain plug oil tank M 24 x 1,5 inhex.-head, w.a.f. 12 47 Nm (80 Nm)

2600

2500

3100 4200

11089

Illustration: Bottom Oil Tank Cover


Repair Retarder – Removing, Installing Oil Tank Cover Page 134

Repair Retarder – Removing, Installing Oil Tank Cover

Attention! Two versions of screw plugs (4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing rings must be checked for possible damages during the installation of the heat exchanger; replace complete screw plug if necessary. B) Version with loose inserted copper-sealing ring. In this Aftersales Service Manual is excluding the variant A (series version) described. If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings are generally to be renew.

Installation note Pay attention to the mounting position of the gasket and the cover!

6

Tighten all combined-hex.-head screws in specified sequence 1 to 17 first with 14 to 19 Nm.

5 4

The combined-hex.-head screws are then tightened in the same sequence with 30 Nm.

7

3

8 2

7

1

9

16

10 15

11 14

12 13


Repair Retarder – Removing, Installing Oil Tank Cover Seite 135

11090

Repair Retarder – Removing, Installing Non-Return Valve (Outlet) 6.7

Removing, Installing Non-Return Valve (Outlet) Prior job •

Retarder oil drained (see page 26 ff) 1600 Valve cover Heed mounting position! 1700 O-ring 60 x 3, renew, coat with silicon-free and non-corrosive grease for installation 2100 Non-return valve (outlet) Heed mounting position! coat bore with silicon-free and non-corrosive grease for installation

. Nr h. ac Nr .-S hKd ac -S ith

Vo

2105

2105 O-ring 34 x 3, renew, coat with silicon-free and non-corrosive grease for installation 2106 O-ring 54 x 3, renew, coat with silicon-free and non-corrosive grease for installation

2106 1700 1600 2100

3100 Combined hex.-head screw M 8 x 30 hex.-head, w.a.f. 13 30 Nm

3100

11091

Illustration: Non-Return Valve (Outlet) Lubricant O-ring



Repair Retarder – Removing, Installing Non-Return Valve (Outlet) Page 136

Repair Retarder – Removing, Installing Non-Return Valve (Outlet) Special tool

153.00005210

Puller non-return valve (outlet) 71/1


Repair Retarder - Removing, Installing Non-Return Valve (Outlet) Page 137

Repair Retarder – Removing, Installing Non-Return Valve (Outlet) Removing 1.

Screw out combined hex.-head screws (3100) of valve cover (1600).

2.

Remove valve cover (1600).

3.

Position puller (71/1) up to engaging to torque limiter valve and pull out non-return valve of its seat.

4.

Remove O-rings (1700, 2106 and 2105).

71/1 11092

71/1 Puller Installing 1.

Install non-return valve in reverse sequence.


Repair Retarder – Removing, Installing Non-Return Valve (Outlet) Page 138

Control Parts

7.

Control Parts 7.1 7.2 7.3 7.4

Removing, Installing Proportional Valve and Damping Plate....................140 Removing, Installing Temperature Sensor Cooling Water........................141 Removing, Installing Temperature Sensor Oil ..........................................142 Removing, Installing Pressure Sensor......................................................143


Control Parts Page 139

Control Parts – Removing, Installing Proportional Valve and Damping Plate 7.1

Removing, Installing Proportional Valve and Damping Plate 3850

Prior jobs •


•


•

Supply-air pressure discharged

3800

3850

3900 Plug at the proportional valve as well as connector checked for damage or wear (notches). 26 Compressed-air line pv

4000

39

39 Electrical connection lead

3900

3700 Proportional valve 3800 Damping plate, renew if necessary

3700 26

4000

3850 O-ring 16 x 3, renew coat with silicon-free and non-corrosive grease for installation 3900 Hex.-head screw M 8 x 20, renew, hex.-head, w.a.f. 13, 30 Nm 4000 Hex.-had nut M8, renew, 18 Nm 11093

Illustration: Proportional Valve and Damping Plate

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

Lunbricant O-ring



Control Parts – Removing, Installing Proportional Valve and Damping Plate Page 140

Control Parts – Removing, Installing Temperature Sensor Cooling Water 7.2

Removing, Installing Temperature Sensor Cooling Water Prior jobs •


•


•


5200

5200 Temperature sensor cooling water, 28 Nm

5300

5300 Sealing ring A14 x 20, renew

Attention! Risk of injury! The cooling water is hot!

