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Training
cbtd 2000-0153.2688.10
Aftersales Service Manual
VOITH Retarder 120-3
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Content
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Table of Contents
(Continue)
4.9 Checking Pump Pressure ...................................................................4.9/14.10 Table of Measurements ................................................................................. 4.10/14.11 Operational Check .........................................................................................4.11/1
5. Removing, Installing Retarder .................................................................5/15.1 Removing, Installing Retarder (Gearbox Attachment) ..................................... 5.1/1
6. Repair .....................................................................................................6/16.1 Overall Illustration of Main Components.......................................................... 6.1/16.2 Removing, Checking and Installing Casing Ventilation ................................... 6.2/16.3 Removing, Checking and Installing
Non-Return Valve (Stainless-Steel Heat Exchanger) ...................................... 6.3/16.4 Removing, Cleaning and Installing Silencer .................................................... 6.4/16.5 Removing, Installing Bottom Cover ................................................................. 6.5/16.6 Checking, Removing and Installing Closing Cover Retarder Housing............. 6.6/16.7 Removing, Installing Labyrinth Ring (Output Side),
Renewing Radial Shaft Sealing Ring............................................................... 6.7/16.8 Removing, Installing Centering Cover (Input Side)
Renewing Radial Shaft Sealing Ring............................................................... 6.8/1
7. Removing, Checking and Installing Heat Exchanger ..............................7/17.1 Removing, Checking and Installing Stainless-Steel Heat Exchanger..............7.1/17.2 Removing, Checking and Installing Aluminium Heat Exchanger..................... 7.2/1
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Content
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Table of Contents
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8. Control Parts ...........................................................................................8/18.1 Removing, Installing Proportional Valve and Damping Plate ..........................8.1/18.2 Removing, Installing Adapter and Pipes.......................................................... 8.2/18.3 Removing, Installing Cooling-Water Temperature Pick-Up .............................8.3/18.4 Removing, Installing Oil Temperature Pick-Up................................................ 8.4/1
9. Annex ......................................................................................................9/1Data SheetConversion TablesTightening Torques
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Preface 1 Preface
The present service manual serves as training material of the basics course.The information and instructions which is given to you furthermore provide the basis for appropriate andprofessional maintenance and repair at the VOITH Retarder 120-3.
We ask you firmly to notice the safety and warning notes which you will find in these instructions.
Caution!
is associated for safety instructions and for warning notes at dangerous situations for persons,at reduction of quality of workmanship and the possibility of damage to property.
Notice
is associated for general notices for a better handling during maintenance of the retarder.
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Preface 1 Preface
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Caution!
The switched-on retarder will not secure the parked vehicle.
During a failure of the Retarders, or while the temperature-adaptation is effective, the vehicle-speed must be settled by using the service-brake and the lowest possible gear is in use (increaseof the engine-speed). This vehicle condition must be held as long as the retarder is available withits full performance again.
Unauthorized changes at the retarder 120-3 as well as the application of spare parts, accessories,attachments and special-productions, not tested and released from VOITH, can influence the secu-
rity of the entire vehicle negatively. No liability takes place for damages resulting from it.
The retarder 120-3 is built after the the state-of -the-art technology and the recognized safety-rela-ted rules. Nevertheless dangers and damages can originate during improper use, maintenance andrepair.
VOITH will take on no liability for injuries and/or damages, that originate through non-observance ofthe security-hints of the service manual or through injuries of the diligence-duty with the handling,at the service, with the care and maintenance or repair of the retarders 120-3.
Repair and maintenance work may only be enforced by qualified specialist-staff.
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Preface 1 Preface
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Note
The used position numbers used in this manual corresponds to the position numbers in the spareparts lists in chapter 9 Annex.Exception:Items or parts with one -, as well as two-digit position-numbers are no spare parts and not listed inthe spare parts lists.Items or components shown with an oblique-number are not available.
For VOITH It is not possible to warn expressly of all possible situations at each position in thisservice manual, that could have a risk of injury for the worker and/or a damage for the retarder
120-3 to the consequence. Therefore it is desperately necessary, that everyone, entrusted with theservice, care, maintenance or repair of the retarder 120-3, does not endanger its own securitythrough the chosen operation and that the retarder gets no negative impairments, especially ofsafety-related types.VOITH is not liable for injury to persons and or damages caused through improper and unprofes-sional work.
The pertinent accident-prevention-regulation, other broadly rules of the security-technology andworking-medicine and the traffic admission law are to be kept. VOITH is not liable for damages, that
originate through contempt of these rugulations.
With the contact with oils, greases and other chemical substances, the current safety regulationsfor these products are to be heeded!
Caution with the contact with hot fuels! Danger of burn and scald!
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Preface 1 Preface
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Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situationswhich might entail the risk of injury for the person carrying out the work. It is therefore imperative thatany person carrying out repair work on VOITH retarders uses his professional knowledge to make surethat his own safety is not endangered and that the retarder suffers no negative effects, in particularsafety-wise, through the chosen working procedure. For these reasons, no liability can be assumed fordamage incurred.
It is therefore expressly pointed out that all working procedures described must be carried out only incompliance with the valid general directions and regulations of the locally responsible authorities, of thehealth protection, accident prevention and environmental protection organisations.
The technical status of the present instructions can be seen from the date (see footer on left). There maybe discrepancies between the actual technical status of the retarders and the descriptions owing to
continuous development and improvement of the retarders.VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and without priornotification.
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General
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2 General
2.1 Retarder Data.............................................................................................2.1/1
2.2 Assembly Overview ....................................................................................2.2/1
With Stainless-Steel Heat Exchanger.................................................................2.2/1With Aluminium Heat Exchanger.......................................................................2.2/3
2.3 Function and Operation Scheme................................................................2.3/1
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General
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2.1 Retarder Data
The retarder data (arrow) of the retarder 120-3 is punched on the output side of the retarder housing.
The retarder data plate provides the following information:
1. Serial number:
six-digit number
2. Item number:eight -digit number
Notice
Please, always quote the retarder serial-No. and item-No. when submitting queries or orderingspare parts.
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2.2 Assembly Overview
Illustration VOITH Retarder R 120-3
Basic group with stainless-steel
heat exchanger
100/1 Retarder data plate
1000 Heat exchanger
1200 Non-return valve
1900 Oil filler/check plug M 30 x 1,5
Combined hex.-head, w.a.f. 24
21000 Damping plate
22000 Proportional valve
26000 Constant-air pressure line py30000 Pressure pick-up
33000 Oil temperature pick-up
34000 Cooling-water temperature pick-up
1900
100/1
1000
22000
33000
30000
34000
21000
26000
1200
18002
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2.2 Assembly Overview
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Illustration VOITH Retarder R 120-3
Basic group with stainless-steel
heat exchanger (Continue)
1000 Heat exchanger1001 Coolant drain plug
M 18 x 1,5
Inhex.-head, w.a.f. 8
1700 Retarder oil drain plug
M 22 x 1,5
Inhex.-head, w.a.f. 10
1700
1001
1000
18003
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2.2 Assembly Overview
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Illustration VOITH Retarder R 120-3
Basic group with aluminium heat exchanger
100/1 Retarder data plate
1000 Heat exchanger
1001 Coolant drain plug M 12 x 1,5Combined hex.-head, w.a.f. 13
1900 Oil filler/check plug M 30 x 1,5
Combined hex.-head, w.a.f. 24
21000 Damping plate
22000 Proportional valve
26000 Constant-air pressure line py30000 Pressure pick-up
33000 Oil temperature pick-up
Note
The cooling-water temperature pick-up isplaced in the pipeline.
