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Aftersales Service Manual

Voith Retarder 115 E

Aftersales Service Manual Voith Retarder 115 E


15300009710 / cbtsd 02-11
Table of Content

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

2. General ................................................................................. 9
2.1 Assembly Overview ....................................................................................10
2.2 Retarder Data Plate ....................................................................................12
2.3 Data Plate of Retarder-Control Unit ............................................................13
2.4 Function- and Operation Scheme ...............................................................15

3. Maintenance ....................................................................... 19
3.1 Maintenance Work / Oil Change Intervals ..................................................20
3.2 Inspection of Oil Level.................................................................................23
3.3 Oil Change ..................................................................................................26

4. Diagnosis / Troubleshooting ............................................... 32


4.1 Electrical Connections Diagram..................................................................33
4.2 Overview of Control Parts ...........................................................................37
4.3 Troubleshooting Diagram............................................................................38
4.4 Troubleshooting and Remedies ..................................................................41
4.5 Checking Supply-Air Pressure (pv) .............................................................77
4.6 Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) ...............78
4.7 Checking Control Current of Proportional Valve .........................................86
4.8 Checking Pressure Sensor .........................................................................88
4.9 Checking Temperature Adaption ................................................................90
4.10 Table of Measurements ..............................................................................93

Aftersales Service Manual Voith Retarder 115 E Table of Content


15300009710 / cbtsd 02-11 Page 2
Table of Content

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

6. Repair Retarder ................................................................ 110


6.1 Overall Illustration of Main Components ...................................................111
6.2 Removing, Checking and Installing Casing Ventlation .............................112
6.3 Removing, Cleaning and Installing Silencer .............................................122
6.4 Removing and Installing Water Neck........................................................123
6.5 Removing, Checking, Installing Heat Exchanger......................................124
6.6 Removing, Installing Oil Tank Cover.........................................................133
6.7 Removing, Installing Non-Return Valve Outlet .........................................136

7. Control Parts ..................................................................... 139


7.1 Removing, Installing Proportional Valve and Damping Plate....................140
7.2 Removing, Installing Temperature Sensor Cooling Water........................141
7.3 Removing, Installing Temperature Sensor Oil ..........................................142
7.4 Removing, Installing Pressure Sensor......................................................143

8. Appendix ........................................................................... 144


8.1 Retarder Data Sheet .................................................................................145
8.2 Tightening Torques ...................................................................................146

Aftersales Service Manual Voith Retarder 115 E Table of Content


15300009710 / cbtsd 02-11 Page 3
Preface

1. Preface
This Aftersales Service Manual provides information and instructions on maintenance and repair
of the Voith Retarder 115 E. These instructions present the basis for performing appropriate and
expert 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.

Aftersales Service Manual Voith Retarder 115 E Preface


15300009710 / cbtsd 03-01 Page 4
Preface

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 to
slow down the vehicle and switch into the lowest possible gear (target: high engine speed). This
vehicle 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.

Aftersales Service Manual Voith Retarder 115 E Preface


15300009710 / cbtsd 03-01 Page 5
Preface

Attention!

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

• Therefore, Voith is not capable of warning the user in this Aftersales Service Manual about any
situation conceivable in which he may suffer injuries and/or cause damage to the retarder. As a
consequence, 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 that
the 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 and
unprofessional work.

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

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

Aftersales Service Manual Voith Retarder 115 E Preface


15300009710 / cbtsd 03-01 Page 6
Preface

Notice

• The item numbers used in this documentation are the same as the item numbers in the spare
parts lists.
Exception:
Items and components with one- or two-digit item numbers are no spare parts and therefore are
not included in the spare parts lists.
Also items and components with dash numbers are no spare parts and therefore not included in
the spare parts lists.

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

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

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

• Information on the safe, technically correct and economical operation of the Voith Retarder 115
E 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 service
will only be rendered if there is proof that the parts in question are really defective.

Aftersales Service Manual Voith Retarder 115 E Preface


15300009710 / cbtsd 03-01 Seite 7
Preface

If you have any questions or if you are uncertain about work steps, which are not described in this
documentation, 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: service-retarder@voith.com

Direct dials:
Customer service line and spare parts:
32-401
32-422
32-1860

Aftersales Service Manual Voith Retarder 115 E Preface


15300009710 / cbtsd 03-01 Seite 8
General

2. General
2.1 Assembly Overview ....................................................................................10
2.2 Retarder Data Plate ....................................................................................12
2.3 Data Plate of Retarder-Control Unit ............................................................13
2.4 Function- and Operation Scheme ...............................................................15

Aftersales Service Manual Voith Retarder 115 E General


15300009710 / cbtsd 02-11 Page 9
General – Assembly Overview

2.1 Assembly Overview


3700
Basic Group with Heat Exchanger 4100

100 Retarder housing


3700 Proportional valve
4100 Oil filler plug
M 30 x 1,5
6400 Heat exchanger

6400
100

11001
Illustration: Voith Retarder R115 E

Aftersales Service Manual Voith Retarder 115 E General – Assembly Overview


15300009710 / cbtsd 02-11 Page 10
General – Assembly Overview

Basic Group with Heat Exchanger

5500/1
103 Screw plug
M 12 x 1,5
107 Oil drain plug 3700
M 24 x 1,5
3500 Screw plug with sieve
M 30 x 1,5
3700 Proportional valve
4200 Oil drain plug
M 24 x 1,5 3500
5500/1 Ventilation
6400 Heat exchanger
103

6400

107
4200

11002
Illustration: Voith Retarder 115 E

Aftersales Service Manual Voith Retarder 115 E General – Assembly Overview


15300009710 / cbtsd 02-11 Page 11
General – Retarder Data Plate

2.2 Retarder Data Plate


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

The following details are on the data plate:

a) Type of Retarder
b) Serial number a b
6-digit number
c) Year of manufacturing
d) Retarder ratio (iRet)
e) Customer-item number
Type R 115 E
f) Voith-item number
8-digit number Serial No

Year of Man. c
d
Cust. item No

Voith-item-No
Notice Kd.

Voi
-S
ac

-S
th
h-

ac
h-
Nr.
Nr.

Please, always quote the retarder data when


submitting queries or ordering spare parts. e f
In this case a quick and working is possible.

11003e
Illustration: Retarder Data Plate

Aftersales Service Manual Voith Retarder 115 E General – Retarder Data Plate
15300009710 / cbtsd 02-11 Page 12
General – Data Plate of Retarder-Control

2.3 Data Plate of Retarder-Control


Unit Digiprop

The data plate of the Digiprop-control unit


is mounted on the control unit and
contains following information:

1. Basic-number
8-digit number
The last two digits show the
software version. Ba
s
Co is-N
Example: .12 = version 1.2 Se de-N r.:
rie r.:
VO n- 53
IT Nr.
2. Code-number H : .
xx xxxx
x .12
xx
3-digit number xx
/

(Adjusting of control unit)


3. Serial-number
5-digit number
with date of coding
4. Voith precast unit number as
well as customer number, if ne-
cessary

Notice Basic-No.:
Please, always quote the retarder data and
Code-No.:
retarder control unit data when submitting Serial-No.:
queries or ordering spare parts. VOITH
In this case a quick and working is possible.
11004e

Illustration: Data Plate of Retarder Control Unit Digiprop

Aftersales Service Manual Voith Retarder 115 E General – Data Plate of Retarder-Control
15300009710 / cbtsd 02-11 Page 13
General – Data Plate of Retarder-Control

Data Plate of Retarder-Control

Unit VERA

The data plate of the VERA-control unit is moun-


ted on the control unit and contains following

0
*0
84
20 *
54
5/
*9
information:

45
/2
TD

2
*7
e1
.S
RA 1
E - 0
V 08 3
it 2- X
1. Serial-number U n 200
l
t ro / 2 0
n X 3. 2
Co XX 76 X
4-digit number / date er .
X .2
7
r d No 6
t a ia l- o . . 1
e
R e r rt -N - N o X
2. Spare-part-number S a M
P E

BO
O

UR
8-digit number

T
H
IT
VO
3. OEM-number

Notice

Please, always quote the retarder data and


retarder control unit data when submitting
queries or ordering spare parts.
In this case a quick and working is possible.

Retarder Control Unit VE RA.STD

VOITH T URBO

e1*72/245*95/54*2084*00
Serial-No. XXXX / 2002-08-01
Part-No. 67.2763.20
OEM-No.

X1 X2 X3
11005

Illustration: Data Plate of Retarder Control Unit VERA

Aftersales Service Manual Voith Retarder 115 E General – Data Plate of Retarder-Control
15300009710 / cbtsd 02-11 Page 14
General – Function- and Operation Scheme

2.4 Function- and Operation Scheme

26 A R
42 21
23 72

36
25
20
1/1 1 1/2
63

Vehicle
electronic

19

46
22
44
62
64
43
55 41

Oil sump Coolant (water)


Supply-air pressure p v Pump pressure p P
Constant-air pressure p y

11006e

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

23 Casing ventilation 63 Non-return valve (inlet)

25 Air-pressure line „A“ constant-air pressure (py) 64 Non-return valve (outlet)

26 Air-pressure line supply-air pressure (pv) 72 Pressure sensor (OEM-specific)

36 Exhaust line „R“

Aftersales Service Manual Voith Retarder 115 E General - Function- and Operation Scheme
15300009710 / cbtsd 02-11 Page 15
General – Function- and Operation Scheme

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 ratio
enables the retarder to achieve high braking torques right down to low r.p.m. ranges with the compactest
configuration (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 must
be settled by using the service-brake and the lowest possible gear.

Aftersales Service Manual Voith Retarder 115 E General – Function- and Operation Scheme
15300009710 / cbtsd 02-11 Page 16
General – Function- and Operation Scheme

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

The temperature sensors are installed in the cooling system of the vehicle (cooling-return circle from the
retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and
oil temperature to the control unit (2).To prevent the temperatures preset in the control unit (2) for water
and oil being exceeded, the retarder braking torque is adapted to protect the vehicle cooling system and
the retarder.

