Transmissão Voith Retarder 120-3 131 Pag

8/11/2019 Transmisso Voith Retarder 120-3 131 Pag.

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Training

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Aftersales Service Manual

VOITH Retarder 120-3


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Content

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Table of Contents

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4.9 Checking Pump Pressure ...................................................................4.9/14.10 Table of Measurements ................................................................................. 4.10/14.11 Operational Check .........................................................................................4.11/1

5. Removing, Installing Retarder .................................................................5/15.1 Removing, Installing Retarder (Gearbox Attachment) ..................................... 5.1/1

6. Repair .....................................................................................................6/16.1 Overall Illustration of Main Components.......................................................... 6.1/16.2 Removing, Checking and Installing Casing Ventilation ................................... 6.2/16.3 Removing, Checking and Installing

Non-Return Valve (Stainless-Steel Heat Exchanger) ...................................... 6.3/16.4 Removing, Cleaning and Installing Silencer .................................................... 6.4/16.5 Removing, Installing Bottom Cover ................................................................. 6.5/16.6 Checking, Removing and Installing Closing Cover Retarder Housing............. 6.6/16.7 Removing, Installing Labyrinth Ring (Output Side),

Renewing Radial Shaft Sealing Ring............................................................... 6.7/16.8 Removing, Installing Centering Cover (Input Side)

Renewing Radial Shaft Sealing Ring............................................................... 6.8/1

7. Removing, Checking and Installing Heat Exchanger ..............................7/17.1 Removing, Checking and Installing Stainless-Steel Heat Exchanger..............7.1/17.2 Removing, Checking and Installing Aluminium Heat Exchanger..................... 7.2/1

Aftersales Service Manual VOITH Retarder 120-3Page IHV/2


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Content

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8. Control Parts ...........................................................................................8/18.1 Removing, Installing Proportional Valve and Damping Plate ..........................8.1/18.2 Removing, Installing Adapter and Pipes.......................................................... 8.2/18.3 Removing, Installing Cooling-Water Temperature Pick-Up .............................8.3/18.4 Removing, Installing Oil Temperature Pick-Up................................................ 8.4/1

9. Annex ......................................................................................................9/1Data SheetConversion TablesTightening Torques

Aftersales Service Manual VOITH Retarder 120-3Page IHV/3


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Preface 1 Preface

The present service manual serves as training material of the basics course.The information and instructions which is given to you furthermore provide the basis for appropriate andprofessional maintenance and repair at the VOITH Retarder 120-3.

We ask you firmly to notice the safety and warning notes which you will find in these instructions.

Caution!

is associated for safety instructions and for warning notes at dangerous situations for persons,at reduction of quality of workmanship and the possibility of damage to property.

Notice

is associated for general notices for a better handling during maintenance of the retarder.

Aftersales Service Manual VOITH Retarder 120-3Page 1/1


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Caution!

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

During a failure of the Retarders, or while the temperature-adaptation is effective, the vehicle-speed must be settled by using the service-brake and the lowest possible gear is in use (increaseof the engine-speed). This vehicle condition must be held as long as the retarder is available withits full performance again.

Unauthorized changes at the retarder 120-3 as well as the application of spare parts, accessories,attachments and special-productions, not tested and released from VOITH, can influence the secu-

rity of the entire vehicle negatively. No liability takes place for damages resulting from it.

The retarder 120-3 is built after the the state-of -the-art technology and the recognized safety-rela-ted rules. Nevertheless dangers and damages can originate during improper use, maintenance andrepair.

VOITH will take on no liability for injuries and/or damages, that originate through non-observance ofthe security-hints of the service manual or through injuries of the diligence-duty with the handling,at the service, with the care and maintenance or repair of the retarders 120-3.

Repair and maintenance work may only be enforced by qualified specialist-staff.



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Note

The used position numbers used in this manual corresponds to the position numbers in the spareparts lists in chapter 9 Annex.Exception:Items or parts with one -, as well as two-digit position-numbers are no spare parts and not listed inthe spare parts lists.Items or components shown with an oblique-number are not available.

For VOITH It is not possible to warn expressly of all possible situations at each position in thisservice manual, that could have a risk of injury for the worker and/or a damage for the retarder

120-3 to the consequence. Therefore it is desperately necessary, that everyone, entrusted with theservice, care, maintenance or repair of the retarder 120-3, does not endanger its own securitythrough the chosen operation and that the retarder gets no negative impairments, especially ofsafety-related types.VOITH is not liable for injury to persons and or damages caused through improper and unprofes-sional work.

The pertinent accident-prevention-regulation, other broadly rules of the security-technology andworking-medicine and the traffic admission law are to be kept. VOITH is not liable for damages, that

originate through contempt of these rugulations.

With the contact with oils, greases and other chemical substances, the current safety regulationsfor these products are to be heeded!

Caution with the contact with hot fuels! Danger of burn and scald!



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Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situationswhich might entail the risk of injury for the person carrying out the work. It is therefore imperative thatany person carrying out repair work on VOITH retarders uses his professional knowledge to make surethat his own safety is not endangered and that the retarder suffers no negative effects, in particularsafety-wise, through the chosen working procedure. For these reasons, no liability can be assumed fordamage incurred.

It is therefore expressly pointed out that all working procedures described must be carried out only incompliance with the valid general directions and regulations of the locally responsible authorities, of thehealth protection, accident prevention and environmental protection organisations.

The technical status of the present instructions can be seen from the date (see footer on left). There maybe discrepancies between the actual technical status of the retarders and the descriptions owing to

continuous development and improvement of the retarders.VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and without priornotification.



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General

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2 General

2.1 Retarder Data.............................................................................................2.1/1

2.2 Assembly Overview ....................................................................................2.2/1

With Stainless-Steel Heat Exchanger.................................................................2.2/1With Aluminium Heat Exchanger.......................................................................2.2/3

2.3 Function and Operation Scheme................................................................2.3/1



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2.1 Retarder Data

The retarder data (arrow) of the retarder 120-3 is punched on the output side of the retarder housing.

The retarder data plate provides the following information:

1. Serial number:

six-digit number

2. Item number:eight -digit number

Notice

Please, always quote the retarder serial-No. and item-No. when submitting queries or orderingspare parts.

Aftersales Service Manual VOITH Retarder 120-3Page 2.1/1

18001


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General

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2.2 Assembly Overview

Illustration VOITH Retarder R 120-3

Basic group with stainless-steel

heat exchanger

100/1 Retarder data plate

1000 Heat exchanger

1200 Non-return valve

1900 Oil filler/check plug M 30 x 1,5

Combined hex.-head, w.a.f. 24

21000 Damping plate

22000 Proportional valve

26000 Constant-air pressure line py30000 Pressure pick-up

33000 Oil temperature pick-up

34000 Cooling-water temperature pick-up

1900

100/1

1000

22000

33000

30000

34000

21000

26000

1200

18002



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Basic group with stainless-steel

heat exchanger (Continue)

1000 Heat exchanger1001 Coolant drain plug

M 18 x 1,5

Inhex.-head, w.a.f. 8

1700 Retarder oil drain plug

M 22 x 1,5


1700

1001

1000

18003



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Basic group with aluminium heat exchanger

100/1 Retarder data plate

1000 Heat exchanger

1001 Coolant drain plug M 12 x 1,5Combined hex.-head, w.a.f. 13

1900 Oil filler/check plug M 30 x 1,5


21000 Damping plate


26000 Constant-air pressure line py30000 Pressure pick-up

33000 Oil temperature pick-up

Note

The cooling-water temperature pick-up isplaced in the pipeline.

