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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Aftersales Service ManualVoith Retarder 115 E
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Table of Content
Table of ContentPage 2
Aftersales Service Manual Voith Retarder 115 E
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
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Table of Content
Table of ContentPage 3
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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
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Preface
Preface Page 4
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 03-01
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.
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Preface
Preface Page 5
Aftersales Service Manual Voith Retarder 115 E
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.
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Preface
Preface Page 6
Aftersales Service Manual Voith Retarder 115 E
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!
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Preface
Preface Seite 7
Aftersales Service Manual Voith Retarder 115 E
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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.
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Preface
Preface Seite 8
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 03-01
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
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General
General Page 9
Aftersales Service Manual Voith Retarder 115 E
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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
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General – Assembly Overview Page 10
Aftersales Service Manual Voith Retarder 115 E
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General – Assembly Overview
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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General – Assembly Overview Page 11
Aftersales Service Manual Voith Retarder 115 E
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General – Assembly Overview
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
3700 Proportional valve
4200 Oil drain plugM 24 x 1,5
5500/1 Ventilation
6400 Heat exchanger
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General – Retarder Data Plate Page 12
Aftersales Service Manual Voith Retarder 115 E
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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.
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General – Data Plate of Retarder-Control Page 13
Aftersales Service Manual Voith Retarder 115 E
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General – Data Plate of Retarder-Control
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.
In this case a quick and working is possible.
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General – Data Plate of Retarder-Control
General – Data Plate of Retarder-Control Page 14
Aftersales Service Manual Voith Retarder 115 E
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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.
In this case a quick and working is possible.
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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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General – Function- and Operation Scheme
General – Function- and Operation Scheme Page 16
Aftersales Service Manual Voith Retarder 115 E
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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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General – Function- and Operation Scheme
General – Function- and Operation Scheme Page 17
Aftersales Service Manual Voith Retarder 115 E
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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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General – Function- and Operation Scheme
General – Function- and Operation Scheme Page 18
Aftersales Service Manual Voith Retarder 115 E
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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.
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Maintenance
Maintenance Page 19
Aftersales Service Manual Voith Retarder 115 E
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3. Maintenance
3.1 Maintenance Work / Oil Change Intervals .................................................. 203.2 Inspection of Oil Level................................................................................. 233.3 Oil Change.................................................................................................. 26
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Maintenance – Maintenance Work / Oil Change Intervals
Maintenance – Maintenance Work / Oil Change Intervals Page 20
Aftersales Service Manual Voith Retarder 115 E
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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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Maintenance – Maintenance Work / Oil Change Intervals
Maintenance – Maintenance Work / Oil Change Intervals Page 21
Aftersales Service Manual Voith Retarder 115 E
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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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Maintenance – Maintenance Work / Oil Change Intervals
Maintenance – Maintenance Work / Oil Change Intervals Page 22
Aftersales Service Manual Voith Retarder 115 E
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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.
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Maintenance – Inspection of Oil Level
Maintenance – Inspection of Oil Level Page 23
Aftersales Service Manual Voith Retarder 115 E
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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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Maintenance – Inspection of Oil Level
Maintenance – Inspection of Oil Level Page 24
Aftersales Service Manual Voith Retarder 115 E
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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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Maintenance – Inspection of Oil Level
Maintenance – Inspection of Oil Level Page 25
Aftersales Service Manual Voith Retarder 115 E
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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.
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Maintenance – Oil Change
Maintenance – Oil Change Page 26
Aftersales Service Manual Voith Retarder 115 E
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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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Maintenance – Oil Change
Maintenance – Oil Change Page 27
Aftersales Service Manual Voith Retarder 115 E
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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.
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.
M i t Oil Ch g
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Maintenance – Oil Change Page 28
Aftersales Service Manual Voith Retarder 115 E
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Maintenance – Oil Change
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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Maintenance – Oil Change
Maintenance – Oil Change Page 29
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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
Maintenance Oil Change
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Maintenance – Oil Change
Maintenance – Oil Change Page 30
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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)!