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

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 above
the 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 used
to control the vehicle.

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

Pressure regulating valve (62)

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

Aftersales Service Manual Voith Retarder 115 E General – Function- and Operation Scheme
15300009710 / cbtsd 02-11 Page 17
General – Function- and Operation Scheme

Pressure sensor (72)

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

Casing ventilation (23)

During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) and
the 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 and
the 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 heat
exchanger (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 from
the proportional valve to the oil tank of the retarder.

Aftersales Service Manual Voith Retarder 115 E General – Function- and Operation Scheme
15300009710 / cbtsd 02-11 Page 18
Maintenance

3. Maintenance
3.1 Maintenance Work / Oil Change Intervals ..................................................20
3.2 Inspection of Oil Level.................................................................................23
3.3 Oil Change ..................................................................................................26

Aftersales Service Manual Voith Retarder 115 E Maintenance


15300009710 / cbtsd 02-11 Page 19
Maintenance – Maintenance Work / Oil Change Intervals

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

Aftersales Service Manual Voith Retarder 115 E Maintenance – Maintenance Work / Oil Change Intervals
15300009710 / cbtsd 02-11 Page 20
Maintenance – Maintenance Work / Oil Change Intervals

Oil change intervals, operating specification

Single grade-mineral oil Synth. / part synth. oil Synthetic oil 1)


1) 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- HD HC HC
ter
to DIN 51502

Class of viscosity SAE 10W SAE 0W40 SAE 75W80


to DIN 51511 SAE 20W20 SAE 5W30
SAE 30 SAE 5W40
SAE 5W50
SAE 10W30
SAE 10W40

Performance API - CC/SF API - CC/SF Emgard


category and higher and higher MTF,Henkel

1) according operating specification


2) carry out change oil at the latest after 1 year, if fewer kilometres are travelled
3) 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).

Aftersales Service Manual Voith Retarder 115 E Maintenance – Maintenance Work / Oil Change Intervals
15300009710 / cbtsd 02-11 Page 21
Maintenance – Maintenance Work / Oil Change Intervals

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 are
improved.

With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as other
factors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervals
between 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.

Aftersales Service Manual Voith Retarder 115 E Maintenance – Maintenance Work / Oil Change Intervals
15300009710 / cbtsd 02-11 Page 22
Maintenance – Inspection of Oil Level

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 and
to 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 to
print.
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 in
brackets are valid.
The copper-sealing rings have to be renewed in general.

Aftersales Service Manual Voith Retarder 115 E Maintenance – Inspection of Oil Level
15300009710 / cbtsd 02-11 Page 23
Maintenance – Inspection of Oil Level

107 Oil drain plug M 24 x 1,5


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

Work scope
107
1. Push a clean vessel under retarder.
4200 11007

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)!

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.

Aftersales Service Manual Voith Retarder 115 E Maintenance – Inspection of Oil Level
15300009710 / cbtsd 02-11 Page 24
Maintenance – Inspection of Oil Level

Caution!

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

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

Notice

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

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)

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 after the described
work process again.

10. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 times
for 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.

Aftersales Service Manual Voith Retarder 115 E Maintenance – Inspection of Oil Level
15300009710 / cbtsd 02-11 Page 25
Maintenance – Oil Change

3.3 Oil Change

Notice

The gearbox- and retarder oil tanks are seperated from each other at the gearbox-retarder-system. Both
oil 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 table
page 29) and to use only oils specified in the operating specifications page 21 for operating the retarder
in 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 the
retarder must be switched off!

Aftersales Service Manual Voith Retarder 115 E Maintenance – Oil Change


15300009710 / cbtsd 02-11 Page 26
Maintenance – Oil Change

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 to
print.
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 in
brackets are valid.
The copper-sealing rings have to be renewed in general.

Aftersales Service Manual Voith Retarder 115 E Maintenance – Oil Change


15300009710 / cbtsd 02-11 Page 27
Maintenance – Oil Change

107 Oil drain plug


M 24 x 1,5
Inhex-head w.a.f. 12 4100
47 Nm (80 Nm)
3500 Screw plug with sieve
M 30 x 1,5
Inhex-head w.a.f. 17
100 Nm (100 Nm)
Clean sieve with appropriate
cleaning agent and blow out with
compressed-air
4100 Oil filler plug
M 30 x 1,5
Inhex-head w.a.f. 17
100 Nm (100 Nm)
4200 Oil drain plug oil tank
M24x1,5
Inhex-head w.a.f. 12
47 Nm (80 Nm)

Lubricants and cleaning agents h-


Nr
.
ac .
.-S Nr
Kd h-
ac
-S
ith
Vo

Sieve in screw plug Benzine 107

3500 4200 4200

11008

Illustration: Oil change Retarder R 115 E

Aftersales Service Manual Voith Retarder 115 E Maintenance – Oil Change


15300009710 / cbtsd 02-11 Page 28
Maintenance – Oil Change

Oil filling with heat exchanger

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

After exchange of heat exchanger 7,5 l

Work scope

1. Push an oil collecting pan under the retarder.

Attention! Risk of injury!

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

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)

107

4200 4200

11009

Aftersales Service Manual Voith Retarder 115 E Maintenance – Oil Change


15300009710 / cbtsd 02-11 Page 29
Maintenance – Oil Change

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.
Nr.
h-
ac
-S Nr.
Kd. ac
h-
th-S

8. Screw in screw plug with sieve hand-tight then tighten it.


Voi

Tightening torque screw plug (3500): 100 Nm (100 Nm)


3500

11010

9. Screw out oil filler plug (4100).


4100

Attention!

The retarder must only be filled with oil via the bore of the 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 filler
plug, specified in accordance to the service filling (see table page 29).
This work step is required to the correct ventilation of the retarder system.

11011

Aftersales Service Manual Voith Retarder 115 E Maintenance – Oil Change


15300009710 / cbtsd 02-11 Page 30
Maintenance – Oil Change

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)

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 after the described
work process again.

13. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 times
for 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.

Aftersales Service Manual Voith Retarder 115 E Maintenance – Oil Change


15300009710 / cbtsd 02-11 Page 31
Diagnosis / Troubleshooting

4. Diagnosis / Troubleshooting
4.1 Electrical Connections Diagram..................................................................33
4.2 Overview of Control Parts ...........................................................................37
4.3 Troubleshooting Diagram............................................................................38
4.4 Troubleshooting and Remedies ..................................................................41
4.5 Checking Supply-Air Pressure (pv) .............................................................77
4.6 Checking Constant-Air Pressure (py) and Pump Pressure (pdyn) ...............78
4.7 Checking Control Current of Proportional Valve .........................................86
4.8 Checking Pressure Sensor .........................................................................88
4.9 Checking Temperature Adaption ................................................................90
4.10 Table of Measurements ..............................................................................93

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting


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Diagnosis / Troubleshooting – Elektrical Connections Diagram

4.1 Elektrical Connections P U 72


70 47 15 21 19 20
Diagram 1 2 4 14 13 11 12 10 1 9 5 8 4 3 2 7 6

18
(Voith-Wiringharness Digiprop without
.

87 87a 30
- +
CAN) + - + -

2 Control unit .
4 Connection terminal 15
.
15 ABS-signal
16 Retarder stage switch
17 X3 X2
17 Retarder pilot light
18 Brake light relay
.4 8 11 10 12 7 9 4 5 6 1 2 3 2 3 1 6 5 4 9 8 7

2
19 Temperature sensor
cooling water 18 17 16 6 5 4 9 8 10 11 12 13 14 15 7 3 2 1
X1
20 Temperature sensor oil
21 Proportional valve
47 Speedometer signal
7 6 5 2 3 8 4 4
69 Plug ISO-interface 3 2 1 4

69
70 Plug optional function
72 Pressure sensor
(OEM-specific) 16

11012

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Diagnosis / Troubleshooting – Elektrical Connections Diagram

Digiprop with CAN


P U 72
21 19 20
2 Control unit 1 2 4

4 Connection terminal 15
16 Retarder stage switch
- + + - + -
17 Retarder pilot light
19 Temperature sensor
cooling water
20 Temperature sensor oil
21 Proportional valve
72 Pressure sensor 17 X3 X2
(OEM-specific) .4 12 8 11 10 7 9 4 5 6 1 2 3 2 3 1 6 5 4 9 8 7

2
18 17 16 6 5 4 9 8 10 11 12 13 14 15 7 3 2 1
X1

CAN
4

16

11013

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Diagnosis / Troubleshooting – Elektrical Connections Diagram

VERA „general“
P U 72
2 Control unit 80 21 20 19 81 82
1 2 4

4 Connection terminal 15
15 ABS-signal
+ - + - + - + -
16 Retarder stage switch
18
17 Retarder pilot light

87 87a 30
18 Brake light relais
19 Temperature sensor
cooling water
20 Temperature sensor oil X3 X2
9 7 8 10 11 12 3 4 5 6 2 1 8 7 6 4 5 9 3 2 1
21 Proportional valve
47 Speedometer signal 2
17
72 Pressure sensor
(OEM-specific)
.4 16 15 4 5 6 8 9 18 10 17 11 12 13 14 7 3 2 1
X1

80 On/off valve
81 Input (3 times)
CAN
82 Output (3 times) 4

83 ISO-diagnosis
83
16 47 15

11014

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Diagnosis / Troubleshooting – Elektrical Connections Diagram

VERA „DAFBUS“
72 21 20 19 90 94 91 96
2 Control unit P U

4 Connection terminal 15 1 2 4

16 Retarder stage switch + - + - + -

18 Brake light relais


18
19 Temperature sensor

87 87a 30
cooling water
20 Temperature sensor oil
21 Proportional valve
72 Pressure sensor X3 X2
(OEM-specific) 9 7 8 10 11 12 3 4 5 6 2 1 8 7 6 1 9 2 3 4 5

