Transmissão Voith Retarder 120-3 57 Pag.

Operating Instructions Voith Retarder 120-3

Status: December 1999 Voith Article Number 67.3787.10

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VOITH VOITH T URBO URBO O per per ating ating Instructions Retar Retarde derr 120120-3 3

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Preface 1 Vo it h Ret Ret arder – Safety travels travels with you y ou

As the Voith Ret Retard arde er is a safety un u nit, no n owad wada ays, the modern comm co mmerci ercia al vehicle is almost unthinkable unthinkable with w ithout out it. The The retard retarde er has established a solid ground in i n road road tr affic thanks to more safety and high efficiency. We are pleased that the Voith Retarder has become more and more a standard sta ndard component compo nent in the th e comm co mmer erci cial al vehicle and that you are also using this technology in yours. Please contact us or one of our partners for further information. We always wish you GOOD TRIP!

Voith oit h T urbo GmbH GmbH & C o. KG KG Reta Retarder rder Product Product Group Grou p Voithstraße 1 P.O. Box15 55 D-74 D-745 555 Cra Cr ailsheim

Telephone Telephone 07951 / 32-4 3 2-401 01,, -42 -422 2 F ax 07951 / 32-75 32-756 6 e-mail: r [email protected]

December 1999 Pr inted inted in Germ Germ any

VOITH TURBO TURBO O perating perating Instru Instr uctions Reta Retarr der 120120- 3

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1 Preface These operating instructions contain important informati on for f or a safe, sa fe, pr oper an a nd eco e conomical nomical operatio operation n of o f the th e Voith Retarder 120-3. The use of the Voith Retarder as hydrodynamic permanent bra br ake in commerci commercia al vehicle vehi cles s is con co nsid si dered as a s proper use. The The dir d irect ective ives s for proper use of o f the the retard retarde er are a re to be observed served strictly by the perso pe rsons ns in char char ge, in i n particula particular, r, by the staff st aff in charg ha rge e of operation and repair. The The user i s lili able for an a ny hazard azar dous situa situ ation and damages re r esulting sultin g from improper use u se..

If the retarder is installed subsequently, i.e. not directly by the vehicle manufacturer, it is necessary to fill in the m odificat difica ti on certificate attache attach ed to th t his instruction manual and to return it to Voith Turbo, cbqr Dept. For the purpose of technical development of our products and to keep up with the progress, we reserve the r ight ight for modification of th t he V Vo oi th Reta Ret ar der 120-3 ou o utlined in these operating instructions and for the applicable tech te chnica nicall info inform rmat atio ion n and form fo rm..

Copyright December 1999 - Voith Turbo Observe the information – in particular, the safety information ma tion – for opera pe ration tion an a nd perform the specified servi service ce work in regular intervals and in time using the specified operating fluids. Only qualified staff is allowed to do the repair and maii nten ma te nance wor wor k. Ente Enterr the work performe perfor med d in the service check list provided for this purpose enabling you to clai clai m full full warra warr anty. nt y. Use only original spare parts in the event of a repair, because only this guarantees that your retarder meets the tr affic ff ic safe safetty a an nd the des d esii gn standa standard rd on ship sh ipm m ent. nt .

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Contents 1.

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.

2.

Safety Info nformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.

3.

System Identifi ification ion

4.

3.1

R etard ta rder er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .

3.2

R etard ta rder er Contro Contr ol Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Illust lustrrati ations ons Vo Voith ith Ret Retarder rder 12 120-3 0-3 4.1

Illu Ill ustratio strat ions ns with stainless steel steel Heat Excha Exchan nger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.2

Illu Ill ustratio strat ions ns with aluminium Heat Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

5.

General Descripti ption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 17

6.

Operati on 6.1

F unctional D escription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 .9 1

6.2

T empe mpera ratu ture re Ada Ad apta pt ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 21

6.3

F unctions and and Indications of Re Retarder ta rder Sta St age Switch (without push button for "Constant Speed" function), Retarder Piot Light . . . . . . . . . . . . . . . 23

6.4

F unctions and and Indications of Re Retarder ta rder Sta St age Switch (with push button for "Constant Speed" function), Retarder Pilot Light . . . . . . . . . . . . . . . . . 27

6.5

Ped Pe dal Op O perat era ti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 .3 3

6.6

C ustome sto merr Optio pt ions. ns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 37 VOITH TURBO O per per ating ating Instructions Retar Retard der 120120-3 3

3

Contents 7.

Maintenance 7.1 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 7.2 Oil Change (stainless steel Heat Exchanger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 7.3 Oil Change (aluminium Heat Exchanger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

8.

Maintenance Work, Cooling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9.

Oil Change Intervals, Operating Fluids Instructions . . . . . . . . . . . . . . . . . . . . . . . . 50

10.

