TrainingAftersales Service Manual Gearbox-Retarder-System GO170 - GO210 with R 115 E Content 7DEOH RI &RQWHQWV 1 2 Preface ....................................................................................................1/1 General....................................................................................................2/1 2.1 2.2 2.3 2.4 2.5 2.6 Illustration Gearbox-Retarder-System ............................................................. 2.1/1 Function and Operation Scheme Gearbox ...................................................... 2.2/1 Function and Operation Scheme Retarder ...................................................... 2.3/1 Gearbox Identification...................................................................................... 2.4/1 Retarder Identification...................................................................................... 2.5/1 Retarder Control-Unit Identification ................................................................. 2.6/1 3 Maintenance............................................................................................3/1 3.1 3.2 3.3 3.4 3.5 Maintenance Work / Oil Change Intervals ....................................................... 3.1/1 Checking Oil Level of Gearbox ........................................................................ 3.2/1 Checking Oil Level of Retarder........................................................................ 3.3/1 Oil Change of Gearbox .................................................................................... 3.4/1 Oil Change of Retarder.................................................................................... 3.5/1 4 Diagnosis / Troubleshooting Gearbox .....................................................4/1 4.1 Troubleshooting Diagram A to E...................................................................... 4.1/1 Content 7DEOH RI &RQWHQWV (Continue) 5 Diagnosis / Troubleshooting Retarder.....................................................5/1 5.1 Troubleshooting Diagram A to C ..................................................................... 5.1/1 Electrical Connectrions Diagram ..................................................................... 5.1/6 5.2 Troubleshooting and Remedies....................................................................... 5.2/1 5.3 Illustration Control System............................................................................... 5.3/1 5.4 Checking Supply-Air Pressure......................................................................... 5.4/1 5.5 Checking Constant-Air Pressure (py)............................................................... 5.5/1 5.6 Checking Control Current of Proportional Valve.............................................. 5.6/1 5.7 Checking Temperature Adaption ..................................................................... 5.7/1 5.8 Checking Pressure Sensor .............................................................................. 5.8/1 5.9 Checking Pump Pressure ................................................................................ 5.9/1 5.10 Table of Measurements ................................................................................. 5.10/1 5.11 Operational Check ......................................................................................... 5.11/1 6 Removing, Installing Gearbox .................................................................6/1 6.1 Removing, Installing Gearbox.......................................................................... 6.1/1 7 Removing, Installing Retarder .................................................................7/1 7.1 Removing, Installing Retarder ......................................................................... 7.1/1 ......................................5 9..Content 7DEOH RI &RQWHQWV (Continue) 8 Repair Gearbox ...............6 Removing............1 Overall Illustration of Main Components.......... Checking and Installing Casing Ventlation ........................................................................5 Removing............................... 9..6/1 B Bottom Oil Tank Cover ..... 9. 8..................3 Removing.... Cleaning and Installing Silencer ..................... Installing Sensor/Switch at Gearbox............... 9... 8............................................................. Installing Water Neck..... 9................................................................4/1 8................6/1 8.............9/1 9...............2 Removing.........6/1 A Top Oil Tank Cover .......................... Installing Clutch Servo and Adjusting Wear Indicator .6/2 ......................................4 9......................................................... Checking...5/1 8.............................. 9.. Installing Oil Tank Cover ........................................... 9.........4/1 Removing............................5/1 Removing.............. 8...... 8.....2/1 Removing......2 9..........1 9.............3/1 8...................................8/1 8............... 9............................6 Overall Illustration of Main Components............................1/1 Removing.. 8............................./6.2/1 8.................................. Installing Breather........................ Installing Shift ............ Installing Heat Exchanger.......................................... Installing Output Flange Renewing Radial Shaft Sealing Ring...... Cover Countershaft and Closing Cover 5...3/1 Removing... 9........-Gear ....................1/1 8..................................... 8............ 8.........................................................7/1 9 Repair Retarder.....7 Removing..........................3 9............4 Removing.. Installing Front Housing Cover.................. .Content 7DEOH RI &RQWHQWV (Continue) 10 Control Parts Retarder ...........4/1 11 Annex ..........................2 10....................................... 10..................................3/1 Removing..... 10................11/1 Data Sheet Conversion Table Operating Specifications: ....10/1 10............4 Removing...........Cooling Water Quality Spare Parts Lists Other Information .............................. Installing Pressure Sensor...................................................3 10.1 10............. Installing Oil Temperature Pick-Up........2/1 Removing................... Installing Cooling-Water Temperature Pick-up.............................Oil Specifications Gearbox ............1/1 Removing.....Oil Specifications Retarder ................... 10..... 10......... Installing Proportional Valve ................... The information and instructions which are given to you furthermore provide the basis for appropriate and professional maintenance and repair at the gearbox-retarder-system. We ask you firmly to notice the safety and warning notes which you will find in these instructions. Note is associated for general notices for a better handling during maintenance of the gearbox-retarder-system. at reduction of quality of workmanship and the possibility of damage to property.Preface 3UHIDFH The present service manual serves as training material for the training. Caution! is associated for safety instructions and for warning notes at dangerous situation for persons. . Preface 3UHIDFH (Continue) Caution! • • The switched-on retarder will not secure the parked vehicle! During a failure of the Retarders. No liability takes place for damages resulting from it The gearbox-retarder-system is built after the state-of -the-art technology and the recognized safety-related rules. that originate through non-observance of the security-hints of the service manual or through injuries of the diligence-duty with the handling. This vehicle condition must be held as long as the retarder again is available with its full performance. or while the temperature-adaptation is effective. not tested and released from Voith. the vehiclespeed must be settled by using the service-brake and the lowest possible gear is in use (increase of the engine-speed). • • • • . at the service. maintenance and repair. accessories. Repair and maintenance work may only be enforced by qualified specialist-staff. Unauthorized changes at the gearbox-retarder-system as well as the use of spare parts. with the care and maintenance or repair of the gearbox-retarder-system. We will take on no liability for injuries and/or damages. can influence the security of the entire vehicle negatively. attachments and special-productions. Nevertheless dangers and damages can originate during improper use. The terms of the parts for the gearbox correspond to the DaimlerChrysler-EPC-documentation. • .Preface 3UHIDFH (Continue) Note • The used position numbers used in this manual corresponds to the position numbers in the spare parts lists in chapter 9 „Annex“. Example: 26 / 100 image board • / 35 part in drawing gearbox-design-group • Inevitably. Exception: Items or parts with one -. that originate through contempt of these rugulations. Items and parts from the retarder sector shown with an oblique number are no spare parts and therefore not listed in the spare parts lists. as well as two-digit position-numbers are no spare parts and not listed in the spare parts lists. through the chosen working procedure. For these reasons. no liability can be assumed for damage incurred. We are not liable for damages. It is therefore imperative that any person carrying out repair work on the gearbox-retarder-system uses his professional knowledge to make sure that his own safety is not endangered and that the retarder suffers no negative effects. The pertinent accident-prevention-regulation. it is impossible for us to warn at each position in these service manual to assess all situations which might entail the risk of injury for the person carrying out the work. other broadly rules of the security-technology and working-medicine and the traffic admission law are to be kept. in particular safety-wise. please contact the responsible person in the appropriate organisation of the country involved or: DaimlerChrysler AG Business unit gearbox Sales Hauptstraße 107 D-76568 Gaggenau Telephone 07225 / 61-65 56 Fax 07225 / 61-65 51 e-mail: sales.Preface 3UHIDFH (Continue) • With the contact with
[email protected] Voith Turbo GmbH & Co. KG Production group retarder Voithstraße 1 Post box 15 55 D-74555 Crailsheim Telephone 07951 / 32-401. -422 Fax 07951 / 32-756 e-mail: retarder@voith. proper and economic operation of the retarder gearbox-retarder-system. Should you have any queries and queries about the working steps not described in this manual. the current safety regulations for these products are to be heeded! Caution with the contact with hot fuels! Danger of burn and scald! Please read the hints in the operation manual to the safe. greases and other chemical substances.de • • • Copyright October 1999 .Voith Turbo / DaimlerChrysler . ..2 2..................................................2..1/1 Function and Operation Scheme Gearbox......................2.....2...5 2.............2...........................4/1 Retarder Identification ..........2.....................3 2....................5/1 Retarder Control-Unit Identification ............................2/1 Function and Operation Scheme Retarder............6 Illustration Gearbox-Retarder-System..............4 2..................General *HQHUDO 2................................................................1 2..........3/1 Gearbox Identification .......6/1 .................2.......................................... f.-head.a.a.f.5 Inhex.5 Inhex. w.5 Inhex.-head. 17 3700 Proportional valve retarder control * = optional 26/400/089 26/250/068 3700 26/100/125 26/400/083 26/100/122 26/100/125 3500 26/100/206 M+P-07A-1708 M+P-07A-1708 26/100/116 Remark: Terms of parts from DaimlerChrysler-EPC-documentation . w. w.General .5 Inhex. w.OOXVWUDWLRQ *HDUER[5HWDUGHU6\VWHP Illustration gearbox-retarder-system 26/250/047 26/100/116 Screw plug oil sieve M38x1.f.a. 17 (removing height 120 mm) 26/100/122 Oil filler plug gearbox M24x1.-head.f. 14 26/100/125 Oil drain plug gearbox M24x1.a. 14 (bottom) 26/100/206 Speedometer sensor 26/250/047 Switch for starter lock * 26/250/068 Inductive sensor for overspeed protection * 26/400/083 Oil temperature pick-up gearbox * 26/400/089 Switch reversing light * 3500 Screw plug with sieve M30x1.-head. w.General . 17 Heat exchanger retarder 26/350/ 4100 6400 3700 6400 * = option 26/150/ 25/250/068 26/250/068 26/400/089 26/250/047 26/250/ M+P-07A-1710 Remark: Terms for items from DaimlerChrysler-EPC-documentation .-head.f.a.5 Inhex.OOXVWUDWLRQ *HDUER[5HWDUGHU6\VWHP (Continue) Illustration gearbox-retarder-system (Continue) 25/250/068 26/150/ 26/250/ 26/250/047 26/250/068 26/350/ 26/400/089 3700 4100 Clutch servo * Drive shaft Clutch wear indicator * Switch for starter lock * Inductive sensor for overspeed protection * Shift Switch reversing light * Proportional valve retarder control Oil filler screw retarder M30x1. a.a. w. 12 6400 Heat exchanger 3700 100/1 3500 103 6400 107 4200 M+P-07A-1484 .5 Inhex.5 Inhex. 6 107 Oil drain plug retarder M24x1.5 Inhex.f. 17 3700 Proportional valve 4200 Oil drain plug oil tank M24x1.OOXVWUDWLRQ *HDUER[5HWDUGHU6\VWHP (Continue) Illustration gearbox-retarder-system (Continue) 100/1 Retarder data plate 103 Screw plug Measure point pump pressure M12x1.-head.f.a. 12 3500 Screw plug with sieve M30x1. w.-head.f.-head.5 Inhex.General .-head.f. w. w.a. General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH *HDUER[ Illustration gearbox force diagram . Gear wheel 5. Gear wheel 2. Gear wheel 3.General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH *HDUER[ Illustration gearbox-longitudinal section 9 10 11 18 12 13 18 14 15 18 16 17 18 19 5 7 4 3 2 1 6 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1. Gear wheel 4. Gear wheel Reverse gear wheel Countershaft Oil pump Drive shaft Pilot bearing Switch lever Switch rails Sliding sleeve Synchromesh ring Synchromesh body Synchromesh cone Mainshaft Actuating lever Fly wheel . Gear wheel 3.General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH *HDUER[ Illustration gearbox-longitudinal section 9 10 11 18 12 13 18 14 15 18 16 17 18 19 5 7 4 3 2 1 6 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1. Gear wheel Reverse gear wheel Countershaft Oil pump Drive shaft Pilot bearing Switch lever Switch rails Sliding sleeve Synchromesh ring Synchromesh body Synchromesh cone Mainshaft Actuating lever Fly wheel . Gear wheel 2. Gear wheel 5. Gear wheel 4. General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH *HDUER[ Illustration gearbox-sectional view 11 12 20 25 21 26 27 22 23 18 7 17 24 28 7 11 12 17 18 20 21 22 23 24 25 26 27 28 Countershaft Switch lever Switch rails Mainshaft Actuating lever Cross shift Reverse gear lock Actuating lever bolt Gearbox housing Loose wheel bearing Shift link (option) Shift ramifications Cam follower Reverse idler gear . 3 are not identical with the reference numbers of the spare parts lists.General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH 5HWDUGHU Illustration retarder 70 47 15 17 4 18 23 42 26 72 21 A R 25 20 2 63 1/1 1 1/2 36 19 46 22 6 8 4 44 64 16 62 43 55 Oil sump Supply-air pressure p V Constant-air pressure p y 41 Coolant (water) Pump pressure p P 69 FD914be Note The reference numbers indicated in section 2. 1 1/1 1/2 2 4 6 8 15 16 17 18 19 20 21 22 23 25 26 36 41 42 43 44 46 47 55 62 63 64 69 70 72 Heat exchanger complete Retarder oil-cooling circuit Gearbox oil-cooling circuit Control unit Connection Terminal 15 Fuse (8A) Connection Ground ABS-signal Retarder stage switch Retarder pilot light Stop light relay Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Ventilation Casing ventilation Air pressure line “A” constant-air pressure (py) Air pressure line supply-air pressure (pv) Ventilation line “R” Oil duct Oil tank Oil sump Stator Rotor Speedometer signal Oil-drain plugs Pressure regulating valve Check valve (inlet) Check valve (outlet) Plug ISO-interface Plug additional functions Pressure sensor . The switched-on retarder will not secure the parked vehicle. The retarder is driven and braking torque is transmitted by pinions in the gearbox. hydrodynamic continous brake of compact design.p. Retarder braking torque is sustained even when gear changes are made. the service brake must be used to regulate the vehicle speed.m.General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH 5HWDUGHU (Continue) Description of the function The Voith retarder 115 E is a powerful. The transmission ratio enables the retarder to achieve high braking torques right down to low r. . ranges with the compactest configuration (small rotor/stator). In the event of a retarder failure or when the temperature adaption is effective. which is taken from the vehicle air-tank for auxiliary equipment. the stator (44) is fixed to the retarder housing. the memorized „Constant Speed“ is deleted. the retarder brakes in braking stage 1 to 4.General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH 5HWDUGHU (Continue) c Action of the retarder R 115 E with Digiprop control system A retarder stage switch (16) with 5 switch stages is used to operate the Voith retarder 115 E. The rotor (46) is connected with the drive shaft of the retarder. the control unit (2) provides a control current which is passed on to the proportional valve (21). The proportional valve (21). In the maximum position of the retarder stage switch (16) the braking torque of the Voith retarder is at maximum. a b FD299 The hydrodynamic principle a Rotor (46) b Stator (44) c Oil flow . provides a constant-air pressure (py) on the oil sump (43). If the function „Constant Speed“ is re-activated the new present speed is memorized. depending on the operating conditions (prop-shaft speed). The constant-air pressure (py) in the oil sump (43). the retarder stage switch (16) in conjunction with ABS can be combined with a 3-stage treadle brake valve or a pressure switch unit for the service brake. The control medium for the Voith retarder 115 E is compressed air. From this input signal. When shifting the retarder stage switch (16) into position 2 to 5. depending on the magnitude of the control current. forces a certain quantity of oil into the working chamber between rotor (46) and stator (44). or if a braking stage is engaged (position 2 to 5). When the retarder stage switch (16) is shifted to position 1. When the retarder stage switch (16) is operated. If the retarder is switched-off (position 0). an input signal is fed to the control unit (2). In a special version. the function „Constant Speed“ is activated. The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit of the maximum possible braking torque. The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking of the rotor (46) and consequently to braking of the vehicle. 