transmissão voith retarder 115 e 147 pag

8/11/2019 Transmissão Voith Retarder 115 E 147 Pag.

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Aftersales Service Manual Voith Retarder 115 E

15300009710 / cbtsd 02-11

Aftersales Service ManualVoith Retarder 115 E



Table of Content

Table of Content


15300009710 / cbtsd 02-11

1. Preface.................................................................................. 4

2. General ................................................................................. 92.1 Assembly Overview .................................................................................... 102.2 Retarder Data Plate .................................................................................... 122.3 Data Plate of Retarder-Control Unit ............................................................ 132.4 Function- and Operation Scheme ............................................................... 15

3. Maintenance ....................................................................... 193.1 Maintenance Work / Oil Change Intervals .................................................. 203.2 Inspection of Oil Level................................................................................. 233.3 Oil Change .................................................................................................. 26

4. Diagnosis / Troubleshooting ............................................... 324.1 Electrical Connections Diagram.................................................................. 334.2 Overview of Control Parts........................................................................... 374.3 Troubleshooting Diagram............................................................................ 384.4 Troubleshooting and Remedies.................................................................. 414.5 Checking Supply-Air Pressure (p v) ............................................................. 77

4.6 Checking Constant-Air Pressure (p y) and Pump Pressure (p dyn )............... 784.7 Checking Control Current of Proportional Valve ......................................... 864.8 Checking Pressure Sensor ......................................................................... 884.9 Checking Temperature Adaption ................................................................ 904.10 Table of Measurements .............................................................................. 93



Table of Content

Table of Content


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

6. Repair Retarder ................................................................ 1106.1 Overall Illustration of Main Components ................................................... 1116.2 Removing, Checking and Installing Casing Ventlation ............................. 1126.3 Removing, Cleaning and Installing Silencer ............................................. 1226.4 Removing and Installing Water Neck........................................................ 123

6.5 Removing, Checking, Installing Heat Exchanger...................................... 1246.6 Removing, Installing Oil Tank Cover......................................................... 1336.7 Removing, Installing Non-Return Valve Outlet ......................................... 136

7. Control Parts ..................................................................... 1397.1 Removing, Installing Proportional Valve and Damping Plate.................... 140

7.2 Removing, Installing Temperature Sensor Cooling Water........................ 1417.3 Removing, Installing Temperature Sensor Oil .......................................... 1427.4 Removing, Installing Pressure Sensor...................................................... 143

8. Appendix........................................................................... 1448.1 Retarder Data Sheet ................................................................................. 145

8.2 Tightening Torques ................................................................................... 146



Preface

Preface


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1. Preface

This Aftersales Service Manual provides information and instructions on maintenance and repairof the Voith Retarder 115 E. These instructions present the basis for performing appropriate andexpert maintenance and repair.

It is indispensable that you observe the safety instructions and warning notes in this manual.

Nevertheless, the user is obliged to exercise pertinent and professional care when handling

machines, aggregates and hot media such as for example oil or water.

Attention!

... points out safety instructions and warning notes where persons are endangered, quality of work-manship is reduced or property damage may occur.

Notice

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



Preface

Preface


15300009710 / cbtsd 03-01

Attention!

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

• Make sure that the retarder is fully functional during all vehicle manoeuvres!

Non-observance may inflict damages to the retarder!

• When towing the vehicle, the following restrictions apply for the retarder:

- tow distance: up to 100 km

- towing speed: max 40 km/h.

• The activated retarded may not be used as parking brake!

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

• Unauthorized changes to the retarder, the use of spare parts, accessories, attachments and spe-

cial features not tested and released by Voith may negatively affect the security of the entire ve-hicle. Voith does not assume any liability for damages arising as a result.



Preface

Preface


15300009710 / cbtsd 03-01

Attention!

• The retarder is constructed according to the state of the art in technology and acknowledgedsafety regulations. Nevertheless, hazardous situations and property damages may occur duringimproper use, maintenance and repair.

• Therefore, Voith is not capable of warning the user in this Aftersales Service Manual about anysituation conceivable in which he may suffer injuries and/or cause damage to the retarder. As aconsequence, it is indispensable that any person engaged in operation, servicing, maintenance

and repair of the retarder does not endanger his or her personal safety with the work and thatthe retarder is not affected adversely, particularly with regard to the safety regulations.

Voith assumes no liability for personal and/or property damage caused by improper andunprofessional work.

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

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



Preface

Preface Seite 7


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Notice

• The item numbers used in this documentation are the same as the item numbers in the spareparts lists.

Exception :

Items and components with one- or two-digit item numbers are no spare parts and therefore arenot included in the spare parts lists.

Also items and components with dash numbers are no spare parts and therefore not included inthe spare parts lists.

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

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

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

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

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

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



Preface

Preface Seite 8


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If you have any questions or if you are uncertain about work steps, which are not described in thisdocumentation, please ask your contact person responsible for your country or contact:

Voith Turbo GmbH & Co. KG

Department Retarder

PO box 1555

D-74555 Crailsheim

Phone: ++49 +7951 / 32-0

Fax: ++49 +7951 / 32-756

E-mail: [email protected]

Direct dials:

Customer service line and spare parts:32-401

32-422

32-1860



General

General


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2. General

2.1 Assembly Overview .................................................................................... 102.2 Retarder Data Plate .................................................................................... 122.3 Data Plate of Retarder-Control Unit ............................................................ 132.4 Function- and Operation Scheme ............................................................... 15



General – Assembly Overview


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Illustration: Voith Retarder R115 E

2.1 Assembly Overview

Basic Group with Heat Exchanger4100

100

6400

3700

11001

100 Retarder housing

3700 Proportional valve

4100 Oil filler plugM 30 x 1,5

6400 Heat exchanger





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Basic Group with Heat Exchanger

Illustration: Voith Retarder 115 E

11002

103

107

4200

3700

6400

3500

5500/1103 Screw plug

M 12 x 1,5

107 Oil drain plugM 24 x 1,5

3500 Screw plug with sieveM 30 x 1,5


4200 Oil drain plugM 24 x 1,5

5500/1 Ventilation

6400 Heat exchanger



General – Retarder Data Plate


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General – Retarder Data Plate

Illustration: Retarder Data Plate

2.2 Retarder Data Plate

The data plate is mounted on the left below ofthe retarder housing in right direction of tra-velling.

The following details are on the data plate:

a

d

e f

b

Voith-item-No

c

Type R 115 E

11003e

Serial No

Year of Man.

Cust. item No

Kd.-Sach-Nr.

Voith-Sach-Nr.

a) Type of Retarder

b) Serial number6-digit number

c) Year of manufacturing

d) Retarder ratio (i Ret )

e) Customer-item number

f) Voith-item number8-digit number

Notice

Please, always quote the retarder data whensubmitting queries or ordering spare parts.

In this case a quick and working is possible.



General – Data Plate of Retarder-Control


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Illustration: Data Plate of Retarder Control Unit Digiprop

2.3 Data Plate of Retarder-Control

Unit Digiprop

The data plate of the Digiprop-control unitis mounted on the control unit andcontains following information:

Basis-Nr.: 53.xxxx.12

Code-Nr.: xxx

Serien-Nr.: xxxx/

VOITH

Basic -No .:Code -No .:

S er ia l-No .:VOITH

11004e

1. Basic-number8-digit number

The last two digits show thesoftware version.

Example: .12 = version 1.2

2. Code-number

3-digit number

(Adjusting of control unit)

3. Serial-number

5-digit number

with date of coding

4. Voith precast unit number aswell as customer number, if ne-cessary

Notice

Please, always quote the retarder data and

retarder control unit data when submittingqueries or ordering spare parts.







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Illustration: Data Plate of Retarder Control Unit VERA

Data Plate of Retarder-Control

Unit VERA

The data plate of the VERA-control unit is moun-ted on the control unit and contains followinginformation:

R etarder C ontrol U nit VE RA.STDS erial -N o . XXXX / 2002-08-01P art -N o . 67.2763.20OEM-N o .

V O I T H T U R B O

X1 X2 X3 e

1 * 7 2 / 2 4 5 * 9 5 / 5 4 * 2 0 8 4 * 0 0

R e t a r

d e r C

o n t r

o l U

n i t V

E R A . S

T D

S e r

i a l - N

o . X X X X

/ 2 0

0 2 - 0

8 - 0 1

P a r t - N

o . 6 7 . 2 7

6 3 . 2 0

O E M - N o .

V O I T H T U R B O

X 1

X 2

X 3

e 1 * 7 2 / 2 4 5 * 9 5 / 5 4 * 2 0 8 4 * 0 0

11005

1. Serial-number4-digit number / date

2. Spare-part-number 8-digit number

3. OEM-number

Notice

Please, always quote the retarder data and

retarder control unit data when submittingqueries or ordering spare parts.




General – Function- and Operation Scheme

2.4 Function- and Operation Scheme

Illustration: Functional Drawing Retarder 115 E Digiprop

Notice

Example of application hand control Digiprop. Further OEM-specific versions are possible.

The given position numbers aren't identical with the position numbers of the spare part lists.

1 Heat exchanger complete 41 Filling duct

1/1 Retarder-oil cooling circuit 42 Oil tank

1/2 Gearbox-oil cooling circuit 43 Oil sump

19 Temperature sensor cooling water 44 Stator

20 Temperature sensor oil 46 Rotor

21 Proportional valve 55 Oil drain plugs

22 Ventilation 62 Pressure regulating valve

25

2623

36

1

19

63

20

43

4622

4462

55

64

A R2142

Oil sumpSupply-air pressure pConstant-air pressure p y

Coolant (water)

11006e

Pump pressure p P

41

1/1 1/2

72

Vehicle electronic

v






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Functional Description

The Voith Retarder 115 E is a powerful, hydrodynamic continous brake of compact design.

The retarder is driven and braking torque is transmitted by pinions in the gearbox. The transmission ratioenables the retarder to achieve high braking torques right down to low r.p.m. ranges with the compactestconfiguration (small rotor/stator).

Retarder braking torque is sustained even when gear changes are made.

Do not use the switched-on retarder as handbrake while vehicle is in still-stand!