Maintenance – Oil Change
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Maintenance Oil Change
Maintenance – Oil Change Page 31
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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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Diagnosis / Troubleshooting
Diagnosis / Troubleshooting Page 32
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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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Diagnosis / Troubleshooting – Elektrical Connections Diagram Page 33
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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
21 Proportional valve
47 Speedometer signal
69 Plug ISO-interface
70 Plug optional function
72 Pressure sensor(OEM-specific)
Diagnosis / Troubleshooting – Elektrical Connections Diagram
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Diagnosis / Troubleshooting – Elektrical Connections Diagram Page 34
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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
17 Retarder pilot light
19 Temperature sensorcooling water
20 Temperature sensor oil
21 Proportional valve
72 Pressure sensor(OEM-specific)
Diagnosis / Troubleshooting – Elektrical Connections Diagram
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Diagnosis / Troubleshooting – Elektrical Connections Diagram Page 35
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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
17 Retarder pilot light
18 Brake light relais
19 Temperature sensorcooling water
20 Temperature sensor oil21 Proportional valve
47 Speedometer signal
72 Pressure sensor(OEM-specific)
80 On/off valve
81 Input (3 times)
82 Output (3 times)
83 ISO-diagnosis
Diagnosis / Troubleshooting – Elektrical Connections Diagram
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Diagnosis / Troubleshooting – Elektrical Connections Diagram Page 36
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
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
18 Brake light relais
19 Temperature sensorcooling water
20 Temperature sensor oil
21 Proportional valve
72 Pressure sensor(OEM-specific)
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
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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
19 Temperature sensorcooling water
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
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Diagnosis / Troubleshooting – Troubleshooting Diagram Seite 38
Aftersales Service Manual Voith Retarder 115 E
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
Diagnosis / Troubleshooting – Troubleshooting Diagram
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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
Diagnosis / Troubleshooting – Troubleshooting Diagram
Prior work
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• 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
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 41
Aftersales Service Manual Voith Retarder 115 E
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 ).
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 42
Aftersales Service Manual Voith Retarder 115 E
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.
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 43
Aftersales Service Manual Voith Retarder 115 E
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
5 Retarder stage switch, Position 2
6 Retarder stage switch, Position 1
7 Terminal 158 Retarder stage switch, Position 5
9 Retarder stage switch, Position 4
10 Retarder stage switch +
11 ISO-interface, L-lead
12 ISO-interface, K-lead
13 Connected with terminal 15
14 Not in use
15 Terminal 31
16 Output / high side 2 „HS2“
17 Not in use
18 Output / high side 1 „HS1“
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 44
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Plug X2 control unit (Digiprop)
Plug X3 control unit (Digiprop)
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“
5 Input / pull down „DID 1“
6 Pressure-sensor ground
7 Pressure-sensor signal voltage
8 Retarder pilot light
9 Input / pull down „DID 3“
10 Pressure-sensor supply voltage
11 Stop light relais
12 Input / pull down / PWM-in „DID4“
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 45
Aftersales Service Manual Voith Retarder 115 E
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
1 Retarder stage switch +
2 Input / pull down „DID 1“3 Input / pull down „DID 2“
4 Input / pull down „DID 3“
5 Input / pull down / PWM -in „DID 4“
6 Input / pull up „DIU 1“
7 Pressure-sensor Ground
8 Pressure-sensor signal voltage
9 Pressure-sensor supply voltage
10 Output / high side „HS1“
11 Output / high side 2 „HS2“
12 Not operational
13 Terminal 15
14 Terminal 31
2 1
4 3
11024
1 K-lead
2 L-lead
3 Terminal 15
4 Terminal 31
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 46
Aftersales Service Manual Voith Retarder 115 E
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
4 Retarder stage switch, Position 0
5 Retarder stage switch, Position 1
6 Retarder stage switch, Position 2
7 Terminal 15 = battery voltage8 Retarder stage switch, Position 3
9 Retarder stage switch, Position 4
10 Retarder stage switch +
11 Speedometer signal
12 ISO-interface, K-lead
13 ABS-signal
14 Terminal 31 = Ground
15 Retarder pilot light
16 Brake light relais
17 Engine speed
18 Retarder stage switch, Position 5
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 47
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Plug X2 control unit (VERA)
Plug X3 control unit (VERA)
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)
7 Not in use (boot 2)
8 Not in use (boot 3)
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 -
7 Pressure-sensor signal voltage
8 Pressure-sensor Ground
9 Pressure-sensor supply voltage
10 Not in use (switch valve +)
11 Not in use (switch valve -)
12 Not in use
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 48
Aftersales Service Manual Voith Retarder 115 E
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
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 49
Aftersales Service Manual Voith Retarder 115 E
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
4 Retarder stage switch +
5 Position 3
6 Position 2
7 Position 1
8 Bridge to pin 4
Diagnosis / Troubleshooting – Troubleshooting and remedies
h f l d d l f l
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 50
Aftersales Service Manual Voith Retarder 115 E
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
Diagnosis / Troubleshooting – Troubleshooting and remedies
F lt d t i t d il t light bli ki g d
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 51
Aftersales Service Manual Voith Retarder 115 E
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.