Data Sheet Voith Retarder 120-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

11.

Service Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

12.

Modification Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

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VOITH TURBO Operating Instructions Retarder 120-3

2 Safety Information To guarantee sound operation of the Voith Retarder 120-3 and to exclude any risks due to improper handling, please read and follow the safety information mentioned on this and the next page as well as in each chapter!

The safety symbols are explained below:

Warning!

Precautions and safety regulations protecting persons from i njuries or danger to their life.

Caution!

Special information and precautions preventing damage to the retarder or vehicle. Non-observance leads to exclusion of warranty.

Note Special information for better handling when operating the retarder and for maintenance work.

VOITH TURBO O perating Instructions Retarder 120-3

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2 Safety Information For empty running vehicles, single vehicles or vehicles without body (e.g. transfer) operate the retarder carefully! 

Warning!

Unauthorized modifications on the retarder and the use of spare parts, accessories, attachments and special equipment not tested and released by Voith, may have a negative effect on the safety of the complete vehicle, for which liability is excluded for any resulting damages. 

When in contact with oils, greases and other chemical substances, e.g. retarder oil, observe the safety regulations applicable to these products. 

Be cautious when you are in contact with hot operating fluids! Danger of burning or scald! 

In case of unsafe road conditions (slick ice, snow, gravel etc.) or risk of aquaplaning, operate the retarder carefully and gradually only. In an extreme case, leave the retarder switched off! Observe these precautions, in particular, for vehicles without ABS! Switch off the reatarder main switch (if available - see vehicle operating i nstructions) for vehicles without ABS. 

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VOITH T URBO O perating Instructions Retarder 120 - 3

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

In the event of retarder failure or when the temperature adaptation is active (see chapter 6.2: Temperature Adaptation), use the service brake to adapt the vehicle speed. 

2 Safety Information  Voith

Caution!  The

Voith Retarder 120-3 is manufactured to the latest design standards and approved safety regulations. Nevertheless, hazards and damage to property may occur in case of improper use. The user/owner has the obligation to always operate the retarder in sound condition. 

 In

case of malfunctions, observe the relevant informa-

tion.

is not in the position to give explicit warning everywhere in this instruction manual, in case of any thinkable situation, which may lead to a risk of injury for the operator and/or damage to the retarder. It is therefore absolutely necessary that everyone in charge of operation and maintenance of the Voith Retarder 120-3 does not put its own safety at risk by the selected mode of operation and that it has no negative effect on the retarder, in particular, with regard to safety. Voith is not liable for personal injury and/or damage to property caused by improper or unprofessional operation.

 Voith

will not assume liability for injuries and/or damage to property resulting from non-observance of the safety information, instruction manual or violation of the duty of care in handling, operation, maintenance and repair of the retarder.

VOITH TURBO O perating Instructions Retarder 120-3

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2 Safety Information Caution!

Keep the operating instructions together with the vehicle operating instructions on hand in the vehicle. Replace immediately any incomplete or illegible instruction manual. 

 Observe

the relevant regulations for prevention of accidents, any other generally accepted safety regulations and industrial medical service and the Regulations Authorizing the Use of Vehicles for Road Traffic (StVZO). Voith is not liable for any damages resulting from nonobservance of these regulations.  Do

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not start the vehicle without oil in the retarder.

VOITH TURBO Operating Instructions Retarder 120 -3

3.1

System Identification: Retarder

You will find the retarder identification (nameplate) on the output side of retarder housing (see arrow).

M+P-07A-1181

Information given on the nameplate: 1. Serial n umber, 6-digit number. 2. Voith i tem number, 8-digit number.

Please enter the serial and article number indicated on your Voith r etarder on the left-hand side nameplate. Please let us know these data in the event of any queries or spare parts orders.

1501

Serial Number: Voith Item Number:


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3.2 System Identification: Retarder Control Unit You will find the Digiprop control unit identification on the control unit which is:

M+P-07A-1617

1. Voith item number, 8-digit number The last two digits identify the software version. Example: .12 = version 1.2 Vo it Co h-N Se de-Nr .: Kur ien- r .: nd Nr . en : -N r .:

53 .x xxx xxx .12 xxx x/ Da tum

2. Code number, 3-digit number (adjustment of control unit) 3. Serial number, 5-digit number also indicating the coding date 4. Customer number (optionally)

Voith-No Code-No Serial-No

Please enter the identification data, indicated on your control unit, on the left-hand side nameplate. Please let us know these data in the event of any queries or spare parts orders.

Date:

Customer-No

1522

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4.1 Illustrations: Voith Retarder 120-3 with stainless steel Heat Exchanger 100/1 Retarder identification 1000 Heat exchanger 1900 Oil filler/check plug M 30x1.5 hex. head screw, w.a.f. 24

Note

The item numbers used in these operating instructions correspond to the item numbers in the spare parts lists. Parts or components with item number and dash number (e.g. 100/1) cannot be procured and are not mentioned in the spare parts lists.