During a failure of the retarder, or while the temperature-adaptation is effective, the vehicle-speed mustbe settled by using the service-brake and the lowest possible gear.






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Temperature Sensor Cooling Water (19), Oil (20)

The temperature sensors 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 waterand oil being exceeded, the retarder braking torque is adapted to protect the vehicle cooling system andthe retarder.

The braking torque and consequently the heat generated are reduced until a balance is obtained betweenthe braking energy of the retarder and the amount of heat which can be dissipated by the vehicle coolingsystem.

If the cooling water temperature rises into the temperature adaption range, the consequence is an adap-tion of the retarder braking torque to protect the vehicle cooling system. If the temperature rises abovethe temperature adaption range, there is no more braking torque output.

While the temperature adaption is effective or if there is a retarder failure, the service brake must be usedto control the vehicle.

Additionally the control unit cuts back braking torque if oil temperature rises too rapidly - irrespective ofactual oil temperature.

Pressure regulating valve (62)

The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder.






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Pressure sensor (72)

The pressure sensor (72) observes the pneumatic constant-air pressure. At deviation of the permissiblepressure tolerance an error is stored from the control unit displayed in the vehicle display in dependenceof the OEM equipment.

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.

Non-return valve (63) inlet

When the retarder is switched on, the oil sump is pressurized, causing the check valve (63) to open andthe oil to enter the working space.

Non-return valve (64) outlet

The oil pressure in the working space opens the check valve (64), causing the oil to enter the heatexchanger (1), to be cooled and to be returned to the working circuit.

Proportional valve (21)

Depending on the size of the electrical input signal a pneumatic constant-air pressure gets controlled fromthe proportional valve to the oil tank of the retarder.



Maintenance

Maintenance


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3. Maintenance

3.1 Maintenance Work / Oil Change Intervals .................................................. 203.2 Inspection of Oil Level................................................................................. 233.3 Oil Change.................................................................................................. 26



Maintenance – Maintenance Work / Oil Change Intervals



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3.1 Maintenance Work / Oil Change Intervals

Maintenance work

At each oil change:

- Clean sieve of pressure regulating valve

- Check fastening screws of the retarder heat exchanger

- Check all screw plugs on leak and correct fitment

- Carry out visual inspection on possible leak and existing damages

Please note the following data into the service overview of the Operation Manual„Gearbox-Retarder-System / GO170 - GO210 with R 115 E”:

- maintenance work been carried out

- the oil grade used for the oil change






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Oil change intervals, operating specification

1) according operating specification2) carry out change oil at the latest after 1 year, if fewer kilometres are travelled3) carry out change oil at the latest after 2 year, if fewer kilometres are travelled

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

Single grade-mineral oil1)

Synth. / part synth. oil1)

Synthetic oil 1)

Normal duty 135.000 km 2) 180.000 km 3) 300.000 km 3)

Heavy duty 60.000 km 2) 90.000 km 3) 300.000 km 3)

Classification let-ter

to DIN 51502

HD HC HC

Class of viscosity

to DIN 51511SAE 10WSAE 20W20

SAE 30

SAE 0W40SAE 5W30SAE 5W40SAE 5W50SAE 10W30SAE 10W40

SAE 75W80

Performancecategory

API - CC/SFand higher

API - CC/SFand higher

EmgardMTF,Henkel






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1. „Normal duty“

Example:

• Long distance traffic

2. „ Heavy duty“

Subject to more than normal stress.

Examples:

• Use in regions with high ambient temperature (e.g. Saudi-Arabia)

• High max. permissible weight with low rated engine power (< 6 kW / metric ton)• Streches with lots of hills and valleys

• Extreme short-distance traffic with lots of gradients

The given maximum specified figures can be lowered, if overall maintenance cycles for the vehicle 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 must be used.

In doubts please contact our customer service.



Maintenance – Inspection of Oil Level



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3.2 Inspection of Oil Level

Notice

For satisfactory retarder operation it is important to adhere to the specified service filling of 7,0 litres andto use only oils specified in the operating specifications for operating the retarder in the relevant applica-tion.The oil level check must be carried out with the vehicle in a horizontal position.

For the inspection of oil level, temperature of retarder oil must have reached the operating temperature.

Caution!

Two version of the screw plugs (107, 4100, 4200) are possible:

A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going toprint.

The integrated sealing rings must be checked for possible damages during the inspection of oil level;

replace completely if necessary.

B) Version with loose inserted copper-sealing ring.

In this Aftersales Workshop Manual is excluding the variant A (series version) described.

If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques inbrackets are valid.

The copper-sealing rings have to be renewed in general.






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Work scope

1. Push a clean vessel under retarder.

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

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

4. Screw in oil drain plugs and screw them tight.

Tightening torque oil drain plugs (107, 4200): 47 Nm (80 Nm)5. Measure drained oil.

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

4200

107

11007

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

4200 Oil drain plug M 24 x 1,5Inhex.head w.a.f. 12,47 Nm (80 Nm)

Caution! Risk of injury!

The oil drain plugs (107, 4200) and oil filler plug (4100) are hot (oil temperature)!

The retarder must be switched-off during the inspection of oil level!

If the retarder is switched-on during working step 2 and screwed out oil drain plugs and/or oil filler plug,high risk of injury exist by hot leaving oil (increased pressure)!






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

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

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

10. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 timesfor respectively approx. 5 seconds in position 2 at the retarder stage switch or brake stage 1.Take the OEM specific using variants into account to this.

The vehicle must not go slower than 20 km/h at this.

Caution!

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

Notice

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

Hinweis

The following work step is required to the correct ventilation of the retarder system.

Nonobservance can cause oil leak via the ventilation.

If available, the foot control of the retarder must be switched off and switched on first af ter the describedwork process again.



Maintenance – Oil Change



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3.3 Oil Change

Notice

The gearbox- and retarder oil tanks are seperated from each other at the gearbox-retarder-system. Bothoil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder- without limited compromizes.

For satisfacory retarder operation, it is important to adhere to the specified service filling (see tablepage 29 ) and to use only oils specified in the operating specifications page 21 for operating the retarderin the relevant application.

For draining the oil the temperature of the retarder oil must have reached the operating temperature.

Ensure that during the entire oil change no constant-air pressure acts on the retarder, that means theretarder must be switched off!

M i Oil Ch






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Attention!

Two versions of screw plugs (107, 3500, 4100, 4200) are possible:A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going toprint.

The integrated sealing rings must be checked for possible damages during the inspection of oil level;replace completely if necessary.

B) Version with loose inserted copper-sealing ring.In this Aftersales Workshop Manual is excluding the variant A (series version) described.



M i t Oil Ch g





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Illustration: Oil change Retarder R 115 E

Lubricants and cleaning agents

3500

4100

4200 4200

107

11008

Kd.-Sach-Nr.

Voith-Sach-Nr.

107 Oil drain plugM 24 x 1,5Inhex-head w.a.f. 1247 Nm (80 Nm)

3500 Screw plug with sieveM 30 x 1,5Inhex-head w.a.f. 17100 Nm (100 Nm)Clean sieve with appropriatecleaning agent and blow out withcompressed-air

4100 Oil filler plugM 30 x 1,5Inhex-head w.a.f. 17100 Nm (100 Nm)

4200 Oil drain plug oil tank

M24x1,5Inhex-head w.a.f. 1247 Nm (80 Nm)

Sieve in screw plug Benzine

Maintenance Oil Change






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Work scope

1. Push an oil collecting pan under the retarder.

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

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

4. Screw in the oil drain plugs tight.

Tightening torque oil drain plugs (107, 4200): 47 Nm (80 Nm)

Oil filling with heat exchanger

Service filling (oil change, inspection of oil level) 7,0 l

After exchange of heat exchanger 7,5 l

Attention! Risk of injury!

The oil drain plugs (107, 4200) are hot! Oil temperature!

4200

107

4200

11009







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

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

compressed-air.7. Check integrated sealing ring of screw plug with sieve on possible damages,

renew screw plug if necessary.

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

9. Screw out oil filler plug (4100).

10. Fill in slowly over a time period longer than 3 minutes the quantity of oil, via the bore of the oil fillerplug, specified in accordance to the service filling (see table page 29 ).

This work step is required to the correct ventilation of the retarder system.

3500

11010

Kd.-Sach-Nr.

Voith-Sach-Nr.

4100

11011

Attention!

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







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11. Check integrated sealing ring of oil filler plug on possible damages, renew oil filler plug if necessary.

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

13. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 timesfor respectively approx. 5 seconds in position 2 at the retarder stage switch or brake stage 1.Take the OEM specific using variants into account to this.

The vehicle must not go slower than 20 km/h at this.

Achtung!

The following work step is required to the correct ventilation of the retarder system.

Nonobservance can cause oil leak via the ventilation.

If available, the foot control of the retarder must be switched off and switched on first af ter the describedwork process again.

Diagnosis / Troubleshooting






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4. Diagnosis / Troubleshooting

4.1 Electrical Connections Diagram.................................................................. 334.2 Overview of Control Parts........................................................................... 374.3 Troubleshooting Diagram............................................................................ 384.4 Troubleshooting and Remedies.................................................................. 414.5 Checking Supply-Air Pressure (p v) ............................................................. 774.6 Checking Constant-Air Pressure (p y) and Pump Pressure (p dyn )............... 78

4.7 Checking Control Current of Proportional Valve ......................................... 864.8 Checking Pressure Sensor ......................................................................... 884.9 Checking Temperature Adaption ................................................................ 904.10 Table of Measurements .............................................................................. 93

Diagnosis / Troubleshooting – Elektrical Connections Diagram





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g g g

4.1 Elektrical ConnectionsDiagram

(Voith-Wiringharness Digiprop withoutCAN)

18

70 47 15 21

-- +

++ -

19 20

17

4

16

69

4

2

X1

X2X389456132321654971210118

14

8 7 8 7 a

3 0

13 11 12 10 1 9 5 8 4 3 2 7 6

18 17 16 6 5 4 89 1 0 11 1 2 1 3 1 4 1 5 7

43 2 1 4

832567

3 12

7

11012

1 2 4

. .

.

.