1900

100/1

1001

1000

22000

33000

30000

21000

26000

18004



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Basic group with aluminium heat exchanger

(Continue)

1000 Heat exchanger

1001 Cooling-water drain plugM 12 x 1,5


1002 Oil drain plug heat exchanger

M 12 x 1,5


1700 Oil drain plug retarder

M 22 x 1,5


18005

1700

1001

1000

1002



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General 2.3 Function and Operating Scheme

Illustration of VOITH Retarder 120-3

Note

The reference numbers indicated in Section 2.3 are not identical with the reference numbers of the spare parts lists.

1 Heat exchanger

2 Control unit4 Connectio n ter minal 157 Fuses (5A)

8 Connection ground12 Pump pressure test connection15 ABS-Signal16 Reta rder stage switch

37 Ventilati on line R

38 Pressure sensor43 Oil sump44 Stator

45 Stator pins46 Rotor47 Speedometer signal50 Output restrictor D1

R

P

A25

V

y

P

46

44 12 50

52

45

23

53

19

37

67

26

21

7 416 8

2

7015 47177418

69

43 166

20

38

18006e

Supply-air pressure p

Oil sump

Constant-air pressure p

Coolant (water)

Pump pressure p


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General

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2.3 Function and Operation Scheme

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Description of the function

The VOITH Retarder 120-3 is a powerful hydrodynamic continous brake of compact design for busesand commercial vehicles of the medium range. The VOITH Retarder 120-3 is mounted between thegearbox and the rear axle of the vehicle.

The retarder braking torque is sustained even when gear changes are made.The switched-on retarder will not secure a parked vehicle.

A retarder stage switch (16) with a maximum of 5 switching stages is used to control theVOITH Retarders 120-3. A special version combines the retarder stage switch (16) with ABS, a 3-stagepedal-operated brake valve or a service-brake pressure switch.

Operation with function ,,Constant speed"

The retarder is operated by a 5-stage retarder stage switch.

When the retarder stage switch (16) is shifted to position 1, the Constant Speed function is activated.The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limitof the maximum braking torque.

If the retarder is switched off (0 position), or switched to braking stage (position 2 to 5), the memorizedconstant speed is deleted. If the constant speed function is re-activated, the new present speedis memorized.

When the retarder stage switch is shifted to position 2 to 5, braking stage 1 to 4 is energized.

Maximum braking torque is obtained when the retarder stage switch is in the maximum position.

When overstepping the maximum possible cooling performance, the retarder braking torquewill be adapted.



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As a special version, the control system is available with push button operation for constant speed.The retarder is operated in this case by a 4-stage retarder stage switch.

When the push button is pushed in any position of the retarder stage switch, the momentary speed istransferred to memory. In the 0 braking stage, this transfer to memory takes effect and the retarder holds

the vehicle speed downhill constant within the limits of the maximum braking torque. Another push onthe push button in any switch position will delete the speed data.

On a downhill run with constant speed operation, the vehicle can be slowed down within the limits ofthe maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting tobraking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle acceleratesto the speed previously transferred to memory.

Description of operation of retarder R 120-3The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank forauxiliary equipment on the vehicle.

When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2).From this input signal, the control unit (2) provides a control current which flows to theproportional valve (21).

The proportional valve (21), depending on the magnitude of the control current, provides aconstant-air pressure pyon the oil sump (43).

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

c

a b

18007

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



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The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarderhousing.

The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between the rotor (46)and stator (44).

The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking ofthe rotor (46) and consequently to braking of the vehicle.

During braking, the kinetic energy of a deceleration is transformed into heat. To dissipate this heat, partof the circulat ing oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and viafilling ducts to join the circulating flow again.In the heat exchanger (3300), the heat energy of the oil is transferred to the cooling water of the vehicleand dissipated via the vehicle radiator to the ambient air.

If the vehicle ignition is switched on the puls lubrication is activated and lubricates the retarder bearings



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Temperatur pick-up, cooling-water (19), oil (20)

The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from theretarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water andoil temperature to the control unit (2).To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarderbraking torque is limited to protect the vehicle cooling system and the retarder.The constant-air pressure pyis l imited.

The braking torque and consequently the heat generated are reduced until a balance is obtained bet-ween the braking energy of the retarder and the amount of heat which can be dissipated by the vehiclecooling system.

If the cooling water temperature rises into the temperature adaption range, the consequence is a

limitation of the retarder braking torque to protect the vehicle cooling system. If the temperature risesabove thetemperature adaption range, there is no more braking torque output.

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

Additionally the control unit adapts the braking torque if oil temperature rises too rapidly, irrespective ofactual oil temperature.



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Casing ventilation (23)

During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) andthe ventilation system (22) out of the retarder.Once the working circuit is free of air, a float rises and closes the casing ventilation.

Stator pins (45)

When the working chamber is empty, the rotor (46) sets up in it an air flow, which is retarded by the stator(44). To minimize this loss, automatically operating stator pins have been installed in the outer zone ofthe stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent thebuild-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back ontheir seats against the force of the spring and the full space between the blades is available.

Non-return valve (66) stainless-steel heat exchanger

The non-return valve (66) prevents the airflow emptying the heat exchanger insert of oil when idling.



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Maintenance 3 Maintenance

3.1 Maintenance Work / Oil Change Intervals..................................................3.1/1

3.2 Checking Oil Level .....................................................................................3.2/1

3.3 Oil Change .................................................................................................3.3/1

With Stainless-Steel Heat Exchanger ... .........................................................................3.3/1

With Aluminium Heat Exchanger ................................................................................... 3.3/5



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Maintenance 3.1 Maintenance Work / Oil Change Intervals

Overview of maintenance work

Carry out the fo llowing maintenance workat each oil change

Carry out visual inspection on leaks at the complete retarder Check hex.-head screws of prop shaft on correct fitment, or tighten if necessary.

Observe guidelines and instructions! Tighten all screw plugs of the heat exchanger and retarder basic groups with the appropriate

torque (see annex) Excerpt of this are the fastening nuts and -screws of the heat exchanger (see chapter 7).

Caution!

Tighten fastening nuts and -screws of the heat exchanger only in case of leakage betweenheat exchanger and retarder.Tightening torque: 23 Nm



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1) Operating specifications, see annex

2) Change oil at the latest after 2 years if fewer kilometres are travelled.