1900
100/1
1001
1000
22000
33000
30000
21000
26000
18004
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2.2 Assembly Overview
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Illustration VOITH Retarder R 120-3
Basic group with aluminium heat exchanger
(Continue)
1000 Heat exchanger
1001 Cooling-water drain plugM 12 x 1,5
Combined hex.-head, w.a.f. 13
1002 Oil drain plug heat exchanger
M 12 x 1,5
Inhex.-head, w.a.f. 6
1700 Oil drain plug retarder
M 22 x 1,5
Inhex.-head, w.a.f. 10
18005
1700
1001
1000
1002
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General 2.3 Function and Operating Scheme
Illustration of VOITH Retarder 120-3
Note
The reference numbers indicated in Section 2.3 are not identical with the reference numbers of the spare parts lists.
1 Heat exchanger
2 Control unit4 Connectio n ter minal 157 Fuses (5A)
8 Connection ground12 Pump pressure test connection15 ABS-Signal16 Reta rder stage switch
37 Ventilati on line R
38 Pressure sensor43 Oil sump44 Stator
45 Stator pins46 Rotor47 Speedometer signal50 Output restrictor D1
R
P
A25
V
y
P
46
44 12 50
52
45
23
53
19
37
67
26
21
7 416 8
2
7015 47177418
69
43 166
20
38
18006e
Supply-air pressure p
Oil sump
Constant-air pressure p
Coolant (water)
Pump pressure p
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General
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2.3 Function and Operation Scheme
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Description of the function
The VOITH Retarder 120-3 is a powerful hydrodynamic continous brake of compact design for busesand commercial vehicles of the medium range. The VOITH Retarder 120-3 is mounted between thegearbox and the rear axle of the vehicle.
The retarder braking torque is sustained even when gear changes are made.The switched-on retarder will not secure a parked vehicle.
A retarder stage switch (16) with a maximum of 5 switching stages is used to control theVOITH Retarders 120-3. A special version combines the retarder stage switch (16) with ABS, a 3-stagepedal-operated brake valve or a service-brake pressure switch.
Operation with function ,,Constant speed"
The retarder is operated by a 5-stage retarder stage switch.
When the retarder stage switch (16) is shifted to position 1, the Constant Speed function is activated.The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limitof the maximum braking torque.
If the retarder is switched off (0 position), or switched to braking stage (position 2 to 5), the memorizedconstant speed is deleted. If the constant speed function is re-activated, the new present speedis memorized.
When the retarder stage switch is shifted to position 2 to 5, braking stage 1 to 4 is energized.
Maximum braking torque is obtained when the retarder stage switch is in the maximum position.
When overstepping the maximum possible cooling performance, the retarder braking torquewill be adapted.
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2.3 Function and Operation Scheme
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As a special version, the control system is available with push button operation for constant speed.The retarder is operated in this case by a 4-stage retarder stage switch.
When the push button is pushed in any position of the retarder stage switch, the momentary speed istransferred to memory. In the 0 braking stage, this transfer to memory takes effect and the retarder holds
the vehicle speed downhill constant within the limits of the maximum braking torque. Another push onthe push button in any switch position will delete the speed data.
On a downhill run with constant speed operation, the vehicle can be slowed down within the limits ofthe maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting tobraking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle acceleratesto the speed previously transferred to memory.
Description of operation of retarder R 120-3The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank forauxiliary equipment on the vehicle.
When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2).From this input signal, the control unit (2) provides a control current which flows to theproportional valve (21).
The proportional valve (21), depending on the magnitude of the control current, provides aconstant-air pressure pyon the oil sump (43).
The constant-air pressure pyin the oil sump (43), depending on the operating conditions (prop shaftspeed), forces a certain quantity of oil into the working chamber between rotor (46) and stator (44).
c
a b
18007
The hydrodynamic principlea Rotor (46)b Stator (44)c Oil flow
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2.3 Function and Operation Scheme
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The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarderhousing.
The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between the rotor (46)and stator (44).
The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking ofthe rotor (46) and consequently to braking of the vehicle.
During braking, the kinetic energy of a deceleration is transformed into heat. To dissipate this heat, partof the circulat ing oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and viafilling ducts to join the circulating flow again.In the heat exchanger (3300), the heat energy of the oil is transferred to the cooling water of the vehicleand dissipated via the vehicle radiator to the ambient air.
If the vehicle ignition is switched on the puls lubrication is activated and lubricates the retarder bearings
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2.3 Function and Operation Scheme
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Temperatur pick-up, cooling-water (19), oil (20)
The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from theretarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water andoil temperature to the control unit (2).To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarderbraking torque is limited to protect the vehicle cooling system and the retarder.The constant-air pressure pyis l imited.
The braking torque and consequently the heat generated are reduced until a balance is obtained bet-ween the braking energy of the retarder and the amount of heat which can be dissipated by the vehiclecooling system.
If the cooling water temperature rises into the temperature adaption range, the consequence is a
limitation of the retarder braking torque to protect the vehicle cooling system. If the temperature risesabove thetemperature 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 usedto control the vehicle speed.
Additionally the control unit adapts the braking torque if oil temperature rises too rapidly, irrespective ofactual oil temperature.
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2.3 Function and Operation Scheme
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Casing ventilation (23)
During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) andthe ventilation system (22) out of the retarder.Once the working circuit is free of air, a float rises and closes the casing ventilation.
Stator pins (45)
When the working chamber is empty, the rotor (46) sets up in it an air flow, which is retarded by the stator(44). To minimize this loss, automatically operating stator pins have been installed in the outer zone ofthe stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent thebuild-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back ontheir seats against the force of the spring and the full space between the blades is available.
Non-return valve (66) stainless-steel heat exchanger
The non-return valve (66) prevents the airflow emptying the heat exchanger insert of oil when idling.
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Maintenance 3 Maintenance
3.1 Maintenance Work / Oil Change Intervals..................................................3.1/1
3.2 Checking Oil Level .....................................................................................3.2/1
3.3 Oil Change .................................................................................................3.3/1
With Stainless-Steel Heat Exchanger ... .........................................................................3.3/1
With Aluminium Heat Exchanger ................................................................................... 3.3/5
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Maintenance 3.1 Maintenance Work / Oil Change Intervals
Overview of maintenance work
Carry out the fo llowing maintenance workat each oil change
Carry out visual inspection on leaks at the complete retarder Check hex.-head screws of prop shaft on correct fitment, or tighten if necessary.
Observe guidelines and instructions! Tighten all screw plugs of the heat exchanger and retarder basic groups with the appropriate
torque (see annex) Excerpt of this are the fastening nuts and -screws of the heat exchanger (see chapter 7).
Caution!
Tighten fastening nuts and -screws of the heat exchanger only in case of leakage betweenheat exchanger and retarder.Tightening torque: 23 Nm
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Maintenance 3.1 Maintenance Work / Oil Change Intervals
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1) Operating specifications, see annex
2) Change oil at the latest after 2 years if fewer kilometres are travelled.
Single-grade
mineral oil 1)Multi-grade
mineral oil 1)Synthetic /
part synthetic oil 1 )
Truck
Normal duty90.000 km 2) - 135.000 km 2 )
Truck
Heavy duty45.000 km 2) - 90.000 km 2)
BUS
Normal duty135.000 km 2 ) 90.000 km 2) 180.000 km 2 )
BUSHeavy duty
60.000 km 2) 45.000 km 2) 90.000 km 2)
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Maintenance 3.1 Maintenance Work / Oil Change Intervals
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1. Normal duty
Example:- Long distance traffic
2. Heavy dutySubject to more than normal stress.
Examples:- Use in regions with high ambient temperatures- Vehicles at construction sites and timber lorries- High max. permissible weight with low rated engine power (< 6 kW/metric ton)- Stretches 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 areimproved.