90 Fan relais 2 95
93
.4
91 Brake valve
16 15 4 5 6 8 9 10 18 17 11 12 13 14 7 3 2 1

92 Diagnosis K-Lead X1

93 Fault light
94 Operating light
95 Foot Off/On CAN
4
96 Indication light

92
16
11015

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Diagnosis / Troubleshooting – Overview of Control Parts

4.2 Overview of Control Parts

11 33
Notice 71
32 61
The given position-numbers are not identical
with position-numbers of spare parts lists.
R
36 P
25 A 26
1 Heat exchanger
21 31
2 Control unit (e.g. Digiprop/
VERA)
35 34
11 Connection control current of
proportional valve
19 Temperature sensor
cooling water
20 Temperature sensor oil 40
21 Proportional valve 2
39 20
25 Compressed-air pressure line
constant-air pressure (py) 19
26 Compressed-air pressure line
suppla-air pressure (pv)
31 Compressed-air pressure line
(pressure regulator - four-
circuit protection valve)
32 Compressed-air pressure line
(four-circuit protection valve - 72
air tank for auxiliary equip- 1
ment) with with test connec-
tion
11016
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 line
connection „R“
39 Electrical lead (temperature
sensor cooling water) to
control unit, 2 wires)
40 Electrical lead (temperature
sensor oil) to control unit,
2 wires)
61 Four-circuit protection valve
71 Air tank for auxiliary
equipment
72 Pressure sensor
(OEM-specific)

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Diagnosis / Troubleshooting – Troubleshooting Diagram

4.3 Troubleshooting Diagram

A
* Notice:
* Retarder OEM-specific is an on-board-diagnosis
Pilot Light possible (display).
(Standard Notice the information from the vehicle
version) manufacturer to it.

Oil leak via


Complaint ventilation
Retarder
R 115 E
and / or non
or too low
braking
B
efficiency

11017e

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Diagnosis / Troubleshooting – Troubleshooting Diagram

* Retarder * OE M-specific is an on-board-diagnosis


Pilot L ight possible (display).
(Standard Notice the information from the vehicle
version) manufacturer to it.

Permanent light in
position 0 after no function? flashes?
lamp test?

Activate Check
Temperature
flash code fuse
adaption
and read out
fault code *

ABS or
idle switch
active?

Clear fault Check operation


and (during Retarder
erase braking
Check pilot light most possible
fault memory * and renew, engine
if necessary nominal speed)

OK NOK
* Notice the information of the
vehicle manufacturer
Check
temp.-sensors Instruct driver!
(oil / water)
(page 90 ff)

OK NOK

Check vehicle Replace


cooling system: temp.-sensos
- coolant level (page 141, 142)
- Thermostat
- Coolant pump
- Radiator fan
- Radiator on
pollution

11018e

Illustration: Complaint main group A

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Diagnosis / Troubleshooting – Troubleshooting Diagram

Prior work

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

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

B
Oil leak via ventilation
and / or non or
too low
brake efficiency

Outer Leak
(apart ventilation)

Repair
No Yes Retarder

Check retarder
oil level
(page 23 ff)
Check p (dynam.)
At complaint "non or and py (statisch) check py (static)
too low braking (page 78 ff)
OK NOK Water in oil
(page 78 ff)
efficiency": For examination the retarder For examination the retarder (emulsion)
oil level must be correct! oil level must be correct!
Consultation Voith
OK NOK Check Yes No
At complaint OK NOK heat exchanger
"Oil leak via
(page 124 ff)
ventilation":
continue with
checking casing Check
ventilation retarder oil level
too too
Check low high
gear box oil level

Check p (dynamic)
casing ventilation NOK OK NOK
(page 112 ff) py (static)
NOK
OK NOK
Check
gear box oil level
Check control too too
current of prop. high low
Check Replace valve as well as
proportional valve casing ventilation leads und Check
(page 86 ff) (page 112 ff) plug connections Correct gearbox oil level
Correct
NOK OK (page 86 ff) retarder- and
retarder- and
gearbox oil level NOK OK
OK NOK If problem occours again: gearbox oil level
Consultation Voith
Outlet valve
Replace .11 and higher?
proportinal valve
(page 140) Yes No Check Correct
If problem occours again: gearbox oil level
Consultation Voith
retarder oil level
too too
Check supply-
Check temperature high low
air pressure
(page 77) adaption or
temp.-sensors (oil/water)
OK NOK and pressure sensor or
Replace
leads
outlet valve Correct
(page 136 ff)
(page 88 ff) Check
Check vehicle retarder- and
If problem occours again: gearbox ventilation
Replace Proportional valve or compressed-air OK NOK gearbox oil level
proportional valve. system
damping plate
mechanically defect NOK OK
OK NOK
Consultation Replace
Voith temperature sensors
Compressed-air pressure Contact Correct retarder-
or leads Repair gearbox
line to prop. valve vehicle and gearbox
interrupted or (page 141, 142) ventilation;
manufacturer oil level
leaking correct retarder- and If problem occours again:
gearbox oil level Consultation Voith

11019e

Illustration: Complaint main group B

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Diagnosis / Troubleshooting – Troubleshooting and remedies

4.4 Troubleshooting and remedies


Requirements for check

• Battery voltage 18 - 32 V

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

• Fuse for retarder control unit checked and found satisfactory.

• Compressed-air pressure 6 - 11 bar

• Version Digiprop with and without CAN:


for check with multimeter must be at the control unit
pin 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).

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Note

The retarder pilot light additionally has the function of a fault code. An on-board-diagnosis (display) is
OEM-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 limited
extent.

• 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 light
comes on permanently in position 0 to 5 of the retarder stage switch.

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Connector arrangement and pin assignment

Note

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

Plug X1 control unit (Digiprop)

1 Not in use or CAN-LOW


2 Not in use or CAN-GROUND
3 Not in use or CAN-HIGH
16 13 10 7 4 1
4 Retarder stage switch, Position 3
5 Retarder stage switch, Position 2 17 14 11 8 5 2

6 Retarder stage switch, Position 1 18 15 12 9 6 3

7 Terminal 15
8 Retarder stage switch, Position 5 11020
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“

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Plug X2 control unit (Digiprop)

1 Not operational
2 Proportional valve -
3 Proportional valve +
4 Cooling-water temperature-sensor - 7 4 1

5 Cooling-water temperature-sensor + 8 5 2

6 Not operational 9 6 3
7 Not in use
8 Oil-temperature sensor - 11021
9 Oil-temperature sensor +

Plug X3 control unit (Digiprop)

1 Input / pull up „DIU 1“


2 Speedometer signal
3 ABS-signal
4 Input / pull down „DID 2“ 10 7 4 1

5 Input / pull down „DID 1“ 11 8 5 2

6 Pressure-sensor ground 12 9 6 3

7 Pressure-sensor signal voltage


8 Retarder pilot light 11022
9 Input / pull down „DID 3“
10 Pressure-sensor supply voltage
11 Stop light relais
12 Input / pull down / PWM-in „DID4“

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Plug optional functions (cable Digiprop)

1 Retarder stage switch +


2 Input / pull down „DID 1“
3 Input / pull down „DID 2“
2 4 6 8 10 12 14
4 Input / pull down „DID 3“
5 Input / pull down / PWM -in „DID 4“ 1 3 5 7 9 11 13

6 Input / pull up „DIU 1“


7 Pressure-sensor Ground
8 Pressure-sensor signal voltage
11023
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

Plug ISO-interface (cable Digiprop)

1 K-lead
2 L-lead
3 Terminal 15
4 Terminal 31 4 3

2 1

11024

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Connector arrangement and pin assignment

Note

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

Plug X1 control unit (VERA)

1 CAN-LOW
2 CAN-GROUND
3 CAN-HIGH
16 13 10 7 4 1
4 Retarder stage switch, Position 0
5 Retarder stage switch, Position 1 17 14 11 8 5 2

6 Retarder stage switch, Position 2 18 15 12 9 6 3

7 Terminal 15 = battery voltage


8 Retarder stage switch, Position 3 11025
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

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Plug X2 control unit (VERA)

1 Output / highside „OUT 1“


2 Output / highside „OUT 2“
3 Output / highside „OUT 3“
4 Input / analog „IN 3“ 7 4 1

5 Input / analog „IN 1“ 8 5 2

6 Not in use (boot 1)


9 6 3
7 Not in use (boot 2)
8 Not in use (boot 3) 11026
9 Input / digital „IN 2“

Plug X3 control unit (VERA)

1 Cooling-water temperature-sensor -
2 Cooling-water temperature-sensor +
3 Proportional valve +
10 7 4 1
4 Proportional valve -
5 Oil-temperature sensor + 11 8 5 2

6 Oil-temperature sensor - 12 9 6 3

7 Pressure-sensor signal voltage


8 Pressure-sensor Ground 11027
9 Pressure-sensor supply voltage
10 Not in use (switch valve +)
11 Not in use (switch valve -)
12 Not in use

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Plug cooling-water temperature pick-up

Plug oil temperature pick-up

11028

Plug proportional valve

1 Proportional valve +
2 Proportional valve – 4 2
3 Not in use 1 3
4 Not in use

11029

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Plug retarder stage switch

1 Not in use
2 Position 5
3 Position 4
4 Retarder stage switch + 5 6 7 8

5 Position 3 1 2 3 4

6 Position 2
7 Position 1
8 Bridge to pin 4 11030

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Diagnosis / Troubleshooting – Troubleshooting and remedies

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

Special tool

53.8224.10

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 (53.8224.10
only Digiprop), if this function is realised.
An on-board-diagnosis (display) is OEM-specific possible. Heed herefore the statements of the vehicle
manufacturer.

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault memory readout via retarder pilot light blinking code

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) or
retarder stage switch.

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“ on
service 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.

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Diagnosis / Troubleshooting – Troubleshooting and remedies

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 retarder
pilot light is switched off.