Single-grade

mineral oil 1)Multi-grade

mineral oil 1)Synthetic /

part synthetic oil 1 )

Truck

Normal duty90.000 km 2) - 135.000 km 2 )

Truck

Heavy duty45.000 km 2) - 90.000 km 2)

BUS

Normal duty135.000 km 2 ) 90.000 km 2) 180.000 km 2 )

BUSHeavy duty

60.000 km 2) 45.000 km 2) 90.000 km 2)



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1. Normal duty

Example:- Long distance traffic

2. Heavy dutySubject to more than normal stress.

Examples:- Use in regions with high ambient temperatures- Vehicles at construction sites and timber lorries- High max. permissible weight with low rated engine power (< 6 kW/metric ton)- Stretches with lots of hills and valleys- Extreme short-distance traffic with lots of gradients

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

With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as otherfactors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervalsbetween oil changes in individual cases.

For use in extremely cold zones, oils in an appropriately lower viscosity class(TransmaxZ or SEA 5W-40) must be used.

In doubts, please contact VOITH TURBO.



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Maintenance 3.2 Checking Oil Level

Illustration checking oil level

Note

The oil change intervals are listed in chapter3.1, the operating specifications are listed in theannex.

1800 Sealing ring A 30 x 36renew

1900 Oil filler/check plug M 30 x 1,5Combined hex.-head, w.a.f. 24,

150 Nm

Note

The illustration shows a retarder 120-3 withstainless-steel heat exchanger.Checking oil level with aluminium

heat exchanger version is identical.

1800

1900

18008



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Note

For satisfactory retarder operation, it is important to use only oils specified in the operating specifications

(see Annex) for operating the retarder in the relevant application.

Service filling

The service filling for the complete retarder system depends on the version of the mountedheat exchanger, see table on page 3.3/2 and of the mounting position (see data sheet in chapter 9).

For relevant application approved oils

Use only approved oils specified in the operating specifications (see Annex).



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Note

For the oil level check, the temperature of the retarder oil must be higher than 60C (operating tempera-

ture).

The oil level check must be carried out with the vehicle in a horizontalposition.

Mind the slanted mounting position.

The difference between min. and max. mark on oil filler/check plug is approx. 0,5 l.

Job scope

1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec.Repeat this procedure twice.

Caution!

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

2. Switch off the retarder andwait 5 minutes (control function).



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Caution! Risk of injury!

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

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

4. Position oil filler/check plug (1900) plane at the thread.

Do not screw in the oil filler/check plug!

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

6. Top up slowlyany lacking oil through the hole for the oil filler/check plug.

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

Max

Min

1900

18009



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Maintenance 3.3 Oil Change

Illustration oil change R 120 -3

with stainless-steel heat exchanger

1700 Retarder oil drain plug M 22 x 1,5Inhex.-head, w.a.f. 10, 66 Nm

1800 Sealing ring A 30 x 36, Copper,renew

1900 Oil filler/check plug M 30 x 1,5Combined hex.-head, w.a.f. 24,150 Nm


1900

1800

1700

18010


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Note

For satisfactory retarder operation, it is important to adhere to the specified service f illing (see table be-low) and to use only oils specified in the operating specifications (see Annex) for operating the retarderin the relevant application.

* with slant mounted position of the retarder up toapprox. 4 - reduce service filling of approx. 0,25 Litre,approx. 8 - reduce service filling of approx. 0,50 Litre.

The retarder oil temperature must be higher than 60 oC(operating temperature) for the oilto be checked.

Caution!

While the oil is being changed, make sure that no constant-air pressureis acting on the retarder.The retarder and the ignition must be switched off!

Type of heat exchangerService-

filling *

after complete taking apart

and cleaning, as well as

emptied heat exchanger *

after exchange of

heat exchanger *

Stainless-steelheat exchanger

4,5 Litre 5,8 Litre 6,5 Litre



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Job scope

1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec. Repeat this procedure twice.Switch off the retarder andignition and wait 5 minutes (control function).


The oil filler/check plug is hot! Oil temperature!

2. Push an oil collecting pan under retarder.

3. Screw out the oil check plug (1900) and remove sealing ring (1800).


The retarder oil drain plug is hot! Oil temperature!

4. Screw out the retarder oil drain plug (1700) and drain oil.



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5. Check sealing ring of oil drain plug on damages and replace oil drain plug, if necessary.

6. Place oil drain plug (1700) in bore and screw tight.Tightening torque 66 Nm

7. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified(see page 3.3/2) in accordance with the operating specifications (see Annex).

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

Note

Please read the oil change intervals in chapter 3.1 and operating specifications in the annex!



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Illustration oil change R 120-3

with aluminium heat exchanger

1002 Heat exchanger oil drain plug

M 12 x 1,5Inhex.-head, w.a.f. 6, 25 Nm1700 Retarder oil drain plug M 22 x 1,5

Inhex.-head, w.a.f. 10, 66 Nm1800 Sealing ring A 30 x 36

renew1900 Oil filler/check plug M 30 x 1,5

Combined hex.-head, w.a.f. 24,150 Nm


1800

1900

1002

1700

18011


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Note

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

* with slant mounted position of the retarder up toapprox. 4 - reduce service filling of approx. 0,25 Litre,

approx. 8 - reduce service filling of approx. 0,50 Litre.

The retarder oil temperature must be higher than 60 oC(operating temperature) for the oilto be drained.

Caution!

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

Type of heat exchanger Service filling * New filling *

Aluminium heat exchanger 5,5 l 6,0 l



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Job scope


The oil filler/check plug is hot! Oil temperature!

1. Push an oil collecting pan under retarder.

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


The oil-drain plugs are hot! Oil temperature!

3. Screw out the retarder oil drain plug (1700) and the heat exchanger oil drain plug (1002) and drainoil.

4. Check sealing ring of oil drain plug on damages and replace oil drain plug, if necessary.



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5. Place oil drain plug (1700 and 1002) in its appropriate bore and screw them tight.

Retarder oil drain plug (1700), Tightening torque 66 NmOil drain plug heat exchanger (1002), Tightening torque 25 Nm

6. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified(see page 3.3/6) in accordance with the operating specifications (see Annex).

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

Note

Please read the oil change intervals in chapter 3.1 and operating specifications in the annex!