With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as otherfactors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervalsbetween oil changes in individual cases.
For use in extremely cold zones, oils in an appropriately lower viscosity class(TransmaxZ or SEA 5W-40) must be used.
In doubts, please contact VOITH TURBO.
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Maintenance 3.2 Checking Oil Level
Illustration checking oil level
Note
The oil change intervals are listed in chapter3.1, the operating specifications are listed in theannex.
1800 Sealing ring A 30 x 36renew
1900 Oil filler/check plug M 30 x 1,5Combined hex.-head, w.a.f. 24,
150 Nm
Note
The illustration shows a retarder 120-3 withstainless-steel heat exchanger.Checking oil level with aluminium
heat exchanger version is identical.
1800
1900
18008
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Maintenance 3.2 Checking Oil Level
(Continue)
Note
For satisfactory retarder operation, it is important to use only oils specified in the operating specifications
(see Annex) for operating the retarder in the relevant application.
Service filling
The service filling for the complete retarder system depends on the version of the mountedheat exchanger, see table on page 3.3/2 and of the mounting position (see data sheet in chapter 9).
For relevant application approved oils
Use only approved oils specified in the operating specifications (see Annex).
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Maintenance 3.2 Checking Oil Level
(Continue)
Note
For the oil level check, the temperature of the retarder oil must be higher than 60C (operating tempera-
ture).
The oil level check must be carried out with the vehicle in a horizontalposition.
Mind the slanted mounting position.
The difference between min. and max. mark on oil filler/check plug is approx. 0,5 l.
Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec.Repeat this procedure twice.
Caution!
While the oil level is being checked, make sure that retarder and ignition system must havebeen switched off!Risk of injury exists at nonobservance, by hot leaving oil when screw out oil filler/check plug!
2. Switch off the retarder andwait 5 minutes (control function).
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Maintenance 3.2 Checking Oil Level
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Caution! Risk of injury!
The oil filler/check plug (1900) is heated up (oil temperature)!
3. Screw out the oil filler/check plug (1900) and remove sealing ring (1800).Wipe oil off of oil filler/check plug.
4. Position oil filler/check plug (1900) plane at the thread.
Do not screw in the oil filler/check plug!
5. Pull out again the oil filler/check plug (1900).Oil level is correct bewteen min. and max. mark of the oil filler/check plug.
6. Top up slowlyany lacking oil through the hole for the oil filler/check plug.
7. Screw the oil filler/check plug (1900) tight with new sealing ring (1800).Tightening torque 150 Nm
Max
Min
1900
18009
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Maintenance 3.3 Oil Change
Illustration oil change R 120 -3
with stainless-steel heat exchanger
1700 Retarder oil drain plug M 22 x 1,5Inhex.-head, w.a.f. 10, 66 Nm
1800 Sealing ring A 30 x 36, Copper,renew
1900 Oil filler/check plug M 30 x 1,5Combined hex.-head, w.a.f. 24,150 Nm
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1900
1800
1700
18010
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Maintenance 3.3 Oil Change
(Continue)
Note
For satisfactory retarder operation, it is important to adhere to the specified service f illing (see table be-low) and to use only oils specified in the operating specifications (see Annex) for operating the retarderin the relevant application.
* with slant mounted position of the retarder up toapprox. 4 - reduce service filling of approx. 0,25 Litre,approx. 8 - reduce service filling of approx. 0,50 Litre.
The retarder oil temperature must be higher than 60 oC(operating temperature) for the oilto be checked.
Caution!
While the oil is being changed, make sure that no constant-air pressureis acting on the retarder.The retarder and the ignition must be switched off!
Type of heat exchangerService-
filling *
after complete taking apart
and cleaning, as well as
emptied heat exchanger *
after exchange of
heat exchanger *
Stainless-steelheat exchanger
4,5 Litre 5,8 Litre 6,5 Litre
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Maintenance 3.3 Oil Change
(Continue)
Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec. Repeat this procedure twice.Switch off the retarder andignition and wait 5 minutes (control function).
Caution! Risk of injury!
The oil filler/check plug is hot! Oil temperature!
2. Push an oil collecting pan under retarder.
3. Screw out the oil check plug (1900) and remove sealing ring (1800).
Caution! Risk of injury!
The retarder oil drain plug is hot! Oil temperature!
4. Screw out the retarder oil drain plug (1700) and drain oil.
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Maintenance 3.3 Oil Change
(Continue)
5. Check sealing ring of oil drain plug on damages and replace oil drain plug, if necessary.
6. Place oil drain plug (1700) in bore and screw tight.Tightening torque 66 Nm
7. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified(see page 3.3/2) in accordance with the operating specifications (see Annex).
8. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800).Tightening torque 150 Nm
Note
Please read the oil change intervals in chapter 3.1 and operating specifications in the annex!
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Maintenance 3.3 Oil Change
(Continue)
Illustration oil change R 120-3
with aluminium heat exchanger
1002 Heat exchanger oil drain plug
M 12 x 1,5Inhex.-head, w.a.f. 6, 25 Nm1700 Retarder oil drain plug M 22 x 1,5
Inhex.-head, w.a.f. 10, 66 Nm1800 Sealing ring A 30 x 36
renew1900 Oil filler/check plug M 30 x 1,5
Combined hex.-head, w.a.f. 24,150 Nm
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1800
1900
1002
1700
18011
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Maintenance 3.3 Oil Change
(Continue)
Note
For satisfactory retarder operation, it is important to adhere to the specified service filling(see table below) and to use only oils specified in the operating specifications (see Annex) foroperating the retarder in the relevant application.
* with slant mounted position of the retarder up toapprox. 4 - reduce service filling of approx. 0,25 Litre,
approx. 8 - reduce service filling of approx. 0,50 Litre.
The retarder oil temperature must be higher than 60 oC(operating temperature) for the oilto be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressureis acting on the retarder.The retarder and the ignition must have been switched off!
Type of heat exchanger Service filling * New filling *
Aluminium heat exchanger 5,5 l 6,0 l
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Maintenance 3.3 Oil Change
(Continue)
Job scope
Caution! Risk of injury!
The oil filler/check plug is hot! Oil temperature!
1. Push an oil collecting pan under retarder.
2. Screw out the oil filler/check plug (1900) and remove sealing ring (1800).
Caution! Risk of injury!
The oil-drain plugs are hot! Oil temperature!
3. Screw out the retarder oil drain plug (1700) and the heat exchanger oil drain plug (1002) and drainoil.
4. Check sealing ring of oil drain plug on damages and replace oil drain plug, if necessary.
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Maintenance 3.3 Oil Change
(Continue)
5. Place oil drain plug (1700 and 1002) in its appropriate bore and screw them tight.
Retarder oil drain plug (1700), Tightening torque 66 NmOil drain plug heat exchanger (1002), Tightening torque 25 Nm
6. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified(see page 3.3/6) in accordance with the operating specifications (see Annex).
7. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800).Tightening torque 150 Nm
Note
Please read the oil change intervals in chapter 3.1 and operating specifications in the annex!
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Diagnosis /
Troubleshooting
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4 Diagnosis / Troubleshooting
4.1 Troubleshooting Diagram...........................................................................4.1/1Troubleshooting Diagram A to D ................................................................................... 4.1/1Electrical Connections Diagram Variant 1 and 2 ........................................................... 4.1/6
4.2 Troubleshooting and Remedies .................................................................4.2/14.3 Illustration Control System .........................................................................4.3/1
4.4 Checking Supply-Air Pressure ...................................................................4.4/1
4.5 Checking Constant-Air Pressure ................................................................4.5/1
4.6 Checking Control Current of Proportional Valve ........................................4.6/14.7 Checking Temperature Adaption................................................................4.7/1
4.8 Checking Pressure Sensor.........................................................................4.8/1
4.9 Checking Pump Pressure...........................................................................4.9/1
4.10 Table of Measurements..............................................................................4.10/1
4.11 Operational Check......................................................................................4.11/1
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4.1 Troubleshooting Diagram
Illustration troubleshooting diagram main groups
Note
Before starting troubleshooting the oil level of the retarder must be checked and corrected, if necessary (see chapter 3.2 Checking Oil Level).It is important that the specific service filling is kept for a trouble-free operation of the retarder (see chapter 3.3 Oil Change and annex).