Display example for fault code 23 (Digiprop):

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

0,5 sec

0,5 sec

0,5 sec
2 sec

2 sec
1 sec

1 sec

1 sec

1 sec
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 retarder
pilot light switches to permanent light again after the blinking code.
11031
Is there only one stored fault, the retarder pilot light is OFF after the output (only for Digiprop).
Display example for fault code 23 (Digiprop)
E Retarder pilot light ON
A Retarder pilot light OFF
t Time

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Diagnosis / Troubleshooting – Troubleshooting and remedies

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

2 sec

2 sec
Breaks between each ON time: each 1 second

1 sec
11032

Display example for fault code 23 (VERA)


E Retarder pilot light ON
A Retarder pilot light OFF
t Time

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Diagnosis / Troubleshooting – Troubleshooting and remedies

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“ of
service 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.

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Version Digiprop

Note

Meaning of entries in „Measurement/test connection“ column: X 1/15 Ω X3/11


Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test Set point Remedy 2)
connection1)

Code Test step

01 Stop light relay/ slight 1s - Ignition: OFF X 3/11 Ω X 1/15 Relay is Check lead, plugs
- Pull plug X3 out of installed: and relay or
Short circuit to control unit 250-350 Ω consumers
ground

1)
X 1/15 = ground control unit
2)
Only, if no fault is recognizable after a complete check of the periphery: change control unit.

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

03 HS 1 output slight 1s - Ignition: OFF X 1/18 Ω X 1/15 Relay is Check lead, plugs
Short circuit - Pull plug X1 out of installed: and relay
control unit 250-350 Ω or consumers

04 HS 2 output slight 1s - Ignition: OFF X 1/16 Ω X 1/15 Relay is Check lead, plugs
Short circuit - Pull plug X1 out of installed: and relay
control unit 250-350 Ω or consumers

05 Terminal 15 serious 60 s - Ignition: OFF X 1/7 V X 1/15 ≥ 17,5 V Check lead, plugs
Undervoltage - Pull plug X1 out of and fuses
control unit
- Ignition: ON

06 Terminal 15 serious 10 s - Ignition: OFF X 1/7 V X 1/15 ≤ 32,5 V Checking electrical


Overvoltage - Pull plug X1 out of installation of vehicle
control unit (see manufacturer
- Ignition: ON instructions)
- Start engine
(idle speed)

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

08 Cooling-water 1s - Ignition: OFF X 2/5 Ω X 2/4 20°C ± 10°C = Check lead and
09 temperature - Pull plug X2 out of 1039 - 1117Ω sensor
sensor serious/ control unit
Discontinuity / slight * 60°C ± 10°C =
Short circuit to 1194 - 1271Ω
battery
80°C ± 10°C =
1271 - 1347Ω

Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.

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

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

11 Oil temperature 1s - Ignition: OFF X 2/9 Ω X 2/8 20°C ± 10°C = Check lead and
12 sensor serious/ - Pull plug X2 out of 1039 - 1117Ω sensor
Discontinuity / slight * control unit
Short circuit to 60°C ± 10°C =
battery 1194 - 1271Ω

80°C ± 10°C =
1271 - 1347Ω

Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.

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

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

13 1 Retarder stage serious 1s - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and
switch - Retarder stage retarder stage switch
Undefined switch: X 1/6 V X 1/15 0V
switch state Position 0 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

13 2 - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and


- Retarder stage X 1/6 V X 1/15 ≥ 17,5 V retarder stage switch
switch:
Position 1 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

13 3 - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and


- Retarder stage X 1/6 V X 1/15 ≥ 17,5 V retarder stage switch
switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 2
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

13 4 - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and


- Retarder stage X 1/6 V X 1/15 ≥ 17,5 V retarder stage switch
switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 3 X 1/4 V X 1/15 ≥ 17,5 V

X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

13 5 - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and


- Retarder stage X 1/6 V X 1/15 ≥ 17,5 V retarder stage switch
switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 4 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V

X 1/8 V X 1/15 0V

13 6 - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and


- Retarder stage X 1/6 V X 1/15 ≥ 17,5 V retarder stage switch
switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 5 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 ≥ 17,5 V

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Operati- Measurement/ Result/ Cause/
class on Test connec- Set point Remedy
tion

Code Test step

14 Retarder stage serious 10 s - Ignition: OFF X 1/10 V X 1/15 0V Check lead and
switch - Pull plug X1 out of plug
Short circuit to control unit
battery - Ignition: ON
- Retarder stage switch:
Position 0

15 Retarder stage serious 1s - Ignition: OFF X 1/10 Ω X 1/15 Resistor Single check of
switch - Pull plug X1 out of endless stages for
Short circuit to control unit short circuit
battery - Retarder stage switch:
Position 5

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


signal speedometer
Discontinuity

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

18 Speedometer signal serious 2s - Ignition: OFF X 3/2 V X 1/15 ≤ 9V Check lead and
Short circuit to battery - Pull plug X3 out of speedometer
undefined signal control unit
- Ignition: ON

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


Short circuit to ground relay and
ABS-control unit

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


relay and
ABS-control unit

22 Internal fault serious 1s - - - Replace control


ABS-current path unit

23 Proportional valve serious 1s - Ignition: OFF X 2/3 V X 1/15 ≤ 10 V Check lead


Fault No. 1: - Pull plug X2 out of
Short circuit to battery control unit
- Ignition: ON

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

24 1 Proportional valve serious 1s - Ignition: ON X 2/2 Ω X 2/3 18-25 Ω Check lead and
Fault No. 2: - Pull plug X2 out proportional
- Short circuit proportional of control unit valve
valve magnetic (valve block)
- 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

2 - Ignition: OFF X 2/3 Ω X 1/15 Resistor Check lead and


- Pull plug X2 out endless proportional
of control unit valve
(valve block)

3 - Ignition: OFF X 2/2 Ω X 1/15 Resistor Check lead and


- Pull plug X2 out endless valve block
of control unit

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

25 Valve block serious 10 s Replace


Fault No. 3: control unit
defective control unit

27 Valve block serious 2s Replace


Fault No. 5: control unit
defective control unit

28 Terminal 30 serious 60 s - Ignition: OFF X 1/13 V X 1/15 ≥ 17,5 V Check lead,


Undervoltage - Pull plug X1 out of plug and fuse
control unit
- Ignition: ON

29 Fault control unit serious 180 ms Replace


control unit

31 Control unit: serious 100 ms Provide new


Coding fault parameters for
control unit

32 Retarder pilot light: serious 3s - Ignition: OFF X 3/8 V X 1/15 ≥ 17,5 V Check lead,
Discontinuity / - Pull plug X3 out of retarder pilot
Short circuit to ground control unit light and fuse
- Ignition: ON

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Code Test step

33 Retarder pilot light: serious 3s - Ignition: ON X 3/8 V X 1/15 ≤ 2V Check lead and
Short circuit to battery - Retarder stage retarder pilot
switch: light
Position 1

35 Fault control unit serious 500 ms / 123 s Replace


control unit

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


accordance with
OEM - as well as
Voith requirements

38 1 Fault constant-air slight 1 s to 10 s Ignition: ON X 3/7 V X 1/15 0,3-0,7 V Pressure sensor


pressure Position 0 and wiring harness
X 3/10 V X 1/15 4,75-5,25
V If deviation: step 2

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

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Version VERA

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 Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

1 1 Data set heavy immediately af- Parameter setting fault,


fault ter ignition ON new parameter setting

2 1 EEprom heavy immediately af- Replace control unit


fault ter ignition ON

3 1 ROM heavy approx. 10s after Replace control unit


fault ignition ON

4 1 SIBA heavy 60 ms Replace control unit


fault

5 1 Proportional- heavy 1s - Ignition: OFF X 3/3 Ω X 3/4 18 ... 25 Ω Check electrical lead
valve chasssis - disconnect and proportional valve
ground end, plug X3
interruption,
short circuit,
connecting lead

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

5 2 X 3/3 Ω X 1/14 Resistor endless Check electrical lead


and proportional val-
ve

5 3 X 3/3 Ω X 1/14 Resistor endless Check electrical lead


and proportional val-
ve

6 1 Proportional- heavy 1s - Ignition: OFF X 3/3 V X 1/14 ≤10 V Check electrical lead
valve - Pull off plug X1, and plug
battery short cir- X3
cuit - Ignition: ON

8 1 Proportional- heavy 3s Replace control unit


valve-control,
int. fault at con-
trol unit

9 1 Terminal 15 heavy 60s - Ignition: OFF X 1/7 V X 1/14 ≥ 17,5 V Check electrical lead,
undervoltage - Pull off plug X1 fuse and plug
- Ignition: ON

10 1 Terminal 15 heavy 10s - Ignition: OFF X 1/7 V X 1/14 ≤ 32,5 V Check electrical unit
overvoltage - Pull off plug X1, of vehicle (see manu-
X3 facturer´s instruc-
- Ignition: ON tions)

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

11 1 Retarder stage heavy 2s - Ignition: ON X 1/10 V X 1/14 ≥ 17,5 V Check electrical lead,
switch - Retarder stage X 1/5 V X 1/14 0V plug and retarder sta-
undefined con- switch: position 0 X 1/6 V X 1/14 0V ge switch
dition X 1/8 V X 1/14 0V
X 1/9 V X 1/14 0V
X 1/18 V X 1/14 0V

2 - Ignition: ON X 1/10 V X 1/14 ≥ 17,5 V Check electrical lead,


- Retarder stage X 1/5 V X 1/14 ≥ 17,5 V plug and retarder sta-
switch: position 1 X 1/6 V X 1/14 0V ge switch
X 1/8 V X 1/14 0V
X 1/9 V X 1/14 0V
X 1/18 V X 1/14 0V

3 - Ignition: ON X 1/10 V X 1/14 ≥ 17,5 V Check electrical lead,


- Retarder stage X 1/5 V X 1/14 ≥ 17,5 V plug and retarder sta-
switch: position 2 X 1/6 V X 1/14 ≥ 17,5 V ge switch
X 1/8 V X 1/14 0V
X 1/9 V X 1/14 0V
X 1/18 V X 1/14 0V