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Diagnosis /

Troubleshooting

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4 Diagnosis / Troubleshooting

4.1 Troubleshooting Diagram...........................................................................4.1/1Troubleshooting Diagram A to D ................................................................................... 4.1/1Electrical Connections Diagram Variant 1 and 2 ........................................................... 4.1/6

4.2 Troubleshooting and Remedies .................................................................4.2/14.3 Illustration Control System .........................................................................4.3/1

4.4 Checking Supply-Air Pressure ...................................................................4.4/1

4.5 Checking Constant-Air Pressure ................................................................4.5/1

4.6 Checking Control Current of Proportional Valve ........................................4.6/14.7 Checking Temperature Adaption................................................................4.7/1

4.8 Checking Pressure Sensor.........................................................................4.8/1

4.9 Checking Pump Pressure...........................................................................4.9/1

4.10 Table of Measurements..............................................................................4.10/1

4.11 Operational Check......................................................................................4.11/1



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Diagnosis /

Troubleshooting

4.1 Troubleshooting Diagram

Illustration troubleshooting diagram main groups

Note

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

ComplaintR 120-3

Oil lossthrough

ventilation

Retarder

pilot light

Oil loss

input / outputside

No respectivelytoo insufficientretarder braking

effect

B

A

C

i i


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Diagnosis /

Troubleshooting


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Illustration troubleshooting d iagram group A

Oil loss

through

ventilation

A

Checkretarder oil level

NOK OK

Yes No

Water in oil?(emulsion)

YesNo

Water in oil?(emulsion)

see chapter 7

Checkheat exchanger

ContactVOITH

OK NOK

Checkcasing ventilation

(chapter 6.2)

Replacecasing ventilaton

(chapter 6 2)

Check non-return valvein stainless steelheat exchanger

toohigh

toolow

Checkretarder oil level

Correct

retarder oil level

4 1 T bl h ti Di


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Troubleshooting


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Illustration troubleshooting d iagram group B

Retarderpilot light

B

NOKOK

NOKOK

Check temp. pick-up

(water, oil)and its electrical leads

(see chapter 4.7)

Check vehicle cooling

Check operation(during braking with

retarder nominal enginespeed, if possible)

Permanent lightin position 0after light test

Read outfault code

(see chapter 4.2)

Rectify fault anddelete fault memory

(see chapter 4.2)

Driver instruction

Temperatureadaptation

Replace

no function

ContactVOITH

flashes

Di i / 4 1 Troubleshooting Diagram


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Diagnosis /

Troubleshooting


(Continue)

Illustration troubleshooting d iagram group C

Oil lossinput / output

side

C

NOYES

Water in oil

(emulsion)

Replaceheat exchanger(see chapter 8)

Checkradial shaft sealing ring on

input or output side(see chapter 6.7, 6.8)

If problem occours againafter a test trialcontact VOITH

Di i / 4 1 Troubleshooting Diagram


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Diagnosis /

Troubleshooting


(Continue)

Illustration troubleshooting d iagram group D

Check oil level

of retarder

OK NOK

Yes No

Water in oil(emulsion)

YesNo

Water in oil(emulsion)

see chapter 7

Checkheat exchanger

Correct oil levelof retarder *

OK NOK

OKNOK

Checkp (dynamic)

(see chapter 4.9) NOKOK

Check proportionalvalve current

(see chapter 4.6)

NOKOK

Checktemperaturepick-up and

pressure sensor(chapter 4.7, 4.8)

Checkp (static)

(see chapter 4.5)y

Check supply-airpressure

(see chapter 4.4)

No respectivelytoo insufficientretarder braking

effect

D

ContactVOITH

ContactVOITH

C t t C t t

* If problem occours again after a test trialcontinue at "Checking casing ventilation"

Diagnosis / 4 1 Troubleshooting Diagram


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Diagnosis /

Troubleshooting


(Continue)

Electrical connections diagram variant 1 (spli tted connections of temperature pick-ups)

Electrical connections diagram variant 2 (united connection of temperature pick-up)

Pressure sensor + 5V

Stop light relais

Speed signal

Propvalve +

Output / low side 1 LS 1Output / high side HS 2

Output / high side 1 HS 1

Propvalve -

T 30 (Battery)

T 31 (Ground)

Stage switch+

ISO LISO K

Position 5Poition 4Position 3Position 2Position 1CAN-lowCAN-MasseCAN-high

T 15 (Ignition lock)

Switch valve -Switch valve +

Water temp.-Water temp.+

Oiltemp.+Oilltemp.-

ABSblue

white

white

white

black

rosa

pink

blue/white

blue/white

brown/whiteorange/white

orange/white

orange

orange

yellow/green

yellow/green

grey/black

grey

blueviolett

32

3

1211

10

151413181716

21654987

7

32165498

1654987

12

12pol.X3.

9pol.X2.

18pol.X1.

Digiprop

11

10

grey

brownbrown

beige

beige

redred

grey

grey

pinkblue

black/white

black/whiteyellow/green

Input / p.-down / PWM-in DID 4 Pressure sensor signal

Input / pull-down DID 3

Input / pull-up DIU 1Pressure sensor - GroundInput / pull-down DID 1Input / pull-down DID 2

Pilot light

violettviolett

Stop light relais

Speedom. signal

T 31 (Ground)

Position 5Position 4Position 3Position 2Position 1


Propvalve +Propvalve -

Switch valve -Switch valve +

Water temp.-Water temp.+

Oil temp.+Oil temp.-

ABS

Pilot light

9 5 4 3 2 7 6 101112 13 1481

Connection 14 pole"Optional Functions"

"ISO Interface"Connection 4 pole

7653284

3 21 4

Stage switch +

"Stage switch"Connection 8 pole

+

+

Cable Retarder

Cable E-Fach

3

4

2

1Pin

orange

3 21 4

red/white

Connection 4 pole"Pressure sensor" 18017e

Prop valve +

Output / low side 1 LS 1Output / high side HS 2

Output / high side 1 HS 1T 30 (Battery)

T 31 (Ground)

Stage switch +ISO LISO K

Position 5Position 4Position 3Position 2Position 1CAN-lowCAN-GroundCAN-high


3

121110

151413181716

7

32165498

18pol.X1.

Digiprop

T 31 (Ground)

Position 5Position 4Position 3Position 2Position 1


Prop valve +

"ISO Interface"Connection 4 pole

765328

4

3 21 4

Stage switch +

"Stage switch"Connection 8 pole

+

Cable Retarder

Cable E-Fach

2

1Pinpink

white

black

blue/whiteorange/white

orange

brownbrown

beige

red

redgrey

pinkblue

black/whiteyellow/green

violettviolett


45/131


46/131

Diagnosis /

Troubleshooting

cbtd 2000-0153.2688.10

4.2 Troubleshooting and Remedies

(Continue)

Note

The retarder pilot light additionally has the function of a fault code:

Permanent light in position 0 - 5 of retarder stage switch

- slight fault

Braking is still possibleto limited extent.

- serious fault

Braking is no longer possible- the retarder is switched off.