ComplaintR 120-3
Oil lossthrough
ventilation
Retarder
pilot light
Oil loss
input / outputside
No respectivelytoo insufficientretarder braking
effect
B
A
C
i i
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4.1 Troubleshooting Diagram
(Continue)
Illustration troubleshooting d iagram group A
Oil loss
through
ventilation
A
Checkretarder oil level
NOK OK
Yes No
Water in oil?(emulsion)
YesNo
Water in oil?(emulsion)
see chapter 7
Checkheat exchanger
ContactVOITH
OK NOK
Checkcasing ventilation
(chapter 6.2)
Replacecasing ventilaton
(chapter 6 2)
Check non-return valvein stainless steelheat exchanger
toohigh
toolow
Checkretarder oil level
Correct
retarder oil level
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4.1 Troubleshooting Diagram
(Continue)
Illustration troubleshooting d iagram group B
Retarderpilot light
B
NOKOK
NOKOK
Check temp. pick-up
(water, oil)and its electrical leads
(see chapter 4.7)
Check vehicle cooling
Check operation(during braking with
retarder nominal enginespeed, if possible)
Permanent lightin position 0after light test
Read outfault code
(see chapter 4.2)
Rectify fault anddelete fault memory
(see chapter 4.2)
Driver instruction
Temperatureadaptation
Replace
no function
ContactVOITH
flashes
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4.1 Troubleshooting Diagram
(Continue)
Illustration troubleshooting d iagram group C
Oil lossinput / output
side
C
NOYES
Water in oil
(emulsion)
Replaceheat exchanger(see chapter 8)
Checkradial shaft sealing ring on
input or output side(see chapter 6.7, 6.8)
If problem occours againafter a test trialcontact VOITH
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4.1 Troubleshooting Diagram
(Continue)
Illustration troubleshooting d iagram group D
Check oil level
of retarder
OK NOK
Yes No
Water in oil(emulsion)
YesNo
Water in oil(emulsion)
see chapter 7
Checkheat exchanger
Correct oil levelof retarder *
OK NOK
OKNOK
Checkp (dynamic)
(see chapter 4.9) NOKOK
Check proportionalvalve current
(see chapter 4.6)
NOKOK
Checktemperaturepick-up and
pressure sensor(chapter 4.7, 4.8)
Checkp (static)
(see chapter 4.5)y
Check supply-airpressure
(see chapter 4.4)
No respectivelytoo insufficientretarder braking
effect
D
ContactVOITH
ContactVOITH
C t t C t t
* If problem occours again after a test trialcontinue at "Checking casing ventilation"
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4.1 Troubleshooting Diagram
(Continue)
Electrical connections diagram variant 1 (spli tted connections of temperature pick-ups)
Electrical connections diagram variant 2 (united connection of temperature pick-up)
Pressure sensor + 5V
Stop light relais
Speed signal
Propvalve +
Output / low side 1 LS 1Output / high side HS 2
Output / high side 1 HS 1
Propvalve -
T 30 (Battery)
T 31 (Ground)
Stage switch+
ISO LISO K
Position 5Poition 4Position 3Position 2Position 1CAN-lowCAN-MasseCAN-high
T 15 (Ignition lock)
Switch valve -Switch valve +
Water temp.-Water temp.+
Oiltemp.+Oilltemp.-
ABSblue
white
white
white
black
rosa
pink
blue/white
blue/white
brown/whiteorange/white
orange/white
orange
orange
yellow/green
yellow/green
grey/black
grey
blueviolett
32
3
1211
10
151413181716
21654987
7
32165498
1654987
12
12pol.X3.
9pol.X2.
18pol.X1.
Digiprop
11
10
grey
brownbrown
beige
beige
redred
grey
grey
pinkblue
black/white
black/whiteyellow/green
Input / p.-down / PWM-in DID 4 Pressure sensor signal
Input / pull-down DID 3
Input / pull-up DIU 1Pressure sensor - GroundInput / pull-down DID 1Input / pull-down DID 2
Pilot light
violettviolett
Stop light relais
Speedom. signal
T 31 (Ground)
Position 5Position 4Position 3Position 2Position 1
T 15 (Ignition lock)
Propvalve +Propvalve -
Switch valve -Switch valve +
Water temp.-Water temp.+
Oil temp.+Oil temp.-
ABS
Pilot light
9 5 4 3 2 7 6 101112 13 1481
Connection 14 pole"Optional Functions"
"ISO Interface"Connection 4 pole
7653284
3 21 4
Stage switch +
"Stage switch"Connection 8 pole
+
+
Cable Retarder
Cable E-Fach
3
4
2
1Pin
orange
3 21 4
red/white
Connection 4 pole"Pressure sensor" 18017e
Prop valve +
Output / low side 1 LS 1Output / high side HS 2
Output / high side 1 HS 1T 30 (Battery)
T 31 (Ground)
Stage switch +ISO LISO K
Position 5Position 4Position 3Position 2Position 1CAN-lowCAN-GroundCAN-high
T 15 (Ignition lock)
3
121110
151413181716
7
32165498
18pol.X1.
Digiprop
T 31 (Ground)
Position 5Position 4Position 3Position 2Position 1
T 15 (Ignition lock)
Prop valve +
"ISO Interface"Connection 4 pole
765328
4
3 21 4
Stage switch +
"Stage switch"Connection 8 pole
+
Cable Retarder
Cable E-Fach
2
1Pinpink
white
black
blue/whiteorange/white
orange
brownbrown
beige
red
redgrey
pinkblue
black/whiteyellow/green
violettviolett
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(Continue)
Note
The retarder pilot light additionally has the function of a fault code:
Permanent light in position 0 - 5 of retarder stage switch
- slight fault
Braking is still possibleto limited extent.
- serious fault
Braking is no longer possible- the retarder is switched off.
Notice
If the ignition is switched off and on, the retarder is in operation again and the retarder pilot light goes off.If a serious fault remains present or reoccurs, the retarder switches off again and the retarder pilot lightcomes on permanently in position 0 to 5 of the retarder stage switch.
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18019
147101316
258111417
369121518
4.2 Troubleshooting and Remedies
(Continue)
Connector arrangement and pin assignment
Notice
All plugs il lustrated from plug-in side (i.e. leads at back).