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault memory read out with retarder stage switch
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 52
Aftersales Service Manual Voith Retarder 115 E
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
Diagnosis / Troubleshooting – Troubleshooting and remedies
Display example for fault code 20 (only for VERA):
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Aftersales Service Manual Voith Retarder 115 E
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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
Diagnosis / Troubleshooting – Troubleshooting and remedies
Delete fault memory (only for Digiprop)
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Aftersales Service Manual Voith Retarder 115 E
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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.
Diagnosis / Troubleshooting – Troubleshooting and remedies
Version Digiprop
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Aftersales Service Manual Voith Retarder 115 E
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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
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
Code Test step
03 HS 1 outputShort circuit
slight 1 s - Ignition: OFF
- Pull plug X1 out of
control unit
X 1/18 Ω X 1/15 Relay isinstalled:250-350 Ω
Check lead, plugsand relayor consumers
04 HS 2 outputShort circuit
slight 1 s - Ignition: OFF
- Pull plug X1 out of
control unit
X 1/16 Ω X 1/15 Relay isinstalled:250-350 Ω
Check lead, plugsand relayor consumers
05 Terminal 15Undervoltage
serious 60 s - Ignition: OFF
- Pull plug X1 out of
control unit
- Ignition: ON
X 1/7 V X 1/15 ≥ 17,5 V Check lead, plugsand fuses
06 Terminal 15Overvoltage
serious 10 s - Ignition: OFF
- Pull plug X1 out of
control unit - Ignition: ON
- Start engine
(idle speed)
X 1/7 V X 1/15 ≤ 32,5 V Checking electricalinstallation of vehicle
(see manufacturerinstructions)
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Aftersales Service Manual Voith Retarder 115 E
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
- Pull plug X2 out of
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
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
RemedyCode Test step
1112
Oil temperaturesensorDiscontinuity /Short circuit tobattery
serious/ slight *
1 s - Ignition: OFF
- Pull plug X2 out of
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
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
RemedyCode Test step
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
- Retarder stage switch:
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
Check lead, plug andretarder stage switch
13 3 - Ignition: ON
- Retarder stage switch:
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
Check lead, plug andretarder stage switch
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
RemedyCode Test step
13 4 - Ignition: ON
- Retarder stage switch:
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
Check lead, plug andretarder stage switch
13 5 - Ignition: ON
- Retarder stage switch:
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
Check lead, plug andretarder stage switch
13 6 - Ignition: ON
- Retarder stage switch:
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
Check lead, plug andretarder stage switch
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Fault Fault text Fault
class
Trigger time Requirement / Operati-
on
Measurement/
Test connec-tion
Result/
Set point
Cause/
Remedy
Code Test step
14 Retarder stageswitchShort circuit tobattery
serious 10 s - Ignition: OFF
- Pull plug X1 out of
control unit
- Ignition: ON
- Retarder stage switch:Position 0
X 1/10 V X 1/15 0 V Check lead andplug
15 Retarder stageswitchShort circuit tobattery
serious 1 s - Ignition: OFF
- Pull plug X1 out of
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
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
RemedyCode Test step
18 Speedometer signal
Short circuit to battery
undefined signal
serious 2 s - Ignition: OFF
- Pull plug X3 out of
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
23 Proportional valve
Fault No. 1:
Short circuit to battery
serious 1 s - Ignition: OFF
- Pull plug X2 out of
control unit
- Ignition: ON
X 2/3 V X 1/15 ≤ 10 V Check lead
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
RemedyCode Test step
24 1 Proportional valve
Fault No. 2:
- Short circuit proportional
valve magnetic- Short circuit connection
lead proportional valve
- Discontinuity proportio- nal valve magnetic
Valve magnetic
- Discontinuity connec- tion lead proportional
valve
- Short circuit to ground at proportional valve
- Prop.- and shift valve
interchanged
serious 1 s - Ignition: ON
- Pull plug X2 out of control unit
X 2/2 Ω X 2/3 18-25 Ω Check lead andproportionalvalve(valve block)
2 - Ignition: OFF
- Pull plug X2 out of control unit
X 2/3 Ω X 1/15 Resistorendless
Check lead andproportionalvalve(valve block)
3 - Ignition: OFF
- Pull plug X2 out
of control unit
X 2/2 Ω X 1/15 Resistorendless
Check lead andvalve block
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
RemedyCode Test step