Notice

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



47/131

Diagnosis /

Troubleshooting

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18019

147101316

258111417

369121518


(Continue)

Connector arrangement and pin assignment

Notice

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

Plug X1 Control unit

1 Not in use

2 Not in use3 Not in use4 Retarder stage swi tch , position 3 (or)5 Retarder stage swi tch , position 2 (b l)6 Retarder stage swi tch , position 1 (p i)7 Terminal 15 (rd)8 Retarder stage swi tch , position 5 (gr)9 Retarder stage swi tch , position 4 (wh)10 Retarder stage swi tch + ( vi)

11 ISO- interface, L- lead (or/wh)12 ISO- interface, K- lead (bl/wh)13 Connected w ith terminal 15 (b l)14 Not in use15 Terminal 31 (br)16 Output / high side 2 HS2 (bl/wh)17 Output / low side 1 LS1 ( ye/gr )18 Output / high side 1 HS1 (be)



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Diagnosis /

Troubleshooting

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(Continue)


1 Not operational (or)2 Proportional valve - (gr)3 Proportional valve - (pi)4 Cooling water temperature pick-up - (b l)

5 Cooling water temperature pick-up + (ye/gr)6 Not operational/ground (be)7 Not in use8 Oil temperatur e pi ck-up - (wh)9 Oil temperatur e pi ck-up + (vi)


1 Input / pull up DIU 1 (wh)2 Speedometer signal (bl)3 ABS-Signal (bl/wh)4 Input / pull down DID 2 (br/wh)5 Input / pull down DID 1 (bl/wh)

6 Pressure sensor ground (pi)7 Pressure sensor signal voltage (gr/bl)8 Retarder pi lot light (ye/gr)9 Input / pull down DID 3 (or/wh)10 Pressure sensor supply voltage (rd/wh)11 Stop light relay (or)12 Input / pull down / PWM-in DID4 (gr)

18020

147

258

369

18021

14710

25811

36912



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Diagnosis /

Troubleshooting

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(Continue)

Extra o perations plug

1 Retarder stage switch + (vi)2 Input / pull down DID 1 (bl/wh)3 Input / pull down DID 2 (br/wh)4 Input / pull down DID 3 (or/wh)

5 Input / pull down / PWM -in DID 4 (gr )6 Input / pull up DIU 1 (wh)7 Pressure sensor ground (pi)8 Pressure sensor signal voltage (gr/bl)9 Pressure sensor supply vo ltage (rd/wh)10 Output / high side 1 HS1 (be)11 Output / high side 2 HS2 (bl/wh)12 Output / low side 1 LS1 ( ye/gr )13 Terminal 15 (rd)

14 Terminal 31 (br)

ISO-Interface plug

1 K-lead (bl/wh)2 L-lead (or/wh)3 Terminal 15 (rd)4 Terminal 31 (br)

2

1

4

3

6

5

8

7

10

9

12

11

14

13

18022

2 1

4 3

18023



50/131

Diagnosis /

Troubleshooting

cbtd 2000-0153.2688.10


(Continue)

Bajonet socket cooling-water temperature pick-up

Variant 1

1 Cooling-water temperature pick-up + (ye/gn)2 Cooling-water temperature pick-up - (bl )3 Not operational

4 Not operational

Plug cooling-water temperature pick-up

Variant 2

1

2

3

4

18024


18025


51/131

Diagnosis /

Troubleshooting

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(Continue)

Proportional valve plug

1 Proportional valve + (pi)2 Proportional valve - (gr)3 Not operational4 Not operational

Retarder stage switch plug

1 Not in use2 Position 5 - (gr)3 Position 4 - (wh)4 Retarder stage switch + (vi)5 Position 3 - (or)

6 Position 2 - (bl)7 Position 1 - (pi)8 Bridge to pin 4

18026

1 2 3 4

5 6 7 8


1

2

3

4

18024


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Diagnosis /

Troubleshooting

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(Continue)

Plug pressure sensor

1 Pressure sensor - 5V (rd/wh)2 Pressure sensor - Signal (gr /b l)3 Not in use4 Pressure sensor - ground (pi)

1

2

3

4

18024



53/131

Diagnosis /

Troubleshooting

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(Continue)

A. With fault code

Special tool

Commercially available tool

Note

The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-outfrom the fault memory.

Additionally a diagnosis via PC-Software DigiDia and PC-Interface is possible.Therefore, please contact VOITH TURBO or one of our service partner.

Multimeter recommended: Fluke 87

53.8224.10



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Diagnosis /

Troubleshooting

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(Continue)

Fault memory readout via retarder pilot light b linking code

Note

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

Before and after each output of the blinking code you have a break of 3 seconds. The retarder pilot lightis off during this break.

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

The number of tens units first indicated as long ON time: each 2 secondsThe number of single unit then is indicated as short ON time: each 0,5 secondsBreaks between each ON time: each 1 second

Excerption:

The fault Coding faulty is not stored, but the blinking code is displayed.



55/131

Diagnosis /

Troubleshooting

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(Continue)

There are two possibilities for activating the blinking code:

a) Fault memory readout via retarder pilot light blinking code

During the service function (speed = 0, ignition OFF, ignition ON) the blinking code can be displayed

by using the retarder pilot light:

1. Retarder stage switch - engage position 02. Retarder stage switch - engage position 1 ( 2 seconds)3. Retarder stage switch - engage position 04. First fault as blinking code output5. Repeat working step 1 to 3 for further blinking code outputs

b) Fault memory readout via service cable

Requirements

Retarder stage switch in position O.

Vehicle at standstill, ignition ON

1. Service interface L-lead connected to ground 2s. For this pupose, press L - push button atservice cable.

2. First fault as blinking code output.3. Repeat working step 2 and 3 for further blinking code ouputs


18027

2

sec

1

sec

1

sec

1

sec

1

sec

2

sec

0,

5

sec

0,

5

sec

0,

5

sec

Display example for fault code 23

E Retarder pilot light ONA Retarder pilot light OFFt Time

4 2 T bl h i d R di


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Diagnosis /

Troubleshooting

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(Continue)

Delete fault memory

No read outs according to fault memory.

1. Ignition: OFF

2. Service interface L-lead connected to ground.For this pupose, press L - push button at service cable.

3. Ignition: ON

4. Disconnect L-lead of ground after more than 2 seconds.


4 2 T bl h ti d R di


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Diagnosis /

Troubleshooting

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(Continue)

Notice

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

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

Fault Fault text Fault

class

Trigger time Requirement /

Operation

Measurement/

Test connection1 )Result/

Set point

Cause/

Remedy 2)

Code Test step

01 Stop light relay/

Short circuit toground

slight 1 s - Ignition: OFF

- Pull plug X3 out ofcontrol unit

X 3/11 X 1/15 Relay is

installed:250-350

Check lead, plugs

and relay orconsumers

02 LS 1 output

Short circuit tobattery

slight 400 ms - Ignition: OFF- Pull plug X1 out of

control unit- Disconnect plug for extra operation

(e.g. lamp orrelay)

- Ignition: ON

X 1/17 VX 1/15 0 V Check lead, plugsand relay orconsumers


4 2 Tro bleshooting and Remedies


58/131

Diagnosis /

Troubleshooting

cbtd 2000-0153.2688.10


(Continue)


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/

Remedy

Code Test step

03 HS 1 output

Short circuit

slight 1 s - Ignition: OFF- Pull plug X1 out of

control unit

X 1/18 X 1/15 Relay isinstalled:250-350

Check lead, plugsand relayor consumers

04 HS 2 output

Short circuit

slight 1 s - Ignition: OFF- Pull plug X1 out of

control unit

X 1/16 X 1/15 Relay isinstalled:250-350

Check lead, plugsand relayor consumers

05 Terminal 15

Undervoltage

serious 60 s - Ignition: OFF- Pull plug X1 out of

control unit- Ignition: ON

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

06 Terminal 15

Overvoltage


control unit- Ignition: ON- Start engine

(idle speed)

X 1/7 VX 1/15 32,5 V Checking electricalinstallation of vehicle(see manufacturerinstructions)

Aftersales Service Manual VOITH Retarder 120-3Seite 4.2/14

4 2 Troubleshooting and Remedies


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Diagnosis /

Troubleshooting

cbtd 2000-0153.2688.10


(Continue)

* 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/

Remedy

Code Test step

08

09

Cooling-watertemperaturepick-up

Discontinuity /Short circuit tobattery

serious/slight *

1 s - Ignition: OFF- Pull plug X2 out of

control unit

X 2/5 X 2/4 20C 10C =1039 - 1117

60C 10C =1099 - 1271

80C 10C =1271 - 1347

Notice:

The measuringin one tempera-ture rangenormally issufficient.