Plug X1 Control unit
1 Not in use
2 Not in use3 Not in use4 Retarder stage swi tch , position 3 (or)5 Retarder stage swi tch , position 2 (b l)6 Retarder stage swi tch , position 1 (p i)7 Terminal 15 (rd)8 Retarder stage swi tch , position 5 (gr)9 Retarder stage swi tch , position 4 (wh)10 Retarder stage swi tch + ( vi)
11 ISO- interface, L- lead (or/wh)12 ISO- interface, K- lead (bl/wh)13 Connected w ith terminal 15 (b l)14 Not in use15 Terminal 31 (br)16 Output / high side 2 HS2 (bl/wh)17 Output / low side 1 LS1 ( ye/gr )18 Output / high side 1 HS1 (be)
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Plug X2 Control unit
1 Not operational (or)2 Proportional valve - (gr)3 Proportional valve - (pi)4 Cooling water temperature pick-up - (b l)
5 Cooling water temperature pick-up + (ye/gr)6 Not operational/ground (be)7 Not in use8 Oil temperatur e pi ck-up - (wh)9 Oil temperatur e pi ck-up + (vi)
Plug X3 Control unit
1 Input / pull up DIU 1 (wh)2 Speedometer signal (bl)3 ABS-Signal (bl/wh)4 Input / pull down DID 2 (br/wh)5 Input / pull down DID 1 (bl/wh)
6 Pressure sensor ground (pi)7 Pressure sensor signal voltage (gr/bl)8 Retarder pi lot light (ye/gr)9 Input / pull down DID 3 (or/wh)10 Pressure sensor supply voltage (rd/wh)11 Stop light relay (or)12 Input / pull down / PWM-in DID4 (gr)
18020
147
258
369
18021
14710
25811
36912
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(Continue)
Extra o perations plug
1 Retarder stage switch + (vi)2 Input / pull down DID 1 (bl/wh)3 Input / pull down DID 2 (br/wh)4 Input / pull down DID 3 (or/wh)
5 Input / pull down / PWM -in DID 4 (gr )6 Input / pull up DIU 1 (wh)7 Pressure sensor ground (pi)8 Pressure sensor signal voltage (gr/bl)9 Pressure sensor supply vo ltage (rd/wh)10 Output / high side 1 HS1 (be)11 Output / high side 2 HS2 (bl/wh)12 Output / low side 1 LS1 ( ye/gr )13 Terminal 15 (rd)
14 Terminal 31 (br)
ISO-Interface plug
1 K-lead (bl/wh)2 L-lead (or/wh)3 Terminal 15 (rd)4 Terminal 31 (br)
2
1
4
3
6
5
8
7
10
9
12
11
14
13
18022
2 1
4 3
18023
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Bajonet socket cooling-water temperature pick-up
Variant 1
1 Cooling-water temperature pick-up + (ye/gn)2 Cooling-water temperature pick-up - (bl )3 Not operational
4 Not operational
Plug cooling-water temperature pick-up
Variant 2
1
2
3
4
18024
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Proportional valve plug
1 Proportional valve + (pi)2 Proportional valve - (gr)3 Not operational4 Not operational
Retarder stage switch plug
1 Not in use2 Position 5 - (gr)3 Position 4 - (wh)4 Retarder stage switch + (vi)5 Position 3 - (or)
6 Position 2 - (bl)7 Position 1 - (pi)8 Bridge to pin 4
18026
1 2 3 4
5 6 7 8
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1
2
3
4
18024
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(Continue)
Plug pressure sensor
1 Pressure sensor - 5V (rd/wh)2 Pressure sensor - Signal (gr /b l)3 Not in use4 Pressure sensor - ground (pi)
1
2
3
4
18024
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(Continue)
A. With fault code
Special tool
Commercially available tool
Note
The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-outfrom the fault memory.
Additionally a diagnosis via PC-Software DigiDia and PC-Interface is possible.Therefore, please contact VOITH TURBO or one of our service partner.
Multimeter recommended: Fluke 87
53.8224.10
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Fault memory readout via retarder pilot light b linking code
Note
If several faults have been stored in the memory, they are output in the sequence of their occurence, butalways only one fault per triggering.
Before and after each output of the blinking code you have a break of 3 seconds. The retarder pilot lightis off during this break.
If an actual fault is available (before triggering the blinking code the retarder pilot light is switched ON)the retarder pilot light switches to permanent light again after the blinking code.Is only one stored fault available, the retarder pilot light is OFF after the output.
The number of tens units first indicated as long ON time: each 2 secondsThe number of single unit then is indicated as short ON time: each 0,5 secondsBreaks between each ON time: each 1 second
Excerption:
The fault Coding faulty is not stored, but the blinking code is displayed.
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There are two possibilities for activating the blinking code:
a) Fault memory readout via retarder pilot light blinking code
During the service function (speed = 0, ignition OFF, ignition ON) the blinking code can be displayed
by using the retarder pilot light:
1. Retarder stage switch - engage position 02. Retarder stage switch - engage position 1 ( 2 seconds)3. Retarder stage switch - engage position 04. First fault as blinking code output5. Repeat working step 1 to 3 for further blinking code outputs
b) Fault memory readout via service cable
Requirements
Retarder stage switch in position O.
Vehicle at standstill, ignition ON
1. Service interface L-lead connected to ground 2s. For this pupose, press L - push button atservice cable.
2. First fault as blinking code output.3. Repeat working step 2 and 3 for further blinking code ouputs
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18027
2
sec
1
sec
1
sec
1
sec
1
sec
2
sec
0,
5
sec
0,
5
sec
0,
5
sec
Display example for fault code 23
E Retarder pilot light ONA Retarder pilot light OFFt Time
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Delete fault memory
No read outs according to fault memory.
1. Ignition: OFF
2. Service interface L-lead connected to ground.For this pupose, press L - push button at service cable.
3. Ignition: ON
4. Disconnect L-lead of ground after more than 2 seconds.
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Notice
Meaning of entries in Measurement/test connection column: X 1/15 X3/11 Pin 15 to plug X1,Multimeter set for Ohms, Pin 11 to plug X3
1) X 1/15 = ground control unit2) Only, if no fault is recognizable after a complete check of the periphery: change control unit.
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection1 )Result/
Set point
Cause/
Remedy 2)
Code Test step
01 Stop light relay/
Short circuit toground
slight 1 s - Ignition: OFF
- Pull plug X3 out ofcontrol unit
X 3/11 X 1/15 Relay is
installed:250-350
Check lead, plugs
and relay orconsumers
02 LS 1 output
Short circuit tobattery
slight 400 ms - Ignition: OFF- Pull plug X1 out of
control unit- Disconnect plug for extra operation
(e.g. lamp orrelay)
- Ignition: ON
X 1/17 VX 1/15 0 V Check lead, plugsand relay orconsumers
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
03 HS 1 output
Short circuit
slight 1 s - Ignition: OFF- Pull plug X1 out of
control unit
X 1/18 X 1/15 Relay isinstalled:250-350
Check lead, plugsand relayor consumers
04 HS 2 output
Short circuit
slight 1 s - Ignition: OFF- Pull plug X1 out of
control unit
X 1/16 X 1/15 Relay isinstalled:250-350
Check lead, plugsand relayor consumers
05 Terminal 15
Undervoltage
serious 60 s - Ignition: OFF- Pull plug X1 out of
control unit- Ignition: ON
X 1/7 VX 1/15 17,5 V Check lead, plugsand 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 VX 1/15 32,5 V Checking electricalinstallation of vehicle(see manufacturerinstructions)
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* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
08
09
Cooling-watertemperaturepick-up
Discontinuity /Short circuit tobattery
serious/slight *
1 s - Ignition: OFF- Pull plug X2 out of
control unit
X 2/5 X 2/4 20C 10C =1039 - 1117
60C 10C =1099 - 1271
80C 10C =1271 - 1347
Notice:
The measuringin one tempera-ture rangenormally issufficient.
Check lead andtemperature pick-up
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* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
11
12
Oil temperaturepick-up
Discontinuity /Short circuit tobattery
serious/slight *
1 s - Ignition: OFF- Pull plug X2 out of
control unit
X 2/9 X 2/8 20C 10C =1039 - 1117
60C 10C =1099 - 1271
80C 10C =1271 - 1347
Notice:
The measuringin one tempera-ture rangenormally issufficient.