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. The gearbox. Temperature pick-ups. Both oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder without limited compromizes. In the heat exchanger (1). the deceleration energy is transformed into heat. If the cooling water temperature rises into the temperature adaption range. To dissipate this heat. the consequence is an adaption of the retarder braking torque to protect the vehicle cooling system. part of the oil in the working circuit is pumped continuously by the rotor (46) through the heat exchanger (1) and filling ducts and returned to the circuit again. oil (20) The temperature pick-ups 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). . If the temperature rises above the temperature adaption range.General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH 5HWDUGHU (Continue) The rotation of the retarder sets the oil in motion and circulates it in a closed circuit between the rotor (46) and stator (44). During braking. To prevent the temperatures preset in the control unit (2) for water and oil being exceeded. water (19). there is no more braking torque output. the heat energy of the oil is transferred to the cooling water of the vehicle and dissipated via the vehicle radiator to the ambient air.and retarder oil reservoires are seperated from each other at the gearbox-retarder-system. the retarder braking torque is adapted to protect the vehicle cooling system and the retarder. . the service brake must be used to control the vehicle. Once the working circuit is free of air. Non-return valve (63) inlet When the retarder is switched on. a float rises and closes the casing ventilation. Casing ventilation (23) During braking. Additionally the control unit cuts back braking torque if oil temperature rises too rapidly . the oil sump is pressurized. 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).irrespective of actual oil temperature. causing the check valve (63) to open and the oil to enter the working space.General )XQFWLRQ DQG 2SHUDWLRQ 6FKHPH 5HWDUGHU (Continue) While the temperature adaption is effective or if there is a retarder failure. Pressure regulating valve (62) The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder. Note If the check valve (outlet) must be renewed during a repair operation. please contact Voith Turbo or a responsible contract party. the oil displaces the air present in the working circuit via the casing ventilation (23) and the ventilation system (22) out of the retarder. to be cooled and to be returned to the working circuit. Code Serial No 71 4.General *HDUER[ . Note For queries or when ordering spare parts we need the data of the gearbox.6 / 8.2 G 714.2 DAIMLERCHRYSLER Indic. Only with this data a fast and effective run time is possible. 692 L Unit Series Version Left hand drive Ratio 1. DAIMLERCHRYSLER Indic.GHQWLILFDWLRQ The gearbox identification (data plate) s located at the side of the retarder-gearbox-system on the right in direction of travel (see illustration 2 – example). GO 170-6/8.100 L Serial No Gearbox number Gearbox part-No M-Code Version No Code M-Code Variant No M+P-07A-1705e M+P-07A-1704e Illustration 1 Illustration 2 . gear Number of gears Input torque (x 10) Gearbox-Bus GO 170 . Note For queries or when ordering spare parts we need the data of the retarder. Retarder ratio (i Ret) Serial-Number (Brake-Number) 6-digit number Serial-No 000000 45/1999 CW/Year Date of production Serial-No CW/Year Voith Item-Number 8-digit number M+P-07A-1707 DaimlerChrysler part-number M+P-07A-1706e Illustration 1 Illustration 2 .General 5HWDUGHU .GHQWLILFDWLRQ The retarder identification (data plate) is located at the gearbox-retarder-system on the right in direction of travel (see Illustration 2). Only with this data a fast and effective run time is possible. : Client no.GHQWLILFDWLRQ The Digiprop-control unit identification (data plate) is located at the control unit and provides the following information: 1. Code-number 3-digit number (Adjustment of the control unit) 3. Client-number (DaimlerChrysler part-number) Vo it Co h-N r.: Code no.General 5HWDUGHU &RQWURO8QLW .12 = version 1.12 xx xx /D atu m Note For queries or when ordering spare parts we need the data of the control unit. xx xxxx x .: nd Nr.: Serial no.: 53 . Voith-number 8-digit number The software version can be identified by the last two numbers. Voith no.r.2 2.: Se de-N Kurien. Example: . Serial-number 5-digit number with date of coding 4. en : -N r. Only with this data a fast and effective run time is possible.: Date: M+P07A-1617a . ...........................3.5/1 .............................3........1/1 Checking Oil Level at Gearbox.............................Maintenance 0DLQWHQDQFH 3....2/1 Checking Oil Level at Retarder ...................................................................................4 3...2 3.................3.........4/1 Oil Change at Retarder ..............1 3......................3...............3/1 Oil Change at Gearbox...................................3 3.....................3.............................5 Maintenance Work / Oil Change Intervals..... the oil grade used for the oil change .GO210 with R 115 E”: .maintenance work been carried out .QWHUYDOV Maintenance work The following maintenance work has to be carried out at each oil change (gearbox and retarder): Clean the oil sieve (gearbox) Clean the sieve for the pressure regulating valve (retarder) Check fastening screws of the retarder heat exchanger Check all screw plugs on leak and correct fitment Carry out visual inspection on leak and existing damages Please note the following data into the service overview of the Operation Manual „Gearbox-Retarder-System / GO170 .Maintenance 0DLQWHQDQFH :RUN 2LO &KDQJH . QWHUYDOV (Continue) Gearbox Single-grade mineral oil 1) Normal duty Heavy duty 100 000 km 4) 50 000 km 4) Synthetic oil 1) 300 000 km 5) 300 000 km 5) Single-grade mineral oil 2) 135 000 km 4) 60 000 km 4) Retarder 6) Synthetic oil 2) 180 000 km 5) 90 000 km 5) Synthetic oil 3) 300 000 km 5) 300 000 km 5) 1) according to Operating Specifications.11/12 3) according to Operating Specifications. page 11/4 . if fewer kilometres are travelled 6) The oil change intervals for the retarder oils (see note 2) may adapted to the oil change intervals of the single-grade mineral oils for the gearbox – .11/7 2) according to Operating Specifications. if fewer kilometres are travelled 5) change oil at the latest after 2 years.Maintenance 0DLQWHQDQFH :RUN 2LO &KDQJH . page 11/8 . page 11/13 4) change oil at the latest after 1 year. g. In doubts please contact the service departement. oils in an appropriately lower viscosity class must be used. Saudi-Arabia) – High max.QWHUYDOV (Continue) 1. Example: – Use in regions with high ambient temperature (e.9 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. For use in extremely cold zones. permissible weight with low rated engine power (< 5. „Normal duty“ Example: – Long distance traffic 2. With a total-life of the retarder of more than 10%. covered on the vehicle-performance. it may be necessary to shorten the intervals between oil changes in individual cases. if overall maintenance cycles for the vehicle are improved. „Heavy duty“ Subject to more than normal stress. as well as other factors not mentioned here also affect the ageing of the oil.Maintenance 0DLQWHQDQFH :RUN 2LO &KDQJH . . w.Maintenance &KHFNLQJ 2LO /HYHO DW *HDUER[ Illustration checking oil level 26/100/122 Oil filler plug M24x1.5 Inhex. 47 Nm 26/100/128 Sealing ring A24x29 renew 26/100/122 26/100/128 M+P-07A-1716a Remark: Terms of parts from DaimlerChrysler-EPC-documentation . 14.-head.f.a. it is important to adhere to the specified service filling (see annex) for operating the retarder in the relevant application.Maintenance &KHFNLQJ 2LO /HYHO DW *HDUER[ (Continue) Note For satisfactory gearbox operation. The oil level check must be carried out with the vehicle in a horizontal position. Caution! Risk of injury! The oil filler plug is hot! Oil temperature! . the temperature of the gearbox oil must have reached the operating temperature. For the oil level check. Maintenance &KHFNLQJ 2LO /HYHO DW *HDUER[ (Continue) Job scope Caution! Risk of injury! The oil filler plug is hot! Oil temperature! 26/100/122 26/100/128 1. 3. Screw in oil filler plug with new sealing ring and screw them tight. The oil level is correct. Remark: Terms for items from DaimlerChrysler-EPC-documentation Note If there is any lacking oil. 2. Screw out oil filler plug (26/100/122) and remove sealing ring (26/100/128). if the oil level is at the lower edge of the oil check hole (see illustration right). Top up slowly any lacking oil through the hole for the oil filler plug according to the Operation Specifications. the gearbox must be checked for outer leaks. Tightening torque oil filler plug (26/100/122) 47 Nm . w.5 Inhex. 12 65 Nm (80 Nm) 4200 107 M+P-07A-1712 .a.a.f.5 Inhex.-head. w.Maintenance &KHFNLQJ 2LO /HYHO DW 5HWDUGHU Illustration checking oil level A Oil drain and measure method 107 Oil drin plug M24x1. 12 65 Nm (80 Nm) 4200 Oil drin plug M24x1.-head.f. a. w.Maintenance &KHFNLQJ 2LO /HYHO DW 5HWDUGHU (Continue) Illustration checking oil level B With oil check plug 109 Oil check plug M24x1.-head.f.5 Inhex.f. w. 17 100 Nm (150 Nm) 4100 109 M+P-07A-1713 .5 Inhex.-head. 12 65 Nm (80 Nm) 4100 Oil filling plug M30x1.a. . 4200) are possible: A) Version with integrated FPM-sealing ring.0 litres and to use only oils specified in the operating Specifications (see annex) for operating the retarder in the relevant application. The integrated sealing rings must be checked during the oil level check for possible damages. For the oil level check. The oil level check must be carried out with the vehicle in a horizontal position. the temperature of the gearbox oil must have reached the operating temperature. 4100. replace completely if necessary. Caution! Two version of the screw plugs (107.Maintenance &KHFNLQJ 2LO /HYHO DW 5HWDUGHU (Continue) Note Two methods are available for checking the oil level: A Oil drain and measure method B With oil check plug For satisfactory retarder operation it is important to adhere to the specified service filling of 7. these corresponds the standard version at the time going to print. Maintenance &KHFNLQJ 2LO /HYHO DW 5HWDUGHU (Continue) 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 generel to renew. A Oil drain and measure method Job scope 1. Push a clean vessel under retarder. Caution! Risk of injury! The oil drain plugs (107, 4200) and oil filler plug (4100) are hot! Oil temperature! During the oil level check the retarder mustbe switched-off! 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. 4200 107 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) 65 Nm (80 Nm) Maintenance &KHFNLQJ 2LO /HYHO DW 5HWDUGHU (Continue) 5. Measure drained oil. 6. Top up any lacking oil according to the Operating Specifications, chapter 3.1: „Oil Change Intervals“ and chapter 11: „Annex“. 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). Caution! The retarder must only be filled with oil via the bore of the oil filler plug (4100)! Note 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 (150 Nm) Caution! Operate the retarder, after checking oil level, first time during a trail run at a speed of minimum 50 km/h 5 times for approx. 5 seconds each time in position 2 at the retarder stage switch (corresponds braking stage 1). Maintenance &KHFNLQJ 2LO /HYHO DW 5HWDUGHU (Continue) B With oil check plug Job scope 1. Switch vehicle ignition system „OFF“ and then „ON“ again (reset). 2. Operate the retarder in stand-still in switch position 2 at the retarder stage switch (corresponds braking stage 1) and switch it off after approx. 5 seconds. Repeat this procedure twice. 3. Switch off the retarder and wait 5 minutes. Caution! Risk of injury! The oil check plug (109) and oil filler plug (4100) are hot! Oil temperature! While the oil level is being checked, the retarder must be switched off! If the retarder is switched-on during working step 4 and screwed out oil drain plugs and/or oil filler plug, high risk of injury exist by hot leaving oil (increased pressure)! 4. Screw out oil check plug (109). The oil level is correct, if it is at the lower edge of the oil check hole (see illustration). 4100 Caution! The retarder must only be filled with oil via the bore of the oil filler plug (4100)! 109 M+P-07A-1713 specified in accordance to the Operating Specifications. via the bore of the oil filler plug. Tightening torque oil check plug (109): 65 Nm (80 Nm) 8. Note With determined lacking oil quantity check retarder for possible outer leak. renew oil filler plug if necessary. 7.Maintenance &KHFNLQJ 2LO /HYHO DW 5HWDUGHU (Continue) 5. Check sealing ring of oil check plug for possible damages. renew oil check plug if necessary. Check sealing ring of oil filler plug (4100) for possible damages. Tightening torque oil filler plug (4100): 100 Nm (150 Nm) . 9. Screw in oil filler plug and screw it tight. Fill in slowly the quantity of oil. Screw in oil check plug and screw it tight. 6. w.5 Inhex. 60 Nm 26/100/119 Sealing ring A38x46 renew 26/100/122 Oil filler plug M24x1. 47 Nm 26/100/125 Oil drain plug M24x1.f. 14. 17. w.-head.-head.a. w.Maintenance 2LO &KDQJH DW *HDUER[ Illustration oil change 26/100/107 Oil sieve clean sieve with appropriate cleaning agent (Benzine) 26/100/113 Spring 26/100/116 Screw plug (oil sieve) M38x1.5 Inhex. 47 Nm 26/100/128 Sealing ring A24x29 renew 26/100/122 26/100/116 26/100/119 26/100/128 26/100/107 26/100/113 26/100/128 26/100/125 Lubricants and cleaning agents Sieve in screw plug Benzine 26/100/128 26/100/125 M+P-07A-1715 Remark: Terms for items from DaimlerChrysler-EPC-documentation .5 Inhex.f.-head.f. 14.a.a. 5 litre 13. it is important to adhere to the specified service filling (see table below) and to use only oils specified in the Operating Specifications (see annex) for operating the retarder in the relevant application.0 litre . Both oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder without limited compromizes. Caution! Risk of injury! The oil drain plugs are hot! Oil temperature! Oil filling Service filling (oil change) New filling 12. For satisfacory retarder operation.Maintenance 2LO &KDQJH DW *HDUER[ (Continue) Note The gearbox.and retarder oil reservoires are seperated from each other at the gearbox-retarder-system. For draining the oil the temperature of the gearbox oil must have reached the operating temperature. Screw the screw plug (26/100/116) with new sealing ring tight. 5. Screw out screw plugs (26/100/116) and remove sealing rings (26/100/119). remove sealing rings (26/100/128) and drain oil. 6. 7. Fix spring (26/100/113) with oil sieve (100/107) in bore of screw plug (26/100/116).Maintenance 2LO &KDQJH DW *HDUER[ (Continue) 26/100/122 26/100/128 Job scope 1. Check cleaned sieve for possible damages. Fill in slowly oil via the bore of the oil filler plug according to the Operating Specifications. Tightening torque oil drain plugs (26/100/125): 47 Nm 4. Caution! Risk of injury! The oil drain plugs (26/100/125) are hot! Oil temperature! 2. 10. Screw the oil filler plug (26/100/122) with new sealing ring tight. renew if necessary. Screw out oil filler plug (26/100/122) and remove sealing ring (26/100/128). 9. Screw the oil drain plugs (26/100/125) with new sealing rings tight. Screw out oil drain plugs (26/100/125). Push an oil pan under the gearbox. Tightening torque oil filler plug (100/122): 47 Nm 26/100/116 26/100/119 26/100/107 26/100/113 26/100/128 26/100/125 26/100/128 26/100/125 M+P-07A-1715b Remark: Terms of items from DaimlerChrysler-EPC-documentation . 3. Clean oil sieve (26/100/107) with appropriate cleaning agent (Benzine) and blow it out with compressed-air. Tightening torque screw plug oil sieve (26/100/116): 60 Nm 8. Clean sieve with appropriate cleaning agent and blow out with compressed-air 4100 Oil filler plug M30x1.a.a. 17 100 Nm (150 Nm) 4200 Oil drain plug oil tank M24x1.