1900

100/1 1000 1503


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4.1 Illustrations: Voith Retarder 120-3 with stainless steel Heat Exchanger 1000 Heat exchanger 1001 Cooling water drain plug M18x1.5 hex. socket screw, SW 8 1700 Oil drain plug Retarder M22x1.5 hex. socket screw, w.a.f. 10

1700 1588-3

1001

1000 1504

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4.2 Illustrations: Voith Retarder 120-3 with aluminium Heat Exchanger 100/1 Retarder identification 1000 Heat exchanger 1001 Cooling water drain plug M12x1.5 hex. head screw, w.a.f. 13 1900 Oil filler/check plug M30x1.5 hex. head screw, w.a.f. 24

1585-3

1900

100/1

1000 1001


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4.2 Illustrations: Voith Retarder 120-3 with aluminium Heat Exchanger 1000 Heat exchanger 1001 Cooling water drain plug M12x1.5 hex. head screw, w.a.f. 13 1002 Oil drain plug heat exchanger M12x1.5 hex. socket screw, w.a.f. 6 1700 Oil drain plug - retarder M22x1.5 hex. socket screw, w.a.f. 10

1700 1001 1586-3

1002

1000 1506

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5 General Description The Voith Retarder 120-3 is a powerful, hydrodynamic permanent brake of compact design for commercial vehicles of medium range.

Basically, there are two heat exchanger variants:  

Retarder 120-3 with stainless steel heat exchanger Retarder 120-3 with aluminium heat exchanger

The retarder braking torque is also maintained on gear shifting.

Warning!

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


17

5 General Description The following control system is installed: Digiprop control system – Retarder stage switch with 5 switch stages and w ith „constant speed“ function in position 1 as well as 4 brake stages in position 2 to 5.

The control system with push button for „constant speed“ function is available as special design: – Retarder stage switch with 4 switch stages, with push button for „ constant speed“ function as well as 4 brake stages in position 1 to 4.

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Note

In addition, as special version, the Digiprop control system may be combined with a 3-stage or 4-stage pedal actuation via the foot pedal of the vehicle service brake.

Warning! This variant, however, is permissible only in vehicles equipped with ABS!

6.1 Operation: Functional Description The Voith Retarder is controlled by a retarder stage switch with 5 switch stages. In the maximum position of the retarder stage switch, the braking torque is at the maximum. The control medium is compressed air which is taken from the vehicle air tank for auxiliary equipment .

M+P-07A-1589

3

1

2

A constant-air pressure depending on the set brake stage is acting via a proportional valve on the oil sump of the retarder. That means, according to the operating condition (propshaft speed), a certain quantity of oil is forced into the working chamber of the retarder between rotor (1) and stator (2). The rotor is connected with the propshaft of the vehicle, the stator is fixed firmly to the retarder housing.

1507

The hydrodynamic principle


19

6.1 Operation: Functional Description The rotation of the rotor sets the oil in motion and circulates it in a closed circuit (3) between the rotor and the stator. The reduction of the velocity of the oil flow in the stator chambers leads to braking of the rotor and consequently to braking of the vehicle. For Retarder 120-3 the impulse lubrication is activated as soon as the vehicle ignition is switched on.

20


6.2 Operation: Temperature Adaptation The energy generated by braking with the retarder is converted into heat. In order to dissipate this heat, part of the oil in the working chamber is pumped constantly by the rotor through the heat exchanger and fed back into the ci rcuit. In the heat exchanger, the heat of the oil is passed on to the cooling water of the vehicle and dissipated through the vehicle’s cooling system. One temperature pick-up each monitors the cooling water oil temperature transmitting this information to the control unit. This guarantees that the maximum permissible temperatures for cooling water and oil are not exceeded.

Caution!

Observe the following when the retarder pilot light is flashing or the temperature control is active: Adjust the vehicle speed using the service brake and change to the lowest possible gear (increase the engine speed). Maintain this driving condition until the retarder regained its full power.

The control unit includes vehicle-specific cooling water and oil temperature limit settings. To prevent that these temperature limits are exceeded during retarder operation, the retarder braking torque is adapted optimally for protection and effective utilization of vehicle cooling system and retarder. With already significantly reduced braking torque, the retarder pilot light starts flashing.


21

6.2 Operation: Temperature Adaptation By driving or operating the retarder properly, you can increase and/or secure the vehicle cooling performance and thus the availability of the retarder.

M+P-07A-1624

How? 

On retarder braking, shift the gearbox down to reach rated engine speed!