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
serious 60 s - Ignition: OFF
- Pull plug X1 out of
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
serious 3 s - Ignition: OFF
- Pull plug X3 out of
control unit
- Ignition: ON
X 3/8 V X 1/15 ≥ 17,5 V Check lead,retarder pilotlight and fuse
Diagnosis / Troubleshooting – Troubleshooting and remedies
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
RemedyCode Test step
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)
Diagnosis / Troubleshooting – Troubleshooting and remedies
Version VERA
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Aftersales Service Manual Voith Retarder 115 E
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)
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
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
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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Aftersales Service Manual Voith Retarder 115 E
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
heavy 1s - Ignition: OFF
- 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
heavy 10s - Ignition: OFF
- Pull off plug X1, X3
- Ignition: ON
X 1/7 V X 1/14 ≤ 32,5 V Check electrical unit
of vehicle (see manu-facturer s instruc-tions)
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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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
Check electrical lead,plug and retarder sta-ge switch
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
Check electrical lead,plug and retarder sta-ge switch
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
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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Aftersales Service Manual Voith Retarder 115 E
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
Check electrical lead,plug and retarder sta-ge switch
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
Check electrical lead,plug and retarder sta-ge switch
12 1 Retarder stageswitch
chasssis groundend
heavy 1s - Ignition: OFF
- Pull off plug X1- Retarder stage
switch: position 5
X 1/10 Ω X 1/14 Resistor endless Check each stage onchsssis ground end
13 1 Retarder stageswitch
battery shortcir-
cuit
heavy 10s - Ignition: OFF
- Pull off plug X1- Retarder stage
switch: position 0
X 1/10 V X 1/14 0 V Check electrical leadand plug
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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Aftersales Service Manual Voith Retarder 115 E
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
light 1s - Ignition: OFF
- Pull off plug X1,
X3
X 3/2 Ω X 1/14 Resistor endless Check electrical lead
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Blink-Code
Test step
19 1 Oil-temperaturesensor
interruption
light 1s - Ignition: OFF
- 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
light 1s - Ignition: OFF
- 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
heavy 2s - Ignition: OFF
- Pull off plug X1
- Ignition: ON
X 1/11 V X 1/14 ≤ 9 V Check electrical leadand speedometer
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 72
Aftersales Service Manual Voith Retarder 115 E
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Blink-Code
Test step
23 1 Retarder pilotlightinterruption,
chasssis groundend
heavy 1s - Ignition: OFF
- Pull off plug X1
- Ignition: ON
X 1/15 V X 1/14 ≥ 17,5 V Check electrical leadand fuse
24 1 Retarder pilotlightinterruption,
battery shortcir-cuit
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
26 1 Pressure sensor
interruption,
chasssis groundend
light 1s - Ignition: OFF
- Pull off plug X1,
X3
X 3/7 Ω X 1/14 Resistor endless Check electrical leadand pressure-sensor
27 1 Pressure sensor
battery shortcir-cuit
light 1s - Ignition: ON X 3/9 V X 3/8 4,75 ... 5,25 V Check electrical leadand pressure-sensor
28 1 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
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 73
Aftersales Service Manual Voith Retarder 115 E
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
light 1s - Ignition: OFF
- 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,
battery shortcir-cuit
light 1s - Ignition: OFF
- 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
light 1s - Ignition: OFF
- Pull off plug X2X 2/1 Ω X 1/14 At installed con-
sumer
> 150 Ω
Check electrical leadplug and relay or con-sumer
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 74
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Blink-Code
Test step
36 1 Output 1(OUT-1)
interruption,
battery short cir-cuit
light 1s - Ignition: OFF
- Pull off plug X2X 2/1 Ω X 1/14 < 3k Ω Check electrical lead
plug and relay or con-sumer
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
light 1s - Ignition: OFF
- Pull off plug X2X 2/2 Ω X 1/14 At installed con-
sumer> 150 Ω
Check electrical leadplug and relay or con-sumer
38 1 Output 2
(OUT-2)
interruption,
battery shortcir-cuit
light 1s - Ignition: OFF
- Pull off plug X2X 2/2 Ω X 1/14 < 3k Ω Check electrical lead
plug and relay or con-sumer
2 - Ignition: OFF
- Pull off plug X2
- Ignition: ON
X 2/2 V X 1/14 0 V Check electrical leadplug and relay or con-sumer