-head.5 Inhex.f.f. 12 65 Nm (80 Nm) 4100 Lubricants and cleaning agents O-rings Sieve in screw plug Silicone. w. 12 65 Nm (80 Nm) 3500 Screw plug with sieve M30x1.f.f.5 Inhex. w.a.free and non-corrosive grease Benzine 107 3500 4200 4200 M+P-07A-1488 .-head.Maintenance 2LO &KDQJH DW 5HWDUGHU Illustration oil change retarder 107 Oil drain plug M24x1.5 Inhex. w. w.-head.-head. 17 100 Nm (150 Nm).5 Inhex.a. that means the retarder must be switched off! Caution! Two versions of screw plugs (107. 4200) are possible: A) Version with integrated FPM-sealing ring. . 4100. these corresponds the standard version at the time going to print. The integrated sealing rings must be checked during the oil level check for possible damages. For satisfacory retarder operation. chapter 3. 3500. Ensure that during the entire oil change no constant-air pressure acts on the retarder. it is important to adhere to the specified service filling (see table on next page) and to use only oils specified in the Operating Specifications. For draining the oil the temperature of the retarder oil must have reached the operating temperature.1 „Oil Change Intervals“ and chapter 11: „Annex“ for operating the retarder in the relevant application.Maintenance 2LO &KDQJH DW 5HWDUGHU (Continue) Note The gearbox. Both oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder without limited compromizes.and retarder oil reservoires are seperated from each other at the gearbox-retarder-system. replace completely if necessary. If screw plugs with loose inserted copper-sealing rings (variant B) are used. 4200): 65 Nm (80 Nm) 107 4200 4200 M+P-07A-1489 . The copper-sealing rings are generel to renew. In this Aftersales Service Manual is excluding the variant A (series version) described. Screw the oil drain plugs tight. Push an oil collecting pan under the retarder. oil level check) After complete taking apart and cleaning as well as emptied heat exchanger (corresponds new filling) 7. Caution! Risk of injury! The oil drain plugs (107. the tightening torques in brackets are valid.Maintenance 2LO &KDQJH DW 5HWDUGHU (Continue) B) Version with loose inserted copper-sealing ring.8 litre Job scope 1. Check sealing rings of oil drain plugs on possible damages. Screw out the oil drain plugs (107 and 4200) and drain the oil. 4200) are hot! Oil temperature! 2. Tightening torque oil drain plugs (107. 4.0 litre 7. renew oil drain plugs if necessary. Oil filling with heat exchanger Service filling (oil change. 3. Clean sieve in screw plug with appropriate cleaning agent (Benzine) and blow it out with compressed-air. Fit screw plug with sieve and screw it tight. 3500 M+P-07A-1490 Achtung! The retarder must only be filled with oil via the bore of the oil filler plug (4100)! 10. 7.Maintenance 2LO &KDQJH DW 5HWDUGHU (Continue) 5. renew screw plug if necessary. Check sealing ring of screw plug with sieve on possible damages. Tightening torque screw plug (3500): 100 Nm (150 Nm) 9. .5/3 in this chapter) according the Operation Specifications. Screw screw plug with sieve (3500) out of the retarder. 6. 8. Fill in slowly in the bore of the oil filler plug.1: „Oil Change Intervals“ and chapter 11: „Annex“. This working step is necessary for the correct bleeding of the retarder system. chapter 3. over a time period longer than 3 minutes. Screw out oil filler plug (4100). the quantity of oil specified (see table page 3. 12. Tightening torque oil filler plug (4100): 100 Nm (150 Nm) Caution! Operate the retarder after the oil change first during the trial run 5 times with a speed of minimum 50 km/h each time for approx. .Maintenance 2LO &KDQJH DW 5HWDUGHU (Continue) 11. renew oil filler plug if necessary. Fit oil filler plug and screw it tight. Check sealing ring of oil filler plug on possible damages. 5 seconds in position 2 at the retarder stage switch (corresponds braking stage 1). ............ 4..........................................................1 'LDJQRVLV 7URXEOHVKRRWLQJ *HDUER[ Troubleshooting Diagram ........................... 4..........Diagnosis / Troubleshooting 4................4.................1/1 Troubleshooting Diagram A to E...................1/2 ....................................................................................1/1 Troubleshooting Master System ..... but I am not sure .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP Illustration troubleshooting master-system see troubleshooting diagram at page 4.1/2 Please contact DaimlerChrysler at the gearbox-retardersystem.1/2 at gearbox? Complaint at retarder? see troubleshooting diagram at page 5. Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) A1 A2* A3* *Begin of troubleshooting at A1 E elektrical function leaks B shiftability Complaint Gearbox no traction noices D C . at the drive shaft? YES NO at radial shaft sealing ring? YES NO at countershaft cover? YES NO Renew radial shaft sealing ring (chapter 8.2) at the micro capsulated screws? YES NO Renew O-rings (chapter 8.gear? (only GO 210) NO YES at O-rings? YES NO A2 at O-ring? YES NO Renew O-rings (chapter 8.2) at cover 5.2) at surface / surface sealant? YES NO Renew O-rings (chapter 8.2) seal new with released surface sealant (chapter 8.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Illustration troubleshooting diagram A1 A1 leaks Check residual oil quantity./6. Contact product unit gearbox if residual oil quantity smaller 50%.2) Contact product unit gearbox use new micro encapsulated screws Contact product unit gearbox . 3) Threaded components / shift rocker arm bearing ? NO YES Filler cap? Contact product unit gearbox NO Radial shaft sealing rings of cross shift? Radial shaft sealing ring left side? YES NO YES NO Sensor / switch? YES Seal parts new.3) Radial shaft sealing ring right side? YES NO Check sensor / switch for leak leaky sealed Renew cross shift complete (chapter 8.3) Contact product unit gearbox Renew parts and seal them Seal parts new . renew if necessary NO YES A3 renew radial shaft sealing ring (chapter 8.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Illustration troubleshooting diagram A2 A2 leaks at cover oil pump? Contact product unit gearbox YES NO at parting surface of housing? YES NO Contact product unit gearbox am Gehäuseteil? YES NO at cover of gearbox selecting fork right and left? YES NO seal new with surface sealant (chapter 8. 2) Seal new cover / flanges (chapter 8.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Illustration troubleshooting diagram A3 A3 leaks at breather? Breather correct mounted? YES NO YES NO Cover / flanges leak? YES NO Check oil level and correct if necessary (chapter 3.2) Renew breather (chapter 8.2) Paper gasket damaged Contact product unit gearbox YES NO Renew cross shift complete (chapter 8.3) Seal new with released liquid sealant .4) Cover / flanges damaged? YES NO Paper gasket at cross shift leaks between inner and outer cover? YES NO Replace cover / flanges (chapter 8. Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Illustration troubleshooting diagram B B Shiftability Selectability? YES NO outer shift smooth? NO YES Shift at still stand heavy handling? NO YES Smooth shifting of gear? NO YES Contact product unit gearbox Reverse gear heavy handling? YES NO Does clutch disconnect? NO YES Renew cross shift complete (chapter 8.6) .3) Contact product unit gearbox Contact product unit gearbox Contact product unit gearbox Adjust clutch according to vehicle manufacturer instructions Clutch servo in function? YES NO Contact product unit gearbox Change clutch servo (chapter 8. 2). if OK.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Illustration troubleshooting diagram C C Noices noices when shifting? YES NO in reverse gear? Noices during operation in pulling action? YES NO YES NO Check for clutch disconnect according to vehicle manufacturer instructions scratching when shifting? YES NO Check oil level (chapter 3.torsional absorption of clutch Contact product unit gearbox . contact product unit gearbox Noices during stress cycle? NO YES Ambient temperature? COLD WARM Contact product unit gearbox Noices during operation in retarder operation? YES NO Contact product unit gearbox does not appear at operation temperature Check outer shift for easy handling Contact product unit gearbox Rattleing in idle speed? YES NO Check and adjust according to the vehicle manufacturer instructions: .Idle speed of engine . Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Illustration troubleshooting diagram D D no traction Gear shifted at gearbox? (check at gearbox) YES NO Contact product unit gearbox Adjust again outer shift according to the vehicle manufacturer instructions . Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Illustration troubleshooting diagram E E electrical function Does switch exist (switch for reverse gear position or neutral position) YES NO Check contacts of components OK NOK Sensors available? YES NO functioning? Renew components Check contacts of components OK NOK Contact product unit gearbox YES NO Contact product unit gearbox Renew components functioning? Renew components YES NO Contact product unit gearbox Renew components . .......................................1/1 Troubleshooting Master System ..........5...8/1 Checking Pump Pressure...............................4 5........3/1 Checking Supply-Air Pressure .....................5 5.....5...1/6 Troubleshooting and Remedies ..........5..............................................................5...............................7/1 Checking Pressure Sensor.......................................10 5.............5...................................5..............................5.....5/1 Checking Control Current of Proportional Valve .......................................................................7 5...........................5.....................................5.................11 ..............5.......10/1 Operational Check.6 5.................................5........1 'LDJQRVLV 7URXEOHVKRRWLQJ 5HWDUGHU Troubleshooting Diagram .5...8 5......................9/1 Table of Measurements........5..3 5.6/1 Checking Temperature Adaption...............4/1 Checking Constant-Air Pressure (py) .1/1 Troubleshooting Diagram A to C ..5..............................2/1 Illustration Control System ..........................................9 5.............1/2 Electrical Connections Diagram ......................................................................Diagnosis / Troubleshooting 5..............2 5....11/1 5.............................................................................................................................................................................................................. 1/2 Please contact DaimlerChrysler at the gearbox-retardersystem. but I am not sure .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP Illustration troubleshooting master system see troubleshooting diagram at page 4.1/2 at gearbox? Complaint at retarder? see troubleshooting diagram at page 5. Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) A Oil loss through ventilation Complaint Retarder R 115 E Retarder pilot light B No respectively insufficient retarder braking effect C . and gearbox oil level Contact Voith service partner Check control unit (chapter 5.9) Replace casing ventilation Correct retarder.5.and gearbox oil level Contact Voith service partner M+P-07A-1763 ae .5) Contact Voith service partner Check retarder oil level too high too low Check gearbox oil level NOK OK Check gearbox oil level OK NOK Check gearbox oil level too high too low Correct retarder oil level Check casing ventilation (chapter 9. A Oil loss through ventilation Check retarder oil level Water in oil? (emulsion) NO YES OK NOK Water in oil? (emulsion) YES NO Check heat exchanger (chapter 9.2) OK NOK Check gearbox oil level too high too low Correct retarder.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Illustration troubleshooting diagram group Note It is important that the specific service filling is kept for a trouble-free operation of the retarder (see chapter 3.5 „Oil Change“ and chapter 11 „Annex“).4 . if possible) OK NOK Check temperature pick-up oil / water (chapter 5.2) Contact Voith service partner Check operation (during braking with retarder nominal engine speed.7) OK NOK Driver instruction! Check vehicle cooling system: -coolant level -thermostat -coolant pump -radiator fan -radiator grill for dirtiness Replace temperature pick-ups (chapter 10.2) Check retarder pilot light and renew.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) B Retarder pilot light Permanent light in position 0 after light test? no function? flashes? Activate blinking code and read out fault code (chapter 5. if necessary Temperature adaption Rectify fault and delete fault memory (chapter 5.2. 10.3) . 7 / 5.4) OK NOK Check temperature adaption/ pressure sensor (chapter 5.8) OK NOK Contact Voith service partner Correct retarder.and gearbox oil level Proportional valve or damping plate mechanically defect Check vehicle compressed-air pressure system OK NOK Contact Voith service partner Contact Voith service partner Contact Voith service partner Contact vehicle manufacturer .5) OK NOK Check retarder oil level too high too low Check pump pressure (chapter 5.9) OK NOK Contact Voith service partner Check gearbox oil level OK NOK Contact Voith service partner Contact Voith service partner Check current of proportinal valve (chapter 5.5) Check constantair pressure (py) (chapter 5.6) OK NOK Correct retarder oil level Check gearbox oil level too high too low Check supply-air pressure (chapter 5.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) C No respectively too insufficient retarder braking effect Check retarder oil level Water in oil? (emulsion) NO YES OK NOK Water in oil? (emulsion) YES NO Check heat exchanger (chapter 9. . . 4 8 11 10 12 7 9 4 5 6 1 2 3 2 18 17 16 6 5 4 9 8 10 11 12 13 14 15 7 3 2 1 X1 7 6 5 2 3 8 4 3 2 1 4 4 69 16 FD983a . 2 1 - + + - + - 17 X3 X2 2 3 1 6 5 4 9 8 7 .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ 'LDJUDP (Continue) Electrical connections diagram R 115 E (Voith-wiring harness) 2 4 15 16 17 18 19 20 21 47 69 70 72 Control unit Connection Terminal 15 ABS-signal Retarder stage switch Retarder pilot light Stop light relais Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Speedometer signal Plug ISO-Interface Plug optional functions Pressure sensor P 1 2 U 4 72 14 13 11 12 10 1 70 9 5 8 4 3 2 7 6 47 15 21 19 20 18 87 87a 30 . page 3. if necessary (see table. chapter 3. the retarder oil level must be checked and corrected.Diagnosis / Troubleshooting Troubleshooting and remedies Requirements for check 7URXEOHVKRRWLQJ DQG 5HPHGLHV l l l l l Battery voltage 18 . Fuse for retarder control unit checked and found satisfactory. Compressed-air pressure 6 .11 bar For check with the multimeter.32 V Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory. at pin 7 (plug X1) and pin 13 (plug X1) must be connected terminal 15 Note Prior to any troubleshooting.5.5/3). . pin 15 (plug X1) on the control unit (2) must be connected to pin 15 ground (terminal 31). slight fault Permanent light in position 0 . 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.5 of retarder stage switch. braking is no longer possible . . the retarder is in operation again and the retarder pilot light goes off..Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Note The retarder pilot light additionally has the function of a fault code: . braking is still possible to limited extent.the retarder is switched off.5 of retarder stage switch. Note If the ignition is switched off and on.serious fault Permanent light in position 0 . . Position 1 Terminal 15 Retarder stage switch. K-lead connected with terminal 15 Not in use Terminal 31 Output / high side 2 „HS2“ Not in use Output / high side 1 „HS1“ 16 17 18 13 14 15 10 11 12 7 8 9 4 5 6 1 2 3 FD846 . L-lead ISO-interface. Position 1 Retarder stage switch. Plug X1 control unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Not in use Not in use Not in use Retarder stage switch.e. leads at back).Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Connector arrangement and pin assignment Note All plugs illustrated from plug-in side (i. Position 4 Retarder stage switch. Position 2 Retarder stage switch. Position 3 Retarder stage switch + ISO-interface. Diagnosis / Troubleshooting Plug X2 control unit 1 2 3 4 5 6 7 8 9 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Not operational Proportional valve Proportional valve + Cooling-water temperature pick-up Cooling-water temperature pick-up + Not operational Not in use Oil temperature pick-up Oil temperature pick-up + 7 8 9 4 5 6 1 2 3 FD848 Plug X3 control unit 1 2 3 4 5 6 7 8 9 10 11 12 Input / pull up „DIU 1“ Speedometer signal ABS-signal Input / pull down „DID 2“ Input / pull down „DID 1“ Pressure sensor ground Pressure sensor signal voltage Retarder pilot light Input / pull down „DID 3“ Pressure sensor supply voltage Stop light relais Input / pull down / PWM-in „DID4“ 10 11 12 7 8 9 4 5 6 1 2 3 FD847 . Diagnosis / Troubleshooting Plug optional functions 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Retarder stage switch + Input / pull down „DID 1“ Input / pull down „DID 2“ Input / pull down „DID 3“ Input / pull down / PWM -in „DID 4“ Input / pull up „DIU 1“ Pressure sensor ground Pressure sensor signal voltage Pressure sensor supply voltage Output / high side „HS1“ Output / high side 2 „HS2“ No function Terminal 15 Terminal 31 2 4 6 8 10 12 14 1 3 5 7 9 11 13 FD849 Plug ISO-interface 1 2 3 4 K-lead L-lead Terminal 15 Terminal 31 4 2 3 1 FD854 . Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Plug cooling-water temperature pick-up Plug oil temperature pick-up FD851 Plug proportional valve 1 2 3 4 Proportional valve + Proportional valve – No function No function 4 1 2 3 FD850 . Diagnosis / Troubleshooting Plug retarder stage switch 1 2 3 4 5 6 7 8 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Not operational Position 5 Position 4 Retarder stage switch + Position 3 Position 2 Position 1 Bridge to pin 4 5 1 6 2 7 3 8 4 FD853 . 8224. . With fault code Special tool 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) 53.Diagnosis / Troubleshooting A.10 Commercially available tool Multimeter recommended: Fluke 87 Note The blinking code of the retarder pilot light with service-cable can be used to obtain a read-out from the fault memory. Exception: The fault „Coding Fault“ is not held in the memory but is output via the blinking code. Long blinking signals (2 sec. they are output in the sequence of their occurence. The blinking code can be read of the control unit service cable or retarder stage switch. Vehicle at standstill. Meaning l l .pushbutton“ at service cable First fault as blinking code output. Retarder stage switch in position O. For this pupose. 3. ignition ON Service interface L-lead connected to ground ≥ 2s. 2. press „L . Short blinking signals (0. but always only one fault per triggering.5 sec. Item 2 and 3 repeated for more blinking code outputs.) tens unit. Fault memory readout with service cable Requirements l l 1.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault memory readout via retarder pilot light blinking code Note If sveral faults have been stored in the memory.) single unit. Is only one stored fault available. 0. 3. 4.5 sec There is a break of 3 seconds before and after each blinking code output. during this time the retarder pilot light is switched off.5 sec 99-03-fd1620 2 sec 2 sec 1 sec 1 sec 1 sec 1 sec ..5 sec 0. Display example for fault code 23: The number of tens units first indicated as long ON time: The number of single unit then is indicated as short ON time: Breaks between each ON time: each 2 seconds each 0.. 2.5 seconds each 1 second Display example for fault code 23 E Retarder pilot light ON A Retarder pilot light OFF t Time If an actual fault is available (before triggering the blinking code the retarder pilot light is switched ON) the retarder pilot light switches to permanent light again after the blinking code.3 for more blinking code outputs 0. 5. the retarder pilot light is OFF after the output.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) 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 Retarder stage switch in position 1 (≥ 2 seconds) Retarder stage switch in position 0 First fault as blinking code Items from . Diagnosis / Troubleshooting Delete fault memory 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) No marginal notes in accordance with fault memory read out. 1. 2. Vehicle ignition system: OFF Servcie interface L-lead connected to ground. For this purpose, press „L-pushbutton“ of service cable. Vehicle ignition system: ON Release L-lead from ground after ≥ 2 sec. 3. 4. Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) 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 class Trigger time Requirement / Operation Measurement/ Test connection1) Result/ Set point Cause/ Remedy 2) Code 01 Test step Stop light relay/ Short circuit to ground slight 1s - Ignition: OFF - Pull plug X3 out of control unit X 3/11 Ω X 1/15 Relay is installed: 250-350 Ω Check lead, plugs and relay or consumers 1) 2) X 1/15 = ground control unit Only, if no fault is recognizable after a complete check of the periphery: change control unit. Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Code 03 Test step Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy HS 1 output Short circuit slight 1s - Ignition: OFF - Pull plug X1 out of control unit - Ignition: OFF - Pull plug X1 out of control unit - Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Start engine (idle speed) X 1/18 Ω X 1/15 Relay is installed: 250-350 Ω Relay is installed: 250-350 Ω ≥ 17,5 V Check lead, plugs and relay or consumers Check lead, plugs and relay or consumers Check lead, plugs and fuses 04 HS 2 output Short circuit Terminal 15 Undervoltage slight 1s X 1/16 Ω X 1/15 05 serious 60 s X 1/7 V X 1/15 06 Terminal 15 Overvoltage serious 10 s X 1/7 V X 1/15 ≤ 32,5 V Checking electrical installation of vehicle (see manufacturer instructions) 1271Ω 80°C ± 10°C = 1271 . .1117Ω 60°C ± 10°C = 1099 .Pull plug X2 out of control unit X 2/5 Ω X 2/4 20°C ± 10°C = 1039 .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code 08 09 Test step Cooling-water temperature pick-up Discontinuity / Short circuit to battery 1s serious/ slight * .Ignition: OFF .1347Ω Notice: The measuring in one temperature range normally is sufficient. if temperature pick-up for oil and water are defect at the same time. Check lead and sensor * Fault is in serious class. 1117Ω 60°C ± 10°C = 1099 . if temperature pick-up for oil and water are defect at the same time.1271Ω 80°C ± 10°C = 1271 .Ignition: OFF .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code 11 12 Test step Oil temperature pick-up Discontinuity / Short circuit to battery 1s serious/ slight * . .1347Ω Notice: The measuring in one temperature range normally is sufficient. Check lead and sensor * Fault is in serious class.Pull plug X2 out of control unit X 2/9 Ω X 2/8 20°C ± 10°C = 1039 . 5 V 0V 0V 0V 0V ≥ 17.Ignition: ON .Retarder stage switch: Position 2 Check lead.5 V 0V 0V 0V 0V 0V ≥ 17.5 V 0V 0V 0V Check lead.Ignition: ON . plug and retarder stage switch .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Code 13 Test step 1 Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Retarder stage switch Undefined switch state serious 100 ms .Retarder stage switch: Position 0 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 ≥ 17.5 V ≥ 17.Ignition: ON .5 V ≥ 17. plug and retarder stage switch 13 3 .Retarder stage switch: Position 1 Check lead. plug and retarder stage switch 13 2 .5 V ≥ 17. Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Code 13 Test step 4 Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy .5 V ≥ 17.5 V 0V ≥ 17.Ignition: ON .5 V ≥ 17.5 V ≥ 17.5 V ≥ 17.Retarder stage switch: Position 4 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 Check lead.5 V ≥ 17.5 V Check lead.5 V ≥ 17.5 V ≥ 17.5 V ≥ 17.Retarder stage switch: Position 5 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 Check lead.5 V 0V 0V ≥ 17.5 V ≥ 17.Ignition: ON . plug and retarder stage switch 13 5 .Retarder stage switch: Position 3 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 ≥ 17.Ignition: ON .5 V ≥ 17. plug and retarder stage switch .5 V ≥ 17. plug and retarder stage switch 13 6 .5 V ≥ 17. Ignition: OFF .Ignition: ON .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code 14 Test step Retarder stage switch Short circuit to battery serious 10 s .Ignition: OFF .Pull plug X1 out of control unit .Retarder stage switch: Position 0 .Ignition: ON X 1/10 V X 1/15 0V Check lead and plug 15 Retarder stage switch Short circuit to battery Speedometer signal Discontinuity serious 1s X 1/10 Ω X 1/15 Resistor infinite Single check of stages for short circuit 16 serious 2s X 3/2 V X 1/15 ≤ 1V Check lead and speedometer .Retarder stage switch: Position 5 .Pull plug X1 out of control unit . Ignition: ON . relay and ABS-control unit Replace control unit Check lead 21 serious 60 s .Ignition: ON X 3/3 V X 1/15 ≥ 16. relay and ABS-control unit Check lead.Ignition: OFF .Ignition: ON X 2/3 V X 1/15 ≤ 10 V .Ignition: ON X 3/2 V X 1/15 ≤ 9V Check lead and speedometer 19 serious 60 s X 3/3 V X 1/15 ≥ 3.Pull plug X2 out of control unit .Pull plug X3 out of control unit .5 V Check lead.Ignition: OFF .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code 18 Test step Speedometer signal Short circuit to battery undefined signal ABS Short circuit to ground ABS-Signal undefined serious 2s .5 V 22 23 Internal fault ABS-current path Proportional valve Fault No. 1: Short circuit to battery serious serious 1s 1s . Ignition: ON ..Discontinuity proportional valve magnetic Valve magnetic .Discontinuity connection lead proportional valve .Short circuit proportional valve magnetic .Pull plug X2 out of control unit X 2/3 Ω X 1/15 Resistor infinite Check lead and proportional valve (valve block) .and shift valve interchanged serious 1s .Prop.Short circuit to ground at proportional valve .Short circuit connection lead proportional valve .Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code 24 Test step 1 Proportional valve Fault No. 2: .Ignition: OFF .Pull plug X2 out of control unit X 2/2 Ω X 2/3 18-25 Ω Check lead and proportional valve (valve block) 24 2 . Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code 24 Test step 3 . 3: defective control unit Valve block Fault No.Pull plug X1 out of control unit . plug and fuse .Ignition: ON X 1/13 V X 1/15 ≥ 17.Ignition: OFF .Ignition: OFF . 5: defective control unit Terminal 30 Undervoltage serious 10 s X 2/2 Ω X 1/15 Resistor infinite Check lead and valve block Replace control unit 25 27 serious 2s Replace control unit 28 serious 60 s .Pull plug X2 out of control unit Valve block Fault No.5 V Check lead. Pull plug X3 out of control unit .Retarder stage switch: Position 1 X 3/8 V X 1/15 ≥ 17.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code 29 31 Test step Fault control unit Control unit: Coding fault Retarder pilot light: Discontinuity / Short circuit to ground Retarder pilot light: Short circuit to battery serious serious 180 ms 100 ms Replace control unit Provide new parameters for control unit .5 V Check lead.Ignition: ON . retarder pilot light and fuse Check lead and retarder pilot light Replace control unit 32 serious 3s 33 serious 3s X 3/8 V X 1/15 ≤ 2V 35 Fault control unit serious 500 ms / 123 s .Ignition: ON .Ignition: OFF . as well as Voith requirements Ignition: ON Position 0 X 3/7 V X 1/15 and X 3/10 V X 1/15 0.7 V 4.3-0.25 V If deviation: step 2 2 Troubleshooting in wiring harness.75-5.Diagnosis / Troubleshooting 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Fault Fault text Fault class Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code 37 Test step Fault foot operation slight 100 ms / 1 s Check installation in accordance with OEM . proportional valve. pressure sensor. supply-air pressure. ECU (Contact Voith) Pressure sensor wiring harness 38 1 Fault constant-air pressure slight 1 s to 10 s . Diagnosis / Troubleshooting B. . Without fault code 7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue) Note Retarder faults without fault code are not recognized electronically. 2-wires) Four-circuit protection valve Air tank for auxiliary equipment 31 35 40 2 39 29 20 34 1 FD919 .OOXVWUDWLRQ &RQWURO 6\VWHP 11 33 71 Note The reference numbers indicated in section 5. 25 A P R 36 21 26 32 61 1 2 11 19 20 21 25 26 31 32 33 34 35 36 39 40 61 71 Heat exchanger Control unit Connection proportional valve current Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Constant-air pressure line py (connection A) Supply-air pressure line pv (connection P) Compressed-air line (pressure regulator-four circuit protection valve) Compressed-air line (four circuit protection valve air tank for auxiliary equipment) with test connection Compressed-air line (Brake circuit 1) Compressed-air line (Brake circuit 2) Compressed-air line (Parking brake) Ventilation line (Connection R) Electrical lead (cooling-water temperature pick-up to control unit. 2-wires) Electrical lead (oil temperature pick-up to control unit.Diagnosis / Troubleshooting Illustration control system .3 are not identical with the reference numbers of the spare parts lists. Minimum pressure: Maximum pressure: 6 bar 11 bar Note If the pressure is not within the specified range. 32 FD122 . the compressed-air pressure installation must be checked to the manufacturer´s data..Diagnosis / Troubleshooting Job scope test 1. &KHFNLQJ 6XSSO\$LU 3UHVVXUH Connect suitable test pressure gauge to test connection of compressed-air line (32) (four circuit protection valve .air tank for auxiliary equipment) and check supply-air pressure pv. Diagnosis / Troubleshooting Requirements for check &KHFNLQJ &RQVWDQW$LU 3UHVVXUH S\. l l Retarder stage switch in position 0 Vehicle ignition system OFF Special tool 53.1403.10 Compressed-air gauge 0-6 bar . Diagnosis / Troubleshooting &KHFNLQJ &RQVWDQW$LU 3UHVVXUH S\. . replace completely if necessary. the tightening torques in brackets are valid. 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. (Continue) Caution! Two versions of screw plugs (103) are possible: A) Version with integrated FPM-sealing ring. B) Version with loose inserted copper-sealing ring. The integrated sealing rings must be checked during the oil level check for possible damages. these corresponds the standard version at the time going to print. The copper-sealing rings are generel to renew. Diagnosis / Troubleshooting Job scope test &KHFNLQJ &RQVWDQW$LU 3UHVVXUH S\. 1403. 99/1 3. Check sealing ring of screw plug for damages. replace if necessary. Disconnect pressure gauge (99/1). Connect pressure gauge (99/1) to bore of oil filler plug (4100).10/1.10 . 4. Fit oil filler plug (4100) and screw it tight. Tightening torque oil filler plug (4100): 100 Nm (150 Nm) M+P-07A-1488b 99/1 Pressure gauge 53. 5. (Continue) 4100 1. M+P-07A-1488c 2. operate retarder in braking stage 5 and compare read-off value with the values of the constant-air pressure (py) according to table see page 5. Screw out oil filler plug (4100). Plug at valve block and socket checked for damage as well as wear (notch scratches).Diagnosis / Troubleshooting Requirements for check • • • • &KHFNLQJ &RQWURO &XUUHQW RI 3URSRUWLRQDO 9DOYH Battery voltage 18 .8198.32 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.10 Measuring adapter Commercially available tool Multimeter recommended: Fluke 87 . Special tool 53. Diagnosis / Troubleshooting Job scope test 1. 3. 99/3 FD923 99/3 Measuring adapter „Prop current“ 53. &KHFNLQJ &RQWURO &XUUHQW RI 3URSRUWLRQDO 9DOYH (Continue) 21 98/8 Disconnect plug at proportional valve (21) and connect with measuring adapter (99/3).10 99/8 Multimeter . Connect plug of measuring adapter (99/3) with the proportional valve (21). Switch position: mA or A Turn switch „Propvalve“ at measuring adapter (99/3) in position „I“. 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 5. 2.10/1.8198. 4. Connect the Multimeter (98/8) to the measuring socket 1. 5. 10 Temperature simulator Adapter cable . Fuse for retarder control unit checked and found satisfactory.32 V Vehicle ignition system OFF Pressure gauge constant-air pressure (99/9) connected Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory. Special tool Wasser Öl 53.10 53.8207.Diagnosis / Troubleshooting Requirements for check &KHFNLQJ 7HPSHUDWXUH $GDSWLRQ l l l l l Battery voltage 18 .8279. Note Mind the correct connection of the plugs for cooling-water and oil! 2. Set rotary switch of the temperature simulator (99/2) to 125oC cooling water temperature. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. Connect temperature simulator (99/2) with adapter cable (98/5) to plug temperature simulator (57). Set the rotary switch of the temperature simulator (99/2) to 225oC oil temperature. Set the rotary switch of the temperature simulator (99/2) to 185oC oil temperature. Operate the retarder at the highest braking stage.10 98/5 Adapter cable 53. There must be no more output of constant-air pressure py. Set the rotary switch of the temperature simulator (99/2) to 95°C cooling water temperature and 165°C oil temperature. 99/2 FD1455 99/2 Temperature simulator 53. There must be no more output of constant-air pressure py. The constant-air pressure py must drop temporary below the set maximum pressure.8207.rThe constant-air pressure must drop temporary below the set maximum pressure.8279. 4. Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature.Diagnosis / Troubleshooting &KHFNLQJ 7HPSHUDWXUH $GDSWLRQ (Continue) 98/5 57 Arbeitsumfang Prüfung 1. 5. Reconnect electrical lead (57) to temperature pick-up cooling-water and oil. 3.10 . 10 Measuring adapter Commercially available tool Multimeter recommended: Fluke 87 .8198.Diagnosis / Troubleshooting Requirements for check • • • &KHFNLQJ 3UHVVXUH 6HQVRU Ignition ON Pressure gauge constant-air pressure connected Retarder stage switch in position 0 Special tool 53. 2 V 9.0. 99-03-923a 98/8 38 99/3 99-03-923b . 3.3 . 5.5 bar = 2.8 . Connect electrical lead Positive of Multimeter to measuring socket 2. Connect plug of measuring adapter to pressure sensor (38). Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3). After disconnecting the measuring adapter connect electrical lead again to pressure sensor.25 V.75 and 5. Turn switch „Propvalve“ at measuring adapter (99/3) downwards (not in position „I“). 2. Connect electrical lead Ground of Multimeter (98/8) to measuring socket 4 of adapter.7 V 2. 98/8 38 99/3 6. Compare measured voltage in conjunction of constant-air pressure with the following values: 0 bar = 0. 4. Connect electrical lead Positive of Multimeter to measuring socket 1. 7. 8.3. The measured voltage must be between 4.Diagnosis / Troubleshooting Job scope test &KHFNLQJ 3UHVVXUH 6HQVRU (Continue) 1. 