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ASM_R115E
ASM_R115E
March 18, 2018 | Author: franklin972 | Category:
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Voith TurboAftersales Service Manual Voith Retarder VR 115 E – 153.000188xx 153.00009711 I 2007-09 . Nr hac . Nr .-S hKd ac -S ith Vo Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Table of Contents Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 Table of Contents 1 About this Document 5 1.1 1.2 1.3 1.4 1.5 1.6 Purpose of this Document Target Groups Other Applicable Documents Symbols and Identifications Item Numbers Imprint 6 6 6 7 7 7 2 Basic Safety Information 8 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Product Safety Staff Qualification Safety-Conscious Working Environmental Protection Special Tools Diagnosis and Troubleshooting Maintenance and Repair Driving Mode Warranty 9 9 9 9 9 9 9 10 10 3 Design and Function 11 3.1 3.2 3.3 Overview of the Modules Retarder Identification VERA™ Controller Identification 12 14 15 Page 2 Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Table of Contents 3.4 3.5 3.6 Digiprop Controller Identification Function and Control Scheme Function Description 16 17 19 4 Maintenance and Service 21 4.1 4.2 4.3 4.4 Maintenance Intervals Oil Change Checking the Oil Level Draining the Coolant 22 23 26 29 5 Diagnosis and Troubleshooting 31 5.1 5.2 5.3 5.4 Overview Checking Checking Checking 32 42 47 52 6 Removing and Installing the Retarder 54 7 Repair 62 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 Components Overview Top Oil Tank Cover Bottom Oil Tank Cover Cover for Casing Ventilation Casing Ventilation Retarder Ventilation Basic Retarder Inside Part (800) 63 70 72 74 77 81 82 83 of the Possible Complaints the Constant-Air Pressure Control Loop the Pump Pressure pdyn the Proportional Valve Current Page 3 18 Page 4 .12 7.10 7.00009711 I arrtd I 2007-09 © 2007 7.000188xx I Table of Contents Pipe (5900) Water Neck Heat Exchanger Pressure Control Valve Non-Return Valve (inlet) Non-Return Valve (outlet) Oil Temperature Sensor Coolant Temperature Sensor Pressure Sensor Proportional Valve and Damping Plate 85 86 88 93 96 98 101 103 105 106 8 Overview of the Tools 108 Voith Turbo I 153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.13 7.14 7.9 7.16 7.15 7.17 7.11 7. 000188xx I About this Document About this Document 1.2 Target Groups 6 1.00009711 I arrtd I 2007-09 © 2007 1.3 Other Applicable Documents 6 1.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.5 Item Numbers 7 1.6 Imprint 7 Voith Turbo I 153. Page 5 .1 Purpose of this Document 6 1.4 Symbols and Identifications 7 1. 002778xx VR 115 E 153. 1.000900xx Cooling water quality list Approved coolants H67. Voith Retarder Oil change intervals/Oil selection list Oil change intervals and approved oil types 153.1 Purpose of this Document This Aftersales Service Manual provides information and instructions on the maintenance and repair of the Voith Retarder VR 115 E – 153.001085xx) Voith Turbo I 153.2224xx ECU specifications Instructions on diagnosis for the VERA™ controller on request Operating instructions for retarder tester Measured values for constant-air pressure and pump pressure 153.2 Purpose of this Document Target Groups This Aftersales Service Manual is intended for service personnel for maintenance and diagnostics and may not be reproduced or given to third parties.000776xx) Operating instructions for the "WinDia®" diagnostic software Instructions on PC diagnosis for the Digiprop and VERA™ controllers 3623-020900 Conversion instructions for the basic retarder VR 115 E Instructions for removing and installing the basic retarder and returning the basic retarder 153.000188xx I About this Document 1.000188xx. Other Applicable Documents Documents Information Voith item no.001508xx Included in scope of delivery of the retarder tester (153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.002005xx Page 6 .001532xx ventilation conversion instructions Instructions for converting the retarder ventilation 153.3 1.00009711 I arrtd I 2007-09 © 2007 Operating instructions for "DIANA Lite" test software Information on the testing of: • Constant-air pressure control loop • Pump pressure pdyn Included in the scope of delivery of the "DIANA Lite" (153. or two-digit item numbers • item numbers with a slash jury if not prevented. 32-1860 Fax: 00 49 79 51 / 32-756 service-retarder@voith. First step of an action instruction. Distinctions Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 Item Numbers Exceptions: Type and source of danger! Ö Measures for the prevention of danger and its Symbols and Identifications CAUTION Possible imminent danger that could lead to slight injury if not prevented. Voith Turbo Produktgruppe Retarder Postfach 1555 74555 Crailsheim Deutschland Phone: 00 49 79 51 / 32-401. Ö Measures for easier and safer work with the retarder.000188xx I About this Document 1. Other steps follow and are numbered in sequence. 1. contact the respective organization for your area.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 1.com Page 7 . DANGER Possible consequences if not heeded.voith. consequences.5 The item numbers used are usually found in the spare part lists. 