Check lead andtemperature pick-up
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
13 1 Retarder stageswitchUndefinedswitch state
serious 100 ms - Ignition: ON- Retarder stage switch:
Position 0
X 1/10VX 1/15
X 1/6VX 1/15X 1/5 VX 1/15X 1/4VX 1/15X 1/9VX 1/15X 1/8VX 1/15
17,5 V
0 V0 V0 V0 V0 V
Check lead, plug andretarder stage switch
13 2 - Ignition: ON- Retarder stage switch:
Position 1
X 1/10VX 1/15X 1/6VX 1/15
X 1/5VX 1/15X 1/4VX 1/15X 1/9VX 1/15X 1/8VX 1/15
17,5 V 17,5 V
0 V0 V0 V0 V
Check lead, plug andretarder stage switch
13 3 - Ignition: ON
- Retarder stage switch:
Position 2
X 1/10VX 1/15
X 1/6VX 1/15X 1/5 VX 1/15
X 1/4 VX 1/15X 1/9 VX 1/15X 1/8 VX 1/15
17,5 V
17,5 V 17,5 V
0 V0 V0 V
Check lead, plug and
retarder stage switch
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(Continue)
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
13 4 - Ignition: ON- Retarder stage switch:
Position 3
X 1/10 VX 1/15X 1/6VX 1/15X 1/5 VX 1/15X 1/4 VX 1/15
X 1/9VX 1/15X 1/8VX 1/15
17,5 V
17,5 V
17,5 V
17,5 V
0 V0 V
Check lead, plug andretarder stage switch
13 5 - Ignition: ON- Retarder stage switch:
Position 4
X 1/10VX 1/15X 1/6VX 1/15X 1/5 VX 1/15X 1/4 VX 1/15X 1/9 VX 1/15
X 1/8 VX 1/15
17,5 V 17,5 V
17,5 V
17,5 V
17,5 V
0 V
Check lead, plug andretarder stage switch
13 6 - Ignition: ON
- Retarder stage switch:Position 5
X 1/10VX 1/15
X 1/6VX 1/15X 1/5 VX 1/15X 1/4 VX 1/15X 1/9 VX 1/15X 1/8 VX 1/15
17,5 V
17,5 V 17,5 V
17,5 V
17,5 V
17,5 V
Check lead, plug and
retarder stage switch
Aftersales Service Manual VOITH Retarder 120-3Page 4.2/18
Diagnosis / 4.2 Troubleshooting and Remedies
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Diagnosis /
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4.2 Troubleshooting and Remedies
(Continue)
Fault Fault text Fault
class
Trigger time Requirement / Operati-
on
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
14 Retarder stageswitchShort circuit tobattery
serious 10 s - Ignition: OFF- Pull plug X1 out of
control unit- Ignition: ON- Retarder stage switch:
Position 0
X 1/10VX 1/15 0 V Check lead andplug
15 Retarder stage
switchShort circuit tobattery
serious 1 s - Ignition: OFF
- Pull plug X1 out ofcontrol unit
- Retarder stage switch:Position 5
X 1/10X 1/15 Resistor
infinite
Single check of
stages forshort circuit
16 SpeedometersignalDiscontinuity
serious 2 s - Ignition: ON X 3/2VX 1/15 1 V Check lead andspeedometer
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Diagnosis /
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4.2 Troubleshooting and Remedies
(Continue)
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
18 Speedometer signal
Short circuit to battery
serious 2 s - Ignition: OFF- Pull plug X3 out of
control unit- Ignition: ON
X 3/2VX 1/15 9 V Check lead andspeedometer
19 ABSShort circuit to ground
serious 60 s - Ignition: ON X 3/3VX 1/15 3,5 V Check lead,relay andABS-control unit
21 ABS-Signal undefined serious 60 s - Ignition: ON X 3/3VX 1/15 16,5 V Check lead,relay andABS-control unit
22 Internal faultABS-current path
serious 1 s - - - Replace controlunit
23 Proportional valveFault No. 1:
Short circuit to battery
serious 1 s - Ignition: OFF- Pull plug X2 out of
control unit- Ignition: ON
X 2/3VX 1/15 10 V Check lead
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(Continue)
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
24 1 Proportional valveFault No. 2:- Short circuit proportional
valve magnetic- Short circuit connection
lead proportional valve- Discontinuity proportio- nal valve magnetic
Valve magnetic- Discontinuity connec- tion lead proportional
valve- Short circuit to ground at proportional valve- Prop.- and shift valve
interchanged
serious 1 s - Ignition: ON- Pull plug X2 out of control unit
X 2/2X 2/3 18-25 Check lead andproportionalvalve(valve block)
24 2 - Ignition: OFF- Pull plug X2 out of control unit
X 2/3X 1/15 Resistorinfinite
Check lead andproportionalvalve(valve block)
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Troubleshooting
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
29 Fault control unit serious 180 ms Replacecontrol unit
31 Control unit:Coding fault
serious 100 ms Provide new para-meters for controlunit
32 Retarder pilot light:Discontinuity /
Short circuit to ground
serious 3 s - Ignition: OFF- Pull plug X3 out of
control unit- Ignition: ON
X 3/8VX 1/15 17,5 V Check lead,retarder pilot
light and fuse
33 Retarder pilot light:Short circuit to battery
serious 3 s - Ignition: ON- Retarder stage
switch:Position 1
X 3/8VX 1/15 2 V Check lead andretarder pilotlight
35 Fault control unit serious 500 ms / 123 s Replace
control unit
37 Fault foot operation slight 100 ms / 1 s Check installationaccording toOEM- e.g.Voith instructions
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Troubleshooting
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
38 1 Fault Constant-airpressure
slight 1 s to 10 s Ignition: ONPosition 0
X 3/7 VX 1/15
X 3/10VX 1/15
0 bar =0,3-0,7 V
2,5 bar=2,8 - 3,2 V
4,75-5,25 V
Pressure pick-upWiring harness
At deviations:
Step 2
2 Troubleshooting inwiring harness,pressure pick-up,proportional valve,supply-air pressure,ECU (contact VOITHTURBO)
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(Continue)
B. Without fault code
Note
Retarder faults without fault code are not recognized electronically.
Aftersales Service Manual VOITH Retarder 120-3Page 4.2/25
Diagnosis /
Troubleshooting
4.3 Illustration Control System
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Illustration checking control system
Note
The reference numbers indicated in Section 4.3are not identical with the reference numbers of
the spare parts li sts.
1 Heat exchanger2 Con tro l un it
11 Proportional valve
current connection19 Temperatur pick-up cooling water
alternative: positions 19 and 20joining in the central-plug
(see electrical diagram Version 2)20 Temperature pick-up oil21 Proportional valve25 Constant-air pressure line py
(Connection A)26 Supply-air pressure line pv
(Connection P)
31 Compressed air line(pressure regulator - four-circuitprotection valve)
32 Compressed-air pressure line
(four-circuit protection valve -air tank for auxiliary equipmentwith test connection
33 Compressed-air line(brake circuit No. 1)
34 Compressed-air line(brake circuit No. 2)
35 Compressed-air line
(parking brake)37 Ventilation line R39 Electrical lead (cooling-water
temperature pick-up to control unit,2 wires)
40 Electrical lead (oil temperature
pick-up to control unit, 2 wires)61 Four-circuit protection valve71 Air tank for auxiliary equipment
P
A
7132
33
31
3435
61
39
19
1
40
202
25
11
21
26
18028
Diagnosis /
T bl h i
4.4 Checking Supply-Air Pressure
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Troubleshooting
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Checking supply-air pressure pv
1. Connect test pressure gauge (99/1) to test connection of compressed-air line (32)(four circuit protection valve - air tank for auxiliary equipment) and check supply-air pressure pv.
Minimum pressure 6 bar
Maximum pressure 11 bar
Note
If the pressure is not within the specified range, the service brake must be checked to the manufacturer sdata.