P U 72

2 Control unit

4 Connection terminal 15

15 ABS-signal

16 Retarder stage switch

17 Retarder pilot light

18 Brake light relay

19 Temperature sensorcooling water

20 Temperature sensor oil


47 Speedometer signal

69 Plug ISO-interface

70 Plug optional function

72 Pressure sensor(OEM-specific)






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g g g

Digiprop with CAN21

- - ++ + -

19 20

17

4

16

4

2

X1

X2X3

894561323216549712 10118

18 17 16 6 5 4 89 10 11 12 13 14 15 7 3 1 2

7

1 2 4

.

P U 72

CAN

11013

2 Control unit

4 Connection terminal 1516 Retarder stage switch











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VERA „general“

11014

47

4

2

X1

X2X3

8 94 56 13 23 2 16549 7 1210 118

18

8 7 8 7 a

3 0

21

18 1716 654 8 9 1 0 11 1 2 1 3 1 415 7 3 12

7

-+

19

+ -

201 2 4

P U 72

17

4.

CAN

80

-+ -+

16 15

83

82812 Control unit

4 Connection terminal 1515 ABS-signal

16 Retarder stage switch


18 Brake light relais


20 Temperature sensor oil21 Proportional valve



80 On/off valve

81 Input (3 times)

82 Output (3 times)

83 ISO-diagnosis






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VERA „DAFBUS“

11015

4

2

X1

X2X3

8 9 4 56 1 323 2 16549 7 1210 118

18

8 7 8 7 a

3 0

21

18 1716 654 8 9 10 11 12 13 1415 7 3 12

7

-+

19

+ -

20

1 2 4

P U

72

93

CAN

-+

90 94

16

92

91

4.

96

95

2 Control unit

4 Connection terminal 1516 Retarder stage switch






90 Fan relais

91 Brake valve

92 Diagnosis K-Lead

93 Fault light

94 Operating light

95 Foot Off/On

96 Indication light

Diagnosis / Troubleshooting – Overview of Control Parts

4 2 O i f C t l P t



4.2 Overview of Control Parts

7132

33

31

3435

40

61

11016

3919

1

202

21

26

72

P36

11

25 A

R

Notice

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

1 Heat exchanger

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

11 Connection control current ofproportional valve


20 Temperature sensor oil21 Proportional valve

25 Compressed-air pressure lineconstant-air pressure (p y)

26 Compressed-air pressure linesuppla-air pressure (p v)

31 Compressed-air pressure line(pressure regulator - four-circuit protection valve)

32 Compressed-air pressure line(four-circuit protection valve -air tank for auxiliary equip-ment) with with test connec-tion

33 Compressed-air pressure line(brake circuit 1)

34 Compressed-air pressure line(brake circuit 2)

35 Compressed-air pressure line(parking brake)

36 Ventilation lineconnection „R“

39 Electrical lead (temperaturesensor cooling water) tocontrol unit, 2 wires)

40 Electrical lead (temperaturesensor oil) to control unit,2 wires)

61 Four-circuit protection valve

71 Air tank for auxiliaryequipment

72 Pressure sensor

(OEM-specific)

Diagnosis / Troubleshooting – Troubleshooting Diagram



Diagnosis / Troubleshooting – Troubleshooting Diagram Seite 38


15300009710 / cbtsd 02-11

4.3 Troubleshooting Diagram

ComplaintRetarder R 115 E

A

RetarderPilot Light(Standardversion)

BOil leak viaventilation

and / or nonor too lowbraking

efficiency

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

11017e




Activateflash code

and read outfault code *

* Retarder P ilot L ight(S tandardversion)

A

Permanent light inposition 0 after

lamp test?

Clear faultand

erasefault memory *

no function?

Check pilot lightand renew,if necessary

flashes?

Temperatureadaption

OK NOK

Check operation

(during Retarderbrakingmost possible

enginenominal speed)

Instruct driver!

OK NOK

Checktemp.-sensors

(oil / water)(page 90 ff)

Replacetemp.-sensos

(page 141, 142)

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

Checkfuse

ABS oridle switch

active?

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

* Notice the information of the vehicle manufacturer


Prior work



• Check retarder system on outer leaks (apart from ventilation)

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

Check retarderoil level

(page 23 ff)

OK NOK

Yes No

Water in oil(emulsion)

(page 124 ff)

Checkheat exchanger

Correctretarder oil level

OK NOKNOKOK

Check p (dynam.)

and p y (statisch)(page 78 ff)For examination the retarder

oil level must be correct!

Check temperatureadaption or

temp.-sensors (oil/water)and pressure sensor or

leads(page 88 ff)

OKNOK

Checkgearbox oil level

check p (static)(page 78 ff)y

B

Checkretarder oil level

toolow

toohigh

NOKOK

Checkgear box oil level

Checkgear box oil level

toohigh

toolow

Correctretarder- and

gearbox oil level

Checkgearbox oil level

toohigh

toolow

Correctd d

YesNo

Outer Leak(apart ventilation)

RepairRetarder

Correctretarder- and

gearbox oil levelIf problem occours again:

Consultation Voith

Check

For examination the retarderoil level must be correct!

At complaint "non ortoo low brakingefficiency":

Consultation Voith

At complaint"Oil leak viaventilation":continue with

checking casingventilation

NOKOK

Check supply-air pressure(page 77)

NOKOK

Checkcasing ventilation

(page 112 ff)

OK NOK

Replacecasing ventilation

(page 112 ff)

p (dynamic)NOK

p (static)NOK

y

Checkproportional valve

(page 86 ff)

NOK OK

Replace

proportinal valve(page 140)If problem occours again:

Consultation Voith

No Yes

Outlet valve.11 and higher?

Replaceoutlet valve

( 136 ff)

O il leak via ventilationand / or non or

too lowbrake efficiency

Check controlcurrent of prop.valve as well as

leads undplug connections

(page 86 ff)

Diagnosis / Troubleshooting – Troubleshooting and remedies





15300009710 / cbtsd 02-11

4.4 Troubleshooting and remediesRequirements for check

• Battery voltage 18 - 32 V

• Vehicle electrical system checked in accordance with the Owner s Manual for the vehicle and foundsatisfactory.

• Fuse for retarder control unit checked and found satisfactory.

• Compressed-air pressure 6 - 11 bar

• Version Digiprop with and without CAN:

for check with multimeter must be at the control unitpin 15 (plug X1) Ground (terminal 31),

at pin 7 and pin 13 (plug X1) must be connected terminal 15

• Version VERA:

for check with multimeter must be at the control unit

pin 14 (plug X1) Ground (terminal 31),

at pin 7 (plug X1) must be connected terminal 15

Note

Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary

(see page 29 ).






15300009710 / cbtsd 02-11

Note

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

• slight fault

Permanent light in position 0 - 5 of retarder stage switch, braking is still possible to limitedextent.

• serious fault

Permanent light in position 0 - 5 of retarder stage switch,, braking is no longer possible -

the retarder is switched off.

Note

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






15300009710 / cbtsd 02-11

Connector arrangement and pin assignment

Plug X1 control unit (Digiprop)

Note

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

11020

147101316

258111417

369121518

1 Not in use or CAN-LOW

2 Not in use or CAN-GROUND

3 Not in use or CAN-HIGH

4 Retarder stage switch, Position 3



7 Terminal 158 Retarder stage switch, Position 5


10 Retarder stage switch +

11 ISO-interface, L-lead

12 ISO-interface, K-lead

13 Connected with terminal 15

14 Not in use

15 Terminal 31

16 Output / high side 2 „HS2“

17 Not in use







15300009710 / cbtsd 02-11



11021

147

258

369

1 Not operational

2 Proportional valve -3 Proportional valve +

4 Cooling-water temperature-sensor -

5 Cooling-water temperature-sensor +

6 Not operational

7 Not in use

8 Oil-temperature sensor -

9 Oil-temperature sensor +

11022

14710

25811

36912

1 Input / pull up „DIU 1“2 Speedometer signal

3 ABS-signal

4 Input / pull down „DID 2“


6 Pressure-sensor ground

7 Pressure-sensor signal voltage



10 Pressure-sensor supply voltage

11 Stop light relais

12 Input / pull down / PWM-in „DID4“






15300009710 / cbtsd 02-11

Plug optional functions (cable Digiprop)

Plug ISO-interface (cable Digiprop)

2

1

4

3

6

5

8

7

10

9

12

11

14

13

11023


2 Input / pull down „DID 1“3 Input / pull down „DID 2“


5 Input / pull down / PWM -in „DID 4“

6 Input / pull up „DIU 1“

7 Pressure-sensor Ground



10 Output / high side „HS1“


12 Not operational

13 Terminal 15

14 Terminal 31

2 1

4 3

11024

1 K-lead

2 L-lead

3 Terminal 15

4 Terminal 31






15300009710 / cbtsd 02-11

Connector arrangement and pin assignment

Plug X1 control unit (VERA)

Note

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

11025

147101316

258111417

369121518

1 CAN-LOW

2 CAN-GROUND

3 CAN-HIGH




7 Terminal 15 = battery voltage8 Retarder stage switch, Position 3




12 ISO-interface, K-lead

13 ABS-signal

14 Terminal 31 = Ground



17 Engine speed







15300009710 / cbtsd 02-11



11026

147

258

369

1 Output / highside „OUT 1“

2 Output / highside „OUT 2“3 Output / highside „OUT 3“

4 Input / analog „IN 3“

5 Input / analog „IN 1“

6 Not in use (boot 1)



9 Input / digital „IN 2“

11027

14710

25811

36912

1 Cooling-water temperature-sensor -2 Cooling-water temperature-sensor +

3 Proportional valve +

4 Proportional valve -

5 Oil-temperature sensor +

6 Oil-temperature sensor -


8 Pressure-sensor Ground


10 Not in use (switch valve +)

11 Not in use (switch valve -)

12 Not in use






15300009710 / cbtsd 02-11

Plug cooling-water temperature pick-up

Plug oil temperature pick-up

Plug proportional valve

11028

12

3

4

11029

1 Proportional valve +

2 Proportional valve –

3 Not in use

4 Not in use






15300009710 / cbtsd 02-11

Plug retarder stage switch

11030

1 2 3 4

5 6 7 8

1 Not in use

2 Position 53 Position 4


5 Position 3

6 Position 2

7 Position 1

8 Bridge to pin 4


h f l d d l f l





15300009710 / cbtsd 02-11

A. With fault code, e.g. retarder control unit reports fault

Special tool

Service cable (only Digiprop)

Commercially available tool

Multimeter recommended: Fluke 87

Note

The fault memory can be read-out from blinking code of retarder pilot light via service-cable (53.8224.10only Digiprop), if this function is realised.