4 - Ignition: ON X 1/10 V X 1/14 ≥ 17,5 V Check electrical lead,


- Retarder stage X 1/5 V X 1/14 ≥ 17,5 V plug and retarder sta-
switch: position 3 X 1/6 V X 1/14 ≥ 17,5 V ge switch
X 1/8 V X 1/14 ≥ 17,5 V
X 1/9 V X 1/14 0V
X 1/18 V X 1/14 0V

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

11 5 - Ignition: ON X 1/10 V X 1/14 ≥ 17,5 V Check electrical lead,


- Retarder stage X 1/5 V X 1/14 ≥ 17,5 V plug and retarder sta-
switch: position 4 X 1/6 V X 1/14 ≥ 17,5 V ge switch
X 1/8 V X 1/14 ≥ 17,5 V
X 1/9 V X 1/14 ≥ 17,5 V
X 1/18 V X 1/14 0V

6 - Ignition: ON X 1/10 V X 1/14 ≥ 17,5 V Check electrical lead,


- Retarder stage X 1/5 V X 1/14 ≥ 17,5 V plug and retarder sta-
switch: position 5 X 1/6 V X 1/14 ≥ 17,5 V ge switch
X 1/8 V X 1/14 ≥ 17,5 V
X 1/9 V X 1/14 ≥ 17,5 V
X 1/18 V X 1/14 ≥ 17,5 V

12 1 Retarder stage heavy 1s - Ignition: OFF X 1/10 Ω X 1/14 Resistor endless Check each stage on
switch - Pull off plug X1 chsssis ground end
chasssis ground - Retarder stage
end switch: position 5

13 1 Retarder stage heavy 10s - Ignition: OFF X 1/10 V X 1/14 0V Check electrical lead
switch - Pull off plug X1 and plug
battery shortcir- - Retarder stage
cuit switch: position 0

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

16 1 Temperature- heavy 1s See blinking code 17


sensors to 20
(both sensors
defect)

17 1 Cooling-water light 1s - Ignition: OFF X 3/1 Ω X 3/2 20°C ± 10 °C = Check electrical lead,
temperature - Pull off plug X3 1039 - 1117Ω sensor and plug
sensor
60°C ± 10 °C =
interruption
1194 - 1271Ω

80°C ± 10 °C =
1271 - 1347Ω

Note:
The measuring in
one temperature
range normally is
sufficient.

18 1 Cooling-water light 1s - Ignition: OFF X 3/2 Ω X 1/14 Resistor endless Check electrical lead
temperature - Pull off plug X1,
sensor X3
chasssis ground
end

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

19 1 Oil-temperature light 1s - Ignition: OFF X 3/5 Ω X 3/6 20°C ± 10 °C = Check electrical lead
sensor - Pull off plug X3 1039 - 1117Ω and plug
interruption
60°C ± 10 °C =
1194 - 1271Ω

80°C ± 10 °C =
1271 - 1347Ω

Note:
The measuring in
one temperature
range normally is
sufficient.

20 1 Oil-temperature light 1s - Ignition: OFF X 3/5 Ω X 1/14 Resistor endless Check electrical lead
sensor - Pull off plug X1, and plug
chasssis ground X3
end

21 1 Speedometer heavy 2s - Ignition: ON X 1/11 V X 1/14 ≤1V Check electrical lead


signal and speedometer
interruption

22 1 Speedometer heavy 2s - Ignition: OFF X 1/11 V X 1/14 ≤9V Check electrical lead
signal - Pull off plug X1 and speedometer
battery shortcir- - Ignition: ON
cuit

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

23 1 Retarder pilot heavy 1s - Ignition: OFF X 1/15 V X 1/14 ≥ 17,5 V Check electrical lead
light - Pull off plug X1 and fuse
interruption, - Ignition: ON
chasssis ground
end

24 1 Retarder pilot heavy 3s - Ignition: ON X 1/15 V X 1/14 ≤2V Check electrical lead
light - Retarder stage and retarder pilot
interruption, switch: position 1 light
battery shortcir-
cuit

25 1 Pressure sensor light 0,5s - Ignition: ON X 3/8 V X 3/9 4,75 ... 5,25 V Check electrical lead
fault (supply)

26 1 Pressure sensor light 1s - Ignition: OFF X 3/7 Ω X 1/14 Resistor endless Check electrical lead
interruption, - Pull off plug X1, and pressure-sensor
chasssis ground X3
end

27 1 Pressure sensor light 1s - Ignition: ON X 3/9 V X 3/8 4,75 ... 5,25 V Check electrical lead
battery shortcir- and pressure-sensor
cuit

28 1 Pressure sensor light 10s - Ignition: ON X 3/7 V X 3/8 0,3 ... 0,7 V Check electrical lead
unplausible - Retarder stage and pressure-sensor
signal switch: position 0

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

29 1 ABS heavy 60s - Ignition: ON X 1/13 V X 1/14 ≥ 3,5 V Check electrical lead,
chasssis ground relay and ABS-con-
end trol unit

30 1 ABS heavy 5s - Ignition: ON X 1/13 V X 1/14 ≥ 16,5 V Check electrical lead,


undefined con- relay and ABS-con-
dition trol unit

31 1 ABS heavy 1s Replace control unit


int. fault at con-
trol unit

33 1 Brake light relay light 1s - Ignition: OFF X 1/16 Ω X 1/14 At installed relay Check electrical lead
chasssis ground - Pull off plug X1 250-350 Ω plug and relay or con-
end sumer

34 1 Brake light relay light 1s - Ignition: OFF X 1/16 Ω X 1/14 < 1,5kΩ Check electrical lead
interruption, - Pull off plug X1 plug and relay or con-
battery shortcir- sumer
cuit

2 - Ignition: OFF X 1/16 V X 1/14 0V Check electrical lead


- Pull off plug X1 plug and relay or con-
- Ignition: ON sumer

35 1 Output 1 light 1s - Ignition: OFF X 2/1 Ω X 1/14 At installed con- Check electrical lead
(OUT-1) - Pull off plug X2 sumer plug and relay or con-
chasssis ground > 150Ω sumer
end

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

36 1 Output 1 light 1s - Ignition: OFF X 2/1 Ω X 1/14 < 3kΩ Check electrical lead
(OUT-1) - Pull off plug X2 plug and relay or con-
interruption, sumer
battery short cir-
cuit

2 - Ignition: OFF X 2/1 V X 1/14 0V Check electrical lead


- Pull off plug X2 plug and relay or con-
- Ignition: ON sumer

37 1 Output 2 light 1s - Ignition: OFF X 2/2 Ω X 1/14 At installed con- Check electrical lead
(OUT-2) - Pull off plug X2 sumer plug and relay or con-
chasssis ground > 150 Ω sumer
end

38 1 Output 2 light 1s - Ignition: OFF X 2/2 Ω X 1/14 < 3kΩ Check electrical lead
(OUT-2) - Pull off plug X2 plug and relay or con-
interruption, sumer
battery shortcir-
cuit

2 - Ignition: OFF X 2/2 V X 1/14 0V Check electrical lead


- Pull off plug X2 plug and relay or con-
- Ignition: ON sumer

39 1 Output 3 light 1s - Ignition: OFF X 2/3 Ω X 1/14 At installed con- Check electrical lead
(OUT-3) - Pull off plug X2 sumer plug and relay or con-
chasssis ground > 150Ω sumer
end

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Diagnosis / Troubleshooting – Troubleshooting and remedies

Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test connection Set point Remedy

Blink- Test step


Code

40 1 Output 3 light 1s - Ignition: OFF X 2/3 Ω X 1/14 < 3kΩ Check electrical lead
(OUT-3) - Pull off plug X2 plug and relay or con-
interruption, sumer
battery shortcir-
cuit

2 - Ignition: OFF X 2/3 V X 1/14 0V Check electrical lead


- Pull off plug X2 plug and relay or con-
- Ignition: ON sumer

41 1 CAN-fault mes- heavy 1s Check electrical con-


sages failing to nections and leads of
appear, inter- vehicle CAN-Bus
ruption

42 1 CAN heavy 200ms Check electrical con-


BusOff nections and leads of
vehicle CAN-Bus

46 1 Retarder foot- light 500ms - Ignition: ON X 2/4 V X 1/14 > 0,4 V Check analoge foot-
switch pedal, electrical lead
chasssis ground and plug
end (IN-3)

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Diagnosis / Troubleshooting – Troubleshooting and remedies

B. Without fault code

Hinweis

Retarder faults without fault code are not recognized electronically.

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

4.5 Checking Supply-Air Pressure (pv)


Work scope test

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 (pv).
• Minimum pressure: 6 bar
• Maximum pressure: 11 bar

Notice

If pressure is not within the specified range, the compressed-air system must be checked according to 32
11033
the manufacturer´s data.

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

4.6 Checking Constant-Air


Pressure (py) and
Pump Pressure (pdyn) 4100

Requirements for check 103

• Retarder stage switch in position 0

• Vehicle ignition OFF K


V
oi
d.
-S
th
ac
-S
ac
h-
N
h-
N
r.

r.

103 Screw plug


(test connection pump pressure)
M12x1,5
Inhex-head w.a.f. 6
13 Nm (20 Nm)
4100 Oil filler plug
M30x1,5
Inhex-head, w.a.f. 17
100 Nm (100 Nm)

Notice

The pump pressure check provides e.g.


information on internal leaks and on the
correct operation of the retarder.

11034

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

Requirements for check

• Retarder stage switch in position 0

• 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:

H53.478810

Compressed-air Oil-pressure gauge


pressure gauge
0 - 6 bar 0 - 25 bar
99/7 99/1

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

Attention!

Two version of the screw plugs (107, 3500, 4100, 4200) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to
print.
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 in
brackets are valid.
The copper-sealing rings have to be renewed in general.

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

Work scope check


4100

Attention! Risk of injury!

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

1. Screw out oil filler plug (4100).

11035

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

11036

99/7 Air-pressure gauge 53.1403.10

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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!

3. Screw out screw plug (103).

103

11037

Attention!