10 Oil pressure gauge 0-25 bar M+P-07A-1491 . w.Diagnosis / Troubleshooting Prior jobs • • &KHFNLQJ 3XPS 3UHVVXUH Retarder stage switch in braking stage 0 Ignition OFF 103 Screw plug (measuring point pump pressure) M12x1.4788.a.5 Inhex.f.-head. 6 13 Nm (20 Nm) 103 Note The pump pressure check provides information on internal leaks and on the correct operation of the retarder. Special tool 53. replace completely if necessary. . The integrated sealing rings must be checked during the oil level check for possible damages. Compressed-air pressure 6 . If screw plugs with loose inserted copper-sealing rings (variant B) are used. In this Aftersales Service Manual is excluding the variant A (series version) described. The copper-sealing rings are generel to renew.32 V Vehicle electrical system checked in accordance with the Operating Manual for the vehicle and found satisfactory. the tightening torques in brackets are valid. Fuse for retarder control unit checked and found satisfactory. these corresponds the standard version at the time going to print.Diagnosis / Troubleshooting Requirements for check &KHFNLQJ 3XPS 3UHVVXUH (Continue) l l l l l l Battery voltage 18 . B) Version with loose inserted copper-sealing ring.11 bar No external leaks at the retarder Retarder stage switch in braking stage 0 Caution! Two versions of screw plugs (103) are possible: A) Version with integrated FPM-sealing ring. Connect up pressure gauge (99/1) to the retarder housing. Job scope test 1. but has no effect on the function of the retarder. 2.Diagnosis / Troubleshooting &KHFNLQJ 3XPS 3UHVVXUH (Continue) Caution! Risk of injury! The screw plug (103) and the oil is hot! 103 103 Caution! Easy oil-exit is caused constructively. however. Screw out screw plug (103). 99/1 M+P-07A-1493 . please contact your Voith service partner. Check sealing ring of screw plug for damages.m. and drive with an engine speed of 1000 r. but the minimum value of the dynamic pump pressure is not reached. Caution! Risk of injury! Hot oil can leave when disconnecting the presure gauge! 6. 5.Diagnosis / Troubleshooting &KHFNLQJ 3XPS 3UHVVXUH (Continue) 3. 7. Screw in screw plug tight. Shift the retarder stage switch to position 5 while on the move and read pump pressure off test pressure gauge (99/1) at prop shaft speed vps = 1000 r. Put in direct gear (gear ratio 1:1). .p. Tightening torque screw plug (103): 13 Nm (20 Nm). Caution! If the constant-air pressure (py) is obtained in the test at stillstand (see chapter 5.p.10/1. 4. Drive the vehicle with a prop shaft speed of v ps = 1000 r.p.m.5). Disconnect pressure gauge.m. renew if necessary. Compare read-off pump pressure with the value of dynamic pump pressure according to the table see page 5. m. The manufacturer reserves the right to make further modifications.058 059.596 409 .640 Retarder stage switch in highest braking stage! The code number is to be found on the control unit If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!). 079.75 .10 .p.30 .2. minimum value [bar] 17 19 23 055 056 .Diagnosis / Troubleshooting 7DEOH RI 0HDVXUHPHQWV Code number 2) Control current mA1) 3) 5) Constant-air pressure (py) (static) 4) 1) set value [bar] 2. Decisive is the pressure which has built up itself after 30 seconds (stabilized.50 2.609 440 . 080 1) 2) 3) 4) 5) 396 . The values are not steadily because of continuous control in the closed loop (however within the stated range).2. . constant pressure).30 2. Note These values represent the state of the art at the time going to print.2.95 Pump pressure (dynamic) 1) vps = 1000 r. braking operations are possible (partly with reduced braking torque).Diagnosis / Troubleshooting Requirements for check • • • • 2SHUDWLRQDO &KHFN Battery voltage 18 .. Constant-air pressure 6 -11 bar Retarder oil level satisfactory The following operational states are indicated by the retarder pilot light: Retarder pilot light without indication The retarder is switched off.5 of the retarder stage switch. serious fault The retarder pilot light shows permanent light in position 0 .e. There are no more braking operations possible .5 of the retarder stage switch. Retarder pilot light permanently on The retarder is switched on. The retarder pilot light additionally has the function of a fault indicator. There is no fault in the memory.the retarder is switched off. slight fault Continous light in position 0 . - . one of the four possible retarder braking stages or „Constant Speed“ operation has been selected with the retarder stage switch. i.32 V Electrical system checked in accordance with the Operating Manual for the vehicle and found satisfactory. If the fault occurs again.the retarder regulates back its braking torque. the retarder is in operation and the retarder pilot light is going off. These flash function however.Diagnosis / Troubleshooting 2SHUDWLRQDO &KHFN (Continue) Note If the ignition is switched off and on again. the retarder switches off again and the retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch. is only realized at defined regulation variants! . Retarder pilot light flashes during retarder braking The temperature adaption is effective . or retarder does not brake properly. 5 sec. retarder brakes in stages 1 to 5. 2 Retarder Vehicle on move . Retarder pilot light comes on.Diagnosis / Troubleshooting 2SHUDWLRQDO &KHFN (Continue) Test step 1 Scope of check Retarder pilot light Requirement / Operation Ignition: ON Result / Set point Retarder pilot light comes on and goes off after approx.1/2 .Shift retarder stage switch to stage 1 to 5. Retarder pilot light does not come on. Cause / Remedy Retarder pilot light trouble-free Troubleshooting as on page 5. Note. or does not go off.1/2 Retarder operates trouble-free. Retarder pilot light does not come on. Troubleshooting as on page 5. ..........QVWDOOLQJ *HDUER[ Removing...........1/1 ...................6..................... Installing 6...1 5HPRYLQJ ...Gearbox Removing...... Installing Gearbox . -head screw M10x45. Removing.QVWDOOLQJ *HDUER[ (Continue) Illustration removing. if necessary • Clutch servo removed. engine and gearbox propper! 20 4 1 25/250/119 M+P-07A-1773 1 3 4 5 6 7 19 20 21 26 25/250/119 Plug switch reversing light Connecting piece Plug speedometer sensor Hex. installing gearbox Prior jobs • Ignition OFF • Shift linkage removed • Clutch output cylinder removed • Engine bonnet removed. if necessary (chapter 8.Gearbox.6) Weight in kg: approx. Installing 5HPRYLQJ . 45 Nm Remark: Terms of parts from DaimlerChrysler-EPC-documentation . if necessary • Engine compartment enclosed casing removed.195 kg without clutch housing 5 6 21 19 7 3 3 26 Achtung Verletzungsgefahr! Secure vehicle. renew Propeller shaft Plug switch for starter lock Plug cooling-water temperature pick-up Plug oil temperature pick-up Plug proportional valve Compressed-air line supply-air pressure Hex.-head nut. Installing Workshop equipment Gearbox lifter Nr.Gearbox Removing.QVWDOOLQJ *HDUER[ (Continue) Manufacturer: e. 06752 / 93110 Fax 06752 / 71751 M+P-07A-1775 . g. 554 5HPRYLQJ . Fa. Kirner Obersteinstraße 139 D-55602 Kirn Tel. Wagner Dieselstraße 9-11 D-70829 Gerlingen Tel. B. Fa. Installing 5HPRYLQJ .QVWDOOLQJ *HDUER[ (Continue) Adapter for gearbox lifter Nr. WBM 0079.06 Manufacturer: e. Hywema . 07156 / 22013 Fax 07156 / 22014 M+P-07A-1776 Commercially available equipments Wheel gripper tool RG 5/2HD2 z. g.Gearbox Removing. Fa. Pull the plug (19) from cooling-water temperature pick-up. 8. (heed the statements of the vehicle-manufacturer). 7. Pull the plug (21) from proportional valve. 12.QVWDOOLQJ *HDUER[ (Continue) 1. Lift the vehicle with 4 wheel gripper to the wished working height. Prop up engine with suitable device.5). Remove connecting pieces (3) from heat exchanger. 10. Pull the plug (1) from switch reversing light. 4. Drain oil of gearbox and retarder (chapter 3. . 11. Remove eventually existing cross bars. 5. Pull the plug (7) from switch for starter lock.Gearbox Removing. Note for installation Tightening torque: 55-65 Nm 6. Remove compressed-air line (26) from proportional valve. Pull the plug (20) from the oil temperature pick-up. 2. Installing Removing. 13. Pull the plug (4) from speedometer sensor.4 and 3. 9. Drain coolant (heed the statements of the vehicle-manufacturer). which are in the way with the removal of the gearbox. installing 5HPRYLQJ . 3. 15. . Screw out bottom hex.-head screws from bracket / engine bearing right and left. Note for installation: Tightening torque: 165-195 Nm 18. Note for installation: Tightening torque: 180-210 Nm 16. Installing 5HPRYLQJ . Note for installation: Use new self-locking hex. Slightly lift the gearbox.-head screw from clutch housing / engine. Lift the gearbox higher and drive out it to the rear. adjust gearbox lifter and secure with safety chain. Screw out top hex.Gearbox Removing. Drive gearbox lifter with adapter below the gearbox. Note for installation: Tightening torque: 39-46 Nm 20.-head screw from clutch housing / engine. Note for installation: Tightening torque: 39-46 Nm 17. Remove both rear engine bearing brackets.-head nuts. Remove propeller shaft (6) from retarder. Screw out hex.QVWDOOLQJ *HDUER[ (Continue) 14. 19. Tightening torque according to vehicle manufacturer instructions. 3: „Checking Oil Level of Retarder“. Enforce a visual examination on leaks after taken place test drive. Clean the drive shaft and grease it wafer-thin. Top up oil of gearbox and retarder. . screws and nuts. plugs and terminals must be in propper conditions. 24. Note Connections as hoses. Top up coolant: See statements of the vehicle-manufacturer. 23. Engage retaining ring before installation of the clutch output cylinder by pulling at the clutch release fork. Clean all parts.5. hose ties. and renew parts if necessary. Install in reverse sequence. Check the function by pushing. 22.QVWDOOLQJ *HDUER[ (Continue) 21. Check gearbox oil level: See chapters 3. Therefore see Operating Specifications of vehicle manufacturer.4 and 3.Gearbox Removing. Installing 5HPRYLQJ .2: „Checking Oil Level of Gearbox” and 3. 25. Top up coolant according to the vehicle manufacturer instructions. check for wear. Defective parts must be renewed. Therefore heed chapter 3. Heed the cooling water-quality in chapter 11. ..............................1/1 ....1 5HPRYLQJ .7...........QVWDOOLQJ 5HWDUGHU Removing. Installing 7.......... Installing Retarder ...........Retarder Removing...... w. 15. 17 100 Nm (150 Nm) 25000 Balance washer 25100 O-ring. 58 Nm 850 25000 (26/860/020*) 25300 25300 25200 4100 25100 (26/860/023*) 25200 850/001 M+P-07A-1497 * DaimlerChrysler position number .-head.a.a. 15 58 Nm 25300 Hex.a.f.-head screw M10x70 Hex.-head screw M10x60 Hex.-head. renew coat with silicone-free and noncorrosive grease for installation 25200 Hex.Retarder Removing.5) Output flange removed (see chapter 8.-head. w.4) Speedometer sensor removed (see chapter 8.7) 850 Outer race Remove only. installing retarder Prior jobs • • • • Gearbox (with retarder) removed (see chapter 6. Installing 5HPRYLQJ .QVWDOOLQJ 5HWDUGHU Illustration removing.1) Connecting pieces removed (see chapter 9. if taper roller bearing is renewed or a new balance washer is added (DC-tool) 850/001 Taper roller bearing 4100 Screw plug M30x1.f.5 Inhex.f. w. DIN 17100 (1.10 on inquiry Puller for outer race on inquiry Impact tool for outer race Control device Measuring device Tool for local fabrication M10 15 80 0073ae Material: St37-2.3056. Installing Special tools 5HPRYLQJ .10 67.80) Threaded bolt M10x80 .Retarder Removing.2713.QVWDOOLQJ 5HWDUGHU (Continue) 67. Two versions of 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 during the oil level check for possible damages. B) Version with loose inserted copper-sealing ring. The copper-sealing rings are generelly to be renew.Retarder Removing. the tightening torques in brackets are valid.3056.10 has to be calibrated annually! The workshop using this device is responsible for calibration and the propper condition of the device. . replace completely if necessary. Installing 5HPRYLQJ .QVWDOOLQJ 5HWDUGHU (Continue) Lubricants and locking agents O-rings Retarder housing Silicone-free and non-corrosive grease Omnifit FD10-1042 Caution! The measuring device 67. If screw plugs with loose inserted copper-sealing rings (variant B) are used. In this Aftersales Service Manual is excluding the variant A (series version) described. Service- Retarder Removing, Installing 5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue) 25200 Caution! Risk of injury! Secure retarder before working step 1 (prop up)! 25300 Caution! Remove speedometer sensor before working step 1 (see chapter 8.5)! Removing, installing 1. Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove retarder with suitable lifter device from gearbox. 2. Remove O-rings (25100) from gearbox. 25200 M+P-07A-1498 25000 850 Note You must execute the following working-step only, if: - a new retarder is installed - the taper roller bearing (850/001) is renewed or - the gearbox is renewed 3. Dismantle outer race (850) with puller for outer race (DaimlerChrysler tool F3 6280 0 486 285) and remove balance washer (25000). 850/1 25100 M+P-07A-1499 Retarder Removing, Installing Installing 1. 5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue) Determine the thickness of the balance washer like follows: Note Determine the thickness of the balance washer only, if: - one or both taper roller bearings of the retarder was renewed - the retarder was dismantled or changed or - the gearbox was dismantled or changed a M+P-07A-1444 The following described measurements may only being carried out at room temperature! 1.1 Take measuremnets of the spacing „a” between the surface of the gearbox housing (320) on retarder side and the surface of the balance washer. Note down the measured value as dimension „a“. Place measuring device (98/1) on supporting plate (60). Push vernier caliper (61) at measuring plate (62) and set to zero by using the reset key (63). 61 62 63 1.2 1.3 60 M+P-07A-1976 98/1 Measuring device 67.3056.10 Retarder Removing, Installing 1.4 1.5 5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue) 62 Place outer race (850) on taper roller bearing (850/1). Place measuring plate (62) on outer race (850) and check correct and gap-free seat by rotation. Then press with one hand powerful onto the measuring plate (62) and turn the driving wheel (arrow) 2 turns clockwise and 2 turns counter-clockwise. 850 850/1 M+P-07A-1977 1.6 Place the measuring device (98/1) in the way on the retarder housing, that both plastic bolts mesh in the flat surface. Place vernier caliper (61) at measuring plate (62) and read-off value. 1.7 61 Note The measured value must be between +0,86 mm and -0,28 mm, contact Voith if necessary. 1.8 Calculate dimension „b“. Dimension „b“ plus or minus the read-off value from working step 1.7 (heed sign at scale). Note down the calculated value as dimension b. 98/1 Measuring device 67.3056.10 M+P-07A-1978 62 98/1 Place outer race (850 . Place balance washer (25000) into gearbox housing (if dismantled).9 5HPRYLQJ .10 Push vernier caliper (61) at measuring plate (60) and check.QVWDOOLQJ 5HWDUGHU (Continue) Place again the measuring device at the supporting plate (60). Note 25000 850 If taper roller bearing was renewed. 3. renew also outer race (850). M+P-07A-1446 . 63 60 1.if removed) into the gearbox housing and knock it in with the impact tool for the outer race (DaimlerChrysler tool) as far as it will go.02 mm 2. Installing 1. if zero position still is set. 1. if necessary press reset key to repeat measuring procedure. 61 62 Note The measuring device must display zero. M+P-07A-1976 Thickness of balance washer = dimension „a“ minus dimension „b“ minus 0.Retarder Removing.11 Calculate thickness of balance washer. Retarder Removing. Clean sealing surface of gearbox housing and coat it with locking agent Omnifit FD10-1042. M+P-07A-1501 5. 25100 M+P-07A-1448 . 8. 7.QVWDOOLQJ 5HWDUGHU (Continue) 1 Clean sealing surface of retarder housing (1). Coat O-rings (25100) with silicone-free and non-corrosive grease and place into the gearbox. Turn the gearbox until the sealing surface does show upwards (gearbox is in vertically position). The threaded bolts are required so that the sealing surfaces (gearbox/retarder) can be installed congruent. 6. Screw in two threaded bolts M10x80 (see arrows) into the gearbox housing. Installing 4. 5HPRYLQJ . -head screws (25200).-head screws 58 Nm Unscrew the two threaded bolts M10x80 again. Tightening torque hex. 25300 M+P-07A-1502a 12.QVWDOOLQJ 5HWDUGHU (Continue) 25200 25200 25200 Place retarder at gearbox and screw it tight with 5 hex. Turn gearbox with fixed retarder in the horizontally position again.Retarder Removing. Screw in the 17 hex. 13.-head screws (25300) and screw them tight. Installing 9. 5HPRYLQJ . 4100 M+P-07A-1497a .-head screws 58 Nm 10. Screw out screw plugs (4100) out of retarder housing. 11. Tightening torque hex. A 98/2 Note Over the threaded bore of the speedometer sensor (arrow) can be determined.Retarder Removing. Installing 14.10 15. B M+P-07A-1979 98/2 Control device 67. 5HPRYLQJ .QVWDOOLQJ 5HWDUGHU (Continue) 98/2 4100 Press threaded spindle of control device (98/2) into direction of arrow as far as it will go. Screw control device (98/2) via „B“ into the drive shaft until it is turning too. if the impulse ring itself and so the drive shaft turns. M+P-07A-1997 M+P-07A-1503 98/2 Control device 67. 