An on-board-diagnosis (display) is OEM-specific possible. Heed herefore the statements of the vehiclemanufacturer.

53.8224.10


F lt d t i t d il t light bli ki g d





15300009710 / cbtsd 02-11

Fault memory readout via retarder pilot light blinking code

Fault memory readout with service cable (only Digiprop)

Requirements

• Retarder stage switch in position O.

• Vehicle at standstill, ignition ON

1. L-lead of service interface connected to ground ≥ 2s. For this pupose, press „L - pushbutton“ onservice cable

2. First fault as blinking code output.

3. Item 2 and 3 repeated for more blinking code outputs.

Meaning

• Long blinking signals (2 sec.) tens unit.

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

Note

If sveral faults have been stored in the memory, they are output in the sequence of their occurence,but always only one fault per triggering.

Exception:

The fault „Coding Fault“ is not held in the memory but is output via the blinking code.

The blinking code can be read-out of control unit by using the service cable (only Digiprop) orretarder stage switch.


Fault memory read out with retarder stage switch





15300009710 / cbtsd 02-11

Fault memory read out with retarder stage switch

The blinking code can be triggered with the retarder stage switch during the service function

(vehicle ignition system ON and v = 0):1. Retarder stage switch in position 0

2. Retarder stage switch in position 1

3. Retarder stage switch in position 0

4. First fault as blinking code

5. Items from ...3 for more blinking code outputs

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

Display example for fault code 23 (Digiprop)

E Retarder pilot light ON

A Retarder pilot light OFF

t Time

Display example for fault code 23 (Digiprop):

The number of tens units first indicated as long ON time: each 2 seconds

The number of single unit then is indicated as short ON time: each 0,5 seconds

Breaks between each ON time: each 1 second

If an actual fault occours (before triggering blinking code of retarder pilot light is switched ON) the retarderpilot light switches to permanent light again after the blinking code.

Is there only one stored fault, the retarder pilot light is OFF after the output (only for Digiprop).

2 s

e c

1 s

e c

0 , 5

s e c

1 s

e c

1 s

e c

1 s

e c

0 , 5

s e c

0 , 5

s e c

2 s

e c

11031


Display example for fault code 20 (only for VERA):





15300009710 / cbtsd 02-11

Display example for fault code 23 (VERA)

E Retarder pilot light ON

A Retarder pilot light OFF

t Time

Display example for fault code 20 (only for VERA):

The number of tens units first indicated as long ON time: each 2 seconds

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

Breaks between each ON time: each 1 second 2

s e c

1 s

e c

2 s

e c

11032


Delete fault memory (only for Digiprop)





15300009710 / cbtsd 02-11

Delete fault memory (only for Digiprop)

No marginal notes in accordance with fault memory read out.

1. Vehicle ignition system: OFF

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

3. Vehicle ignition system: ON

4. Release L-lead from ground after ≥ 2 sec.

Delete fault memory (only for VERA)

It is only possible to delete fault memory via WinDia.


Version Digiprop





15300009710 / cbtsd 02-11

g p p

1) X 1/15 = ground control unit2) Only, if no fault is recognizable after a complete check of the periphery: change control unit.

Note

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

Fault Fault text Faultclass

Trigger time Requirement /Operation

Measurement/ Test

connection 1)

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 of

control unit

X 3/11 Ω X 1/15 Relay isinstalled:250-350 Ω

Check lead, plugsand relay orconsumers






15300009710 / cbtsd 02-11



Measurement/ Test connection

Result/ Set point

Cause/Remedy

Code Test step

03 HS 1 outputShort circuit



control unit


Check lead, plugsand relayor consumers

04 HS 2 outputShort circuit



control unit


Check lead, plugsand relayor consumers

05 Terminal 15Undervoltage

serious 60 s - Ignition: OFF


control unit

- Ignition: ON

X 1/7 V X 1/15 ≥ 17,5 V Check lead, plugsand fuses

06 Terminal 15Overvoltage



control unit - Ignition: ON

- Start engine

(idle speed)

X 1/7 V X 1/15 ≤ 32,5 V Checking electricalinstallation of vehicle

(see manufacturerinstructions)






15300009710 / cbtsd 02-11

* Fault is in serious class, if temperature sensor 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/

RemedyCode Test step

0809

Cooling-watertemperaturesensorDiscontinuity /Short circuit tobattery

serious/

slight *

1 s - Ignition: OFF


control unit

X 2/5 Ω X 2/4 20°C ± 10°C =

1039 - 1117 Ω

60°C ± 10°C =

1194 - 1271 Ω

80°C ± 10°C =

1271 - 1347 Ω

Notice:

The measuringin one tempera-ture rangenormally is

sufficient.

Check lead andsensor






15300009710 / cbtsd 02-11

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


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/


1112

Oil temperaturesensorDiscontinuity /Short circuit tobattery

serious/ slight *

1 s - Ignition: OFF


control unit

X 2/9 Ω X 2/8 20°C ± 10°C =

1039 - 1117 Ω

60°C ± 10°C =

1194 - 1271 Ω

80°C ± 10°C =

1271 - 1347 Ω

Notice:

The measuringin one tempera-ture rangenormally is

sufficient.

Check lead andsensor






15300009710 / cbtsd 02-11


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/


13 1 Retarder stageswitchUndefinedswitch state

serious 1s - Ignition: ON

- Retarder stage switch:

Position 0

X 1/10 V X 1/15

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

≥ 17,5 V

0 V

0 V

0 V

0 V

0 V

Check lead, plug andretarder stage switch

13 2 - Ignition: ON


Position 1

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

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

≥ 17,5 V

≥ 17,5 V

0 V

0 V

0 V

0 V


13 3 - Ignition: ON


Position 2

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

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

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

0 V

0 V

0 V







15300009710 / cbtsd 02-11


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/


13 4 - Ignition: ON


Position 3

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

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

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

0 V

0 V


13 5 - Ignition: ON


Position 4

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

X 1/8 V X 1/15

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

0 V


13 6 - Ignition: ON


Position 5

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

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V







15300009710 / cbtsd 02-11


class

Trigger time Requirement / Operati-

on

Measurement/

Test connec-tion

Result/

Set point

Cause/

Remedy

Code Test step

14 Retarder stageswitchShort circuit tobattery



control unit

- Ignition: ON

- Retarder stage switch:Position 0

X 1/10 V X 1/15 0 V Check lead andplug

15 Retarder stageswitchShort circuit tobattery



control unit

- Retarder stage switch:Position 5

X 1/10 Ω X 1/15 Resistorendless

Single check ofstages forshort circuit

16 Speedometersignal

Discontinuity

serious 2 s - Ignition: ON X 3/2 V X 1/15 ≤ 1 V Check lead andspeedometer






15300009710 / cbtsd 02-11


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/



Short circuit to battery

undefined signal



control unit

- Ignition: ON

X 3/2 V X 1/15 ≤ 9 V Check lead andspeedometer

19 ABS

Short circuit to ground

serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ 3,5 V Check lead,

relay andABS-control unit

21 ABS-Signal undefined serious 1 s - Ignition: ON X 3/3 V X 1/15 ≥ 16,5 V Check lead,relay andABS-control unit

22 Internal faultABS-current path

serious 1 s - - - Replace controlunit


Fault No. 1:

Short circuit to battery



control unit

- Ignition: ON

X 2/3 V X 1/15 ≤ 10 V Check lead






15300009710 / cbtsd 02-11


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/


24 1 Proportional valve

Fault No. 2:

- Short circuit proportional

valve magnetic- Short circuit connection

lead proportional valve

- Discontinuity proportional valve magnetic

Valve magnetic

- Discontinuity connection lead proportional

valve

- Short circuit to ground at proportional valve

- Prop.- and shift valve

interchanged

serious 1 s - Ignition: ON

- Pull plug X2 out of control unit

X 2/2 Ω X 2/3 18-25 Ω Check lead andproportionalvalve(valve block)

2 - Ignition: OFF

- Pull plug X2 out of control unit


Check lead andproportionalvalve(valve block)

3 - Ignition: OFF

- Pull plug X2 out

of control unit


Check lead andvalve block






15300009710 / cbtsd 02-11


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/


25 Valve block

Fault No. 3:

defective control unit

serious 10 s Replacecontrol unit

27 Valve block

Fault No. 5: defective control unit

serious 2 s Replace

control unit

28 Terminal 30Undervoltage



control unit

- Ignition: ON

X 1/13 V X 1/15 ≥ 17,5 V Check lead,plug and fuse

29 Fault control unit serious 180 ms Replacecontrol unit

31 Control unit:

Coding faultserious 100 ms Provide new

parameters forcontrol unit

32 Retarder pilot light:

Discontinuity / Short circuit to ground



control unit

- Ignition: ON

X 3/8 V X 1/15 ≥ 17,5 V Check lead,retarder pilotlight and fuse






15300009710 / cbtsd 02-11


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/


33 Retarder pilot light:Short circuit to battery

serious 3 s - Ignition: ON

- Retarder stage

switch:

Position 1

X 3/8 V X 1/15 ≤ 2 V Check lead andretarder pilotlight

35 Fault control unit serious 500 ms / 123 s Replace

control unit37 Fault foot operation slight 100 ms / 1 s Check installation in

accordance withOEM - as well asVoith requirements

38 1 Fault constant-airpressure

slight 1 s to 10 s Ignition: ONPosition 0

X 3/7 V X 1/15and

X 3/10 V X 1/15

0,3-0,7 V

4,75-5,25V

Pressure sensorwiring harness

If deviation: step 2

2 Troubleshooting inwiring harness,pressure sensor,proportional valve,supply-air pressure,ECU(Contact Voith)


Version VERA





15300009710 / cbtsd 02-11

Note

- X1 / 14 = Ground control unit

- replace control unit first, if complete check of periphery did not yield any faults