Check lead andtemperature pick-up


Di i / 4 2 Troubleshooting and Remedies


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Diagnosis /

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(Continue)

* 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/

Remedy

Code Test step

11

12

Oil temperaturepick-up

Discontinuity /Short circuit tobattery

serious/slight *

1 s - Ignition: OFF- Pull plug X2 out of

control unit

X 2/9 X 2/8 20C 10C =1039 - 1117

60C 10C =1099 - 1271

80C 10C =1271 - 1347

Notice:

The measuringin one tempera-ture rangenormally issufficient.

Check lead andtemperature pick-up


Di i / 4 2 Troubleshooting and Remedies


61/131

Diagnosis /

Troubleshooting

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(Continue)


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/

Remedy

Code Test step

13 1 Retarder stageswitchUndefinedswitch state

serious 100 ms - Ignition: ON- Retarder stage switch:

Position 0

X 1/10VX 1/15

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

17,5 V

0 V0 V0 V0 V0 V

Check lead, plug andretarder stage switch

13 2 - Ignition: ON- Retarder stage switch:

Position 1

X 1/10VX 1/15X 1/6VX 1/15

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

17,5 V 17,5 V

0 V0 V0 V0 V


13 3 - Ignition: ON

- Retarder stage switch:

Position 2

X 1/10VX 1/15

X 1/6VX 1/15X 1/5 VX 1/15

X 1/4 VX 1/15X 1/9 VX 1/15X 1/8 VX 1/15

17,5 V

17,5 V 17,5 V

0 V0 V0 V

Check lead, plug and

retarder stage switch


Diagnosis / 4.2 Troubleshooting and Remedies


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Diagnosis /

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(Continue)


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/

Remedy

Code Test step


Position 3

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

X 1/9VX 1/15X 1/8VX 1/15

17,5 V

17,5 V

17,5 V

17,5 V

0 V0 V



Position 4

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

X 1/8 VX 1/15

17,5 V 17,5 V

17,5 V

17,5 V

17,5 V

0 V


13 6 - Ignition: ON

- Retarder stage switch:Position 5

X 1/10VX 1/15

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

17,5 V

17,5 V 17,5 V

17,5 V

17,5 V

17,5 V

Check lead, plug and

retarder stage switch




63/131

Diagnosis /

Troubleshooting

cbtd 2000-0153.2688.10


(Continue)


class

Trigger time Requirement / Operati-

on

Measurement/

Test connection

Result/

Set point

Cause/

Remedy

Code Test step

14 Retarder stageswitchShort circuit tobattery


control unit- Ignition: ON- Retarder stage switch:

Position 0

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

15 Retarder stage

switchShort circuit tobattery

serious 1 s - Ignition: OFF

- Pull plug X1 out ofcontrol unit

- Retarder stage switch:Position 5

X 1/10X 1/15 Resistor

infinite

Single check of

stages forshort circuit

16 SpeedometersignalDiscontinuity

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




64/131

Diagnosis /

Troubleshooting

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(Continue)


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/

Remedy

Code Test step

18 Speedometer signal

Short circuit to battery



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

19 ABSShort circuit to ground

serious 60 s - Ignition: ON X 3/3VX 1/15 3,5 V Check lead,relay andABS-control unit

21 ABS-Signal undefined serious 60 s - Ignition: ON X 3/3VX 1/15 16,5 V Check lead,relay andABS-control unit

22 Internal faultABS-current path

serious 1 s - - - Replace controlunit

23 Proportional valveFault No. 1:

Short circuit to battery



X 2/3VX 1/15 10 V Check lead




65/131

Diagnosis /

Troubleshooting

cbtd 2000-0153.2688.10

g

(Continue)


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/

Remedy

Code Test step

24 1 Proportional valveFault No. 2:- Short circuit proportional

valve magnetic- Short circuit connection

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

24 2 - Ignition: OFF- Pull plug X2 out of control unit

X 2/3X 1/15 Resistorinfinite

Check lead andproportionalvalve(valve block)



66/131



67/131

g

Troubleshooting

cbtd 2000-0153.2688.10

(Continue)


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/

Remedy

Code Test step

29 Fault control unit serious 180 ms Replacecontrol unit

31 Control unit:Coding fault

serious 100 ms Provide new para-meters for controlunit

32 Retarder pilot light:Discontinuity /

Short circuit to ground



X 3/8VX 1/15 17,5 V Check lead,retarder pilot

light and fuse

33 Retarder pilot light:Short circuit to battery

serious 3 s - Ignition: ON- Retarder stage

switch:Position 1

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

35 Fault control unit serious 500 ms / 123 s Replace

control unit

37 Fault foot operation slight 100 ms / 1 s Check installationaccording toOEM- e.g.Voith instructions




68/131

g

Troubleshooting

cbtd 2000-0153.2688.10

(Continue)


class


Operation

Measurement/

Test connection

Result/

Set point

Cause/

Remedy

Code Test step

38 1 Fault Constant-airpressure

slight 1 s to 10 s Ignition: ONPosition 0

X 3/7 VX 1/15

X 3/10VX 1/15

0 bar =0,3-0,7 V

2,5 bar=2,8 - 3,2 V

4,75-5,25 V

Pressure pick-upWiring harness

At deviations:

Step 2

2 Troubleshooting inwiring harness,pressure pick-up,proportional valve,supply-air pressure,ECU (contact VOITHTURBO)




69/131

Troubleshooting

cbtd 2000-0153.2688.10

(Continue)

B. Without fault code

Note

Retarder faults without fault code are not recognized electronically.


Diagnosis /

Troubleshooting

4.3 Illustration Control System


70/131

Illustration checking control system

Note

The reference numbers indicated in Section 4.3are not identical with the reference numbers of

the spare parts li sts.