Thus: 15

– High delivery rate of water pump – High fan speed

20

10 25

Result: 30

– It is possible to make optimal use of the vehicle cooling system performance!

u/pm

Fuel consumption is not affected by the high engine speed as the fuel injection system goes to zero delivery in overrun condition. 1 2 3 4 5 1508

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6.3 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light (without push button for „Constant Speed“ function) A

M+P-07A-1590

B

A

B 0 1 2 3 4 5

1509

0 1 2 3 4 5

Retarder pilot light (vehicle-specific ins tallation s ite) Retarder stage switch (vehicle-specific ins tallation s ite) Retarder OFF Constant speed Brake stage 1 Brake stage 2 Brake stage 3 Brake stage 4

Caution!

Operate the retarder stage switch only step-by-step to reach the required braking torque (do not just „skip the gears“)! In an emergency situation it is permitted to „skip gears“ when operating the retarder stage switch. To reduce the braking torque set at that moment, it is possible to skip several stages at one time with the retarder stage switch.


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6.3 Operation: Functions, Indications of Retarder Stage Switch (without push button for „Constant Speed“ function), Retarder Pilot Light

Note

In case of very low outside temperatures, the braking action on first retarder braking starts with a response delay after starting to drive. For vehicles with zero gas switch, the „ constant speed“ function or the active brake stage is cleared on application of the gas pedal. After releasing the pedal, the new momentary „ constant speed“ is stored or the previously applied brake stage is reactivated. For vehicles with cr uise control, dependent on the equipment, it is possible to clear the cruise control automatically by actuating the „constant speed“ function.

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The retarder pilot light has the additional function of fault indication that enables to find the fault in the electronic system even without service unit. The indication of an fault can be realized by the flash code of the retarder pilot light.

Caution!

Only qualified staff is allowed to activate the flash code and to perform any repair work which might be necessary.

6.3 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light (without push button for „Constant Speed“ function)

0 1 2 3 4

Off (symbol for retarder pilot light may differ from vehicle to vehicle)

Light test: Retarder pilot light 5 sec. steady light

Ignition ON 0 1 2 3 4

Steady light: „constant speed“

0 1 2 3 4

Steady light: Brake stages 1-4

0 1 2 3 4

Steady light in position 0 to 4 Minor fault: Retarder braking may partly occur at reduced braking torque. Consult a qualified workshop! Major fault: Retarder braking no longer possible – the retarder is switched off. Continue driving only with substantially reduced speed - consult a qualified workshop immediately!

0 1 2 3 4

Flashing light: Temperature adaptation


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6.3 Operation: Functions, Indications of Retarder Stage Switch (without push button for „Constant Speed“ function), Retarder Pilot Light M+P-07A-1618

1 Adapt the speed.

0 1 2 3 4

1

2 Activate „constant speed“ at the wanted speed. The retarder keeps this vehicle speed constant within the maximum braking torque. Should the vehicle accelerate in spite of „constant speed“, it is necessary to apply the service brake in addition. Continued shifting to gear stage 4 does not increase the braking action. When leaving the „constant speed“ lever po sition, automatic control is cleared immediately.

5

0 1 2 3 4

2

6 %

10 km

5

0 1 2 3 4

3

3 Switch off the retarder or adapt to the traffic situation using a brake stage.

5 1510

26


6.4 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light (with push button for „Constant Speed“ function) A

M+P-07A-1688

A

C

B

0 1 2 3 4

1511

Retarder pilot light (vehicle-specific ins tallation s ite) B Retarder stage switch (vehicle-specific ins tallation s ite) C Push button „ constant speed“ 0 Retarder OFF 1 Brake stage 1 2 Brake stage 2 3 Brake stage 3 4 Brake stage 4

Caution!

Operate the retarder stage switch only step-by-step to reach the required braking torque (do not just „skip the gears“)! In an emergency situation it is permitted to „skip gears“ when operating the retarder stage switch. To reduce the braking torque set at that moment, it is possible to skip several stages at one time with the retarder stage switch.


27

6.4 Operation:

Functions, Indications of Retarder Stage Switch, Retarder Pilot Light (with push button for „Constant Speed“ function)

Note

In case of very low outside temperatures, the braking action on first retarder braking starts with a response delay after starting to drive. For vehicles with zero gas switch, the „ constant speed“ function or the active brake stage is cleared on application of the gas pedal. After releasing the pedal, the new momentary „ constant speed“ is stored or the previously applied brake stage is reactivated. For vehicles with cr uise control, dependent on the equipment, it is possible to clear the cruise control automatically by actuating the „constant speed“ function.

28


The retarder pilot light has the additional function of fault indication that enables to find the fault in the electronic system even without service unit. The indication of an fault can be realized by the flash code of the retarder pilot light.

Caution!