- Project specifically is normally only a part of the listed pins used (e.g.: ABS not via pin X1/13, but via CAN)




Result/ Set point

Cause/Remedy

Blink-Code

Test step

1 1 Data set

faultheavy immediately af-

ter ignition ONParameter setting fault,new parameter setting

2 1 EEprom

faultheavy immediately af-

ter ignition ONReplace control unit

3 1 ROM

faultheavy approx. 10s after

ignition ONReplace control unit

4 1 SIBA

faultheavy 60 ms Replace control unit

5 1 Proportional-valve chasssisground end,

interruption,

short circuit,

connecting lead

heavy 1s - Ignition: OFF

- disconnect

plug X3

X 3/3 Ω X 3/4 18 ... 25 Ω Check electrical leadand proportional valve





Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

class Operation Test connection Set point Remedy

Blink-Code Test step

5 2 X 3/3 Ω X 1/14 Resistor endless Check electrical leadand proportional val-ve

5 3 X 3/3 Ω X 1/14 Resistor endless Check electrical leadand proportional val-

ve

6 1 Proportional-valve

battery short cir-cuit


- Pull off plug X1,

X3

- Ignition: ON

X 3/3 V X 1/14 ≤ 10 V Check electrical leadand plug

8 1 Proportional-valve-control,

int. fault at con-trol unit

heavy 3s Replace control unit

9 1 Terminal 15

undervoltageheavy 60s - Ignition: OFF

- Pull off plug X1

- Ignition: ON

X 1/7 V X 1/14 ≥ 17,5 V Check electrical lead,fuse and plug

10 1 Terminal 15

overvoltage


- Pull off plug X1, X3

- Ignition: ON

X 1/7 V X 1/14 ≤ 32,5 V Check electrical unit

of vehicle (see manu-facturer s instruc-tions)





Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

class Operation Test connection Set point Remedy

Blink-Code

Test step

11 1 Retarder stageswitchundefined con-dition

heavy 2s - Ignition: ON

- Retarder stage

switch: position 0

X 1/10 V X 1/14X 1/5 V X 1/14

X 1/6 V X 1/14

X 1/8 V X 1/14

X 1/9 V X 1/14

X 1/18 V X 1/14

≥ 17,5 V

0 V

0 V

0 V

0 V

0 V

Check electrical lead,plug and retarder sta-ge switch

2 - Ignition: ON

- Retarder stage

switch: position 1

X 1/10 V X 1/14X 1/5 V X 1/14

X 1/6 V X 1/14

X 1/8 V X 1/14

X 1/9 V X 1/14

X 1/18 V X 1/14

≥ 17,5 V

≥ 17,5 V

0 V

0 V

0 V

0 V


3 - Ignition: ON

- Retarder stage

switch: position 2

X 1/10 V X 1/14X 1/5 V X 1/14

X 1/6 V X 1/14

X 1/8 V X 1/14

X 1/9 V X 1/14

X 1/18 V X 1/14

≥ 17,5 V ≥ 17,5 V

≥ 17,5 V

0 V

0 V

0 V


4 - Ignition: ON

- Retarder stage switch: position 3

X 1/10 V X 1/14

X 1/5 V X 1/14 X 1/6 V X 1/14

X 1/8 V X 1/14

X 1/9 V X 1/14

X 1/18 V X 1/14

≥ 17,5 V

≥ 17,5 V ≥ 17,5 V

≥ 17,5 V

0 V

0 V

Check electrical lead,

plug and retarder sta-ge switch





Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

p p y

Blink-Code

Test step

11 5 - Ignition: ON

- Retarder stage

switch: position 4

X 1/10 V X 1/14X 1/5 V X 1/14

X 1/6 V X 1/14

X 1/8 V X 1/14

X 1/9 V X 1/14

X 1/18 V X 1/14

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

0 V


6 - Ignition: ON

- Retarder stage

switch: position 5

X 1/10 V X 1/14X 1/5 V X 1/14

X 1/6 V X 1/14

X 1/8 V X 1/14

X 1/9 V X 1/14

X 1/18 V X 1/14

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V

≥ 17,5 V


12 1 Retarder stageswitch

chasssis groundend


- Pull off plug X1- Retarder stage

switch: position 5

X 1/10 Ω X 1/14 Resistor endless Check each stage onchsssis ground end

13 1 Retarder stageswitch

battery shortcir-

cuit


- Pull off plug X1- Retarder stage

switch: position 0

X 1/10 V X 1/14 0 V Check electrical leadand plug





Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

y

Blink-Code

Test step

16 1 Temperature-sensors

(both sensorsdefect)

heavy 1s See blinking code 17to 20

17 1 Cooling-water

temperaturesensor

interruption

light 1s - Ignition: OFF

- Pull off plug X3

X 3/1 Ω X 3/2 20°C ± 10 °C =

1039 - 1117 Ω

60°C ± 10 °C =

1194 - 1271 Ω

80°C ± 10 °C =

1271 - 1347 Ω

Note:

The measuring inone temperaturerange normally issufficient.

Check electrical lead,

sensor and plug

18 1 Cooling-watertemperaturesensor

chasssis groundend


- Pull off plug X1,

X3

X 3/2 Ω X 1/14 Resistor endless Check electrical lead





Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

Blink-Code

Test step

19 1 Oil-temperaturesensor

interruption


- Pull off plug X3X 3/5 Ω X 3/6 20°C ± 10 °C =

1039 - 1117 Ω

60°C ± 10 °C =

1194 - 1271 Ω

80°C ± 10 °C =

1271 - 1347 Ω

Note:

The measuring inone temperaturerange normally issufficient.

Check electrical leadand plug

20 1 Oil-temperaturesensor

chasssis groundend


- Pull off plug X1,

X3

X 3/5 Ω X 1/14 Resistor endless Check electrical leadand plug

21 1 Speedometersignalinterruption

heavy 2s - Ignition: ON X 1/11 V X 1/14 ≤ 1 V Check electrical leadand speedometer

22 1 Speedometersignal

battery shortcir-cuit


- Pull off plug X1

- Ignition: ON

X 1/11 V X 1/14 ≤ 9 V Check electrical leadand speedometer





Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

Blink-Code

Test step

23 1 Retarder pilotlightinterruption,

chasssis groundend


- Pull off plug X1

- Ignition: ON

X 1/15 V X 1/14 ≥ 17,5 V Check electrical leadand fuse

24 1 Retarder pilotlightinterruption,


heavy 3s - Ignition: ON

- Retarder stage

switch: position 1

X 1/15 V X 1/14 ≤ 2 V Check electrical leadand retarder pilotlight

25 1 Pressure sensor

fault (supply)light 0,5s - Ignition: ON X 3/8 V X 3/9 4,75 ... 5,25 V Check electrical lead


interruption,

chasssis groundend


- Pull off plug X1,

X3

X 3/7 Ω X 1/14 Resistor endless Check electrical leadand pressure-sensor



light 1s - Ignition: ON X 3/9 V X 3/8 4,75 ... 5,25 V Check electrical leadand pressure-sensor


unplausiblesignal

light 10s - Ignition: ON

- Retarder stage

switch: position 0

X 3/7 V X 3/8 0,3 ... 0,7 V Check electrical leadand pressure-sensor





Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

Blink-Code

Test step

29 1 ABS

chasssis groundend

heavy 60s - Ignition: ON X 1/13 V X 1/14 ≥ 3,5 V Check electrical lead,relay and ABS-con-trol unit

30 1 ABS

undefined con-

dition

heavy 5s - Ignition: ON X 1/13 V X 1/14 ≥ 16,5 V Check electrical lead,relay and ABS-con-

trol unit31 1 ABS

int. fault at con-trol unit

heavy 1s Replace control unit

33 1 Brake light relay

chasssis groundend


- Pull off plug X1X 1/16 Ω X 1/14 At installed relay

250-350 Ω

Check electrical leadplug and relay or con-sumer

34 1 Brake light relay

interruption,



- Pull off plug X1X 1/16 Ω X 1/14 < 1,5k Ω Check electrical lead

plug and relay or con-sumer

2 - Ignition: OFF

- Pull off plug X1

- Ignition: ON

X 1/16 V X 1/14 0 V Check electrical leadplug and relay or con-

sumer35 1 Output 1

(OUT-1)

chasssis groundend


- Pull off plug X2X 2/1 Ω X 1/14 At installed con-

sumer

> 150 Ω






Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

Blink-Code

Test step

36 1 Output 1(OUT-1)

interruption,

battery short cir-cuit


- Pull off plug X2X 2/1 Ω X 1/14 < 3k Ω Check electrical lead


2 - Ignition: OFF - Pull off plug X2

- Ignition: ON

X 2/1 V X 1/14 0 V Check electrical leadplug and relay or con-sumer

37 1 Output 2

(OUT-2)

chasssis groundend



sumer> 150 Ω


38 1 Output 2

(OUT-2)

interruption,





2 - Ignition: OFF

- Pull off plug X2

- Ignition: ON


39 1 Output 3

(OUT-3)

chasssis groundend



sumer

> 150 Ω






Result/ Set point

Cause/Remedy





15300009710 / cbtsd 02-11

Blink-Code

Test step

40 1 Output 3(OUT-3)

interruption,





2 - Ignition: OFF - Pull off plug X2

- Ignition: ON


41 1 CAN-fault mes-sages failing toappear, inter-ruption

heavy 1s Check electrical con-nections and leads ofvehicle CAN-Bus

42 1 CAN

BusOffheavy 200ms Check electrical con-

nections and leads ofvehicle CAN-Bus

46 1 Retarder foot-switch

chasssis groundend (IN-3)

light 500ms - Ignition: ON X 2/4 V X 1/14 > 0,4 V Check analoge foot-pedal, electrical leadand plug



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

4.5 Checking Supply-Air Pressure (p v)

Work scope test



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


15300009710 / cbtsd 02-11

1. Connect appropriate test pressure gauge to test connection of compressed-air line (32) at

four-circuit protection valve - air tank for auxiliary equipment and check supply-air pressure (p v).