1 Heat exchanger2 Con tro l un it


current connection19 Temperatur pick-up cooling water

alternative: positions 19 and 20joining in the central-plug

(see electrical diagram Version 2)20 Temperature pick-up oil21 Proportional valve25 Constant-air pressure line py

(Connection A)26 Supply-air pressure line pv

(Connection P)

31 Compressed air line(pressure regulator - four-circuitprotection valve)

32 Compressed-air pressure line

(four-circuit protection valve -air tank for auxiliary equipmentwith test connection

33 Compressed-air line(brake circuit No. 1)

34 Compressed-air line(brake circuit No. 2)

35 Compressed-air line

(parking brake)37 Ventilation line R39 Electrical lead (cooling-water

temperature pick-up to control unit,2 wires)

40 Electrical lead (oil temperature

pick-up to control unit, 2 wires)61 Four-circuit protection valve71 Air tank for auxiliary equipment

P

A

7132

33

31

3435

61

39

19

1

40

202

25

11

21

26

18028

Diagnosis /

T bl h i

4.4 Checking Supply-Air Pressure


71/131

Troubleshooting

cbtd 2000-0153.2688.10

Checking supply-air pressure pv

1. Connect test pressure gauge (99/1) to test connection of compressed-air line (32)(four circuit protection valve - air tank for auxiliary equipment) and check supply-air pressure pv.

Minimum pressure 6 bar

Maximum pressure 11 bar

Note

If the pressure is not within the specified range, the service brake must be checked to the manufacturer sdata.


1802932

Diagnosis /

T bl h ti

4.5 Checking Constant-Air Pressure


72/131

Troubleshooting

cbtd 2000-0153.2688.10

Requirements for check

Retarder stage switch in position 0

Vehicle ignition system OFF

Special tool

Compressed-air gauge0 to 6 bar

53.1403.10


Diagnosis /

Troubleshooting

4.5 Checking Constant-Air Pressure

(Continue)


73/131

Troubleshooting

cbtd 2000-0153.2688.10

(Continue)

Job scope test

1. Screw out oil filler/check plug M 30x1,5 (1900) and remove sealing ring (1800).

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

3. Shift the retarder stage switch to switch position 5 and compare read-off value with the given valuesof the constant-air pressure pyon table in chapter 4.10.

4. Screw oil filler/check plug (1900) tight with new sealing ring (1800).

Tightening torque 150 Nm

1800

1900

18030

99

99/7

18031

99/7 Pressure gauge 53.1403.10


Diagnosis /

Troubleshooting

4.6 Checking Control Current of Proportional Valve


74/131

Troubleshooting

cbtd 2000-0153.2688.10


Battery voltage 18 - 32 V Vehicle electrical system checked in accordance with the Owner s Manual for the vehicle and found

satisfactory. Fuse for retarder control unit checked and found satisfactory. Plug at proportional valve and socket for damage as well as wear (notch scratches) checked and

found satisfactory.

Special tool

Measuring adapter



53.8198.10


Diagnosis /

Troubleshooting

4.6 Checking Control Current of Proportional Valve

(Continue)


75/131

Troubleshooting

cbtd 2000-0153.2688.10

(Continue)

Job scope

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

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

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

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

5. Shift the retarder stage switch in position 5 and compare the read-off value with the given valuesof the control current of the proportional valve in accordance with the tables (see page 4.10).

Notice

If the control current is reached but the constant-air pressure pyis not, there are either outer leakyness,or the proportional valve is defective and must be renewed.If both values are not reached, please read chapter 4.2 Troubleshooting and Remedies.

99/3 Measuring adapter Propstrom 53.8198.10

98/8 Multimeter


18032

98/8

99/3

21

Diagnosis /

Troubleshooting

4.7 Checking Temperature Adaption


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Troubleshooting

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Battery voltage 18 - 32 V

Vehicle ignition system OFF

Pressure gauge constant-air pressure (99/7) connected

Connected measuring adapter (99/3)

Vehicle electrical system checked in accordance with the Owners Manual for the vehicle and

found satisfactory. Fuse for retarder control unit checked and found satisfactory.

Special tool

Temperature- Adapter cable

simulator


Wasser l

53.8207.10 53.8279.10


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Diagnosis /

Troubleshooting

4.7 Checking Temperature Adaption

(Continue)


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(Continue)

Job scope test

Prior job

Ignition ON

1. Set the rotary switch of the temperature simulator (99/2) to 95C cooling water temperature and

165C oil temperature operate the retarder at the highest stage.The constant-air pressure pyand the control current must reach the values (see page 4.10/1).

2. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. Theconstant-air pressure pymust drop temporary below the set maximum value. Set rotary switch ofthe temperature simulator (99/2) to 125oC cooling water temperature. There must be no more out-put of constant-air pressure py.

3. Ignition OFF

4. Reconnect ellectrical connection to temperatur pick-ups for cooling-water (39) and oil (19).

5798/5

99/2

18033

99/2 Temperature simulator 53.8207.10


Diagnosis /

Troubleshooting

4.8 Checking Pressure Sensor


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Ignition OFF Pressure gauge constant-air pressure connected Retarder stage switch in position 0

Special tool

Measuring adapter



53.8198.10


Diagnosis /

Troubleshooting

4.8 Checking Pressure Sensor

(Continue)


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( )

Job scope test

1. Disconnect plug from pressure pick-up (38) and connect to measuring adapter (99/3).

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

3. Connect ground lead of multimeter (98/8) to measuring plug 4 of the adapter (99/3).

4. Turn switch Propvalve at measuring adapter (99/3) downwards (not in position I ).

5. Connect the positive lead of multimeter to measuring plug 1.

6. If ignition is ON, the measured voltage must be between 4,75 and 5,25 V.

7. Connect the positive lead of multimeter to measuring plug 2.

8. Compare measured voltage in dependency of the constant-air pressure with the following values :0 bar = 0,3 - 0,7 V2,5 bar = 2,8 - 3,2 V

9. Ignition OFF

10. After removing the measuring adapter, connect again electrical lead with pressure sensor (38).


18034

98/8

99/3

38

18035

98/8

99/3

38

Measurements of the signal voltage atmeasuring plug 2 and measuring plug 4

Measurements of the supply voltage at

measuring plug 1 and measuring plug 4


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Diagnosis /

Troubleshooting

4.9 Checking Pump Pressure

(Continue)


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Preconditions for test

Constant-a ir pressure (py) checked and found satisfactory No outer leakages at the retarder


The screw plug is hot!

Job scope

1. Screw out hex.-head screw M12x1,5 (101) at retarder housing.

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

99/1

18037

99/1 Pressure gauge 53.4788.10


Diagnosis /

Troubleshooting

4.9 Checking Pump Pressure

(Continue)


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Job scope dynamic

1. Drive the vehicle with a prop shaft speed of vps = 1000 r.p.m..Engage direct gear (gear ratio 1:1), and drive with an engine speed of 1000 r.p.m..

2. While on the move, shift the retarder stage switch (16) to position 5 and read dynamicpump pressure off test pressure gauge (99/1) at prop shaft speed vps= 1000 r.p.m..

3. Compare read-off pump pressure with the value of dynamic pump pressure according to the table(see page 4.10/1).

Caution!

If the setpoint is obtained in the test at a standstill (see chapter 4.5), but the minimum value is notreached in the dynamic test, please contact VOITH TURBO!


The screwings of the pressure gauge and retarder are hot!