Easy oil-exit is caused constructively, but has no effect on function of retarder, however.
99/1
4. Connect oil-pressure gauge (99/1) to bore of screw plug (103).

11038

99/1 Oil-pressure gauge 53.4788.10

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

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

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..

6. Shift the retarder stage switch to position 5 while on move at prop shaft speed vps = 1000 r.p.m. and
read-off pump pressure (pdyn) 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 (py) with determined value of constant-air pressure (py)
according tables on pages 93 ff.

Attention!

If the nominal value of the constant-air pressure (py) 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 (py), either a
leak of the retarder or a defect is due to the control (see troubleshooting diagram).
The constant-air pressure (py) must not change during the drive.

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

Attention! Risk of injury!

Screwing of oil-pressure gauge and retarder are hot!


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

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

99/1

11039

99/1 Oil-pressure gauge 53.4788.10

103
Notice

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

10. Screw tight screw plug (103).


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

11040

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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!

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


99/7

11041

99/7 Air-pressure gauge 53.1403.10

4100

Notice

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

12. Screw tight oil filler plug (4100).


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

11042

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
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Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve

4.7 Checking Control Current of Proportional Valve


Requirements for check

• Battery voltag 24 - 28 V

• Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found
satisfactory

• Fuse for retarder control unit checked and found satisfactory

• Plug at proportional valve and socket 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!)

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve
15300009710 / cbtsd 02-11 Page 86
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).
21
2. Connect plug of measuring adapter (99/3) with the proportional valve (21).
3. Connect the Multimeter (98/8). Switch position: mA. 98/8

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 of
the 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.

99/3
11043
98/8 Multimeter
99/3 Measuring adapter 53.8198.10

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Control Current of Proportional Valve
15300009710 / cbtsd 02-11 Page 87
Diagnosis / Troubleshooting – Checking Pressure Sensor

4.8 Checking Pressure Sensor


Requirements for check

• 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

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Pressure Sensor
15300009710 / cbtsd 02-11 Page 88
Diagnosis / Troubleshooting – Checking Pressure Sensor

Work scope check

1. Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3).
98/8
2. Connect plug of measuring adapter (99/3) to pressure sensor (38).
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“.
38
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. 99/3

11044
Notice
98/8 Multimeter
If there is an error (wire or sensor), the supply voltage is switched off by the control unit. Check the wire 99/3 Measuring adapter 53.8198.10
or the sensor and replace the defect part, if necessary.

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 the
purpose of comparison a manometer "py" 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.

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Pressure Sensor
15300009710 / cbtsd 02-11 Page 89
Diagnosis / Troubleshooting – Checking Temperature Adaption

4.9 Checking Temperature Adaption


Requirements for check

• 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 found
satisfactory

• 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

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Temperature Adaption
15300009710 / cbtsd 02-11 Page 90
Diagnosis / Troubleshooting – Checking Temperature Adaption

Work scope check

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

99/2

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.
Wasser Öl

11045
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 oil
temperature.
3. Switch-on vehicle ignition!
4. Operate retarder at highest braking stage.
Constant-air pressure (py) control current must reach values given on table on pages 93 ff.
5. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. The
constant-air pressure py must drop below the set maximum pressure. Set rotary switch of
temperature simulator (99/2) to 125oC cooling water temperature.
There must be no more output of constant-air pressure py.
6. Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature.

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Temperature Adaption
15300009710 / cbtsd 02-11 Page 91
Diagnosis / Troubleshooting – Checking Temperature Adaption

7. Set rotary switch of temperature simulator (99/2) to 185oC oil temperature.


The constant-air pressure must drop below the set maximum pressure.
8. Set rotary switch of temperature simulator (99/2) to 225oC oil temperature.
There must be no more output of constant-air pressure py.
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) to
temperature sensors cooling water (19) and oil (20).

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Checking Temperature Adaption
15300009710 / cbtsd 02-11 Page 92
Diagnosis / Troubleshooting – Table of Measurements

4.10 Table of Measurements


Digiprop without CAN
With pressure sensor

Code-Number 2) Amperage Constant-air pressure (py) Pump pressure


control current mA1) 3) 5) (static) 4) 1) (dynamic) 1) vps = 1000 r.p.m.
OLD NEW
nominal value [bar] (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 15

052 152 396 - 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

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).
.

Notice

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

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 93
Diagnosis / Troubleshooting – Table of Measurements

Digiprop with CAN


With pressure sensor

Code-Number 2) Amperage Constant-air pressure (py) Pump pressure


control current mA1) 3) 5) (static) 4) 1) (dynamic) 1) vps = 1000 r.p.m.
nominal value [bar] (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

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).

Notice

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

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 94
Diagnosis / Troubleshooting – Table of Measurements

Without pressure sensor / without CAN

Code-Number 2) Amperage Constant-air pressure (py) Pump pressure


control current mA1) 3) 5) (static) 4) 1) (dynamic) 1) vps = 1000 r.p.m.
OLD NEW nominal value [bar] (minimum value) [bar]

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

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).

Notice

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

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 95
Diagnosis / Troubleshooting – Table of Measurements

VERA DAFBUS

Serial-Number Amperage Constant-air pressure (py) Pump pressure


control current mA1) 2) 4) (static) 3) 1) (dynamic) 1) vps = 1000 r.p.m.
nominal value [bar] (minimum value) [bar]

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

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).

Notice

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

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 96
Diagnosis / Troubleshooting – Table of Measurements

Voltage measurement at the pressure sensor

5
4,5
4
3,5
3
[ V ] 2,5
2
1,5
1
0,5
0
0,5 1 1,5 2 2,5 3 3,5 4
0
[ BAR ]
11046

Notice

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

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 97
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

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 right
to make further modifications.

Aftersales Service Manual Voith Retarder 115 E Diagnosis / Troubleshooting – Table of Measurements
15300009710 / cbtsd 02-11 Page 98
Removing, Installing Retarder

5. Removing, Installing Retarder

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 99
Removing, Installing Retarder

Prior work
25300
• Cooling water drained *
25000
25300
• Oil drained of retarder 850
(see page 26)

• Propeller shaft at the gearing flange


25200
removed *

• Oil drained of gearbox *

• Waterneck removed
(see page 123)

• Speedometer sensor removed *


25100
• Output shaft-flange removed * 4100

* Notice the information of the vehicle


manufacturer

25200

Notice

The shim must always be determined newly,


if: 850/1
• taper roller bearing (800) is renewed
11047
• Retarder is installed at gearbox Illustration: Removing, installing retarder
• Retarder was repaired
• Gearbox was repaired

850/1 Taper roller bearing


850 Outer race
Only removing, if the tapered
roller bearing is replaced or a
new shim enclosed
4100 Screw plug
M 30 x 1,5
Inhex-head w.a.f. 17
100 Nm (100 Nm)
25000 Shim
25100 O-Ring, renewed
coat with silicone-free and
non-corrosive grease for
installation
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

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 100
Removing, Installing Retarder

Special tools: Tool for local fabrication

15

M10
FJ 6280 0
486 265

80
67.3224.10 67.3319.10 67.3320.10 Material: St37-2, DIN 17100 (1.80)
28028e

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 and


non-corrosive grease

Retarder housing Omnifit FD 10-1042

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 101
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 to
print.
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 in
brackets are valid.
The copper-sealing rings have to be renewed in general.

Removing

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

4100

25200
11049

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 102
Removing, Installing Retarder

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

Notice
25000
Carry out following working step, if: 850
- taper roller bearing (800) is renewed
- Retarder is installed at gearbox 98/4

265
00
628
486
FJ
- Retarder was repaired 25100
- Gearbox was repaired
11050
3. Pull off outer ring (850) with puller bearing outer ring (98/4) and remove shim (25000). 98/4 Puller bearing outer ring 67.3320.10

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 103
Removing, Installing Retarder

Assembling

1. Determine thickness of shim as follows:

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

Attention!

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

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

11051

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 104
Removing, Installing Retarder

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

850

850/1

11052

1.3 Put measuring device (98/1) on gearbox and tighten hex.-head screws handtight (3 Nm).
Pos.1 Pos. 2
1.4 Put the lever from position 1 in position 2 to pressurize the drive shaft with a defined preload of
approx. 400 N.

1.5 Turn the pinion by hand 15 times clockwise and after that 15 times counterclockwise.
98/1

11053
98/1 Measuring device 67.3224.10

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 105
Removing, Installing Retarder

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

11054

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

11055

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 106
Removing, Installing Retarder

Notice

The thicker shim must always be placed first in the gearbox housing.

2. Put shim (25000) into the gearbox housing (if removed).

Notice 25000
If taper roller bearing was replaced, also replace the bearing outer ring (850). 850

98/3

Notice 11056

If necessary warm housing for the simpler assembly in the area of the bearing outer ring to 98/3 Drive in tool 67.3319.10
approx. 80°C.

3. Insert bearing outer ring (850 if removed) into the gearbox housing and knock this with the drive in
tool (98/3) in as far as possible.

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 107
Removing, Installing Retarder

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


1

11057

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.
25100
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 assembled
congruently.