39 1 Output 3
(OUT-3)
chasssis groundend
light 1s - Ignition: OFF
- Pull off plug X2X 2/3 Ω X 1/14 At installed con-
sumer
> 150 Ω
Check electrical leadplug and relay or con-sumer
Diagnosis / Troubleshooting – Troubleshooting and remedies
Fault Fault text Faultclass
Trigger time Requirement /Operation
Measurement/ Test connection
Result/ Set point
Cause/Remedy
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Diagnosis / Troubleshooting – Troubleshooting and remedies Page 75
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Blink-Code
Test step
40 1 Output 3(OUT-3)
interruption,
battery shortcir-cuit
light 1s - Ignition: OFF
- Pull off plug X2X 2/3 Ω X 1/14 < 3k Ω Check electrical lead
plug and relay or con-sumer
2 - Ignition: OFF - Pull off plug X2
- Ignition: ON
X 2/3 V X 1/14 0 V Check electrical leadplug and relay or con-sumer
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
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Diagnosis / Troubleshooting – Checking Supply-Air Pressure (pv)
4.5 Checking Supply-Air Pressure (p v)
Work scope test
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Diagnosis / Troubleshooting – Checking Supply-Air Pressure (pv) Page 77
Aftersales Service Manual Voith Retarder 115 E
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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
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 78
Aftersales Service Manual Voith Retarder 115 E
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.
Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Requirements for check
• Retarder stage switch in position 0
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 79
Aftersales Service Manual Voith Retarder 115 E
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
Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Attention!
Two version of the screw plugs (107, 3500, 4100, 4200) are possible:
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 80
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
p g ( ) p
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.
Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Work scope check 4100
Attention! Risk of injury!
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 81
Aftersales Service Manual Voith Retarder 115 E
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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
Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Attention! Risk of injury!
The screw plug (103) and the oil are hot! Oil temperature!
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 82
Aftersales Service Manual Voith Retarder 115 E
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.
Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
5. Drive the vehicle with a prop shaft speed of v ps = 1000 r.p.m.
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 83
Aftersales Service Manual Voith Retarder 115 E
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.
Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Attention! Risk of injury!
Screwing of oil-pressure gauge and retarder are hot!
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 84
Aftersales Service Manual Voith Retarder 115 E
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.
Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Attention! Risk of injury!
The screwing of the air-pressure gauge and the retarder are hot!
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Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) Page 85
Aftersales Service Manual Voith Retarder 115 E
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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
Requirements for check
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Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve Page 86
Aftersales Service Manual Voith Retarder 115 E
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
Commercially available tool
Multimeter Fluke 87 or 79 (otherwise possible differing in measurements!)
Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve
Work scop check
1. Disconnect plug at proportional valve (21) and connect with measuring adapter (99/3).
2. Connect plug of measuring adapter (99/3) with the proportional valve (21).21
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Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve Page 87
Aftersales Service Manual Voith Retarder 115 E
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
Requirements for check
V hi l i i i OFF
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Diagnosis / Troubleshooting – Checking Pressure Sensor Page 88
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
• Vehicle ignition OFF
• Connected pressure gauge constant-air pressure
• Retarder stage switch in position 0
• Electrical lead and plug-in connection checked (visual examination) and found satisfactory
Special tool:
Measuring adapter
99/3
Commercially available tool
Multimeter recommended: Fluke 87
Diagnosis / Troubleshooting – Checking Pressure Sensor
Work scope check
1. Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3).