16.10 .2713.2713. Screw control device (98/2) via „A“ hand tight into the retarder housing. Seite 4/1Service-Handbuch VOITH Retarder 115 E 98/2 64 98/2 Control device 67. 19. 6 to 8 bar).3 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time about 360°. 5HPRYLQJ . 4100 99/8 98/2 98/2 Control device 67. Check gap of taper roller bearings as following: M+P-07A-1980 M+P-07A-1503 0HDVXUHPHQW 19. 19.Retarder Removing.2713.10 M+P-07A-1981 . 18.1 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with compressed-air (approx.10 19.2713. Place test prod with initial tension at surface (arrow) of control device (98/2) and set scale of dial gauge to zero.4 Place test prod with initial tension at the marked position and set scale of dial gauge to zero. Installing 17. Make marking at surface of control device at the point you can read-off the lowest value of the dial gauge.2 Turn shaft of the control device (64) three times about its own axis.QVWDOOLQJ 5HWDUGHU (Continue) Fix the holder (99/8) with dial gauge at retarder housing. 19. 6 Turn shaft of the control device (64) three times about its own axis. contact Voith if necessary.10 Caution! M+P-07A-1982 M+P-07A-1503 If the set value is not reached. Installing 0HDVXUHPHQW 5HPRYLQJ . Set value: 0. 4100 20. 22. Tightening torque: 100 Nm (150 Nm) M+P-07A-1497a .QVWDOOLQJ 5HWDUGHU (Continue) 19. To this all working steps described in this chapter must be carried out once again. the retarder must be removed and be installed again with another corresponding balance washer. Screw in screw plug (4100) again and screw it tight. 4100 98/2 64 98/2 Control device 67. 19.5 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with compressed-air (approx. renew if necessary.12 mm. 6 to 8 bar). 21. 19. The smallest value corresponds the bearing gap. Check sealing ring of screw plug (4100) on damages.7 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time about 360°. Remove control device again.2713.02 to 0.Retarder Removing. ..3/1 Removing. Installing Clutch Servo and Adjusting Wear Indicator .......8.............................. Installing Front Housing Cover..8./6................................... Installing Breather ..........8.....8..............4/1 Removing.....8................................. Cover Countershaft and Closing Cover 5......2 8.........5 8..5/1 Removing.........................1 8....................8..............1/1 Removing.....6/1 Removing......7 5HSDLU *HDUER[ Overall Illustration of Main Components ......................................2/1 Removing....7/1 ......3 8.................................................. Installing Output Flange Renewing Radial Shaft Sealing Ring .............................Gear.Repair Gearbox 8........ Installing Sensor/Switch at Gearbox .........................6 8.... Installing Shift....................................................8.....4 8....... Repair Gearbox 2YHUDOO .-head screw Front housing cover O-ring Radial shaft sealing ring Hex.-head screw Oil sieve Spring Screw plug Sealing ring * = option 26/100/122 26/100/125 26/100/128 26/100/194 26/100/197 26/100/200 26/100/203 26/100/206 26/250/047 26/250/068 26/350/065 26/350/071 26/350/080 26/350/083 26/350/101 26/350/ 26/400/083 26/400/089 26/860/014 26/860/017 26/860/026 Oil filler plug Oil drain plug Sealing ring Sealing ring Anti-fatigue screw O-ring O-ring Speedometer sensor Switch starter lock * Inductive sensor for overspeed protection * Hex.-head screw Closing cover 5.OOXVWUDWLRQ RI 0DLQ &RPSRQHQWV Illustration main components gearbox GO170 .-head screw Countershaft cover Hex./6.-head screw .-head screw Breather complete Cover bearing reverse gear end stop Radial shaft sealing ring Hex.-gear O-ring Hex.-head screw Clutch servo Cover metal sheet Hex.-head screw Shift Oil temperature pick-up gearbox * Switch reversing light * Radial shaft sealing ring Radial shaft sealing ring Hex.GO210 26/350/083 26/100/056 26/100/053 26/100/059 26/350/101 26/100/032 25/250/020 26/100/038 26/100/014 26/100/008 26/350/080 26/250/047 26/100/206 26/860/026 26/860/017 26/860/014 26/860/026 26/100/197 26/100/203 26/100/200 26/100/194 26/400/083 26/100/128 26/100/125 26/100/128 26/400/089 26/100/122 26/100/023 26/100/029 26/100/128 26/100/125 25/250/008 25/250/113 26/350/ 25/250/068 26/350/071 26/250/068 26/100/113 26/100/116 26/100/107 26/100/119 26/350/065 25/250/110 25/250/008 25/250/020 25/250/068 25/250/110 25/250/113 26/100/008 26/100/014 26/100/023 26/100/029 26/100/032 26/100/038 26/100/053 26/100/056 26/100/059 26/100/107 26/100/113 26/100/116 26/100/119 Clutch housing Hex. renew coat with silicone-free and noncorrosive grease for installation 26/100/023 Radial shaft sealing ring.1) Gearbox housing removed Clutch servo removed (chapter 8.Repair Gearbox Prior jobs • • • • 5HPRYLQJ .-head screw 30 Nm 26/100/056 26/100/053 26/100/059 26/100/023 26/100/008 26/100/014 26/100/032 26/100/038 26/100/029 M+P-07A-1774 Remark: Terms of parts from DaimlerChrysler-EPC-documentation ./6.) Gearbox removed (chapter 6. coat with sealant Omnifit FD10-1042 26/100/014 O-ring.QVWDOOLQJ )URQW +RXVLQJ &RYHU &RYHU &RXQWHUVKDIW DQG &ORVLQJ &RYHU *HDU (Cont.6) Clutch release removed 26/100/008 Housing cover front. coat with sealant Omnifit FD10-1042 26/100/038 Hex.gear 26/100/056 O-ring..-head screw M10x35 30 Nm 26/100/053 Closing cover 5.-head screw 30 Nm 26/100/032 Cover countershaft. renew coat with silicone-free and noncorrosive grease for installation 26/100/059 Hex. renew 26/100/029 Hex. 1.-Gang Silicon.Repair Gearbox 5HPRYLQJ .-head screws (26/100/059).-gear (26/100/053) with O-ring (26/100/056) ab. Only with gearbox G0210: 1.1 Screw out hex.2 Remove closing cover 5.und säurefreies Fett Omnifit FD10-1042 To remove. Note for installation Coat new O-ring (26/100/56) with silicone-free and non-corrosive grease. Tightening torque: 30 Nm 26/100/056 26/100/053 26/100/059 M+P-07A-1779 Remark: Terms of parts from DaimlerChrysler-EPC-documentation ./6.) Sealants and Lubricants Runddichtringe Gehäusedeckel Vorgelegewellendeckel Verschlußdeckel 5.QVWDOOLQJ )URQW +RXVLQJ &RYHU &RYHU &RXQWHUVKDIW DQG &ORVLQJ &RYHU *HDU (Cont. to install 1./6. Clean sealing surface. Remove O-ring (26/100/014). 2. 26/100/008 26/100/029 M+P-07A-1781 4. Note for installation Install new radial shaft sealing ring (26/100/023) pin drift. Clean sealing surface. Tightening torque: 30 Nm 26/100/023 26/100/014 M+P-07A-1778 Remark: Terms of parts from DaimlerChrysler-EPC-documentation .QVWDOOLQJ )URQW +RXVLQJ &RYHU &RYHU &RXQWHUVKDIW DQG &ORVLQJ &RYHU *HDU (Cont.Repair Gearbox 5HPRYLQJ . thus the sealing lip shows upwards Coat new O-ring (26/100/014) with silicone-free and non-corrosive grease. Remove front housing cover (26/100/008). Coat sealing surfaces of housing cover with sealant Omnifit FD10-1042. Screw out hex. 3. Remove radial shaft sealing ring (26/100/023).-head screw (26/100/029). 5.) Note Do not damage oil spin disk in front housing cover (26/100/008)! Therefore perform working step 2 to 5 only with gearbox in vertical positioned gearbox (drive shaft up). Note for installation Coat sealing surfaces of housing cover with sealant Omnifit FD10-1042.QVWDOOLQJ )URQW +RXVLQJ &RYHU &RYHU &RXQWHUVKDIW DQG &ORVLQJ &RYHU *HDU (Cont.Repair Gearbox 6. Install in reverse sequence.-head screws (26/100/038). Tightening torque: 30 Nm 26/100/032 26/100/038 8. Remove countershaft cover (26/100/032).) Screw out hex. 7. 5HPRYLQJ . M+P-07A-1780 Remark: Terms of parts from DaimlerChrysler-EPC-documentation . Clean sealing surface. renew 26/350/101 Hex. shift Omnifit FD10-1042 26/350/x 26/350/65 M+P-07A-1777 Remark: Terms of parts from DaimlerChrysler-EPC-documentation .-head screw M8x60 16-21 Nm 26/350/080 Bearing cover of reverse gear end stop.-head screw 16-21 Nm 26/350/x Shift.Repair Gearbox Prior jobs • • 5HPRYLQJ . coat with sealant Omnifit FD10-1040 26/350/083 Radial shaft sealing ring. coat with sealant Omnifit FD10-1040 26/350/083 26/350/080 26/350/101 Sealant Cover bearing of reverse gear end stop.QVWDOOLQJ 6KLIW Gearbox selector rod removed Switch for starter lock removed (if available) 26/350/065 Hex. Remove bearing cover reverse gear end stop (26/350/080). Tightening torque: 16-21 Nm 7. Install in reverse sequence. Remove shift (26/350/X). Tightening torque: 16-21 Nm 5. Screw out hex. 4. Remove radial shaft sealing ring (26/350/083). Screw out hex. . Note for installation Knock in new radial shaft sealing ring with suitable pin drift. 3. Coat sealing surface of bearing cover reverse gear end stop with sealant Omnifit FD10-1042.-head screws (26/350/101). 6.Repair Gearbox To remove. 2. to install 1.QVWDOOLQJ 6KLIW (Continue) Switch gearbox in neutral position.-head screws (26/350/65). Note for installation Coat sealing surface of shift with sealant Omnifit FD10-1042. 5HPRYLQJ . -head screw 20 Nm Spring washer Bush Oil sieve Neck 1 2 26/350/071 3 4 5 M+P-07A-1782 Remark: Terms of parts from DaimlerChrysler-EPC-documentation .QVWDOOLQJ %UHDWKHU Engine bonnet removed. if necessary 26/350/071 1 2 3 4 5 Breather complete Hex. if necessary Engine compartment enclosed casing removed.Repair Gearbox Prior jobs • • 5HPRYLQJ . if necessary 26/100/89 Switch reverse gear * 40-52 Nm 26/100/206 Speedometer sensor 32-42 Nm 26/250/47 Switch for starter lock * 26/250/68 Induktive sensor for overspeed protection * 26/400/83 Oil temperature pick-up gearbox * 40Nm 26/250/047 * = option 26/100/206 26/100/089 26/250/068 26/400/083 M+P-07A-1772 Remark: Terms of parts from DaimlerChrysler-EPC-documentation .QVWDOOLQJ 6HQVRU6ZLWFK DW *HDUER[ Engine bonnet removed.Repair Gearbox Prior jobs • • 5HPRYLQJ . if necessary Engine compartment enclosed casing removed. if necessary Engine compartment enclosed casing removed.QGLFDWRU Engine bonnet removed.-head screw.Repair Gearbox Prior jobs • • 5HPRYLQJ. 40 Nm Tappet Cover metal sheet Spacer Neck Sealing rings. renew Compressed-air pressure line Hydraulic pipe Banjo bolt Closing cover Banjo bolt 25/250/113 38 39 45 40 41 25/250/068 35 25/250/110 M+P-07A-1798 42 44 40 43 Remark: Terms of parts from DaimlerChrysler-EPC-documentation .QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU . if necessary 25/250/068 25/250/113 35 25/250/110 38 39 40 41 42 43 44 45 Clutch servo Hex. 5HPRYLQJ. 42 41 M+P-07A-1799 2.QGLFDWRU (Continue) Remove compressed-air pressure line (41) and hydraulic pipe (42) from clutch servo. Screw out hex. 25/250/068 25/250/113 M+P-07A-1800 Remark: Terms of parts from DaimlerChrysler-EPC-documentation .Repair Gearbox To remove 1.QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU .-head screws (25/250/113) and remove clutch servo (25/250/068) with the cover metal sheet (25/250/110). M+P-07A-1801 2. Snap in by hand the clutch release bearing. with the help of the clutch release fork (arrow). 3.-head screws (25/250/113) tight. Align clutch servo (25/250/068) with cover metal sheet (25/250/110) at clutch dome.Repair Gearbox To install 5HPRYLQJ. Screw the hex. 25/250/068 25/250/113 M+P-07A-1800 Remark: Terms of parts from DaimlerChrysler-EPC-documentation .QGLFDWRU (Continue) 1.QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU . Tightening torque: 40 Nm. through the opening of the clutch housing into the stress ring of the clutch. 5HPRYLQJ.QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU .-head nut (52). banjo bolt (45) and closing cover (44) to clutch servo (37).4 Fit cover cap (54). 42 44 45 39 43 40 25/250/71 38 6.3 Screw in wear indicator (53) as far as the indicator (51) is flush with the wear indicator (arrow). Install hydraulic pipe (42) with spacer (38). Bleed hydraulically clutch actuation.QGLFDWRU (Continue) Install compressed-air pressure line (41) with banjo bvolt (43) and new sealing ring (40) to clutch servo (25/250/71). 7. 41 M+P-07A-1803 Remark: Terms of parts from DaimlerChrysler-EPC-documentation Adjust mechanical wear indicator: 7.2 Release hex. 52 53 54 M+P-07A-1804 . neck (39). 51 7.1 Pull cover cap (54) off. 5.Repair Gearbox 4. 7. 51 M+P-07A-1805 8.2 Check wear of clutch disk.Repair Gearbox 8.3 Fit cover cap (54).1 Pull cover cap (54) off. 54 8. Wear control: 5HPRYLQJ.QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU . . Note The clutch disk is wear out.QGLFDWRU (Continue) 8. if the back edge of the indicator (51) is flush with the back edge of the wear indicator (arrow). -head nut. renew coat with silicone-free and noncorrosive grease for installation 26/100/197 Anti-fatigue screw.Repair Gearbox Prior jobs • • 5HPRYLQJ . renew 450 Nm 26/100/200 O-ring. renew coat with silicone-free and noncorrosive grease for installation 31 Hex.QVWDOOLQJ 2XWSXW )ODQJH 5HQHZLQJ 5DGLDO 6KDIW 6HDOLQJ 5LQJ 31 26/100/197 32 26/100/200 26/100/194 26/100/203 26/860/017 26/860/014 Engine bonnet removed. if necessary 26/860/014 Radial shaft sealing ring. if necessary Engine compartment enclosed casing removed. renew coat with silicone-free and noncorrosive grease for installation 26/100/203 O-ring. renew 26/860/017 Radial shaft sealing ring. renew 26/100/194 O-ring. renew 32 Propeller shaft Lubricants O-ring Silicone-free and non-corrosive grease Remark: Terms of parts from DaimlerChrysler-EPC-documentation M+P-07A-1797 . Remove propeller shaft from output flange. Install in reverse sequence. (26/100/200) and 100/203). Note for installation Coat new O-rings (26/100/200 und 26/100/203) with silicone-free and non-corrosive grease and use new anti-fatigue screw. to install 5HPRYLQJ . 3. Tightening torque: 396 .484 Nm. Screw out anti-fatigue screw (26/100/197) and remove O-rings (26/100/194). Note for installation Install new radial shaft sealing rings (26/860/014 and 26/860/017) with suitable pin drift. 5. 2.-head nut (31). Tightening torque according to vehicle manufacturer instructions.Repair Gearbox To remove. 4. Remove radial shaft sealing rings (26/860/014 and 26/860/017). Note for installation Use new self-locking hex. .QVWDOOLQJ 2XWSXW )ODQJH 5HQHZLQJ 5DGLDO 6KDIW 6HDOLQJ 5LQJ (Continue) 1. Pull off output flange. 9...........3/1 Removing................................3 9.9.....6/1 B Bottom Oil Tank Cover ........ Installing Oil Tank Cover ............ Checking and Installing Heat Exchanger .........4 9........................................................2/1 Removing..5/1 Removing.......9...............4/1 Removing............5 9.Repair Retarder 9........................................................................................................9..........................6/1 A Top Oil Tank Cover .................6/2 ..........9.........................1/1 Removing.............................. Installing Water Neck ..1 9................................. Cleaning and Installing Silencer. Checking and Installing Casing Ventilation ..........................9........2 9..9....6 5HSDLU 5HWDUGHU Overall Illustration of Main Components ..........9. 12 Outer race Top cover Casing ventilation Bgr. 12 Temperature pick-up 5300 5400 5500 5600 6100 6101 6400 6600 6700 7200 7300 7400 7500 7600 7800 8000 9000 20000 20200 20300 25000 Sealing ring A14x20 Corrugated spring Disc (silencer) D30x4 Circlip Pipe O-ring 15. 6 Shim (selection row) .-head screw with flange M14x40 Washer Throttle disc 39/15x3 O-ring 15x4 O-ring 40x2 O-ring 45x5 O-ring 25x4 O-ring 34x3 Intermediate plate 196x144x2 Pressure sensor 0-4 bar Water neck Combined hex.a.-head.5. 17 Screw plug M24x1. 12 Screw plug M24x1.a.f.-head.f.5. w.5.f. w. w. 13 Screw plug with sieve.-head nut M8 Screw plug M30x1.4 Heat exchanger Hex. 13 Hex. w.f. Inhex. 19 alternative: hex.-head screw M8x20. Inhex. w. w.-head screw M14x40. Inhex.3x2.a. Gasket Combined hex. w.-head screw M8x30.-head.-head screw M8x30.5.a.-head screw M8x80.-head.-head.f.a.a.a.f. Inhex. Inhex.f.a.Repair Retarder 2YHUDOO . w.f. 13 Combined hex. w.OOXVWUDWLRQ RI 0DLQ &RPSRQHQWV Illustration main components R 115 E 6101 3300 6100 6101 9000 3850 3850 3800 3900 8000 6600 6700 3700 2900 2300 4000 5400 5500 5600 7500 109 850 6400 7300 5200 5300 7500 2600 2500/1 3100 4200 4200 107 4100 6700 6600 20300 M+P-07A-1504b 4100 3100 2000/1 3300 2800/1 25000 2301 7600 20100 20000 20300 20200 20300 5200 5300 6700 6600 20000 20200 103 3500 7300 20100 103 107 109 850 2000/1 2300 2301 2500/1 2600 2800/1 2900 3100 3300 3500 3700 3800 3850 3900 4000 4100 4200 5200 Screw plug M12x1.-head screw M14x1. 6 Screw plug M24x1.f.a. w.5.a.5.-head. Inhex. M30x1.a. D30x38. w. die casting O-ring 55x3 Bottom cover Bottom gasket Cover casing ventilation Bgr.f.a. w.f. 13 Hex.f. 17 Proportional valve Damping plate O-ring 16x3 Combined hex.5. 1) Caution! Risk of injury! The retarder housing is hot! .Repair Retarder Illustration casing ventilation 5HPRYLQJ &KHFNLQJ DQG .QVWDOOLQJ &DVLQJ 9HQWLODWLRQ Note This step can be performed with the retarder removed or installed. Prior jobs • • • Ignition OFF Retarder OFF Proportional valve and damping plate removed (chapter 10. 2x2. renew coat with silicone-free and noncorrosive grease for installation 3300 6101 2800/1 6101 2900 2300/1 2300 2301 2300/2 2300/3 6100 Lubricants and sealing agents O-ring Float silicone-free and non-corrosive grease Methylated Spirit M+P-07A-1505 .4. renew Hex.-head screw M8x80 Hex. coat with silicone-free and noncorrosive grease for installation Cover casing ventilation Gasket casing ventilation.-head. renew. w.f.Repair Retarder 2300 2300/1 2300/2 2300/3 2301 5HPRYLQJ &KHFNLQJ DQG . 25 Nm Pipe O-ring 15.a.QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue) 2800/1 2900 3300 6100 6101 Casing ventilation D30x38 Valve insert Float specified weight 11g ± 1 g Float cage O-ring 55x3. 13 renew. 