Aftersales Service Manual VOITH Retarder 120-3Page 4.4/1
1802932
Diagnosis /
T bl h ti
4.5 Checking Constant-Air Pressure
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Troubleshooting
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Requirements for check
Retarder stage switch in position 0
Vehicle ignition system OFF
Special tool
Compressed-air gauge0 to 6 bar
53.1403.10
Aftersales Service Manual VOITH Retarder 120-3Page 4.5/1
Diagnosis /
Troubleshooting
4.5 Checking Constant-Air Pressure
(Continue)
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Troubleshooting
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(Continue)
Job scope test
1. Screw out oil filler/check plug M 30x1,5 (1900) and remove sealing ring (1800).
2. Connect pressure gauge (99/7) to the retarder housing.
3. Shift the retarder stage switch to switch position 5 and compare read-off value with the given valuesof the constant-air pressure pyon table in chapter 4.10.
4. Screw oil filler/check plug (1900) tight with new sealing ring (1800).
Tightening torque 150 Nm
1800
1900
18030
99
99/7
18031
99/7 Pressure gauge 53.1403.10
Aftersales Service Manual VOITH Retarder 120-3Page 4.5/2
Diagnosis /
Troubleshooting
4.6 Checking Control Current of Proportional Valve
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Troubleshooting
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Requirements for check
Battery voltage 18 - 32 V Vehicle electrical system checked in accordance with the Owner s Manual for the vehicle and found
satisfactory. Fuse for retarder control unit checked and found satisfactory. Plug at proportional valve and socket for damage as well as wear (notch scratches) checked and
found satisfactory.
Special tool
Measuring adapter
Commercially available tool
Multimeter recommended: Fluke 87
53.8198.10
Aftersales Service Manual VOITH Retarder 120-3Page 4.6/1
Diagnosis /
Troubleshooting
4.6 Checking Control Current of Proportional Valve
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(Continue)
Job scope
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 or A
4. Turn switch Propvalve at measuring adapter (99/3) in position I .
5. Shift the retarder stage switch in position 5 and compare the read-off value with the given valuesof the control current of the proportional valve in accordance with the tables (see page 4.10).
Notice
If the control current is reached but the constant-air pressure pyis not, there are either outer leakyness,or the proportional valve is defective and must be renewed.If both values are not reached, please read chapter 4.2 Troubleshooting and Remedies.
99/3 Measuring adapter Propstrom 53.8198.10
98/8 Multimeter
Aftersales Service Manual VOITH Retarder 120-3Page 4.6/2
18032
98/8
99/3
21
Diagnosis /
Troubleshooting
4.7 Checking Temperature Adaption
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Troubleshooting
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Requirements for check
Battery voltage 18 - 32 V
Vehicle ignition system OFF
Pressure gauge constant-air pressure (99/7) connected
Connected measuring adapter (99/3)
Vehicle electrical system checked in accordance with the Owners Manual for the vehicle and
found satisfactory. Fuse for retarder control unit checked and found satisfactory.
Special tool
Temperature- Adapter cable
simulator
Aftersales Service Manual VOITH Retarder 120-3Page 4.7/1
Wasser l
53.8207.10 53.8279.10
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Diagnosis /
Troubleshooting
4.7 Checking Temperature Adaption
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(Continue)
Job scope test
Prior job
Ignition ON
1. Set the rotary switch of the temperature simulator (99/2) to 95C cooling water temperature and
165C oil temperature operate the retarder at the highest stage.The constant-air pressure pyand the control current must reach the values (see page 4.10/1).
2. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. Theconstant-air pressure pymust drop temporary below the set maximum value. Set rotary switch ofthe temperature simulator (99/2) to 125oC cooling water temperature. There must be no more out-put of constant-air pressure py.
3. Ignition OFF
4. Reconnect ellectrical connection to temperatur pick-ups for cooling-water (39) and oil (19).
5798/5
99/2
18033
99/2 Temperature simulator 53.8207.10
Aftersales Service Manual VOITH Retarder 120-3Page 4.7/3
Diagnosis /
Troubleshooting
4.8 Checking Pressure Sensor
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Requirements for check
Ignition OFF Pressure gauge constant-air pressure connected Retarder stage switch in position 0
Special tool
Measuring adapter
Commercially available tool
Multimeter recommended: Fluke 87
53.8198.10
Aftersales Service Manual VOITH Retarder 120-3Page 4.8/1
Diagnosis /
Troubleshooting
4.8 Checking Pressure Sensor
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( )
Job scope test
1. Disconnect plug from pressure pick-up (38) and connect to measuring adapter (99/3).
2. Connect plug of measuring adapter (99/3) to pressure sensor (38).
3. Connect ground lead of multimeter (98/8) to measuring plug 4 of the adapter (99/3).
4. Turn switch Propvalve at measuring adapter (99/3) downwards (not in position I ).
5. Connect the positive lead of multimeter to measuring plug 1.
6. If ignition is ON, the measured voltage must be between 4,75 and 5,25 V.
7. Connect the positive lead of multimeter to measuring plug 2.
8. Compare measured voltage in dependency of the constant-air pressure with the following values :0 bar = 0,3 - 0,7 V2,5 bar = 2,8 - 3,2 V
9. Ignition OFF
10. After removing the measuring adapter, connect again electrical lead with pressure sensor (38).
Aftersales Service Manual VOITH Retarder 120-3Page 4.8/2
18034
98/8
99/3
38
18035
98/8
99/3
38
Measurements of the signal voltage atmeasuring plug 2 and measuring plug 4
Measurements of the supply voltage at
measuring plug 1 and measuring plug 4
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Diagnosis /
Troubleshooting
4.9 Checking Pump Pressure
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Preconditions for test
Constant-a ir pressure (py) checked and found satisfactory No outer leakages at the retarder
Caution! Risk of injury!
The screw plug is hot!
Job scope
1. Screw out hex.-head screw M12x1,5 (101) at retarder housing.
2. Connect up pressure gauge (99/1) to retarder housing.
99/1
18037
99/1 Pressure gauge 53.4788.10
Aftersales Service Manual VOITH Retarder 120-3Page 4.9/2
Diagnosis /
Troubleshooting
4.9 Checking Pump Pressure
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Job scope dynamic
1. Drive the vehicle with a prop shaft speed of vps = 1000 r.p.m..Engage direct gear (gear ratio 1:1), and drive with an engine speed of 1000 r.p.m..
2. While on the move, shift the retarder stage switch (16) to position 5 and read dynamicpump pressure off test pressure gauge (99/1) at prop shaft speed vps= 1000 r.p.m..
3. Compare read-off pump pressure with the value of dynamic pump pressure according to the table(see page 4.10/1).
Caution!
If the setpoint is obtained in the test at a standstill (see chapter 4.5), but the minimum value is notreached in the dynamic test, please contact VOITH TURBO!
Caution! Risk of injury!
The screwings of the pressure gauge and retarder are hot!
4. Disconnect the pressure gauge.
5. Check sealing ring of screw plug on damages; renew screw plug, if necessary.
6. Screw screw plug (101) tight.Tightening torque 25 Nm
Aftersales Service Manual VOITH Retarder 120-3Page 4.9/3
Diagnosis /
Troubleshooting
4.10 Table of Measurements
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The data represent the state of the art at the time of going to print.The manufacturer reserves the right to m ake further modifications.
1) The code number is to be found on the control unit.2) If a commercially available multimeter is used for measurements (without real effective measuring),
exact readings cannot be made ( indication jumps).3) Decisive is the pressure which has built up itself after 10 seconds (stabilized, constant pressure).4) Retarder stage switch in highest braking stage.5) As a result of permanent readjustments in the control circuit, the values may under circumstances
not be constant (but within the specified range).