2. Connect plug of measuring adapter (99/3) to pressure sensor (38).98 / 8
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Diagnosis / Troubleshooting – Checking Pressure Sensor Page 89
Aftersales Service Manual Voith Retarder 115 E
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
Requirements for check
• Battery voltage 24 28 V
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Diagnosis / Troubleshooting – Checking Temperature Adaption Page 90
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
• Battery voltage 24 - 28 V
• Vehicle ignition OFF
• 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
• Electrical lead and plug-in connection checked (visual examination) and found satisfactory
Special tool:
Temperature simulator 99/2
Diagnosis / Troubleshooting – Checking Temperature Adaption
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
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Diagnosis / Troubleshooting – Checking Temperature Adaption Page 91
Aftersales Service Manual Voith Retarder 115 E
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.
Diagnosis / Troubleshooting – Checking Temperature Adaption
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
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Diagnosis / Troubleshooting – Checking Temperature Adaption Page 92
Aftersales Service Manual Voith Retarder 115 E
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
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Diagnosis / Troubleshooting – Table of Measurements Page 93
Aftersales Service Manual Voith Retarder 115 E
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.
Diagnosis / Troubleshooting – Table of Measurements
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.
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Diagnosis / Troubleshooting – Table of Measurements Page 94
Aftersales Service Manual Voith Retarder 115 E
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
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Diagnosis / Troubleshooting – Table of Measurements
Without pressure sensor / without CAN
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]
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Diagnosis / Troubleshooting – Table of Measurements Page 95
Aftersales Service Manual Voith Retarder 115 E
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
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Diagnosis / Troubleshooting – Table of Measurements
VERA DAFBUS
Serial-Number Amperagecontrol current mA 1) 2) 4)
Constant-air pressure (p y)(static) 3) 1)
nominal value [bar]
Pump pressure(dynamic) 1) vps = 1000 r.p.m.
(minimum value) [bar]
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Diagnosis / Troubleshooting – Table of Measurements Page 96
Aftersales Service Manual Voith Retarder 115 E
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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
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Diagnosis / Troubleshooting – Table of Measurements
Voltage measurement at the pressure sensor
54 5
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Diagnosis / Troubleshooting – Table of Measurements Page 97
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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
Diagnosis / Troubleshooting – Table of Measurements
Resistance measuring at the temperature sensor
Temperature Resistor
20°C ± 10 °C 1039 - 1117 Ω
60°C ± 10 °C 1194 - 1271 Ω
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Diagnosis / Troubleshooting – Table of Measurements Page 98
Aftersales Service Manual Voith Retarder 115 E
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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
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Removing, Installing Retarder Page 99
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Removing, Installing Retarder
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
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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
Removing, Installing Retarder
Special tools: Tool for local fabrication
F J 6 2 8 0 04 8 6 2 6 5 151
0
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Removing, Installing Retarder Page 101
Aftersales Service Manual Voith Retarder 115 E
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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)
Removing, Installing Retarder
Achtung!
Two version of the screw plugs (4100) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going toprint.
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Removing, Installing Retarder Page 102
Aftersales Service Manual Voith Retarder 115 E
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Removing
1. Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove withappropiate lifting device retarder from gearbox.
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.
25300
11049
25200
25200
4100
Removing, Installing Retarder
2. Remove O-Ring (25100) from gearbox.
850
25000NoticeCarry out following working step, if:
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Removing, Installing Retarder Page 103
Aftersales Service Manual Voith Retarder 115 E
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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
Removing, Installing Retarder
Assembling
1. Determine thickness of shim as follows:
Notice
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Removing, Installing Retarder Page 104
Aftersales Service Manual Voith Retarder 115 E
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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)!