085 kg Note The test ring can also be ordered from Voith Turbo .Repair Retarder Special tools 5HPRYLQJ &KHFNLQJ DQG .5 mm 60 mm 7 mm M+P-07A-1758 a 53.10 Material: St 37 Weight 0.9428.7712.QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue) Tool for local fabrication 40. .10 53.2757.10.Voith code number 67. Remove cover (2800/1) with gasket (2900) from retarder housing.Repair Retarder 5HPRYLQJ &KHFNLQJ DQG . 2800/1 2900 M+P-07A-1507 .-head screws (3300). Screw out hex.QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue) To remove 1. 3300 M+P-07A-1506 2. Clean sealing surface. QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue) 6101 6100 6101 3. M+P-07A-1508 4.Repair Retarder 5HPRYLQJ &KHFNLQJ DQG .7712. Use the impact tool (99/5) and adapter (98/9) to extract the valve insert of the retarder housing (1).10 . Remove pipe (6100) and O-rings (6101). 99/5 1 98/9 M+P-07A-1509 99/5 Impact tool 53. Lever O-ring (2301) out of the groove of valve isert (2300/1) and pull it off. Take float (2300/2) and float cage (2300/3) out of the retarder housing (1).Repair Retarder 5HPRYLQJ &KHFNLQJ DQG . 2300/3 M+P-07A-1510 6. 2300/1 2301 M+P-07A-1020 .QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue) 2300/2 1 5. If necessary. Check sealing edge of shaft sealing ring (arrow) in the valve insert (2300/1). Specified weight 11 g ± 1 g. If the weight is more than the specified weight renew complete casing ventilation. the retarder is impaired in its operation. 99/7 2300/2 2300/1 M+P-07A-1730 . Weight the float (2300/2). If the sealing edge is not damaged. 2. renew the complete casing ventilation. 2300/2 2300/2 Note Oil has penetrated into the float.Repair Retarder To check 5HPRYLQJ &KHFNLQJ DQG . the fluid level must not alter in the course of 1 minute. Check the float (2300/2) for damages to the surface and sealing surface (arrow). FD194 FD194 3. Put down the valve insert (2300/1) on the float (2300/2) than weigh down the valve insert with the test ring (99/7).QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue) 1. Fill up the hollow space between float and upper edge of valve insert with methylated spirit. 2000 6100 M+P-07A-1511 . Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on to the valve insert (2300/1). 2. 3.Repair Retarder To install 5HPRYLQJ &KHFNLQJ DQG . Use the impact puller (99/5) and adapter (98/9) to knock in the casing ventilation (2300). Insert the float (2300/2) and float cage (2300/3) into the valve seat.QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue) 1.9428.10 98/9 Adapter 53.10 5. Insert the casing ventilation into the retarder housing. Put pipe (6100) with new O-rings in cover (2000). 99/5 1 98/9 M+P-07A-1509 99/5 Impact tool 53. 4.7712. Tightening torque hex.-head screws: 25 Nm. 6100 3300 2800/1 M+P-07A-1512 .QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue) Place cover (2800/1) with new gasket into air-pipe (6100) on the retarder housing and screw the hex.Repair Retarder 6.-head screws (3300) tight. 5HPRYLQJ &KHFNLQJ DQG . 5400 5500 5600 5400 5500 5600 Corrugated spring Disc (Silencer) D30x4.2 konvex side must face the silencer Cleaning agents Silencer Benzine M+P-07A-1456 .QVWDOOLQJ 6LOHQFHU Note This step can be performed with the retarder removed or in situ. clean with suitable cleaning agent (Benzine) and blast out with compressed-air Circlip JL30x1.Repair Retarder Illustration Silencer 5HPRYLQJ &OHDQLQJ DQG . w.-head screw M14x1.-head screw M8x80 Hex.Repair Retarder Prior jobs • • • Ignition OFF Retarder OFF Cooling-water drained 5HPRYLQJ DQG .f.QVWDOOLQJ :DWHU 1HFN 20000 20100 20200 20300 Water neck Gasket. 6 28 Nm 20100 20000 20200 20100 20000 20200 M+P-07A-1568 .a.5 Inhex head. 13 28 Nm Hex.-head.f. renew Hex. w.a. a.f. 12. w. w.a.a.-head.f.1) With retarder installed: • Proportional valve and damping plate removed (see chapter 10.-head. renew coat with silicone-free and non-corrosive grease for installation O-ring 45x5. Prior jobs • • Ignition OFF Retarder removed (see chapter 7. renew 6700 7300 7500 7600 Washer. renew Initial torque: 35 Nm Final turn: 30° turn alternative: hex. 65 Nm (80 Nm) Oil-drain plug oil tank M24x1. 65 Nm (80 Nm) Heat exchanger Hex. 19. 19.5.QVWDOOLQJ +HDW ([FKDQJHU 6700 7500 6600 7300 7600 6400 7500 7300 4200 107 M+P-07A-1513 6700 6600 4200 Note The heat exchanger can also be removed with installed retarder.Repair Retarder Illustration heat exchanger 5HPRYLQJ &KHFNLQJ DQG . renew coat with silicone-free and non-corrosive grease for installation Lubricant O-ring Silicone-free and non-corrosive grease . w. renew O-ring 15x4. Inhex.4) 107 4200 6400 6600 Oil-drain plug retarder M24x1.4) • Cooling-water drained • Water neck removed (see chapter 9.5.a.1) • Oil drained from retarder (see chapter 3.-head screw M14x40 with flange. renew coat with silicone-free and non-corrosive grease for installation O-ring 25x4. 12.f.f.-head screw M14x40. Inhex. w. The copper-sealing rings are generally to be renew. The integrated sealing rings must be checked for possible damages during the installation of the heat exchanger. the tightening torques in brackets are valid. these corresponds the standard version at the time going to print.QVWDOOLQJ +HDW ([FKDQJHU (Continue) Caution! Two versions of screw plugs (107. . replace complete screw plug if necessary. 4200) are possible: A) Version with integrated FPM-sealing ring.Repair Retarder 5HPRYLQJ &KHFNLQJ DQG . 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. B) Version with loose inserted copper-sealing ring. Repair Retarder Special tool 5HPRYLQJ &KHFNLQJ DQG .QVWDOOLQJ +HDW ([FKDQJHU (Continue) 67. Messrs Richard Abr. Herder Post box 10 08 67 D-42659 Solingen Tel.g.1948. 0212/ 888-0 Ordering No.10 Pressure-test equipment Commercially available tool Turning angle measuring tool 3/4“ e. 8200-02 . QVWDOOLQJ +HDW ([FKDQJHU (Continue) Note If this job sequence is performed with the retarder in situ. Screw out oil-drain plugs (107 and 4200) as well as the oil filler plug (for quicker drain) and drain oil. 107 4200 4200 M+P-07A-1489 . Pull cooling-water hoses off the heat exchanger. 2.Repair Retarder 5HPRYLQJ &KHFNLQJ DQG . the following prior jobs must be performed: 1. 6400 6600 6600 6600 3.QVWDOOLQJ +HDW ([FKDQJHU (Continue) To remove 1. 2. M+P-07A-1514 7500 7300 7300 7600 7500 7300 M+P-07A-1515 . Remove O-rings (7300. Remove heat exchanger (6400).-head screws (6600).Repair Retarder 5HPRYLQJ &KHFNLQJ DQG . 7500 and 7600). Screw out the four hex. QVWDOOLQJ +HDW ([FKDQJHU (Continue) 99/6 6400 1. the heat exchanger must be renewed. the heat exchanger leaks and must be renewed. 99/6 6400 Note If air bubbles form in the hot water. Fill heat exchanger (6400) on water side with hot water (approx.10 .1498. 10 bar overpressure (oil section of the heat exchanger). 10 bar overpressure (oil section of the heat exchanger). 2. 3. New heat exchanger are wetted with corrosion-inhibiting oil in the water. Slowly pressurize the heat exchanger (6400) from 0 to max. Note M+P-07A-1580 If air bubbles form in the hot water or has outer leaks. 99/6 Pressure-test equipment 67.Repair Retarder To check 5HPRYLQJ &KHFNLQJ DQG .10 4.and oil section of the heat exchanger.1948. 5. Connect compressed-air line to top connection (arrow). Prior to installing a new heat exchanger. drain any corrosion-inhibiting oil which may have collected and flush it out with hot water in the water section of the heat exchanger. Fit pressure-test equipment (99/6) together with O-rings to heat exchanger (6400) and connect compressed-air line to bottom connection (arrow). Slowly pressurize the heat exchanger (6400) from 0 to max. M+P-07A-1581 99/6 Pressure-test equipment 67. 70 oC). Align heat exchanger (6400) with retarder housing and screw the hex. 2. 7500 and 7600) in the bores.QVWDOOLQJ +HDW ([FKDQJHU (Continue) 7600 7500 1.-head screws (6600) tight. Initial torque: 35 Nm Final turn: 30° turn 7300 7300 7500 7300 M+P-07A-1516 6600 2400 6600 6600 6600 M+P-07A-1517 .Repair Retarder Einbauen 5HPRYLQJ &KHFNLQJ DQG . Fit new O-rings (7300. Repair Retarder 5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU (Continue) 3. Install the retarder, if necessary (see chapter 7: „Removing, Installing Retarder“). 4. If available, open the check valves in the flow and return pipe of the cooling-water section. Fill in cooling-water and bleed cooling-water circuit. Caution! 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: 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. Check sealing rings of oil-drain plugs for possible damages; renew oil-drain plug if necessary. 107 4200 4200 M+P-07A-1489 Repair Retarder - 5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU (Continue) Screw oil-drain plug tight Tightening torque oil-drain plug (107, 4200): 65 Nm (80) Fill in retarder oil (chapter 3.5) - 6. If heat exchanger had been leaking, deoil cooling- and heating system of vehicle according to the vehicle manufacturer instructions. Repair Retarder A Top oil tank cover Prior jobs • • Ignition OFF Retarder OFF 5HPRYLQJ DQG ,QVWDOOLQJ 2LO 7DQN &RYHU 6101 6100 6101 3300 9000 Note 3100 This job sequence can also be performed with the retarder installed. 2000/1 Caution! Risk of injury! The retarder housing is hot! 2000/1 3100 Top cover Hex.-head screw M8x30 Hex.-head, w.a.f. 13 renew, 25 Nm Hex.-head screw M8x80 Hex.-head, w.a.f. 13 renew, 25 Nm Pipe O-ring 15,2x2,4, renew coat with silicone-free and noncorrosive grease for installation Intermediate plate Pressure sensor 8000 3300 6100 6101 M+P-07A-1518 8000 9000 -head. heed tightening sequence! 25 Nm Oil drain plug oil tank M24x1.-head screw M8x30 Hex. w. w. 12 65 Nm (80 Nm) 4200 2600 2500/1 3100 4200 M+P-07A-1519 .4) 2500/1 2600 3100 Bottom cover Bottom gasket.f.a.f.QVWDOOLQJ 2LO 7DQN &RYHU (Continue) Ignition OFF Retarder OFF Retarder oil drained (see chapter 3. 13 renew. renew Hex.-head.5 Inhex.Repair Retarder Illustration oil tank cover B Bottom oil tank cover Prior jobs • • • 5HPRYLQJ DQG .a. Repair Retarder 5HPRYLQJ DQG . replace complete screw plug if necessary. .QVWDOOLQJ 2LO 7DQN &RYHU (Continue) Caution! 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. In this Aftersales Service Manual is excluding the variant A (series version) described. the tightening torques in brackets are valid. B) Version with loose inserted copper-sealing ring. The copper-sealing rings are generally to be renew. If screw plugs with loose inserted copper-sealing rings (variant B) are used. The integrated sealing ring must be checked during for possible damages during the installation of the oil tank cover. QVWDOOLQJ 2LO 7DQN &RYHU (Continue) Heed the mounting position of the gasket and the cover. 4 17 16 15 6 5 3 2 1 7 8 9 10 11 14 13 M+P-07A-1368 12 . Tighten all hex.19 Nm torque.Repair Retarder Note for installation 5HPRYLQJ DQG .-head screws in defined sequence from 1 to 17 initially with 14 . Then tighten in the same sequence with 25 Nm torque. ...2 10............4 &RQWURO 3DUWV 5HWDUGHU Removing......................1 Removing...... Installing Cooling-Water Temperatur Pick-Up................10.Control Parts Retarder 10.........................................3 Removing......10.....10........................4 .....10.. Installing Oil Temperature Pick-Up ............... Installing Pressure Sensor .......3 10..1 10.......... Installing Proportional Valve..2 Removing.. -head nuts (4000) or the hex. .-head screws (3900) have to be unscrewed the antivibration plate also has to be checked on mechanical and aging damages and to be renewed.-head.f.a.QVWDOOLQJ 3URSRUWLRQDO 9DOYH Removing. 18 Nm Caution! If. if necessary. renew.Control Parts Retarder Illustration proportional valve 5HPRYLQJ .-head screw M8x20 Hex. 30 Nm Hex. renew if necessary O-ring 16x3.-head nut M8. renew Hex. w. installing proportional valve Prior jobs • • • • Ignition OFF Retarder OFF Supply-air discharged Plug at proportional valve and socket checked for damages as well as wear (notch scratches) 3850 3800 3850 3900 4000 39 3900 3700 26 4000 26 39 3700 3800 3850 3900 4000 Constant-air pressure line pv Electrical lead Proportional valve Damping plate. 13 renew. during repair work the hex. 28 Nm Sealing ring A14x20.QVWDOOLQJ &RROLQJ:DWHU 7HPSHUDWXUH 3LFN8S Removing. renew 5200 5300 Caution! Risk of injury! The coolant is hot! Note Please.Control Parts Retarder 5HPRYLQJ DQG . bear in mind to the instructions regarding the quality of coolant given from the vehicle manufacturer or Voith Turbo. installing cooling-water temperature pick-up Prior jobs • • • Ignition OFF Retarder OFF Cooling-water drained 5200 5300 Cooling-water temperature pick-up. M+P-07A-1569 . Control Parts Retarder Prior jobs • • Ignition OFF Retarder OFF 5HPRYLQJ DQG . renew 5300 5200 32 M+P-07A-1495 . 28 Nm Sealing ring A14x20.QVWDOOLQJ 2LO 7HPSHUDWXUH 3LFN8S 32 5200 5300 Electrical lead Oil temperature pick-up. QVWDOOLQJ 3UHVVXUH 6HQVRU 9000 9000 Pressure sensor. 30 Nm M+P-07A-1496 .Control Parts Retarder Prior jobs • • Ignition OFF Retarder OFF 5HPRYLQJ DQG . Cooling Water Quality Spare Parts Lists Other Information .Oil Specifications Retarder .Oil Specifications Gearbox .Gearbox / Retarder Operating Specifications: .Annex $QQH[ Data Sheet: Conversion Tables . 53 .17 6.80 8. input torque [Nm] (Standard value depending on respective use) GO190-6 – R 115 E GO210-6 – R 115 E 320 1750 1900 2100 Ratio range / expanded scale 8.Annex 'DWD 6KHHW GO170-6 – R 115 E Gearbox input power up to [kW] max.00 8.17 .0.16 Braking torque up to [Nm] / Braking power up to [kW] Permissible vehicle cross weight [t] 3750 / 700 W W .1. 443 1.528 3.000 7.000 7.650 2.170 4.711 2.170 4.683 GO210-6 – R 115 E 6.136 . gear 4. gear 6.Annex 'DWD 6KHHW (Continue) Ratio 1.000 0.650 2.250 1.790 1.810 1.683 GO190-6 – R 115 E 8. gear 5.250 1. gear 2.790 1. gear Reverse-gear GO170-6 – R 115 E 8.231 1. gear 3.810 1.799 6. 3 lbf-ft 14 lbf-ft 14.5 lbf-ft 27.6 °F -49 °F 50 oF 68 oF 140 oF 176 oF 203 oF 221 oF 257 oF 329 °F 365 oF 437 oF 9.7 lbf-ft 18 lbf-ft 19.4 lbf-ft 24.6 lbf-ft 13.3 lbf-ft 28 lbf-ft 29.4 lbf-ft 31.9 lbf-ft USA 12.1 lbf-ft 9.6 °F -49 °F 50 oF 68 oF 140 oF 176 oF 203 oF 221 oF 257 oF 329 °F 365 oF 437 oF 9.2 lbf-ft D 18 Nm 19 Nm 20 Nm 21 Nm 25 Nm 28 Nm 30 Nm 32 Nm 35 Nm 39 Nm 40 Nm 42 Nm 45 Nm 46 Nm 47 Nm GB 12.4 lbf-ft 24.5 lbf-ft 27.4 lbf-ft 31.8 lbf-ft 11.6 lbf-ft 21 lbf-ft 22.6 lbf-ft 13.9 lbf-ft .2 lbf-ft USA -34.5 lbf-ft 32.7 lbf-ft 18 lbf-ft 19.5 lbf-ft 32.2 lbf-ft 32.1 lbf-ft 9.34.6 lbf-ft 21 lbf-ft 22.Annex &RQYHUVLRQ 7DEOHV D -37 °C -45 °C 10 oC 20 oC 60 oC 80 oC 95 oC 105 oC 125 oC 165 °C 185 oC 225 oC 13 Nm 14 Nm 16 Nm GB .3 lbf-ft 14 lbf-ft 14.3 lbf-ft 28 lbf-ft 29.2 lbf-ft 32.8 lbf-ft 11. 225 lbf-ft 1.50 bar 2.78 psi 58 psi 87 psi 116 psi 159.5 psi 362.5 psi 275.25 psi 39.5 psi 333.5 psi 333.95 bar 4 bar 6 bar 8 bar 11 bar 17 bar 19 bar 23 bar 25 bar GB 1.330 lbf-ft USA 36.5 lbf-ft 40.4 lbf-ft 38.4 lbf-ft 38.6 lbf-ft 42 lbf-ft 45.30 bar 2.88 psi 42.5 lbf-ft 147 lbf-ft 315 lbf-ft 1.78 psi 58 psi 87 psi 116 psi 159.45 psi 33.225 lbf-ft 1.5 psi 246.5 psi 362.5 psi 246.5 psi 275.5 lbf-ft 56 lbf-ft 70 lbf-ft 105 lbf-ft 115.45 psi 33.6 lbf-ft 42 lbf-ft 45.5 lbf-ft 147 lbf-ft 315 lbf-ft 1.35 psi 36.5 psi USA 1.470 lbf-ft 2.330 lbf-ft D 2100 Nm 3750 Nm 2.5 lbf-ft 40.88 psi 42.5 lbf-ft 126 lbf-ft 136.75 bar 2.10 bar 2.25 psi 39.470 lbf-ft 2.5 psi .Annex &RQYHUVLRQ 7DEOHV (Continue) D 52 Nm 55 Nm 58 Nm 60 Nm 65 Nm 80 Nm 100 Nm 150 Nm 165 Nm 180 Nm 195 Nm 210 Nm 450 Nm 1750 Nm 1900 Nm GB 36.5 lbf-ft 56 lbf-ft 70 lbf-ft 105 lbf-ft 115.625 lbf-ft 30.5 lbf-ft 126 lbf-ft 136.35 psi 36.625 lbf-ft 30. 02 mm 0.889 miles 111.28 mm 0.8 litre 12.2524 inch 0.4 grains 169.889 miles 111.54 gal 1.86 mm 131.4 grains 15.852 miles 186.06 gal 3.420 miles USA 31.000 km 300.000 km 60.000 km GB 31.4 grains 180.30 gal 3.070 miles 37.75 gal 2.852 miles 186.0112 inch 0.Annex &RQYHUVLRQ 7DEOHV (Continue) D 7 litre 7.4 grains 169.43 gal D 50.070 miles 37.5 litre 13 litre GB 1.72 gal 2.0048 inch 0.0048 inch 0.000 km 100.86 gal USA 1.140 miles 83.0008 inch 0.420 miles 1g 11 g 15.85 gal 2.284 miles 55.926 miles 62.0008 inch 0.926 miles 62.000 km 135.12 mm 0.31 mm 0.140 miles 83.0344 inch 5.0112 inch 0.000 km 90.0344 inch 5.000 km 195 Kg 430 pounds 430 pounds 50 Km/h 31 miles/h 31 miles/h 0.284 miles 55.2524 inch . Rom/Italien Elf Lubrifiants. London/England BP Oil International. London/England Calpam Mineralöl-Gesellschaft. 80W. Bern/Schweiz Agip Schmiertechnik. Lanester Cedex/ Frankreich Shell Aseal. Krumpa Agip Petroli. Bochum Armorine.Annex 2SHUDWLQJ 6SHFLILFDWLRQV Operating specification Mineral oil for use in gearbox: SAE 80. 80W/85W Type of oil Addinol Gear Oil GS Agip Rotra Hy DB Antar EP Aral-Gear Oil EP Armorine BM Aseol Gepress 11-508 Autol Gear Oil D8 Avia Gear Oil MZ Aviaricon Gold MZ Caution! Risk of poisoning! Fuels are harmful to health! If a fuel was swallowed. London/England BP Oil International. Würzburg Avia Mineralöl. München Emil Finke Mineralölwerk. visit immediately a doctor! Keep fuels away of children! Supplier Addinol Mineralöl. Paris/Frankreich Aral Lubricants. Aschaffenburg . Bremen BayWa Multi Purpose Gear BayWa. München Oil BP Energear EP BP Energear FE GL4 BP Gear Oil EP Calpam Multi Purpose Gear Oil BP Oil International. Kapstadt/Südafrika Ertoil. Hamburg Fina Pontonic N Frontol Gear Oil MZ M Fuchs Titan Gear MP Galp Transoil Geartex EP-A Gulf Gear Lubricant (EP) Gulf Ultragear 4000 (GB) H.. Lissabon/Portugal Texaco Services (Europe). Petrogal. Köln Zeller+Gmelin. Seoul/Rep.o. Swindon/England Condat. Wuppertal Hyperol Mineralöl-Vertrieb. Stuttgart Igol France. Köln Supplier Caltez (UK) Limited. Paris/Frankreich J. Chasse-sur Rhône/Frankreich Repso Distribución. Homberg. Eislingen Ssang Yong Oil Refining.B. Brüssel/Belgien BP Schmierstoff.Gear Oil ML Hafa MPB Homberg Gear Oil MZ Hyperol Multi Purpose Gear Oil Igol Trans EPA Ina Transmol DB IP Pontiax DB Kompressol Multi Purpose Gear Oil . Hamburg Fuchs Mineralölwerke. Hamburg DEA Mineralöl. & A. Kornárom/Ungarn Castrol. Madrid/Spanien Esso. 80W. Duisburg Engen Petroleum. Brüssel/Belgien SAEL. Cheltenham/ England H. Köln Hafa. Paris/Frankreich INA Rafinerija Zagreb. Madrid/ Spanien DEA Mineralöl. Mannheim Petroleos de Portugal.. Zagreb/Kroatien Italiana Petroli.. Korea Eller-Montan-Comp. Burrenkopf. Hamburg Klöckner Energiehandel. 