Notice Please, bear in mind to the instructions regarding the quality of coolant given from the vehicle manufacturer or Voith Turbo coolingwater quality list (Voith Item-No. 67.2224.10).


1109

Illustration: Temperature Sensor Cooling Water

Control Parts – Removing, Installing Temperature Sensor Cooling Water Page 141

Control Parts – Removing, Installing Temperature Sensor Oil 7.3

Removing, Installing Temperature Sensor Oil Prior jobs •


•


5200 Temperature sensor Oil, 28 Nm 5300 Sealing ring A14 x 20, renew

5300 5200

11095

Illustration: Temperature Sensor Oil


Control Parts – Removing, Installing Temperature Sensor Oil Page 142

Control Parts – Removing, Installing Pressure Sensor 7.4

Removing, Installing Pressure Sensor

9000

Prior jobs •


•


9000 Pressure sensor, 30 Nm

11096

Illustration: Pressure Sensor


Control Parts – Removing, Installing Pressure Sensor Page 143

Appendix

8.

Appendix 8.1 Retarder Data Sheet .................................................................................145 8.2 Tightening Torques ...................................................................................146


Appendix Page 144

Appendix – Retarder Data Sheet 8.1

Retarder Data Sheet Data Sheet Voith Retarder 115 E Max. possible braking torque at prop shaft M (Br) max at retarder ratio 1:2.03 *

3700 Nm

Maximum Retarder Speed

nmax. = 4800 min-1 at vps = 2365 min-1

Working Medium

Oil according Operating Specification

Control Medium

Compressed-Air

Supply-Air Pressure

7 to 10 bar

Service filling: -

Service filling (Oil change, inspection of oil level)

7,0

Litre

-

after exchange of heat exchanger

7,5

Litre

Weight of unit (with het exchanger unit and service filling)

approx. 73 kg

* dependent from the retarder and vehicle configuration


Appendix – Retarder Data Sheet Page 145

Appendix – Tightening Torques 8.2

Tightening Torques Pos.-No.: 103

Title

Dimensions

Tightening torque

Screw plug

M 12 x 1,5, Inhex.-head, w.a.f. 6

With integrated sealing ring: 13 Nm With a loose sealing ring: 20 Nm

105

Screw plug



107

Oil drain plug



1400

Dodecagonal nut

M 38 x 1,5, w.a.f. 55

426 Nm

2810

Vent and air filter

M 12 x 1,5, w.a.f. 17

10 Nm

3100

Combined hex.-head screw

M 8 x 30, Hex.-head, w.a.f. 13

30 Nm

3300



30 Nm

3400

Dowel screw

M 14 x 48, Hex.-head, w.a.f. 19

Initial torque: 50 Nm Final torque: 30° turning angle

3500

Screw plug with sieve



3900



30 Nm

4000

Hex.-head nut

M 8, w.a.f. 13

18 Nm

4100

Oil filler plug / screw plug



4200

Oil drain plug




Appendix – Tightening Torques Page 146

Appendix – Tightening Torques

Pos.-Nr.:

Bezeichnung

Abmessungen

Anziehdrehmoment

5200

Temperature sensor oil / water

M 14 x 1,5, Hex.-head, w.a.f. 21

28 Nm with copper sealing ring

6600


M 14 x 45, Hex.-head, w.a.f. 22

Initial Torque: 50 Nm Final torque: 30° turning angle

9000

Pressure sensor

M 16 x 1,5, Hex.-head, w.a.f. 27

30 Nm

20200



30 Nm

20300

Screx plug

M 14 x 1,5, Hex.-head, w.a.f. 13

32 Nm

25200

Hex.-head screw

M 10 x 70, Hex.-head, w.a.f. 16

58 Nm

25300

Hex.-head screw

M 10 x 60, Hex.-head, w.a.f. 16

58 Nm


Appendix – Tightening Torques Page 147

Transmissão Voith Retarder 115 E 147 Pag.

Recommend Documents