Removing, Installing Retarder
1.2 Put the bearing outer ring (850) on the taper roller bearing (850/1).
850
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Removing, Installing Retarder Page 105
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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
Removing, Installing Retarder
1.6 Set the vernier depth gauge on gearbox seperation area and zero vernier depth gauge.
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Removing, Installing Retarder Page 106
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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
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Removing, Installing Retarder
4. Clean sealing surface of retarder housing (1).1
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Removing, Installing Retarder Page 108
Aftersales Service Manual Voith Retarder 115 E
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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
Removing, Installing Retarder
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
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Removing, Installing Retarder Page 109
Aftersales Service Manual Voith Retarder 115 E
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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
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Repair Retarder Page 110
Aftersales Service Manual Voith Retarder 115 E
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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
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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
M 8 x 80,hex.-head, w.a.f. 13
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
M 8 x 20,hex.-head, w.a.f. 13
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
M 14 x 45,hex.-head, w.a.f. 22
old:hex.-head screw with flange
M 14 x 40,
hex.-head, w.a.f. 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.
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 112
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Prior jobs
• Vehicle ignition switched off
• Retarder switched off
• Proportional valve and damping plate removed ( see page 140 )
Attention! Risk of injury!Retarder housing is hot!
Repair Retarder – Removing, Checking and Installing Casing Ventilation
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
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 113
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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
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Special tools: Tool for local fabrication
Ø 40,5 mm
7 mm
Ø 60 mm
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 114
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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
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Removing
1. Screw out combined hex.-head screws (3300).
3300
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 115
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2. Remove cover (2800) with gasket (2900) from retarder housing.
Clean sealing surface.
11063
11064
2900
2800
Repair Retarder – Removing, Checking and Installing Casing Ventilation
3. Remove air-pipe (6100) and O-Rings (6101).
6101
6100
6101
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 116
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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
Repair Retarder – Removing, Checking and Installing Casing Ventilation
5. Take float (2300/2) and float cage (2300/3) out of retarder housing (100).2300/2
2300/3
100
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 117
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6. Lever out O-Ring (2301) of groove of valve insert (2300/1) and remove this.
11067
11068
2300/1
2301
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Checking
1. Check float (2300/2) on damages of surfaces and sealing surfaces (arrow).
2. Weigh float (2300/2).
The desired weight is 11 g ± 1 g. If the weight is more than the desired weight renew complete casingventilation.
2300/2
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 118
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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
Repair Retarder – Removing, Checking and Installing Casing Ventilation
Installing
1. Coat new O-ring (2301) with silicon-free and non-corrosive grease and pull on valve insert (2300/1).
2300/1
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 119
Aftersales Service Manual Voith Retarder 115 E
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2. Insert float (2300/2) and float cage (2300/3) in valve insert (2300/1).
11071
2301
2300/1
2300/2
2300/3
11072
Repair Retarder – Removing, Checking and Installing Casing Ventilation
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
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Repair Retarder – Removing, Checking and Installing Casing Ventilation Page 120
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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
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Repair Retarder – Removing and Installing Water Neck
6.4 Removing and InstallingWater Neck
Prior jobs
• Vehicle ignition OFF
• Retarder switched off
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Repair Retarder – Removing and Installing Water Neck Page 123
Aftersales Service Manual Voith Retarder 115 E
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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.
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Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 124
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• Vehicle ignition OFF
• 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.
Repair Retarder – Removing, Checking, Installing Heat Exchanger
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
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Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 125
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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
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Attention!
Two versions of screw plugs (107, 4200) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going toprint.
The integrated sealing rings must be checked for possible damages during the installation of the heatexchanger; replace complete screw plug if necessary.
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Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 126
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exchanger; replace complete screw plug if necessary.
B) Version with loose inserted copper-sealing ring.
In this Aftersales Service Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques inbrackets are valid.
The copper-sealing rings are generally to be renew.
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Special tool
67.1948.10
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Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 127
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Pressure test plate
99/6
Commercially available tool
Turning angle measuring tool 3/4“ e.g. Messrs Richard Abr. Herder
Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
Ordering No. 8200-02
Repair Retarder – Removing, Checking, Installing Heat Exchanger
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.
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Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 128
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
4200 420011080
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Removing
1. Screw out hte four hex.-head screws (6600) and remove washers (6700).
2. Remove heat exchanger (6400). 6400
6600
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Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 129
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
3. Remove O-rings (7300, 7500 and 7600).
110816600
66006700
6700
6700
11082
7300
7500
7300
7600
7500
7300
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Checking
1. Install pressure test plate (99/6) with O-rings at heat exchanger (6400) and connect compressd-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
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Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 130
Aftersales Service Manual Voith Retarder 115 E
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.