• Minimum pressure: 6 bar

• Maximum pressure: 11 bar

110332

Notice

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

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

4.6 Checking Constant-AirPressure (p y) andPump Pressure (p dyn ) 4100





15300009710 / cbtsd 02-11

Pump Pressure (p dyn )

Requirements for check

• Retarder stage switch in position 0

• Vehicle ignition OFF

11034

103

Kd.-Sach-Nr.

Voith-Sach-Nr.

103 Screw plug(test connection pump pressure)M12x1,5Inhex-head w.a.f. 613 Nm (20 Nm)

4100 Oil filler plugM30x1,5Inhex-head, w.a.f. 17100 Nm (100 Nm)

Notice

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








15300009710 / cbtsd 02-11

• Vehicle ignition OFF• Vehicle electrical system (e.g. battery voltage, fuse etc.) checked in accordance with the Owner s

Manual for the vehicle and found satisfactory

• Compressed-air pressure 6 - 11 bar

Special tools:

Compressed-air Oil-pressure gaugepressure gauge

0 - 6 bar 0 - 25 bar

99/7 99/1

H53.478810


Attention!

Two version of the screw plugs (107, 3500, 4100, 4200) are possible:





15300009710 / cbtsd 02-11

p g ( ) p








Work scope check 4100






15300009710 / cbtsd 02-11

1. Screw out oil filler plug (4100).

99/7 Air-pressure gauge 53.1403.10

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

11035

j y

The oil filler plug (4100) and the retarder are hot! oil temperature!

99/7

11036



The screw plug (103) and the oil are hot! Oil temperature!





15300009710 / cbtsd 02-11

3. Screw out screw plug (103).

99/1 Oil-pressure gauge 53.4788.10

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

103

11037

11038

99/1

Attention!

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


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





15300009710 / cbtsd 02-11

6. Shift the retarder stage switch to position 5 while on move at prop shaft speed v ps = 1000 r.p.m. andread-off pump pressure (p dyn ) of oil-pressure gauge (99/1).

7. Compare read-off pump pressure with the minimum value of dynamic pump pressure (pdyn

)according to the table see pages 93 ff.

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

Notice

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

Attention!

If the nominal value of the constant-air pressure (p y) is obtained, however the pump pressure is below,the retarder is inside defect.

If the respectively required set point is fallen at the measuring of the constant-air pressure (p y), either aleak of the retarder or a defect is due to the control (see troubleshooting diagram).

The constant-air pressure (p y) must not change during the drive.



Screwing of oil-pressure gauge and retarder are hot!





15300009710 / cbtsd 02-11

99/1 Oil-pressure gauge 53.4788.10

9. Disconnect oil-pressure gauge (99/1).

10. Screw tight screw plug (103).

Tightening torque screw plug (103): 13 Nm (20 Nm)

When screwing out oil-pressure gauge (99/1) hot oil can flow out!

11039

99/1

103

11040

Notice

Check sealing ring of screw plug (103) for a possible damage, replace screw plug (103) if necessary.



The screwing of the air-pressure gauge and the retarder are hot!





15300009710 / cbtsd 02-11

99/7 Air-pressure gauge 53.1403.10

11. Disconnect air-pressure gauge (99/7).

12. Screw tight oil filler plug (4100).

Tightening torque oil filler plug (4100): 100 Nm (100 Nm)

99/7

11041

4100

11042

Notice

Check sealing ring of oil filler plug (4100) for a possible damage, replace oil filler plug (4100), if necessary.

Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve

4.7 Checking Control Current of Proportional Valve






15300009710 / cbtsd 02-11

• Battery voltag 24 - 28 V

• Vehicle electrical system checked in accordance with the Owner s Manual for the vehicle and foundsatisfactory

• Fuse for retarder control unit checked and found satisfactory

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

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

Special tool:

Measuring adapter

99/3


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


Work scop check

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

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





15300009710 / cbtsd 02-11

98/8 Multimeter

99/3 Measuring adapter 53.8198.10

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

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

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

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

11043

98/8

99/3

Diagnosis / Troubleshooting – Checking Pressure Sensor

4.8 Checking Pressure Sensor


V hi l i i i OFF





15300009710 / cbtsd 02-11


• Connected pressure gauge constant-air pressure



Special tool:

Measuring adapter

99/3


Multimeter recommended: Fluke 87


Work scope check

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

2. Connect plug of measuring adapter (99/3) to pressure sensor (38).98 / 8





15300009710 / cbtsd 02-11

98/8 Multimeter

99/3 Measuring adapter 53.8198.10

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

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

5. Now, switch on vehicle ignition!

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

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

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

9. Compare measured voltage in conjunction of constant-air pressure with values on page 93 ff. For thepurpose of comparison a manometer "p y" must be parallelly installed (unless for pressure = 0 / Re-tarder OFF) see page 78 ff.

10. Switch-off vehicle ignition after measurements!

11. Reconnect after removing measuring adapter (99/3) the electrical lead to the pressure sensor.

11044

99/3

38

Notice

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

Diagnosis / Troubleshooting – Checking Temperature Adaption

4.9 Checking Temperature Adaption


• Battery voltage 24 28 V





15300009710 / cbtsd 02-11

• Battery voltage 24 - 28 V


• Pressure gauge constant-air pressure connected

• Vehicle electrical system checked in accordance with the Owner s Manual for the vehicle and foundsatisfactory

• Fuse for retarder control unit checked and found satisfactory


Special tool:

Temperature simulator 99/2


Work scope check

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

3940





15300009710 / cbtsd 02-11

99/2 Temperature simulator 53.8207.10

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

3. Switch-on vehicle ignition!

4. Operate retarder at highest braking stage.

Constant-air pressure (p y) control current must reach values given on table on pages 93 ff.

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

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

Wa sse r Öl

99/2

11045

Notice

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

If the two sensors are too far away from each other, then these have to be checked separated.


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

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

f ff





15300009710 / cbtsd 02-11

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

10. Switch-off vehicle ignition!

11. Reconnect electrical connection lead cooling water (39) and electrical connection lead oil (40) totemperature sensors cooling water (19) and oil (20).

Diagnosis / Troubleshooting – Table of Measurements

4.10 Table of Measurements

Digiprop without CANWith pressure sensor





15300009710 / cbtsd 02-11

1) Retarder stage switch in highest shift position!2) The code-number is on the control unit.3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!)4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).

5) The values are not steadily because of continuous control in the closed loop (however within the stated range).

.

Code-Number 2)

OLD NEW

Amperagecontrol current mA 1) 3) 5)

Constant-air pressure (p y)(static) 4) 1)

nominal value [bar]

Pump pressure(dynamic) 1) vps = 1000 r.p.m.

(minimum value) [bar]

038 138 396 - 596 2,05 - 2,35 18

050 150 365 - 565 1,60 - 1,90 13,5

051 151 379 - 579 1,80 - 2,10 15052 152 396 - 596 2,05 - 2,35 17

053 153 423 - 623 2,45 - 2,75 20

055 155 396 - 596 2,05 - 2,35 17

057 157 409 - 609 2,25 - 2,55 18,5

058 158 409 - 609 2,25 - 2,55 18,5

079 179 440 - 640 2,70 - 3,00 22

080 180 440 - 640 2,70 - 3,00 22

Notice

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


Digiprop with CANWith pressure sensor

Code-Number 2) Amperage

control current mA 1) 3) 5)

Constant-air pressure (p y)

(static) 4) 1)

Pump pressure

(dynamic) 1) vps = 1000 r.p.m.





15300009710 / cbtsd 02-11

1) Retarder stage switch in highest shift position!2) The code-number is on the control unit.3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!)4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).5) The values are not steadily because of continuous control in the closed loop (however within the stated range).

.

( )nominal value [bar]

( y ) p(minimum value) [bar]

502 440 - 640 2,70 - 3,00 22

504 440 - 640 2,70 - 3,00 22

508 440 - 640 2,70 - 3,00 22

510 430 - 630 2,55 - 2,85 21

512 440 - 640 2,70 - 3,00 22

Notice



Without pressure sensor / without CAN

Code-Number 2)

OLD NEW

Amperagecontrol current mA 1) 3) 5)


nominal value [bar]







15300009710 / cbtsd 02-11

1) Retarder stage switch in highest shift position!2) The code-number is on the control unit.3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!)4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).5) The values are not steadily because of continuous control in the closed loop (however within the stated range).

059 159 534 - 546 2,60 - 3,10 22

Notice



VERA DAFBUS

Serial-Number Amperagecontrol current mA 1) 2) 4)


nominal value [bar]







15300009710 / cbtsd 02-11

1) Retarder stage switch in highest shift position!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 30 seconds (stabilized, constant pressure).4) The values are not steadily because of continuous control in the closed loop (however within the stated range).

H67.276320 440 - 640 2,70 - 3,00 22

Notice



Voltage measurement at the pressure sensor

54 5





15300009710 / cbtsd 02-11

Notice

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

0

1

2

3

4

0,5

1,5

2,5

3,5

4,5

00,5 1 1,5 2 2,5 3 3,5 4

[ BAR ]

[ V ]

11046


Resistance measuring at the temperature sensor

Temperature Resistor

20°C ± 10 °C 1039 - 1117 Ω

60°C ± 10 °C 1194 - 1271 Ω





15300009710 / cbtsd 02-11

60 C ± 10 C 1194 1271

80°C ± 10 °C 1271 - 1347 Ω

Notice

The measuring in one temperature area normally is sufficient.