4. Disconnect the pressure gauge.

5. Check sealing ring of screw plug on damages; renew screw plug, if necessary.

6. Screw screw plug (101) tight.Tightening torque 25 Nm


Diagnosis /

Troubleshooting

4.10 Table of Measurements


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The data represent the state of the art at the time of going to print.The manufacturer reserves the right to m ake further modifications.

1) The code number is to be found on the control unit.2) If a commercially available multimeter is used for measurements (without real effective measuring),

exact readings cannot be made ( indication jumps).3) Decisive is the pressure which has built up itself after 10 seconds (stabilized, constant pressure).4) Retarder stage switch in highest braking stage.5) As a result of permanent readjustments in the control circuit, the values may under circumstances

not be constant (but within the specified range).

Setting [Nm] Code Number 1 ) Control current [mA]2) 4) 5) Constant-air pressure py3) 4)

(static)

set point [bar]

Pump pressure dynamic 4)

vps = 1000 r.p.m.

minimum value [bar]

1500 034 376 - 576 1,75 2,05 12

1750 035 396 - 596 2,05 2,35 14

2000 036, 054 416 - 616 2,35 2,65 16


Diagnosis /

Troubleshooting

4.11 Operational Check


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Battery voltage 18 - 32 V Electrical system checked in accordance with the Owner s Manual for the vehicle

and found satisfactory. Constant-air pressure 6 -11 bar Retarder oil level satisfactory

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

Retarder pilot light without indication

The retarder is switched off. There is no fault in the memory.

Retarder pilot light permanently on

The retarder is switched on, i.e., one of the four possible retarder braking stages orConstant Speed operation has been selected with the retarder stage switch.

The retarder pilot light additionally has the function of a fault indicator.

The retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch.- slight fault

Braking operations are possible (the retarder operates with limited braking torque).

- serious faultThere are no more braking operations possible - the retarder is switched off.


R

18038

Diagnosis /

Troubleshooting


(Continue)


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Note

If the ignition is switched off and on again, the retarder is in operation and the retarder pilot lightis going off.If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on in

position 0 to 5 of the retarder stage switch.

Retarder pilot light f lashes

- while the retarder is braking

The temperature limitation is functioning, the retarder cuts back its braking torque.

This flashing function only is realized at defined control variants!


Diagnosis /

Troubleshooting


(Continue)


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Test step Scope of check Requirement /

Operation

Result / Set point Note, Cause / Remedy

1 Retarder pilot light Ignition: ON Retarder pilot light comes on and

goes off after approx. 5 sec.

Retarder pilot light does not comeon, or does not go off.

Retarder pilot light trouble-free

Troubleshooting as on page 4.1/1

2 Retarder Vehicle on move- Shift retarder stage

switch to stage 1 to 5.

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

Retarder pilot light does not come

on, or retarder does not brakeproperly.

Retarder operates trouble-free.

Troubleshooting as on page 4.1/1


Retarder, Remo-

ving, Installing

5 Removing, Installing Retarder


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5.1 Removing, Installing Retarder (Gearbox Attachment)................................5.1/1


Retarder, Remo-

ving, Installing

5.1 Removing, Installing (Gearbox Attachment)


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To install the retarder 120-3 according to regulations to the gearbox or to remove from the gearbox,specific working steps requiring special tools have to be carried out!

Caution!

Observe Voith-Installation instructions and gear-box specific installation instructions.These have to be requested from Voith Turbo.Should these installation instructions be disregarded, the retarder may be completely wrecked!



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Repair Gearbox

Attachment

6.1 Assembly Overview (Retarder Basic Group)

3200

Illustration assembly overview (retarder basic group) for attachment to DaimlerChrysler gearbox G0160 and G0210


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1900

1800

700 850 800

900

2500

28002700

2600

2300

2300/3

2300/22301

2300/1

4300

4500

44004600

101

1100

1000

1200

1300

17001500

1400

2900

3200

3100

3000

3700

18039

3500

3600

101 Screw plug M12x1.5

hexagonal recess, w.a.f. 6, 25 Nm700 Radial shaft sealing ring (80x100x10)800 Labyrinth cover850 O-ring 125x2.5

2300/2 Float body

2300/3 Float cage2301 O-ring 55x32500 Screening plate2600 Spacer D50/42x15.5

Repair Gearbox

Attachment

6.1 Assembly Overview (Retarder Basic Group)

(Continue)

Illustration assembly overview (retarder basic group) for attachment to ZF gearbox S6-1600 and S6-85

3200


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1900

1800

700 850 800

900

2500

28002700

2600

2300

2300/3

2300/22301

2300/1

101

1100

1000

1200

1300

17001500

1400

2900

3200

3100

3000

3700

18040

3500

3600

101 Screw plug M12x1.5hexagonal recess, w.a.f. 6, 25 Nm

700 Radial shaft sealing ring (80x100x10)800 Labyrinth cover850 O-ring 125x2.5900 Hex.-head screw M8x25, w.a.f. 13, 30 Nm

2300/2 Float body2300/3 Float cage

2301 O-ring 55x32500 Screening plate2600 Spacer D50/42x15.52700 Washer B6.4

Repair Gearbox

Attachment

6.2 Checking, Removing and Installing

Casing Ventilation


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Illustration casing ventilation

Prior jobs

Retarder stage switch in switch position 0 Igni ti on OFF Proportional valve and adapter plate

removed (see chapter 8.1 and 8.2)

2300 Casing ventilation2300/1 Valve insert2300/2 Float checking, renew if necessary2300/3 Float cage

2301 O-ring, 55 x 3, renew,coat of silicone-free andnon-corrosive greasefor installation

2500 Cover p late2600 Spacer2700 Washer, B 6,42800 Hex.-head screw M 6 x 12

Inhex.-head, w.a.f. 5, 10 Nm2900 Cover

3000 Partion metal sheet with gasket,renew3100 Washer B 6,43200 Cap screw M 6 x 30

Inhex.-head, w.a.f. 5, 10 Nm


2500

2800

2700

2600

2300

2300/3

2300/2

2301

2300/1

2900

3200

3100

3000

18041

Repair Gearbox

Attachment


Casing Ventilation (Continue)


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Special tools Tool for local fabrication

Note

The tool for local fabrication can also be ordered from Voith Turbo - Voith code number 67.2757.10.

Lubricants and cleaning agents

Mesh strainer Benzine

O-ring Sil icone-free and

non-corrosive grease

Float Methylated Spirit

53.7712.10 53.9428.10


40,5 mm

7mm

60 mm

18042e

Material: St 37

Weight: 0,085 kg

Repair Gearbox

Attachment


Casing Ventilation (Continue)


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To remove

1. Screw out hex.-head screws (3200).

2. Remove washer (3100).

3. Remove the cover (2900) from the retarder housing.

4. Remove the partion metal sheet with gasket (3000) and clean the sealing surface at the cover andthe retarder housing.

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

6. Remove cover plate (2500).

7. Remove spacer (2600).

8. Use the impact puller (99/5) and adapter (98/7) to extract the casing ventilation (2300).

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

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


2300

Documents

Transmissão Voith Retarder 120-3 131 Pag