11058

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 108
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 25200
25200
10. Screw out again the two threaded bolts M 10 x 80.
11. Insert the 17 hex.-head screws (25300) and tighten them. 25200
Tightening torque hex.-head screws (25300): 58 Nm

25300

11059

Aftersales Service Manual Voith Retarder 115 E Removing, Installing Retarder


15300009710 / cbtsd 02-11 Page 109
Repair Retarder

6. Repair Retarder
6.1 Overall Illustration of Main Components ...................................................111
6.2 Removing, Checking and Installing Casing Ventilation.............................112
6.3 Removing, Checking and Installing Silencer.............................................122
6.4 Removing and Installing Water Neck........................................................123
6.5 Removing, Checking and Installing Heat Exchanger................................124
6.6 Removing and Installing Oil Tank Cover...................................................133
6.7 Removing, Installing Non-Return Valve Outlet .........................................136

Aftersales Service Manual Voith Retarder 115 E Repair Retarder


15300009710 / cbtsd 02-11 Page 110
Repair Retarder – Overall Illustration of Main Components

6.1 Overall Illustration of Main Components


3300
6101 4100
6100
6101 9000
3100
2810
3300 3850 2000
3850
3900
2800
3800 8000
2300/1
2301 4000
2300
2300/2 3700 5400
2300/3 2900 5500
5600
6600
6700 7500
109
6700
6400 6600
7300
7600
5300 20100
5200 7500 20000
100
7300 20200
103
20100
5200 20400
3500
5300 20300
6700 20000
4100 20200
6600
107 20400
2600 20300

2500 2105
2106
3100 1700
4200 1600
3100
2100 11060

Illustration: Components Retarder 115 E

100 Retarder housing 2500 Bottom cover 5200 Temperature sensor


103 Screw plug 2600 Bottom gasket 5300 Sealing ring A 14 x 20
M12 x 1,5, 2800 Cover for casing ventilation 5400 Corrugated spring
inhex-head, w.a.f. 6 2810 Vent and air filter 5500 Disc (silencer) D 30 x 4
107 Oil drain plug Retarder M 12 x 1,5, 5600 Retaining ring JL 30 x 1,2
M 24 x 1,5, hex.-head, w.a.f. 17 6100 Pipe
inhex.-head, w.a.f. 12 2900 Gasket 6101 O-Ring 15,3 x 2,4
109 Screw plug 3100 Combined hex.-head screw 6400 Heat exchanger
M 24 x 1,5, M 8 x 30, 6600 Hex.-head screw
inhex.-head, w.a.f. 12 hex.-head, w.a.f. 13 M 14 x 45,
1600 Valve cover 3300 Combined hex.-head screw hex.-head, w.a.f. 22
1700 O-Ring 60 x 3 M 8 x 80, old:
2000 Top cover hex.-head, w.a.f. 13 hex.-head screw with flange
2100 Non-return valve outlet, complete 3500 Screw plug with sieve, M 14 x 40,
2105 O-Ring, 34 x 3 M 30 x 1,5, hex.-head, w.a.f. 19
2106 O-Ring, 54 x 3 inhex.-head, w.a.f. 17 6700 Washer A15
2300 Casing ventilation 3700 Proportional valve 7300 O-Ring 15 x 4
2300/1 Valve insert 3800 Damping plate 7500 O-Ring 45 x 5
2300/2 Float 3850 O-Ring 16 x 3 7600 O-Ring 25 x 4
2300/3 Float cage 3900 Combined hex.-head screw 8000 Intermdiate plate 196 x 144 x 2
2301 O-Ring 55 x 3 M 8 x 20, 9000 Pressure sensor 0 to 4 bar
hex.-head, w.a.f. 13 20000 Water neck
4000 Hex.-head nut M8, 20100 Gasket, renew
hex.-head, w.a.f. 13 20200 Combined hex.-head screw
4100 Screw plug M 8 x 80,
M 30 x 1,5, hex.-head, w.a.f. 13
inhex.-head, w.a.f. 17 20300 Screw plug
4200 Screw plug M 14 x 1,5,
M 24 x 1,5, hex.-head, w.a.f. 13
inhex.-head, w.a.f. 12 20400 Sealing ring A 14 x20

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Overall Illustration of Main Components
15300009710 / cbtsd 02-11 Page 111
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.

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!

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 112
Repair Retarder – Removing, Checking and Installing Casing Ventilation

2300 Casing ventilation


2300/1 Valve insert 3300
2300/2 Float
desired weight 11g ± 1 g 6101

2300/3 Float cage


6100
2301 O-Ring 55 x 3, renew, 2800
coat with silicon-free and non- 6101
corrosive grease for installation
2800 Cover casing ventilation 2900
2900 Gasket casing ventilation,
renew
3300 Combined hex.-head screw
M 8 x 80, renew 2300/1
hex.-head, w.a.f. 13, 30 Nm
6100 Air-pipe 2300 2301
coat with silicon-free and non-
2300/2
corrosive grease for installation
6101 O-Ring 15,2 x 2,4, erneuern
coat with silicon-free and non- 2300/3
corrosive grease for installation

sealant and lubricant

O-Ring silicon-free and


non-corrosive grease

Float Methylated spirit


11061

Illustration: Casing ventilation

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 113
Repair Retarder – Removing, Checking and Installing Casing Ventilation

Special tools: Tool for local fabrication

Ø 40,5 mm

7 mm
Ø 60 mm
Material: St 37
Weight: 0,085 kg 28049e

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.

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 114
Repair Retarder – Removing, Checking and Installing Casing Ventilation

Removing

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

3300

11063

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


Clean sealing surface. 2800

2900

11064

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 115
Repair Retarder – Removing, Checking and Installing Casing Ventilation

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


6101

6100
6101

11065

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

99/5
100

98/7

11066

99/5 Impact puller 53.7712.10


98/7 Adapter 53.9428.10

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 116
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
100

2300/3

11067

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

2300/1

2301

11068

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 117
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 casing 2300/2
ventilation.

Notice
11069
Oil has penetrated into the float, the retarder is impaired in its operation.

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 the 99/7
sealing edge is not damaged, the fluid level must not alter in the course of 1 minute. 2300/2
If necessary, renew complete casing ventilation.

2300/1

11070

99/7 Test ring 67.2757.10

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 118
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

2301

11071

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

2300/1

2300/2

2300/3

11072

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 119
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).
99/5
5. Use the impact puller (99/5) and adapter (98/9) to knock in the casing ventilation. 100

98/7

11073

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. 2000

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


6101

11074

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
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Repair Retarder – Removing, Checking and Installing Casing Ventilation

9. Place new gasket (2900) on retarder housing.

2900

11075

10. Coat bore for air-pipe (6100) in cover (2800) with silicon-free and non-corrosive grease.
11. Slip cover (2800) in air-pipe (6100) and place this at retarder housing. 6100
12. Screw in combined hex.-head screws (3300) and screw them tight.
Tightening torque combined hex.-head screw (3300): 30 Nm. 3300

2800

11076

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking and Installing Casing Ventilation
15300009710 / cbtsd 02-11 Page 121
Repair Retarder – Removing, Cleaning and Installing Silencer

6.3 Removing, Cleaning and


Installing Silencer

Notice 5400
This work step can be performed with retarder
5500
installed or removed.

5600

5400 Corrugated spring


5500 Disc (silencer) D 30 x 4,
clean with appropriate cle-
aning agent (Benzine) and
blow out with compressed-air
5600 Circlip JL 30 x 1,2
dished side must face
silencer

Cleaning agent Kd.


-S
ac

th-S
h-

ac
h-
Nr.
Nr.

Voi

Silencer Benzine

11077

Illustration: Silencer

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Cleaning and Installing Silencer
15300009710 / cbtsd 02-11 Page 122
Repair Retarder – Removing and Installing Water Neck

6.4 Removing and Installing


Water Neck
Prior jobs

• Vehicle ignition OFF

• Retarder switched off

• Cooling water drained 20100


20000
20200
20000 Water neck
20100 Gasket, renew
20200 Combined hex.-head screw
M 8 x 80
hex.-head, w.a.f. 13,
30 Nm

h-
Nr
.
20100
ac .
.-S Nr
Kd h-
ac
-S
ith
Vo

20000

20200

11078

Illustration: Water neck

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing and Installing Water Neck
15300009710 / cbtsd 02-11 Page 123
Repair Retarder – Removing, Checking, Installing Heat Exchanger

6.5 Removing, Checking, Installing Heat Exchanger

Notice

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

Prior jobs

• 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 .10
in the type plate. This must be removed. In connection with this, the retarder control unit has to be
progammed on the latest for this retarder valid code and the non-return valve (outlet) must be installed
as of code number 67.2550.22.

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 124
Repair Retarder – Removing, Checking, Installing Heat Exchanger

107 Oil drain plug retarder


M 24 x 1,5,
inhex.-head, w.a.f. 12,
47 Nm (80 Nm)
4200 Oil drain plug oil tank
7500 6700
M 24 x 1,5,
inhex.-head, w.a.f. 12,
47 Nm (80 Nm)
6400 Heat exchanger 6600
6600 Hex.-head screw
M 14 x 45, renew
hex.-head, w.a.f. 22,
Pre-torque: 50 Nm 7300
Final torque: 30° turning angle
old version: 7600
hex.-head screw
M14 x 40 with flange, 6400
hex.-head, w.a.f. 19
7500
6700 Washer A15
7300 O-ring 15 x 4, renew 6700
coat with silicon-free and non- 7300 6600
corrosive grease for installation
7500 O-ring 45 x 5, renew 4200 4200
coat with silicon-free and non-
107
corrosive grease for installation
7600 O-ring 25 x 4, renew
coat with silicon-free and non-
corrosive grease for installation

Lubricant
11079
O-rings silicon-free and
Illustration: Removing heat exchanger
non-corrosive grease

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 125
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 to
print.

The integrated sealing rings must be checked for possible damages during the installation of the heat
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 in
brackets are valid.
The copper-sealing rings are generally to be renew.

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 126
Repair Retarder – Removing, Checking, Installing Heat Exchanger

Special tool

67.1948.10

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

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 127
Repair Retarder – Removing, Checking, Installing Heat Exchanger

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) and
drain 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. 107

4200 4200
11080

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 128
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

6700

6700
6600
6700
6600 11081

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

7500
7300
7300

7600

7500
7300
11082

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 129
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-air
99/6 6400
pressure lines to bottom connection (arrow).
2. Fill heat exchanger (6400) on water side with hot water (approx. 70oC).
3. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the
heat exchanger).

Notice

If air bubbles form in the hot water the heat exchanger is leaking and must be exchanged.
11083
99/6 Pressure test plate 67.1948.10

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


99/6 6400
5. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the
heat exchanger).