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

Removing, Installing Retarder

5. Removing, Installing Retarder





15300009710 / cbtsd 02-11


Prior work

• Cooling water drained *

• Oil drained of retarder

(see page 26)

• Propeller shaft at the gearing flangeremoved *

• Oil drained of gearbox *

25000

85025300

25300

25200



Illustration: Removing, installing retarder

• Waterneck removed

(see page 123 )

• Speedometer sensor removed *

• Output shaft-flange removed *

* Notice the information of the vehiclemanufacturer

251004100

25200

850/1

11047

Notice

The shim must always be determined newly,if:

• taper roller bearing (800) is renewed

• Retarder is installed at gearbox

• Retarder was repaired

• Gearbox was repaired

850/1 Taper roller bearing

850 Outer raceOnly removing, if the taperedroller bearing is replaced or anew shim enclosed

4100 Screw plugM 30 x 1,5Inhex-head w.a.f. 17100 Nm (100 Nm)

25000 Shim

25100 O-Ring, renewedcoat with silicone-free andnon-corrosive grease forinstallation

25200 Hex.-head screwM 10 x 70Hex head w.a.f. 1658 Nm

25300 Hex.-head screwM 10 x 60Hex head w.a.f. 1658 Nm


Special tools: Tool for local fabrication

F J 6 2 8 0 04 8 6 2 6 5 151

0





15300009710 / cbtsd 02-11

Measuring device Drive in tool Puller Threaded bolt

Bearing outer ring Bearing outer ring

98/1 98/3 98/4

Sealants and lubricants

O-Ring Silicone-free andnon-corrosive grease

Retarder housing Omnifit FD 10-1042

67.3224.10 67.3319.10 67.3320.10

80 M 1

28028eMaterial: St37-2, DIN 17100 (1.80)


Achtung!

Two version of the screw plugs (4100) are possible:






15300009710 / cbtsd 02-11

Removing

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






25300

11049

25200

25200

4100


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

850

25000NoticeCarry out following working step, if:





15300009710 / cbtsd 02-11

98/4 Puller bearing outer ring 67.3320.103. Pull off outer ring (850) with puller bearing outer ring (98/4) and remove shim (25000).

11050

98/4

25100 F

J 6 2

8 0 0

4 8 6

2 6 5

y g g p- taper roller bearing (800) is renewed

- Retarder is installed at gearbox

- Retarder was repaired

- Gearbox was repaired


Assembling

1. Determine thickness of shim as follows:

Notice





15300009710 / cbtsd 02-11

1.1 Measure the distance "B" between bearing surface on retarder side of the gearbox and the bearingsurface of the shim and note value.

Notice

The shim must always be determined newly, if:

• taper roller bearing (800) is renewed

• Retarder is installed at gearbox

• Retarder was repaired

Gearbox was repaired

11051

B

Attention!

The measurings described below may only carried out at ambient temperature and with the retarder invertical position (see illustration)!


1.2 Put the bearing outer ring (850) on the taper roller bearing (850/1).

850





15300009710 / cbtsd 02-11

98/1 Measuring device 67.3224.10

1.3 Put measuring device (98/1) on gearbox and tighten hex.-head screws handtight (3 Nm).

1.4 Put the lever from position 1 in position 2 to pressurize the drive shaft with a defined preload ofapprox. 400 N.

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

850/1

11052

98/1

P os .1 P os . 2

11053


1.6 Set the vernier depth gauge on gearbox seperation area and zero vernier depth gauge.





15300009710 / cbtsd 02-11

1.7 Put vernier depth gauge on the measuring area of the measuring plate.

1.8 Measure distance of measuring area of the measuring plate to seperation area of the retarder

housing and note value "A".

1.9 Determine thickness of shim as follows:

Thickness of shim = dimension B minus dimension A minus 0,02mm

11054

11055




4. Clean sealing surface of retarder housing (1).1





15300009710 / cbtsd 02-11

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

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

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

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

11057

11058

25100


9. Place retarder at gearbox and fix this with 5 hex.-head screws (25200).

Tightening torque hex.-head screws (25200): 58 Nm

10. Screw out again the two threaded bolts M 10 x 80.

11. Insert the 17 hex.-head screws (25300) and tighten them.

Tightening torque hex.-head screws (25300): 58 Nm

2520025200

25200





15300009710 / cbtsd 02-11

25300

11059

Repair Retarder

6. Repair Retarder

6.1 Overall Illustration of Main Components ................................................... 111

6.2 Removing, Checking and Installing Casing Ventilation............................. 1126.3 Removing, Checking and Installing Silencer............................................. 1226 4 R i d I t lli W t N k 123



Repair Retarder


15300009710 / cbtsd 02-11

6.4 Removing and Installing Water Neck........................................................ 1236.5 Removing, Checking and Installing Heat Exchanger................................ 1246.6 Removing and Installing Oil Tank Cover................................................... 1336.7 Removing, Installing Non-Return Valve Outlet ......................................... 136

Repair Retarder – Overall Illustration of Main Components

6.1 Overall Illustration of Main Components

6101

61006101 9000

4100

3900

29003700

4000

3300

3300

2800

5400

3100

2000

80002300/123012300

2300/2

3800

38503850

2810



Illustration: Components Retarder 115 E

42003100

2500

2600107

7500

2900 5500

103

6600

52005300

5600

53005200

109

7300

73007600

7500

6400

2010020000

20200

6600

6600

2000020200

20100

4100

2300/3

3500

6700

6700

2100

2105

2106170016003100

2030020400

6700

11060

100

2030020400

1 00 R et ar de r h ou si ng103 Screw plug

M12 x 1,5,inhex-head, w.a.f. 6

107 Oil drain p lug Re ta rderM 24 x 1,5,inhex.-head, w.a.f. 12

109 Screw plugM 24 x 1,5,inhex.-head, w.a.f. 12

1600 Va lv e c over 1700 O- Rin g 60 x 32000 Top cover 2100 Non-return valve outlet, complete2105 O-R in g, 34 x 32106 O-R in g, 54 x 32300 Cas ing ven ti la tion

2 30 0/ 1 Val ve i ns er t2300/2 Float230 0/3 Fl oa t ca ge

2301 O- Rin g 55 x 3

2500 Bo tt om cove r 2 60 0 B ot to m g as ke t2800 Cover for casing vent i la t ion2 81 0 Ven t a nd ai r fi lt er

M 12 x 1,5, hex.-head, w.a.f. 17

2900 Gasket3100 Combined hex.-head screw

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

3300 Combined hex.-head screw


3500 Screw plug wi th si eve,

M 30 x 1,5,inhex.-head, w.a.f. 17

3700 Proport iona l valve3 80 0 D am pi ng p la te3850 O-R in g 16 x 33900 Combined hex.-head screw


5200 Tempera tu re sensor 5300 Sea ling ring A 14 x 205400 Cor ruga ted spr ing5500 Disc ( si lencer ) D 30 x 4

5600 Retaining r ing JL 30 x 1 ,26100 Pipe6 10 1 O -R in g 1 5, 3 x 2, 46 40 0 H ea t e xc ha ng er6 60 0 H ex .- he ad s cr ew


old:hex.-head screw with flange

M 14 x 40,

hex.-head, w.a.f. 196700 Washer A157300 O- Ri ng 15 x 47500 O- Ri ng 45 x 57600 O- Ri ng 25 x 48000 Intermdiate plate 196 x 144 x 29000 Pressure sensor 0 to 4 bar

20000 Wat er n ec k

Repair Retarder – Removing, Checking and Installing Casing Ventilation

6.2 Removing, Checking and Installing Casing Ventilation

Notice

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





15300009710 / cbtsd 02-11

Prior jobs

• Vehicle ignition switched off

• Retarder switched off

• Proportional valve and damping plate removed ( see page 140 )

Attention! Risk of injury!Retarder housing is hot!


2800

3300

6100

6101

2300 Casing ventilation

2300/1 Valve insert

2300/2 Float

desired weight 11g ± 1 g2300/3 Float cage

2301 O-Ring 55 x 3 renew





15300009710 / cbtsd 02-11

Illustration: Casing ventilation

11061

2300/1

2900

2800

23012300

2300/2

2300/3

6101

2301 O Ring 55 x 3, renew,coat with silicon-free and non-corrosive grease for installation

2800 Cover casing ventilation

2900 Gasket casing ventilation,renew

3300 Combined hex.-head screwM 8 x 80, renewhex.-head, w.a.f. 13, 30 Nm

6100 Air-pipecoat with silicon-free and non-corrosive grease for installation

6101 O-Ring 15,2 x 2,4, erneuern

coat with silicon-free and non-corrosive grease for installation

sealant and lubricant

O-Ring silicon-free andnon-corrosive grease

Float Methylated spirit


Special tools: Tool for local fabrication

Ø 40,5 mm

7 mm

Ø 60 mm





15300009710 / cbtsd 02-11

Impact puller Adapter Test ring

99/5 98/7 99/7

Notice

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

28049e

Material: St 37Weight: 0,085 kg


Removing

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

3300





15300009710 / cbtsd 02-11

2. Remove cover (2800) with gasket (2900) from retarder housing.

Clean sealing surface.

11063

11064

2900

2800


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

6101

6100

6101





15300009710 / cbtsd 02-11

99/5 Impact puller 53.7712.10

98/7 Adapter 53.9428.10

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

11065

11066

99/5100

98/7


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

2300/3

100





15300009710 / cbtsd 02-11

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

11067

11068

2300/1

2301


Checking

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

2. Weigh float (2300/2).

The desired weight is 11 g ± 1 g. If the weight is more than the desired weight renew complete casingventilation.

2300/2





15300009710 / cbtsd 02-11

99/7 Test ring 67.2757.10

3. Check sealing edge of radial shaft sealing ring (arrow) in valve insert (2300/1). Put down valve insert

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

11069

Notice

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

2300/2

2300/1

99/7

11070


Installing

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

2300/1





15300009710 / cbtsd 02-11

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

11071

2301

2300/1

2300/2

2300/3

11072


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

4. Insert casing ventilation in retarder housing (100).

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

100

98/7





15300009710 / cbtsd 02-11

99/5 Impact puller 53.7712.10

98/7 Adapter 53.9428.10

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

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

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

11073

6100

2000

11074

6101



Repair Retarder – Removing and Installing Water Neck

6.4 Removing and InstallingWater Neck

Prior jobs





Repair Retarder – Removing and Installing Water Neck


15300009710 / cbtsd 02-11

Illustration: Water neck

• Cooling water drained

11078

2010020000

20000

20200

20200

20100Kd.-S

ach-Nr.

Voith-Sach-Nr.

20000 Water neck20100 Gasket, renew

20200 Combined hex.-head screwM 8 x 80hex.-head, w.a.f. 13,30 Nm

Repair Retarder – Removing, Checking, Installing Heat Exchanger

6.5 Removing, Checking, Installing Heat Exchanger

Prior jobs

Notice

If necessary, the heat exchanger can be removed also with mounted retarder.