6.4 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light (with push button for „Constant Speed“ function)

0 1 2 3 4

Off (symbol for retarder pilot light may deviate, depending on the vehicle manufacturer)

Light test: Retarder pilot light 5 sec. steady light

Ignition ON 0 1 2 3 4

Steady light: „constant speed“

0 1 2 3 4

Steady light: Brake stages 1-4

0 1 2 3 4

Steady light in position 0 to 5 Minor fault: Retarder braking may partly occur at reduced braking torque. Consult a qualified workshop! Major fault: Retarder braking no longer possible – the retarder is switched off. Continue driving only with substantially reduced speed - consult a qualified workshop immediately!

0 1 2 3 4

Flashing light: Temperature adaptation


29

6.4 Operation:

Functions, Indications of Retarder Stage Switch, Retarder Pilot Light (with push button for „Constant Speed“ function) 1 Adapt the speed.

M+P-07A-1689

0

1

1 2 3 4

1512

30


6.4 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light (with push button for „Constant Speed“ function) 2 Switching on „ constant speed“ at the wanted speed: – Press the push button The present speed is stored, the retarder pilot light lights steadily.

M+P-07A-1690

Retarder stage switch in position 0: The „ constant speed“ function is stored. Retarder stage switch in position 1-4: – Switch retarder stage switch to position 0. „ Constant speed“ function is reactivated.

6 %

2

10 km

The retarder keeps this vehicle speed constant within the maximum braking torque. Should the vehicle accelerate in spite of „constant speed“ , it is necessary to apply the service brake in addition. Continued shifting to gear stage 4 does not increase the braking action.

0 1 2 3 4

1513


31

6.4 Operation:

Functions, Indications of Retarder Stage Switch, Retarder Pilot Light (with push button for „Constant Speed“ function) 3 During downhill run with constant speed, a brake stage (retarder stage switch position 1 to 4) can be switched on additionally to reduce the vehicle speed. When switching the retarder stage switch afterwards again to position 0, the vehicle accelerates to the previously stored speed and keeps it constant within the maximum braking torque.

M+P-07A-1691 0

3

1 2 3 4

4 Switching off „ constant speed“ : Press the push button again. The retarder pilot light extinguishes when the retarder stage switch is in position 0.

4

1514

32


6.5 Operation: Pedal Operation M+P-07A-1591

3

A B 1 2 3

2 1 A

B

Retarder Retarder and service brake Brake stage 1 * Brake stage 2 * Brake stage 3 *

* The brake stages operated with the pedal are normally identical with the brake stages of the hand operation.

1515


33

6.5 Operation:

Pedal Operation

Note

The illustration shows the 3-stage variant, a 4-stage variant also is offered. The main switch „pedal operation ON-OFF“ is located in the dashboard. ON: retarder is ready for operation OFF: e.g. in case of unsafe road conditions For combined hand and pedal operation, the respective higher braking torque applies. In case of very low outside temperatures, the braking action on first retarder braking starts with a r esponse delay. The „constant speed“ function cannot be selected via the foot pedal.

34


The retarder is operated via the 3 or 4-stage foot pedal of the service brake. The maximum braking torque is reached in the maximum position. Foot pedal in position 0: Retader is switched off – no indication on the retarder pilot light. Foot pedal in position 1 to 3 or 1 to 4: The brake stages 1 to 3 or 1 to 4 are selected accordingly – the retarder pilot light lights steadily.

6.5 Operation: Pedal Operation Special functions with combined hand and pedal operation (without push button for „constant speed“ function)

Special f unctions with combined hand and pedal operation (with push button for „ constant speed“ function)

Retarder stage switch in position 1 – „constant speed“, foot p edal in position 1: „Constant speed“ function is cleared when selecting „constant speed“ while the retarder stage switch is in position 1 and the retarder is then operated via the foot pedal. After releasing the foot pedal, the new momentary speed is stored, provided the retarder stage switch remains in position 1 – the retarder pilot light lights steadily.

„Constant speed“ function active, foot pedal in position 1: „Constant speed“ is cleared when selecting „constant speed“ by pressing the push button and the retarder is then operated via the foot pedal. After releasing the foot pedal, the retarder pilot light extinguishes.


35

6.5 Operation:

Pedal Operation

The retarder pilot light can indicate additionally the following operating conditions: Without indication: The retarder is switched off; no fault. Flashing light - during retarder braking: Temperature adaptation is active - the retarder adapts its braking torque. Please see Chapter 6.2: Temperature Adaptation! Steady light - on electronic check: when turning on the vehicle ignition for about 5 seconds – in position 0 to 3 or 0 to 4 a) Minor fault: Retarder brakings may partly occur at reduced braking torque. Consult a qualified workshop! b) Major fault: Retarder brakings are no longer possible – retarder is switched off.