Setting [Nm] Code Number 1 ) Control current [mA]2) 4) 5) Constant-air pressure py3) 4)
(static)
set point [bar]
Pump pressure dynamic 4)
vps = 1000 r.p.m.
minimum value [bar]
1500 034 376 - 576 1,75 2,05 12
1750 035 396 - 596 2,05 2,35 14
2000 036, 054 416 - 616 2,35 2,65 16
Aftersales Service Manual VOITH Retarder 120-3Page 4.10/1
Diagnosis /
Troubleshooting
4.11 Operational Check
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Requirements for check
Battery voltage 18 - 32 V Electrical system checked in accordance with the Owner s Manual for the vehicle
and found satisfactory. Constant-air pressure 6 -11 bar Retarder oil level satisfactory
The following operational states are indicated by the retarder pilot light (arrow):
Retarder pilot light without indication
The retarder is switched off. There is no fault in the memory.
Retarder pilot light permanently on
The retarder is switched on, i.e., one of the four possible retarder braking stages orConstant Speed operation has been selected with the retarder stage switch.
The retarder pilot light additionally has the function of a fault indicator.
The retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch.- slight fault
Braking operations are possible (the retarder operates with limited braking torque).
- serious faultThere are no more braking operations possible - the retarder is switched off.
Aftersales Service Manual VOITH Retarder 120-3Page 4.11/1
R
18038
Diagnosis /
Troubleshooting
4.11 Operational Check
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Note
If the ignition is switched off and on again, the retarder is in operation and the retarder pilot lightis going off.If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on in
position 0 to 5 of the retarder stage switch.
Retarder pilot light f lashes
- while the retarder is braking
The temperature limitation is functioning, the retarder cuts back its braking torque.
This flashing function only is realized at defined control variants!
Aftersales Service Manual VOITH Retarder 120-3Page 4.11/2
Diagnosis /
Troubleshooting
4.11 Operational Check
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Test step Scope of check Requirement /
Operation
Result / Set point Note, Cause / Remedy
1 Retarder pilot light Ignition: ON Retarder pilot light comes on and
goes off after approx. 5 sec.
Retarder pilot light does not comeon, or does not go off.
Retarder pilot light trouble-free
Troubleshooting as on page 4.1/1
2 Retarder Vehicle on move- Shift retarder stage
switch to stage 1 to 5.
Retarder pilot light comes on,retarder brakes in stages 1 to 5.
Retarder pilot light does not come
on, or retarder does not brakeproperly.
Retarder operates trouble-free.
Troubleshooting as on page 4.1/1
Aftersales Service Manual VOITH Retarder 120-3Page 4.11/3
Retarder, Remo-
ving, Installing
5 Removing, Installing Retarder
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5.1 Removing, Installing Retarder (Gearbox Attachment)................................5.1/1
Aftersales Service Manual VOITH Retarder 120-3Page 5/1
Retarder, Remo-
ving, Installing
5.1 Removing, Installing (Gearbox Attachment)
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To install the retarder 120-3 according to regulations to the gearbox or to remove from the gearbox,specific working steps requiring special tools have to be carried out!
Caution!
Observe Voith-Installation instructions and gear-box specific installation instructions.These have to be requested from Voith Turbo.Should these installation instructions be disregarded, the retarder may be completely wrecked!
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Repair Gearbox
Attachment
6.1 Assembly Overview (Retarder Basic Group)
3200
Illustration assembly overview (retarder basic group) for attachment to DaimlerChrysler gearbox G0160 and G0210
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1900
1800
700 850 800
900
2500
28002700
2600
2300
2300/3
2300/22301
2300/1
4300
4500
44004600
101
1100
1000
1200
1300
17001500
1400
2900
3200
3100
3000
3700
18039
3500
3600
101 Screw plug M12x1.5
hexagonal recess, w.a.f. 6, 25 Nm700 Radial shaft sealing ring (80x100x10)800 Labyrinth cover850 O-ring 125x2.5
2300/2 Float body
2300/3 Float cage2301 O-ring 55x32500 Screening plate2600 Spacer D50/42x15.5
Repair Gearbox
Attachment
6.1 Assembly Overview (Retarder Basic Group)
(Continue)
Illustration assembly overview (retarder basic group) for attachment to ZF gearbox S6-1600 and S6-85
3200
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1900
1800
700 850 800
900
2500
28002700
2600
2300
2300/3
2300/22301
2300/1
101
1100
1000
1200
1300
17001500
1400
2900
3200
3100
3000
3700
18040
3500
3600
101 Screw plug M12x1.5hexagonal recess, w.a.f. 6, 25 Nm
700 Radial shaft sealing ring (80x100x10)800 Labyrinth cover850 O-ring 125x2.5900 Hex.-head screw M8x25, w.a.f. 13, 30 Nm
2300/2 Float body2300/3 Float cage
2301 O-ring 55x32500 Screening plate2600 Spacer D50/42x15.52700 Washer B6.4
Repair Gearbox
Attachment
6.2 Checking, Removing and Installing
Casing Ventilation
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Illustration casing ventilation
Prior jobs
Retarder stage switch in switch position 0 Igni ti on OFF Proportional valve and adapter plate
removed (see chapter 8.1 and 8.2)
2300 Casing ventilation2300/1 Valve insert2300/2 Float checking, renew if necessary2300/3 Float cage
2301 O-ring, 55 x 3, renew,coat of silicone-free andnon-corrosive greasefor installation
2500 Cover p late2600 Spacer2700 Washer, B 6,42800 Hex.-head screw M 6 x 12
Inhex.-head, w.a.f. 5, 10 Nm2900 Cover
3000 Partion metal sheet with gasket,renew3100 Washer B 6,43200 Cap screw M 6 x 30
Inhex.-head, w.a.f. 5, 10 Nm
Aftersales Service Manual VOITH Retarder 120-3Page 6.2/1
2500
2800
2700
2600
2300
2300/3
2300/2
2301
2300/1
2900
3200
3100
3000
18041
Repair Gearbox
Attachment
6.2 Checking, Removing and Installing
Casing Ventilation (Continue)
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8/11/2019 Transmisso Voith Retarder 120-3 131 Pag.
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cbtd 2000-0153.2688.10
Special tools Tool for local fabrication
Note
The tool for local fabrication can also be ordered from Voith Turbo - Voith code number 67.2757.10.
Lubricants and cleaning agents
Mesh strainer Benzine
O-ring Sil icone-free and
non-corrosive grease
Float Methylated Spirit
53.7712.10 53.9428.10
Aftersales Service Manual VOITH Retarder 120-3Page 6.2/2
40,5 mm
7mm
60 mm
18042e
Material: St 37
Weight: 0,085 kg
Repair Gearbox
Attachment
6.2 Checking, Removing and Installing
Casing Ventilation (Continue)
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8/11/2019 Transmisso Voith Retarder 120-3 131 Pag.
95/131
cbtd 2000-0153.2688.10
To remove
1. Screw out hex.-head screws (3200).
2. Remove washer (3100).
3. Remove the cover (2900) from the retarder housing.
4. Remove the partion metal sheet with gasket (3000) and clean the sealing surface at the cover andthe retarder housing.
5. Screw out hex.-head screws (2800) and remove Washer (2700).
6. Remove cover plate (2500).
7. Remove spacer (2600).
8. Use the impact puller (99/5) and adapter (98/7) to extract the casing ventilation (2300).
9. Extract the valve insert (2300/1) from float cage (2300/3).
10. Lever O-ring (2301) out of the groove of the valve insert (2300/1).
Aftersales Service Manual VOITH Retarder 120-3Page 6.2/3
2300