15300009710 / cbtsd 02-11


• Retarder removed (see page 99 )

With installed retarder:

• Oil drained from retarder (see page 26 ff)

• Cooling water drained

• Water neck removed (see page 123 )

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

Notice

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


7500

6600

6700

107 Oil drain plug retarderM 24 x 1,5,inhex.-head, w.a.f. 12,47 Nm (80 Nm)

4200 Oil drain plug oil tankM 24 x 1,5,inhex.-head, w.a.f. 12,47 Nm (80 Nm)

6400 Heat exchanger6600 H h d





15300009710 / cbtsd 02-11

Illustration: Removing heat exchanger

Lubricant

4200

11079

1074200

7300

7300

7600

7500

6400

66006700

6600 Hex.-head screwM 14 x 45, renewhex.-head, w.a.f. 22,Pre-torque: 50 NmFinal torque: 30° turning angleold version:hex.-head screwM14 x 40 with flange,hex.-head, w.a.f. 19

6700 Washer A157300 O-ring 15 x 4, renew

coat with silicon-free and non-corrosive grease for installation

7500 O-ring 45 x 5, renewcoat with silicon-free and non-corrosive grease for installation

7600 O-ring 25 x 4, renewcoat with silicon-free and non-corrosive grease for installation

O-rings silicon-free andnon-corrosive grease


Attention!

Two versions of screw plugs (107, 4200) are possible:


The integrated sealing rings must be checked for possible damages during the installation of the heatexchanger; replace complete screw plug if necessary.





15300009710 / cbtsd 02-11

exchanger; replace complete screw plug if necessary.


In this Aftersales Service Manual is excluding the variant A (series version) described.


The copper-sealing rings are generally to be renew.


Special tool

67.1948.10





15300009710 / cbtsd 02-11

Pressure test plate

99/6


Turning angle measuring tool 3/4“ e.g. Messrs Richard Abr. Herder

Post box 10 08 67

D-42659 Solingen

Tel. 0212/ 888-0

Ordering No. 8200-02


107

Notice

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

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

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

3. Remove the cooling water hoses of the heat exchanger.





15300009710 / cbtsd 02-11

4200 420011080


Removing

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

2. Remove heat exchanger (6400). 6400

6600





15300009710 / cbtsd 02-11

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

110816600

66006700

6700

6700

11082

7300

7500

7300

7600

7500

7300


Checking

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

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

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

99/6 6400





15300009710 / cbtsd 02-11

99/6 Pressure test plate 67.1948.10

99/6 Pressure test plate 67.1948.10

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

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

11083

Notice

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

99/6 6400

11084

Notice

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

New heat exchanger are wetted with corrosion-inhibiting oil in the water- and oil section of the heatexchanger.Prior to installing a new heat exchanger, drain any corrosion-inhibiting oil which may have collected and

flush it out with hot water in the water section of the heat exchanger.


Installing

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

7300

7300

75007600





15300009710 / cbtsd 02-11

2. Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) withwashers (6700) tight.

Initial torque: 50 Nm

Final torque: 30° turning angle

11085

75007300

11086

6400

6600

6600

6600

6700

6700

6700



Repair Retarder - Removing, Installing Oil Tank Cover

6.6 Removing, Installing Oil TankCover

A) Top Oil Tank Cover

Prior jobs

• Vehicle ignition switched OFF


6101

6100

6101

2000

90003300

3100Notice

This working step can be performed withretarder removed or installed..



Illustration: Top Oil Tank Cover

Lubricant

8000

11088


The retarder housing is hot!

2000 Top cover

3100 Combined hex.-head screwM 8 x 30, renewhex.-head, w.a.f. 1330 Nm

3300 Combined hex.-head screwM 8 x 80, renewinhex.-head, w.a.f. 1330 Nm

6100 Air-pipe

6101 O-Ring 15,3 x 2,4,renewcoat with silicon-free andnon-corrosive grease forinstallation

8000 Intermediate plate, renew

9000 Pressure sensor

O-ring Silicon-free andnon-corrosive grease

Repair Retarder – Removing, Installing Oil Tank Cover

B) Bottom Oil Tank Cover

Prior jobs

• Vehicle ignition switched OFF


• Retarder oil drained (see page 26 ff)





15300009710 / cbtsd 02-11

Illustration: Bottom Oil Tank Cover11089

4200

3100

2500

2600

2500 Bottom cover

2600 Bottom gasket, renew

3100 Combined hex.-head screwM 8 x 30, renew,hex.-head, w.a.f. 13,Heed tightening sequence!30 Nm

4200 Oil drain plug oil tankM 24 x 1,5inhex.-head, w.a.f. 12

47 Nm (80 Nm)


Attention!

Two versions of screw plugs (4200) are possible:


The integrated sealing rings must be checked for possible damages during the installation of the heatexchanger; replace complete screw plug if necessary.



Repair Retarder – Removing, Installing Oil Tank Cover Seite 135


15300009710 / cbtsd 02-11

Installation note

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

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

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


In this Aftersales Service Manual is excluding the variant A (series version) described.


The copper-sealing rings are generally to be renew.

12

13

14

1516

7

4 32 1

56

78

9

111

11090



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

Special tool

153.00005210



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


15300009710 / cbtsd 02-11

Puller

non-return valve (outlet)

71/1


Removing

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

2. Remove valve cover (1600).

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

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





15300009710 / cbtsd 02-11

71/1 Puller

Installing

1. Install non-return valve in reverse sequence.

1109271/1

Control Parts

7. Control Parts

7.1 Removing, Installing Proportional Valve and Damping Plate.................... 1407.2 Removing, Installing Temperature Sensor Cooling Water........................ 1417.3 Removing, Installing Temperature Sensor Oil .......................................... 1427.4 Removing, Installing Pressure Sensor...................................................... 143



Control Parts


15300009710 / cbtsd 02-11

Control Parts – Removing, Installing Proportional Valve and Damping Plate

7.1 Removing, InstallingProportional Valve andDamping Plate

Prior jobs



• Supply-air pressure discharged

Plug at the proportional valve as well asconnector checked for damage or wear (notch-es).

39

39004000

3800 3850

3850

26 Compressed-air line p v



Illustration: Proportional Valve and Damping Plate

Lunbricant

11093

26

39003700

4000

39 Electrical connection lead


3800 Damping plate,

renew if necessary3850 O-ring 16 x 3, renew

coat with silicon-free andnon-corrosive grease forinstallation

3900 Hex.-head screwM 8 x 20, renew,hex.-head, w.a.f. 13,30 Nm

4000 Hex.-had nut M8,renew,18 Nm

Achtung

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

O-ring Silicon-free andnon-corrosive grease



Control Parts – Removing, Installing Temperature Sensor Oil

7.3 Removing, InstallingTemperature Sensor Oil

Prior jobs



l



Control Parts – Removing, Installing Temperature Sensor Oil

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

Illustration: Temperature Sensor Oil

5300

5200

11095

5200 Temperature sensor Oil,28 Nm

5300 Sealing ring A14 x 20,renew



Appendix – Retarder Data Sheet

8.1 Retarder Data Sheet

Data Sheet Voith Retarder 115 E

Max. possible braking torque at prop shaft M (Br) max at retarder ratio 1:2.03 * 3700 Nm

Maximum Retarder Speed n max. = 4800 min -1 at v ps = 2365 min -1

Working Medium Oil according Operating Specification

Control Medium Compressed-Air

Supply-Air Pressure 7 to 10 bar



Appendix – Retarder Data Sheet


* dependent from the retarder and vehicle configuration

Service filling:

- Service filling (Oil change, inspection of oil level)

- after exchange of heat exchanger

7,0 Litre

7,5 Litre

Weight of unit (with het exchanger unit and service filling) approx. 73 kg

Appendix – Tightening Torques

8.2 Tightening Torques

Pos.-No.: Title Dimensions Tightening torque

103 Screw plug M 12 x 1,5, Inhex.-head, w.a.f. 6 With integrated sealing ring: 13 Nm

With a loose sealing ring: 20 Nm

105 Screw plug M 22 x 1,5, Inhex.-head, w.a.f. 10 With integrated sealing ring: 35 Nm


107 Oil drain plug M 24 x 1,5, Inhex.-head, w.a.f. 12 With integrated sealing ring: 47 Nm






1400 Dodecagonal nut M 38 x 1,5, w.a.f. 55 426 Nm

2810 Vent and air filter M 12 x 1,5, w.a.f. 17 10 Nm

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


3400 Dowel screw M 14 x 48, Hex.-head, w.a.f. 19 Initial torque: 50 Nm

Final torque: 30° turning angle

3500 Screw plug with sieve M 30 x 1,5, Inhex.-head, w.a.f. 17 With integrated sealing ring: 100 Nm



4000 Hex.-head nut M 8, w.a.f. 13 18 Nm

4100 Oil filler plug / screw plug M 30 x 1,5, Inhex.-head, w.a.f. 17 With integrated sealing ring: 100 Nm

With a loose sealing ring: 100 Nm4200 Oil drain plug M 24 x 1,5, Inhex.-head, w.a.f. 12 With integrated sealing ring: 47 Nm



Pos.-Nr.: Bezeichnung Abmessungen Anziehdrehmoment

5200 Temperature sensor oil / water M 14 x 1,5, Hex.-head, w.a.f. 21 28 Nm with copper sealing ring

6600 Combined hex.-head screw M 14 x 45, Hex.-head, w.a.f. 22 Initial Torque: 50 NmFinal torque: 30° turning angle

9000 Pressure sensor M 16 x 1,5, Hex.-head, w.a.f. 27 30 Nm


20300 S l M 14 1 5 H h d f 13 32 N





20300 Screx plug M 14 x 1,5, Hex.-head, w.a.f. 13 32 Nm

25200 Hex.-head screw M 10 x 70, Hex.-head, w.a.f. 16 58 Nm

25300 Hex.-head screw M 10 x 60, Hex.-head, w.a.f. 16 58 Nm

transmissão voith retarder 115 e 147 pag

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