Repair Retarder – Removing, Checking, Installing Heat Exchanger
Installing
1. Fit new O-rings (7300, 7500 and 7600) in the bores and coat them with silicon-free andnon-corrosive grease.
7300
7300
75007600
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Repair Retarder – Removing, Checking, Installing Heat Exchanger Page 131
Aftersales Service Manual Voith Retarder 115 E
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
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Repair Retarder - Removing, Installing Oil Tank Cover
6.6 Removing, Installing Oil TankCover
A) Top Oil Tank Cover
Prior jobs
• Vehicle ignition switched OFF
• Retarder switched off
6101
6100
6101
2000
90003300
3100Notice
This working step can be performed withretarder removed or installed..
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Illustration: Top Oil Tank Cover
Lubricant
8000
11088
Attention! Risk of injury!
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 switched off
• Retarder oil drained (see page 26 ff)
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Repair Retarder – Removing, Installing Oil Tank Cover Page 134
Aftersales Service Manual Voith Retarder 115 E
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)
Repair Retarder – Removing, Installing Oil Tank Cover
Attention!
Two versions of screw plugs (4200) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going toprint.
The integrated sealing rings must be checked for possible damages during the installation of the heatexchanger; replace complete screw plug if necessary.
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Repair Retarder – Removing, Installing Oil Tank Cover Seite 135
Aftersales Service Manual Voith Retarder 115 E
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.
B) Version with loose inserted copper-sealing ring.
In this Aftersales Service Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques inbrackets are valid.
The copper-sealing rings are generally to be renew.
12
13
14
1516
7
4 32 1
56
78
9
111
11090
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Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
Special tool
153.00005210
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Repair Retarder - Removing, Installing Non-Return Valve (Outlet) Page 137
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Puller
non-return valve (outlet)
71/1
Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
Removing
1. Screw out combined hex.-head screws (3100) of valve cover (1600).
2. Remove valve cover (1600).
3. Position puller (71/1) up to engaging to torque limiter valve and pull out non-return valve of its seat.
4. Remove O-rings (1700, 2106 and 2105).
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Repair Retarder – Removing, Installing Non-Return Valve (Outlet) Page 138
Aftersales Service Manual Voith Retarder 115 E
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
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Control Parts Page 139
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Control Parts – Removing, Installing Proportional Valve and Damping Plate
7.1 Removing, InstallingProportional Valve andDamping Plate
Prior jobs
• Vehicle ignition switched off
• Retarder switched off
• 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
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Illustration: Proportional Valve and Damping Plate
Lunbricant
11093
26
39003700
4000
39 Electrical connection lead
3700 Proportional valve
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
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Control Parts – Removing, Installing Temperature Sensor Oil
7.3 Removing, InstallingTemperature Sensor Oil
Prior jobs
• Vehicle ignition switched off
• Retarder switched off
l
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Control Parts – Removing, Installing Temperature Sensor Oil Page 142
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
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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
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Appendix – Retarder Data Sheet Page 145
Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
* 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
With a loose sealing ring: 70 Nm
107 Oil drain plug M 24 x 1,5, Inhex.-head, w.a.f. 12 With integrated sealing ring: 47 Nm
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Appendix – Tightening Torques Page 146
Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
With a loose sealing ring: 80 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
3300 Combined hex.-head screw M 8 x 80, 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
With a loose sealing ring: 100 Nm
3900 Combined hex.-head screw M 8 x 20, Hex.-head, w.a.f. 13 30 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
With a loose sealing ring: 80 Nm
Appendix – Tightening Torques
Pos.-Nr.: Bezeichnung Abmessungen Anziehdrehmoment
5200 Temperature sensor oil / water M 14 x 1,5, Hex.-head, w.a.f. 21 28 Nm with copper sealing ring
6600 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
20200 Combined hex.-head screw M 8 x 80, Hex.-head, w.a.f. 13 30 Nm
20300 S l M 14 1 5 H h d f 13 32 N
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Appendix – Tightening Torques Page 147
Aftersales Service Manual Voith Retarder 115 E 15300009710 / cbtsd 02-11
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