36


Continue driving only with substantially reduced speed - consult a qualified workshop immediately! The retarder pilot light has the additional function that enables to find the fault in the electronic system even without service unit. The indication of a fault can be realized by the flash code of th retarder pilot light.

Caution!


6.6 Operation: Customer options The following descriptions of hand operation, foot operation as well as of retarder pilot light are stored in a software data record in customer-specific form for MAN; in such cases there are differences of certain functions to the Voith standard data record. The descriptions refer exclusively to the current software version of the control unit. MAN bus Hand operation

Function is as the Voith standard (see chapters 6.3, 6.4: Functions and Indications)

Foot operation

Option: 3-stage foot operation

Retarder pilot light

Steady light: if retarder braking torque is > 0 (no steady light if the hand or foot operation is in a sw itch stage > 0 and the retarder braking torque is 0)

LED in the handle of the retarder stage switch

Steady light: if „ constant speed“ function is activated


37

7.1 Maintenance: Oil Level Check 1800 Sealing ringA30x36, DIN 7603 Cu......renew 1900 Oil filler/check plug M30x1.5 hex. head screw, w.a.f. 24 ..................M A = 150 Nm

Max

1900

Min

1800

1592-3

1516

38


7.1 Maintenance: Oil Level Check Caution!

For a sound operation of the retarder it is important to observe the specified oil fill level, chapter 10: Data Sheet. Use only oils released in the specification for operating fluids, chapter 9.

Note The illustration on page 38 shows a retarder 120-3 with stainless steel heat exchanger. Oil level check is identical for aluminium heat exchangers.

Check the oil level with the vehicle in horizontal position! The temperature of the retarder oil must be above 60 °C (operating temperature)!

1. Operate the retarder at the highest stage (highest brake stage) while the vehicle is at standstill and switch it off after about 5 seconds. Repeat this procedure twice. 2. Switch off vehicle ignition.

Warning!

Oil filler/check plug (1900) is hot (oil temperature)! The retarder and the vehicle ignition must be switched off during oil level check! If the vehicle ignition remains switched on from working step 3, with oil filler/check plug removed, there is a higher risk of injury due to hot leaking oil (increased pressure)!


39

7.1 Maintenance: Oil Level Check 3. Unscrew the oil dipstick after about 5 minutes, remove sealing ring (1800) and wipe off the oil filler/check plug. 4. Insert the oil filler/check plug flush with the countersunk taphole - do not screw in. 5. Pull out again the oil filler/check plug.

Oil level is correct between min. and max. mark of the oil filler/check plug. The difference between min. and max. mark is about 0.5 l oil. 6. Fill in any l acking oil via the bore for the oil filler/check plug according to specification for operating fluids and oil fillings. 7. Re-insert the oil filler/check plug with new sealing ring and tighten it. Oil filler/check plug (1900), 150 Nm.

40


7.2 Maintenance: Oil Change (stainless steel Heat Exchanger) 1800 Sealing ring A30x36, DIN 7603 Cu.....renew 1900 Oil filler/check plug M30x1.5 hex. head screw, w.a.f. 24 ..................M A = 150 Nm

1900 1595-3

1800

1517


41

7.2 Maintenance: Oil Change (stainless steel Heat Exchanger) 1700 Oil drain plug Retarder M22x1.5 hex. socket screw, w.a.f. 10 ...............M A = 66 Nm

1596-3

1700

1518

42


7.2 Maintenance: Oil Change (stainless steel Heat Exchanger) 1. Place the oil collecting pan under the retarder. Caution!

For a sound operation of the retarder it is important to observe the specified oil fill level, chapter 10: Data Sheet. Use only oils released in the specification for operating fluids, chapter 9!

2. Operate the retarder at the highest stage (highest brake stage) while the vehicle ist at standstill and switch it off after about 5 seconds. Repeat this procedure twice. 3. Switch off vehicle ignition.

Note For draining the oil, the temperature of the retarder oil must be higher than 60 °C (operating temperature)!

Warning!

Oil drain plug (1700) and oil filler/check plug (1900) are hot (oil temperature)! The retarder and the vehicle ignition must be switched off during oil level check! If the vehicle ignition remains switched on from working step 4, with oil drain plug (1700) and oil filler/check plug (1900) removed, there is a higher risk of injury due to hot leaking oil (increased pressure)!


43

7.2 Maintenance: Oil Change (stainless steel Heat Exchanger) 4. For faster draining of the retarder, unscrew the oil filler/check plug (ventilation) and remove the sealing ring (1800). 5. Unscrew the retarder oil dain plug and drain the oil. Waste disposal of drained oil according to regulations! 6. Check the sealing ring of the oil drain plug for damages; replace the oil drain plug, if necessary. 7. Insert and tighten the oil drain plug. Retarder oil drain plug (1700), 66 Nm.