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 heat
exchanger.
Prior to installing a new heat exchanger, drain any corrosion-inhibiting oil which may have collected and
11084
flush it out with hot water in the water section of the heat exchanger.
99/6 Pressure test plate 67.1948.10

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 130
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 and
non-corrosive grease. 7600
7500

7300
7300

7500
7300
11085

2. Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) with
washers (6700) tight.
6400
Initial torque: 50 Nm

Final torque: 30° turning angle

6600

6700

6700
6600
6700
6600 11086

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 131
Repair Retarder – Removing, Checking, Installing Heat Exchanger

3. Install retarder, if necessary (see page 99 ff).


4. Fill in cooling-water and bleed cooling-water circuit.
If available, open the check valves in the flow- and return pipe of the cooling-water section.

Attention!

If the heat exchanger leaks, there is water present in the retarder. If the retarder is filled up, a mixture of
oil and water is created, causing the oil in the retarder to foam and escape through the casing ventilation
system to the atmosphere. For this reason, it is indispensible to flush out the retarder after repair!

While flushing, apply the brake gently several times to prevent the retarder oil warming up excessively.

5. Flush the retarder, if the heat exchanger has leaked as follows:


To flush the retarder, fill it with 7,0 litres of engine- or flushing oil. Apply the brakes gently several
times to flush out the retarder system and drain the oil through the oil drain plugs (107 and 4200).
Repeat the procedure 2 or 3 times.
6. Check integrated sealing rings of oil-drain plugs for possible damages;
renew oil-drain plug if necessary.
7. Screw oil-drain plug (107, 4200) tight
Tightening torque oil-drain plug (107, 4200): 47 Nm (80 Nm) 107

8. Fill in retarder oil (see page 29).


9. If heat exchanger were leaking, deoil cooling- and heatingsystem of vehicle according manufacturer 4200 4200
instructions. 11087

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Checking, Installing Heat Exchanger
15300009710 / cbtsd 02-11 Page 132
Repair Retarder - Removing, Installing Oil Tank Cover

6.6 Removing, Installing Oil Tank


Cover 6101

A) Top Oil Tank Cover


3300 9000
6100
Prior jobs

• Vehicle ignition switched OFF 6101

• Retarder switched off

3100
Notice

This working step can be performed with


retarder removed or installed..
2000

Attention! Risk of injury!

The retarder housing is hot!

8000

2000 Top cover


3100 Combined hex.-head screw
M 8 x 30, renew
hex.-head, w.a.f. 13
30 Nm
3300 Combined hex.-head screw
M 8 x 80, renew
inhex.-head, w.a.f. 13
30 Nm
6100 Air-pipe
11088
6101 O-Ring 15,3 x 2,4,
renew Illustration: Top Oil Tank Cover
coat with silicon-free and
non-corrosive grease for
installation
8000 Intermediate plate, renew
9000 Pressure sensor

Lubricant

O-ring Silicon-free and


non-corrosive grease

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Oil Tank Cover
15300009710 / cbtsd 02-11 Page 133
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)

2500 Bottom cover


2600 Bottom gasket, renew
3100 Combined hex.-head screw
M 8 x 30, renew, 2600
hex.-head, w.a.f. 13,
Heed tightening sequence!
30 Nm
4200 Oil drain plug oil tank
M 24 x 1,5 2500
inhex.-head, w.a.f. 12
47 Nm (80 Nm)
3100

4200

11089

Illustration: Bottom Oil Tank Cover

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Oil Tank Cover
15300009710 / cbtsd 02-11 Page 134
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 to
print.

The integrated sealing rings must be checked for possible damages during the installation of the heat
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 in
brackets are valid.
The copper-sealing rings are generally to be renew.

Installation note

Pay attention to the mounting position of the gasket and the cover!
6
Tighten all combined-hex.-head screws in specified sequence 1 to 17 first with 14 to 19 Nm.
5 7
The combined-hex.-head screws are then tightened in the same sequence with 30 Nm. 4 3 8
7 2 1 9
16 10
15 11
14 12
13 11090

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Oil Tank Cover
15300009710 / cbtsd 02-11 Seite 135
Repair Retarder – Removing, Installing Non-Return Valve (Outlet)

6.7 Removing, Installing


Non-Return Valve (Outlet)
Prior job

• Retarder oil drained (see page 26 ff)

1600 Valve cover


Heed mounting position!
1700 O-ring 60 x 3, renew,
coat with silicon-free and
non-corrosive grease for
installation
2100 Non-return valve (outlet)
Heed mounting position!
coat bore with silicon-free and
non-corrosive grease for Kd

Vo
.-S

ith
ac

-S
h-

ac
Nr

h-
.

Nr
.

installation
2105
2105 O-ring 34 x 3, renew,
coat with silicon-free and
non-corrosive grease for 2106
installation 1700
1600
2106 O-ring 54 x 3, renew,
coat with silicon-free and 2100 3100
non-corrosive grease for
installation
3100 Combined hex.-head screw
M 8 x 30
hex.-head, w.a.f. 13
30 Nm 11091
Illustration: Non-Return Valve (Outlet)
Lubricant

O-ring Silicon-free and


non-corrosive grease

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
15300009710 / cbtsd 02-11 Page 136
Repair Retarder – Removing, Installing Non-Return Valve (Outlet)

Special tool

153.00005210

Puller
non-return valve (outlet)
71/1

Aftersales Service Manual Voith Retarder 115 E Repair Retarder - Removing, Installing Non-Return Valve (Outlet)
15300009710 / cbtsd 02-11 Page 137
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).

71/1
11092
71/1 Puller

Installing

1. Install non-return valve in reverse sequence.

Aftersales Service Manual Voith Retarder 115 E Repair Retarder – Removing, Installing Non-Return Valve (Outlet)
15300009710 / cbtsd 02-11 Page 138
Control Parts

7. Control Parts
7.1 Removing, Installing Proportional Valve and Damping Plate....................140
7.2 Removing, Installing Temperature Sensor Cooling Water........................141
7.3 Removing, Installing Temperature Sensor Oil ..........................................142
7.4 Removing, Installing Pressure Sensor......................................................143

Aftersales Service Manual Voith Retarder 115 E Control Parts


15300009710 / cbtsd 02-11 Page 139
Control Parts – Removing, Installing Proportional Valve and Damping Plate

7.1 Removing, Installing


Proportional Valve and
Damping Plate
Prior jobs 3850

• Vehicle ignition switched off

• Retarder switched off


3800 3850
• Supply-air pressure discharged
3900
Plug at the proportional valve as well as 4000
connector checked for damage or wear (notch-
es).
39
26 Compressed-air line pv
39 Electrical connection lead
3700 Proportional valve 3900
3700
3800 Damping plate,
renew if necessary 4000
26
3850 O-ring 16 x 3, renew
coat with silicon-free and
non-corrosive grease for
installation
3900 Hex.-head screw
M 8 x 20, renew,
hex.-head, w.a.f. 13,
30 Nm
4000 Hex.-had nut M8,
renew,
18 Nm
11093

Illustration: Proportional Valve and Damping Plate


Achtung

If, during repair work the hex.-head nuts


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

Lunbricant

O-ring Silicon-free and


non-corrosive grease

Aftersales Service Manual Voith Retarder 115 E Control Parts – Removing, Installing Proportional Valve and Damping Plate
15300009710 / cbtsd 02-11 Page 140
Control Parts – Removing, Installing Temperature Sensor Cooling Water

7.2 Removing, Installing


Temperature Sensor Cooling
Water
Prior jobs

• Vehicle ignition switched off

• Retarder switched off

• Cooling water drained 5200


5200 Temperature sensor cooling
water,
28 Nm 5300
5300 Sealing ring A14 x 20,
renew

Attention! Risk of injury!

The cooling water is hot!

Notice

Please, bear in mind to the instructions


regarding the quality of coolant given from the
vehicle manufacturer or Voith Turbo cooling- 1109
water quality list (Voith Item-No. 67.2224.10). Illustration: Temperature Sensor Cooling Water

Aftersales Service Manual Voith Retarder 115 E Control Parts – Removing, Installing Temperature Sensor Cooling Water
15300009710 / cbtsd 02-11 Page 141
Control Parts – Removing, Installing Temperature Sensor Oil

7.3 Removing, Installing


Temperature Sensor Oil
Prior jobs

• Vehicle ignition switched off

• Retarder switched off

5200 Temperature sensor Oil,


28 Nm
5300 Sealing ring A14 x 20,
renew
5300
5200

11095

Illustration: Temperature Sensor Oil

Aftersales Service Manual Voith Retarder 115 E Control Parts – Removing, Installing Temperature Sensor Oil
15300009710 / cbtsd 02-11 Page 142
Control Parts – Removing, Installing Pressure Sensor

7.4 Removing, Installing Pressure


Sensor 9000

Prior jobs

• Vehicle ignition switched off

• Retarder switched off

9000 Pressure sensor,


30 Nm

11096

Illustration: Pressure Sensor

Aftersales Service Manual Voith Retarder 115 E Control Parts – Removing, Installing Pressure Sensor
15300009710 / cbtsd 02-11 Page 143
Appendix

8. Appendix
8.1 Retarder Data Sheet .................................................................................145
8.2 Tightening Torques ...................................................................................146

Aftersales Service Manual Voith Retarder 115 E Appendix


15300009710 / cbtsd 02-11 Page 144
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 nmax. = 4800 min-1 at vps = 2365 min-1

Working Medium Oil according Operating Specification

Control Medium Compressed-Air

Supply-Air Pressure 7 to 10 bar

Service filling:

- Service filling (Oil change, inspection of oil level) 7,0 Litre

- after exchange of heat exchanger 7,5 Litre

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

* dependent from the retarder and vehicle configuration

Aftersales Service Manual Voith Retarder 115 E Appendix – Retarder Data Sheet
15300009710 / cbtsd 02-11 Page 145
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
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 Nm

4200 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

Aftersales Service Manual Voith Retarder 115 E Appendix – Tightening Torques


15300009710 / cbtsd 02-11 Page 146
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 Nm


Final 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 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

Aftersales Service Manual Voith Retarder 115 E Appendix – Tightening Torques


15300009710 / cbtsd 02-11 Page 147