80W/85W Type of oil Type of oil Caltez Universal Gear Oil HD Carrier Hykomol Castrol EP Condat Gear A CS 80 M-EP Deagear EP-A Dearon EP-A Deutz Öl GO-MP Divinal Multi Purpose Gear Oil Dragon Gear TM Ellmo-Multi Purpose Gear Oil Engen Gearlube HP Ertoil Transmissiones F Esso Gear Oil GP-D Supplier Fina Europe. Genua/Italien Kompressol-Öl. o. Madrid/Spanien Gulf Oil (GB).B. London/England MOL Hungarian Oil and Gas Co.Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Mineral oil for use in gearbox: SAE 80. . Athen/Griechenland Pennasol Multi Purpose Gear Oil GL4 Petrol Transol GL4 Petramin Gear Oil MB Q8 T 35 Raloy Transmission EP Rexol MBG Rored EPA Selectol Multi Purpose Gear Oil Shell Spirax MA Sonolgear DBM Spirol XEP Tor Multi Purpose Gear Oil Total EP . O. München Orly International. Ljubljana/Slowenien Petramin Lubricating Oil. d. Santiago Tianguistenco/Mexico Ryazan Oil Refinery. Herford Deutsche Shell. Saarlouis MHG. Vieux-Thann/Frankreich Petrol Ofisi. Haifa/Israel Bharat Petroleum Carpn. Düsseldorf Supplier Leprince & Siveke. Keban EP MB Panolin EP Gear GL4 Parnas Parnalube GP Supplier Mineralöl-Raffinerie Dollbergen Petrol d. Bombay/Indien De Oliebron. Sulzbach-Rosenberg Mobil Schmierstoff. Espoo/Finnland Oest Mineralölwerke. Langenthal/Schweiz Neste Oy Lubrication. Freudenstadt OMV. Hoogvliet RT/Niederlande Raloy Lubricantes. Wien/Österreich Optimol Ölwerke Industrie GmbH.. Jakarta/Indonesien Käppler. Bakanlikar-Ankara/Türkei Panolin. Stuttgart Shell International. Madetswill/Schweiz Parnas/Saksan. Hamburg Bucher.Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Mineral oil for use in gearbox: SAE 80. Zwijndrecht/Niederlande Total Deutschland. London/ England Sonol Israel. 80W. Ryazan/Rußland Pertamina. Hamburg Meguin. 80W/85W Type of oil Type of oil Leprinzol SP Mac MP-Gear Oil megol Multi Purpose Gear Oil GL4 MHG-Manual-Gear Oil EP Mobilube GX-A Motorex Gear Oil EP Neste Gear EP Oest Multi Purpose Gear Oil OMV Gear Oil MP Optimol Multi Purpose Gear Oil Orly XP Luna P. Jeddah/Saudi-Arabien Kuwait Petroleum. 80W. Bremen WLZ-Raiffeisen.Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Mineral oil for use in gearbox: SAE 80. Münster Wisura Mineralölwerk. Gelsenkirchen Veedol International. 80W/85W Type of oil Tranself EP Triathlon Gear Unil EP Unil Opal Gear EP Valvoline X-18 Veba Movara EP-Gear Oil Veedol Multigear Westfalen Grado Gear Oil Wintershall Wiolin Multi Purpose Gear Oil Westfalen Grado Gear Oil Wisura GL WLZ-Raiffeisen Multi Purpose Gear Oil Type of oil Supplier York 791 Zenex Gear Oil ZP Supplier Ginouves Georges La Farlède/Frankreich Zenex Oil. Rueil-Malmaison/ Frankreich Valvoline International Europe. Rivonia/Südafrika Elf Lubrifiants.11 Manual Gear Oil DaimlerChrysler AG. Künzelsau Unil Deutschland. Stuttgart Synthetic oil for use in gearbox: Type of oil Supplier MB 235. Bremen Unil-Opal. Stuttgart A 001 989 2803 Veedol Synmesh-AT Castrol Syntrans-AT Deagear Synth Burmah Oil Technology Burmah Oil Technology DEA Mineralöl GmbH . Münster Schmierstoffraffinerie Salzbergen Westfalen AG. Swindon/England Westfalen AG. Paris/Frankreich Würth. Dardrecht/Niederlande Veba Öl. Here is only allowed to use the synthetic oil documented on page 11/13.CC/SF and higher HC Synthetic oil 2) HC see page 11/13 1) The statements of the vehicle-manufacturer are valid respecting the choice of oil types. the oils documented on the following pages are to be used.Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) The type of oil admitted for the retarder operation must meet the following specifications: Classification group Identification letters to DIN 51502 Single-grademineral oil 1) Synthetic oil/ part-synthetic oil 1) HD Viskosity class to DIN 51511 SAE 10W SAE 20W 20 SAE 30 SAE 0W40 SAE 5W30 SAE 5W40 SAE 5W50 SAE10W30 SAE10W40 SAE 75W-80W Performance class API . If no statements are available. 2) .CC/SF and higher API . 30 Type of oil Type of oil Agip Diesel Sigma S Agip Engine oil HD Aral Basic Turboral Avia Special HDC Avia Engine Oil HD BP Vanellus C3 Castrol CRD-DB DEA Cronus Super DEA Rigis Elf Performance XC Elf Performance XR Elf Performance 3D Elf Performance Super D Essolube X 301 Essolube X 201 Agip Agip Aral Avia Avia BP Burmah Oil DEA DEA Elf Elf Elf Elf Esso Esso Supplier Fina Fina Krafft Mobil Oil Motorex Motorex Multimiles Repsol Repsol Supplier Fina Kappa Super Fina Kappa TC SAE 30 Serie III Mobil Delvac 1300-Serie Extra Cobra Multimiles R/5 mono Repsol Serie 3 SAE 10W Repsol Serie 3 SAE 30 CS Mizar Serie 3 SAE 10W Repsol CS Mizar Serie 3 SAE30 CS Mizar HD SAE 20W Repsol Repsol Shell Rimula X Monograde Shell Shell Rotella MX Glap Diesel Glap Orion Wintershall Rekord 10W Shell Sofomil Sofomil SRS .Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Mineral oil for use in retarder: SAE 10W. 20W 20. 30 Type of oil Wintershall Rekord 20W-20 SRS Wintershall Rekord 30 Havoline Motor Oil Ursa Super LA Total rubia S Unocal Firebird HD Motor Oil SRS Texaco Texaco Total Unocal Supplier Type of oil Agip Diesel Sigma TFE Agip Sigma Super TFE Agip Sigma Ultra TFE Amsoil 10W30 Antar Maxolia 10W40 Aral Extra Turboral SAE 10W40 Aral High Turboral SAE 10W40 Aral Super Turboral SAE 5W30 Aral Mega Turboral SAE 10W40 Avia Synth 5W40 Avia Multi CFE 10W40 Agip Agip Agip Amsoil Antar Aral Aral Aral Aral Avia Avia Supplier Avia Multi CFE Plus 10W40 Avia Avia Turbosynth CFE 10W40 Avia Turbosynth HT-E 10W40 BP Vanellus FE 10W40 Avia Avia BP Oil . 10W40 Mineral oil for use in retarder: SAE 10W.Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Synth. 5W40. 5W50./part-synth. oil for use in retarder: SAE 0W40. 10W30. 20W 20. 5W30. Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Elf Performance Experty 10W40 Elf Performance Experty FE 5W40 Esso Ultra Elf Synth. 5W30. oil for use in retarder: SAE 0W40. 5W40. 5W50. 10W40 Type of oil BP Vanellus FE Extra 10W40 BP Vanellus HT 10W40 BP Vanellus HT Extra 10W40 Castrol Syntruck SAE 5W40 Castrol Dynamax SAE 10W40 Castrol Transmax Z DEA Cronos Synth SAE 5W40 DEA Cronos Premium HC SAE 10W40 DEA Cronos Premium XL SAE 10W40 DEA Cronos Premium FX SAE 10W40 DEA Cronos Premium LD 10W40 Elf Ecomax FE 10W40 BP Oil BP Oil BP Oil Castrol Commercial Castrol Commercial Castrol Commercial DEA DEA DEA DEA DEA Elf Supplier Elf Esso Esso Esso Esso Esso Fina Fina Fina Esso Ultron Esso Ultra Diesel Essolube XTS 301 Essolube XTS 501 Fina Kappa First SAE 15W40 Fina Kappa Ultra SAE 10W40 Fina First 5W40 Titan Unic MC SAE 10W40 Fuchs Titan Unic Plus MC SAE 10W40 Titan Cargo MC SAE 10W40 Emgard MTF 4200 HRD Maxima LD 10W40 Klübersynth GEM 4-68 Mogul Diesel DTT Plus 10W40 Fuchs Fuchs Henkel Huiles Renault Diesel Klüber Koramo Elf Ecomax FE plus 10W40 Elf ./part-synth. 10W30. /part-synth. 2 MM-23 F-H 10W40 Multimiles Fut. 3 MM-23 D-2 10W40 Multimiles Fut. oil for use in retarder: SAE 0W40.Fe 10W40 Oest Paramo Synth. 0W30/40 Multimiles Fut. 5W40.Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Oest gigant Turbo FE 10W40 Trysk Top Tir . 10W40 Type of oil Sintetic 10W40 Gasolina Sintetic 10W40 Diesel Mobil Delvac XHP 10W40 Mobil Delvac XHP Extra 10W40 Krafft Krafft Mobil Oil Mobil Oil Supplier Repsol Competicion 5W40 Repsol Repsol Sintetico Gasolina 10W40 Repsol Sintetico Diesel 10W40 Shell Myrina TX 5W30 Shell Myrina TX 10W40 Glap Synth D 1040 Wintershall TFX Wintershall TFE Wintershall TFG Ursa Super TDX 10W40 Total rubia TIR 8600 Repsol Repsol Shell Shell Sofomil SRS SRS SRS Texaco Total Wameco Wameco Mobil Delvac 1 SHC 5W40 Mobil Oil Carrier Diesel Sint 10W40 MC Power 3 SAE 10W40 MC plus SAE 10W40 Star-Synt SAE 5W50 Multimiles MM-1 Bioil chem. 5W30. 10W30. 2 MM-23 F-HP 10W40 Multimiles Fut. 5W50. 2 MM-23 F-P 5W50 Mol Motorex Motorex Motorex Multimiles Multimiles Multimiles Multimiles Multimiles Wameco Green Rallenter Fluid N Wameco Red Rallenter Fluid N . Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Synthetic oil for use in retarder: SAE 75W-80W Type of oil Emgard MTF Henkel Supplier . however not always meet the drinking water quality. even if anti-freeze-qualities are not necessary. The water of the coolant must fulfil defined requests. It must be brought to the recycling as well as to the waste disposal. the coolant must remain non-seasonal in the cooling system. Information about this can be ordered from us. visit immediately a doctor! Keep fuels away of children! The coolant may not be discharged into the sewage system. that frequently. Before use of the coolants. Water Water itself is not allowable as coolant. the safety-data-sheets and product-information of the respective manufacturer are to be heeded and to keep.From reasons of the corrosion-protection and to the increase of the boiling point. If the water-quality is not sufficient. The coolant is a mixture of water and corrosion-/anti-freeze agent. the water must be purified. because the corrosion-protection will reduce itself.Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Cooling water quality Caution! Risk of poisoning! Fuels are harmful to health! If a fuel was swallowed. The legal regulations as well as regulations for sewage can deviate country-specific and are to be heeded with the waste disposal of used coolants. . Coolants have to be renewed after three years. -% (= maximum antifreeze) corrosion-/antifreeze agent.Annex 2SHUDWLQJ 6SHFLILFDWLRQV (Continue) Corrosion-/anti-freeze agent To avoid damages in the retarder cooling-system: • Use only a released corrosion-/antifreeze agent. if no corrosion-/antifreeze agent is available and no antifreeze is required (for example tropics).-% in the coolant (antifreeze to -37 °C) must be secured. Do not use more than 55 vol. 55 In exceptions. In this case.10. -45 Water Vol. With refills (after coolant-loss) a proportion of corrosion-/antifreeze agent of 50 vol. The feature of antifreeze will be reduced and the heat rejection poor. • • • Ratio for coolant Antifreeze to °C -37 approx. Continuing information can be taken from the Voith cooling-water list. 1 vol. -% = 10 cm3/litre refining agent must be used.2224. This can be ordered from Voith Turbo with the Voith item-number 67. that is released expressly for aluminium by the manufacturer. the coolant is to be renewed annually. . The use of purely glycol is not allowed.-% 50 max.-% 50 45 Corrosion-/ antifreeze agent vol. Annex 6SDUH 3DUWV /LVWV Gearbox spare part recommendation list 26/350/083 26/100/056 26/100/053 26/100/059 26/350/101 26/100/032 25/250/020 26/100/038 26/100/014 26/100/008 26/350/080 Remark: Terms of items from DaimlerChrysler-EPC-documentation 26/250/047 26/100/206 26/860/026 26/860/017 26/860/014 26/860/026 26/100/197 26/100/203 26/100/200 26/100/194 26/400/083 26/100/128 26/100/125 26/100/128 26/400/089 26/100/122 26/100/023 26/100/029 26/100/128 26/100/125 25/250/008 25/250/113 26/350/ 25/250/068 26/350/071 26/250/068 26/100/113 26/100/116 26/100/107 26/100/119 26/350/065 25/250/110 . Annex 6SDUH 3DUWV /LVWV (Continue) 6101 3300 6100 6101 9000 3850 3850 3800 3900 8000 6600 6700 3700 2900 2300 4000 5400 5500 5600 7500 109 850 6400 7300 5200 5300 7500 7600 20100 20000 20300 20200 20300 5200 5300 4100 4200 107 6700 6600 20300 M+P-07A-1504b Retarder spare part recommendation list 4100 3100 2000/1 3300 2800/1 25000 2301 2600 2500/1 3100 4200 103 3500 7300 6700 6600 20000 20200 20100 . Annex 6SDUH 3DUWV /LVWV (Continue) Digiprop Control Unit Vo it Co h-N r.: Ku en-N nd en r. Se de-N : ri r.: -N r.x xx xxx x .12 xx xx /D atu m M+P-07A-1617a Retarder stage switch .: 53 . it.: A 000 997 68 32 VS M12X1.: AZ-Nummer: Typ: Kennwort: Betriebsanl. 2769 .BGR. GR BTA ET-KZ 1 Menge Quantity Revisions-Nr. 2769 . 86 VERSCHLUSSSCHRAUBE SCREW PLUG Kunden-Sachnr.5 OHNE ZCHN 1 850 91 . 10 VERSCHLUSSSCHRAUBE SCREW PLUG Kunden-Sachnr. 20 KOMBI-6KT. 10 VERSCHLUSSCHRAUBE SCREW PLUG MIT SIEB 67. 115 E Abmessung Dimensions Norm-Nr. 53.5 VN 1638 1 107 91 . Sheet No.SCHRAUBE HEXAGON BOLT Kunden-Sachnr. 10 DICHTUNG SEAL Kunden-Sachnr. 2418 .Nr. 1491 . Blatt Nr.1497.: A 000 997 69 32 M24X1.Ersatzteil-Katalog .00 RETARDER 115 SP. 1497 .10 1 3100 53 .11 1 2301 01 .5 OHNE ZCHN 1 109 91 .10 1 . 9454 . 10 DICHTUNG UNTEN SEAL Kunden-Sachnr. 20 KOMBI-6KT.9451. 0647 .Vorschlagsliste Retarder 115 E Schulungsmappe 137975 1 103 01 .2418.9451.90 ZPOSNR Draw. 9457 .SCHRAUBE HEXAGON BOLT Kunden-Sachnr.: Bemerkung. 10 AUSSENRING OUTER RING Kunden-Sachnr.2993.10 1 2900 67 . 2301 D30X38 DRUCKG.1332.1491.: A 006 997 56 48 55X3 VN 3014 1 2600 67 .Stand: 2000-04-13 Gruppe Group Katalog Identification No Benennung Designation Typ Type Zeichnung-/ET-Katalog-Nr. 11 PROFILENTLUEFT. Drawing-/SP-Catalog-No.: A 000 438 14 80 PE-DECKEL 67.2654.PARTS CATALOGUE 01 ET . 1332 .: A 000 438 13 80 67. 0907 .: A 000 997 69 32 M24X1.20 11 3500 67 . 56 RUNDDICHTRING O-RING Kunden-Sachnr. Standard No.20 22 3300 53 .No Sachnummer Identification No ET-VORSCHLAGSLISTE Benennung Designation RET.: Kunden-Nr. 01 53. 2493 .: Kunden-Code: 53. 10 VERSCHLUSSSCHRAUBE SCREW PLUG Kunden-Sachnr.: A 003 430 58 81 beinhaltet Pos. 2301 INCLUDES POS. HOUSING VENTILATION Kunden-Sachnr.: A 000 438 01 12 M802011AP OHNE ZCHN 1 2300 53 .: A 000 438 28 71 M 8 X 80 53.: Werkstatthandb.: A 000 438 27 71 M 8 X 30 53. : A 000 438 00 93 SSB-0118 OHNE ZCHN 2 5500 53 . Sheet No. 1947 . 11 KOMBI-6KT. Blatt Nr.5 OHNE ZCHN 2 5200 67 . 83 RUNDDICHTRING O-RING Kunden-Sachnr.22 1 3800 67 . 9490 . 10 DAEMPFUNGSPLATTE DAMPING PLATE 160X70X22 67.2672.2654. Standard No. 10 WELLENFEDER UNDULATED WASHER Kunden-Sachnr. 0044 . 9452 . 78 RUNDDICHTRING O-RING 15. FOR OTHER USES REPLACED BY 53. 0837 . 47 DICHTRING SEAL RING Kunden-Sachnr.9452. Drawing-/SP-Catalog-No.9451. 2769 .: A 000 438 02 29 beinhaltet Pos.: A 001 540 52 17 M14X1. 10 SICHERUNGSRING CIRCLIP Kunden-Sachnr. 1703 .1091.4 VN 3014 2 .it.5 OHNE ZCHN 2 4200 91 .Stand: 2000-04-13 Gruppe Group Katalog Identification No Benennung Designation Typ Type Zeichnung-/ET-Katalog-Nr. 0041 .3X2. 0150 .No Sachnummer Identification No ET-VORSCHLAGSLISTE Benennung Designation RET. 10 ROHR PIPE Kunden-Sachnr.: A 000 997 71 32 M30X1. 2770 . 6101 M. 10 VERSCHLUSSSCHRAUBE SCREW PLUG Kunden-Sachnr. 115 E Abmessung Dimensions Norm-Nr. 2474 .SCHRAUBE HEXAGON BOLT M 8 X 20 53. 22 PROPORTIONAL-VENTIL PROPORTIONAL VALVE Kunden-Sachnr.3467.0150. 6101 INCLUDES POS.9452. 09 SECHSKANTMUTTER HEXAGON NUT M8 DIN 6927 4 4100 91 .2 90.90 ZPOSNR Draw.5/SW21 67.10 1 6101 01 .: A 000 997 69 32 M24X1. 01 53.20 4000 01 .10 2 5600 90 .: A 000 438 17 81 DIGIPROP 67.11 4 nur noch fuer Befestigung der Dõmpfungsplatte fuer andere Anwendungen ==> Ersatz 53.22 2 5300 01 . 3467 . 0041 . 10 VERSCHLUSSSCHRAUBE SCREW PLUG Kunden-Sachnr. 22 TEMPERATURGEBER THERMOCOUPLE Kunden-Sachnr.20 ONLY FOR MOUNTING OF DAMPING PLATE.10 2 6100 67 .: A 000 438 06 73 JL 30X1.: A 027 997 72 48 16X3 VN 3014 4 3900 53 .: A 000 438 04 67 D30X4 53.10 ist der Reparatursatz 53. 9270 . 3850 01 .1098. GR BTA ET-KZ 2 Menge Quantity 3700 53 .: N 007603 014106 A14X20 DIN 7603 2 5400 91 .9270.1947. 10 SCHEIBE (DAEMPFER) WASHER Kunden-Sachnr. RDR / LUFT 67.1703.Ersatzteil-Katalog .10 1 Bei Sandgussventil 67.10 zuverwenden. 9458. 56 RUNDDICHTRING O-RING Kunden-Sachnr. Standard No. 10 DICHTUNG SEAL Kunden-Sachnr.2178. 2378 . 2178 . 2043 .Z. 0759 .13 1 6600 53 . 10 DRUCKSENSOR PRESSURE SENSOR Kunden-Sachnr.it. 10 SCHRAUBE BOLT Kunden-Sachnr. HEXAGON BOLT Kunden-Sachnr.: A 002 542 64 18 0-4 BAR 53. 10 AUSGLEICHSCH. 2676 . 5 25300 67 . 10 SCHRAUBE BOLT M10X60 O.Z.Z. 20 WASSERSTUTZEN WATER SOCKET Kunden-Sachnr.2069.: A 027 997 31 48 25X4 VN 3014 1 8000 67 .90 ZPOSNR Draw.2378. GR BTA ET-KZ 3 Menge Quantity 6400 67 . 32 RUNDDICHTRING O-RING Kunden-Sachnr.: A 000 438 22 71 M14 X 40 53. 0759 .20 2 20100 67 . Drawing-/SP-Catalog-No. 1 bestehend aus A 629 261 01 52 bis A 629 261 33 52 25100 67 . 2 25200 67 . 13 WAERMETAUSCHER HEAT EXCHANGER 67. 2674 .2654. 2675 . 10 6KT.FL. 9457 .: A 656 997 00 49 WASSERSTUTZEN 67.Stand: 2000-04-13 Gruppe Group Katalog Identification No Benennung Designation Typ Type Zeichnung-/ET-Katalog-Nr. 2683 .: A 656 997 00 72 AD 52 67. 2069 . 10 ZWISCHENPLATTE INTERMEDIATE PLATE Kunden-Sachnr. 20 KOMBI-6KT.2043.(AUSW) SET OF SHIMS R115 AN GO4 O.: A 020 997 62 48 15X4 VN 3014 3 7500 01 .10 1 9000 53 . 63 RUNDDICHTRING O-RING Kunden-Sachnr.11 4 7300 01 . 17 Kunden-Sachnr. Sheet No.8258. 9461 .10 1 20000 67 .9451. 115 E Abmessung Dimensions Norm-Nr.Z.SCHRAUBE HEXAGON BOLT Kunden-Sachnr.20 6 25000 67 . 0759 . 10 O-RING O RING Kunden-Sachnr.10 2 20200 53 .: A 914 126 01 00 51 .: A 000 438 01 84 196X144X2 67. 01 53.: A 024 997 37 48 45X5 VN 3014 2 7600 01 .: A 914 26 01 00 37 M10X70 O.: A 000 438 28 71 M 8 X 80 53. Blatt Nr. 8258 .No Sachnummer Identification No ET-VORSCHLAGSLISTE Benennung Designation RET.Ersatzteil-Katalog .: A 019 997 83 48 D 14 X 4 O.SCHRAUBE M.