Note

When the retarder is in inclined position up to approx. 4 ° - reduce the oil filling by 0.25l approx. 8 ° - reduce the oil filling by 0.5l .

44


8. Fill in the oil quantity specified in the specification for operating fluids through the bore for the oil filler/check plug. Oil filling = 4.5 litres (service filling) 9. Insert and tighten the oil filler/check plug with new sealing ring. Oil filler/check plug (1900), 150 Nm.

7.3 Maintenance: Oil Change (aluminium Heat Exchanger) 1800 Sealing ring A30x36, DIN 7603 Cu.....renew 1900 Oil filler/check plug M30x1.5 hex. head screw, w.a.f. 24 ..................M A = 150 Nm

M+P-07A-1593

1900

1800

1521


45

7.3 Maintenance: Oil Change (aluminium Heat Exchanger) 1002 Oil drain plug WAT M12x1.5 hex. socket screw, w.a.f. 6 .................M A = 25 Nm 1700 Retarder oil drain plug M22x1.5 hex. socket screw, w.a.f. 10 ...............M A = 66 Nm

1594-3

1002

1700

1520

46


7.3 Maintenance: Oil Change (aluminium Heat Exchanger) 1. Place the oil collecting pan under the retarder. Caution!

For a sound operation of the retarder it is important to observe the specified oil fill level, chapter 10: Data Sheet. Use only oils released in the specification for operating fluids, chapter 9!

Note For draining the oil, the temperature of the retarder oil must be higher than 60 °C (operating temperature)!

Warning!

Oil drain plugs (1002, 1700) and oil filler/check plug (1900) are hot (oil temperature)! The retarder and the vehicle ignition must be switched off during oil level check! If the vehicle ignition remains switched on from working step 2, with oil drain plugs and oil filler/check plug removed, there is a higher risk of injury due to hot leaking oil (increased pressure)!

2. For faster draining of retarder, unscrew the oil filler/ check plug (ventilation) and remove the sealing ring (1800). 3. Unscrew the oil drain plugs on retarder and heat exchanger and drain the oil. Waste disposal of drained oil according to regulations!


47

7.3 Maintenance: Oil Change (aluminium Heat Exchanger) 4. Check the sealing rings of oil drain plugs for possible damages; replace the oil drain plugs, if necessary. 5. Insert and tighten the oil drain plugs. Retarder oil drain plug (1700), 66 Nm. Heat exchanger oil drain plug (1002), 25 Nm.

Note

When the retarder is in inclined position up to approx. 4 ° - reduce the oil filling by 0.25l approx. 8 ° - reduce the oil filling by 0.5l 6. Fill in the oil quantity specified in the specificaion for operating fluids through the bore for the oil filler/check plug. Oil filling = 5.5 litres (service filling) 7. Insert and tighten the oil dipstick with new sealing ring. Oil dipstick (1900), 150 Nm.

48


8 Maintenance Work, Cooling Water Quality Maintenance work

Cooling water q uality

on every oil change – Retighten the propshaft screws – Retighten all screw plugs (retarder basic group and heat exchanger). Fastening nuts and bolts of the heat exchanger are excluded.

The vehicle manufacturer’s specifications apply. If there are no specifications, observe Voith’s cooling water list or the service manual - Retarder 120-3. Cooling water list; Voith Article Number 67.2224.10 Service manual; Voith Article Number 53.2676.10

For oil changing intervals and specification for operating f luids, please see chapter 9.


49

9 Oil Changing Intervals, Operating Fluids Instructions Single-grade mineral oil1 )

Multi-grade mineral oil

1)

Synth./ part-synthetic oil 1)

Truck normal duty

90,000 km

2)

–

135,000 km 2 )

Truck heavy duty

45,000 km

2)

–

90,000 km 2 )

Bus normal duty Bus heavy duty

135,000 km 2 )

90,000 km

2)

180,000 km 2 )

2)

45,000 km

2)

90,000 km 2 )

60,000 km

1) according to specification on the next page 2) if the specified mileage is not reached within 2 years, it is necessary to change the oil!

50


9 Oil Changing Intervals, Operating Fluids Instructions 1. „Normal duty“

Example: – long-distance travel 2. „Heavy duty“ Duties exceeding the normal limit.

Examples: – Applications in regions with high outside temperatures (e.g. Saudi Arabia) – Construction-site and timber vehicles – High permissible total weight at low rated engine power (< 8 PS/ton) – Frequent uphill/downhill roads – Extremely short distances with many road downgrades

It is possible to fall below the specified maximum values, if this results in an improvement of operating sequences relative to the overall maintenance of the vehicle. When the total service life of the retarder passed more than 10 %, relative to the vehicle mileage as well as to other factors not mentioned here, but also affecting the aging of retarder oil, it is necessary to shorten the specified oil-changing intervals individually. In case of application in extremely cold zones, use oils of corresponding low viscosity (Transmax Z or SAE 5W 40). In case of doubt, please consult our Service Department.


51

9 Oil Changing Intervals, Operating Fluids Instructions Oil types permitted for use must meet the following specification: Oil type

Code to DIN 51502

Viscosity class to DIN 51511

Performance class

Single-grade mineral oil

HD

SAE 10W SAE 20W 20 SAE 30

API - CC/SF and better

Multi-grade mineral oil

HD

all classes


Synthetic oil / part-synthetic oil

HC

SAE SAE SAE SAE SAE SAE


0W 40 5W 30 5W 40 5W 50 10W 30 10W 40

The vehicle manufacturer’s specifications apply as to the selection of oil types. If there are no specifications, observe Voith’s list of recommended oils which you may obtain from Voith Turbo under Voith Article Number 67.2246.10.

52


10 Data Sheet Voith Retarder 120-3 Max. possible braking torque at propshaft

M(Br)

Working medium

Oil type i ndicated in the operating fluids instructions

Oil filling qu antity: *

With stainless steel heat exchang er:

With aluminium h eat exch anger:

– service filling (oil change, oil level check)

4.5 litres

5.5 litres

– initial filling/re-filling

6.5 litres

6.0 litres

max.

= 2000 Nm

Control medium

Compressed air

Supply-air pressure

7–10 bar

Total weight (incl. flange, heat exchanger, without oil filling)

approx. 70 kg **

approx. 65 kg **

*

When the retarder is in inclined position up to approx. 4 ° - reduce the oil filling by 0.25l approx. 8 ° - reduce the oil filling by 0.5l ** Dependent on the attachment, the total weight may deviate.


53

11 Service Check List Kilometer re ading ..............................  oil change  line filter cle aned  propshaft screws checked  all screw plugs checked  visual check performed

Kilometer re ading ..............................  oil change  line filter cleaned  propshaft screws checked  all screw plu gs checked  visual check p erformed

Firm stamp / Signature


Date: ........................................

Date: ........................................

Kilometer re ading ..............................  oil change  line filter cle aned  propshaft screws checked  all screw plugs checked  visual check performed

Kilometer re ading ..............................  oil change  line filter cleaned  propshaft checked  all screw plu gs checked  visual check p erformed



Date: ........................................

Date: ........................................

54


11 Service Check List Kilometer re ading ..............................  oil change  lin e filte r cleaned  propshaft screws checked  all screw plugs checked  visual check p erformed

Kil om eter readi ng ..............................  oil change  line filt er cleaned  propshaft screws checked  all screw plugs checked  visual check performed



Date: ................................. .......

Date: ........................................

Kilometer re ading ..............................  oil change  lin e filte r cleaned  propshaft screws checked  all screw plugs checked  visual check p erformed

Kil om eter readi ng ..............................  oil change  line filt er cleaned  propshaft screws checked  all screw plugs checked  visual check performed



Date: ................................. .......

Date: ........................................


55

12 Modification Certificate

– to be filled in by the installa tion

If the retarder is installed subsequently, i.e. not directly by the vehicle manufacturer, it is necessary to fill in the modification certificate and to return a copy of the filled in certificate to Voith Turbo, cbqr Dept.!

Retarder data

Vehicle data

Retarder type:

Vehicle type:

. .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. ..

Voith Retarder 120-3

Vehicle Ident. No.

. .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. ..

Gearbox type:

. .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. ..

Gearbox number:

. .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. ..

Control s ystems

Pedal operation yes

q / no q

Parts List No. - gearbox: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial No.:

.. .. .. ... .. .. .. ... .. .. .

Voith Article Number:

.. .. .. ... .. .. .. ... .. .. .

Set max. braking torque:

.. .. .. ... .. .. .. ... .. .. .

Set temperature limit:

.. .. .. ... .. .. .. ... .. .. .

Engin e type:

. .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. ..

Engine number:

. .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. ..

Propshaft length (a fter retarder installation)

Parts List No. - basic group:

.. .. .. ... .. .. .. ... .. .. .

Parts List No. - attaching parts:

.. .. .. ... .. .. .. ... .. .. .

Parts List No. - heat exchanger:

.. .. .. ... .. .. .. ... .. .. .

Parts List No. - cooling circuit:

.. .. .. ... .. .. .. ... .. .. .

Parts List No. - control:

.. .. .. ... .. .. .. ... .. .. .

Gearbox installation:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

Special equipment:

. . . .. . . ... . . .. . . ... . . .. . . ... . . .. . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation workshop: (stamp) Installation date / Signature:

56

.. .. .. ... .. .. .. ... .. .. .

VOITH TURBO Instruction Manual Retarder 120-3

Transmissão Voith Retarder 120-3 57 Pag.

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