32-422. NOTE Information on easier and safer work with the retarder. Imprint For questions and work procedures not described in these documents.4 Symbols and Identifications Structure of warnings LEVEL OF DANGER WARNING Possible imminent danger that could lead to death or serious injury if not prevented. 1. Immediate danger that leads to death or serious in- • one.com www.6 Levels of danger Notes The warnings are categorized into four levels of danger: CAUTION Possible imminent danger that could lead to damage to property if not prevented. Ö One-step action instruction. 2 Staff Qualification 9 2.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.6 Diagnosis and Troubleshooting 9 2.000188xx I Basic Safety Information Basic Safety Information 2. Page 8 .8 Driving Mode 10 2.00009711 I arrtd I 2007-09 © 2007 2.4 Environmental Protection 9 2.9 Warranty 10 Voith Turbo I 153.3 Safety-Conscious Working 9 2.1 Product Safety 9 2.7 Maintenance and Repair 9 2. 4 Environmental Protection Ö Drained fuels and fluids. Page 9 . if necessary. hazardous situations and property damage may occur as a result of improper usage. 2.2 Staff Qualification Ö Allow only qualified professionals to carry out repair and maintenance work.1 Product Safety The retarder is constructed according to the state of the art in technology and acknowledged safety regulations. Ö Carry out diagnosis only while the vehicle is standing still. 2. into Danger of burns via hot parts! account in the diagram of the special tools. Nevertheless. Parts of the retarder may be hot. Damage to property if false special tools are used! The special tools required are described in the respective action instructions. 2. Ö Do not replace parts on mere speculation. sion on. Ö Observe safety and warning information.000188xx I Basic Safety Information 2.942811. Ö Take the last two digits of the Voith item no. Ö Work carefully. the version number is contained in the last two digits of the Voith item no. 2. The chapter "Overview of the Tools" contains an overview of the special tools.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Ö Only use special tools from the specified ver- Ö Work carefully.00009711 I arrtd I 2007-09 © 2007 Voith does not assume any liability for personal injury and/or property damage caused by improper and unprofessional work. Ö Wear protective gloves or use cloths. maintenance and repair. Example: H53.6 Diagnosis and Troubleshooting - Other generally acknowledged safety regulations and occupational health Voith provides a warranty/goodwill service for defective parts only. Danger of burning and scalding via hot coolant! The coolant may be hot. Danger of burning and scalding via squirting oil! The oil in the retarder may be hot. consumables and old parts must be disposed of properly.3 Safety-Conscious Working Voith Turbo I 153. - Motor Vehicle Regulations - Safety regulations for handling chemical substances such as oils and greases Ö Work carefully.7 Maintenance and Repair In the case of special tools that may only be used from a specific version on. Ö Observe the following regulations: - Accident-prevention regulations 2. 2.5 Special Tools Product Safety Danger of accidents if the retarder tester is used improperly! Diagnosis while the vehicle is traveling results in an uncontrollable operating state of the vehicle. Parking Ö Do not use retarder as a parking brake. Ö Ventilating the retarder: - If it exists and if possible: Switch off the retarder foot operation. as it does not act as a brake when the vehicle is standing still. Damage to property via improper cleaning! Ö Do not aim the jet of a high-pressure cleaner (steam-jet device) at valves. i. attachments and special features not tested and approved by Voith. 2.8 Driving Mode Ö Ensure that the retarder is fully functional for all vehicle maneuvers. 5 s each.e. Page 10 .9 Warranty Voith accepts no liability for damage caused by changes to the retarder or the use of spare parts.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 100 km at max. Ö Adjust the speed of the vehicle with the engine/service brake.: Voith Turbo I 153. Ö Use only parts approved by Voith to ensure the safety of the vehicle and functioning of the retarder. accessories.00009711 I arrtd I 2007-09 © 2007 Driving Mode - Retarder is properly filled with oil - Retarder electronic equipment is connected and is functional - Pneumatic control is connected and is functional Oil loss through retarder ventilation. Towing Ö Tow vehicle with retarder max. Air is mixed in the oil! During failure of the retarder. 2. - Move the vehicle with 50 km/h - Activate the retarder in the first braking stage 5 times for approx. or while temperature adaptation is active: Ö Ensure cleanliness.000188xx I Basic Safety Information Damage to property via soiled parts! Driving after oil change/checking the oil level Failure or performance reduction while driving Considerable damage or malfunctions may occur due to soiling. sensors or the exhaust of the retarder. Ö During a temperature adaptation continue driving in this way until the retarder is available at full capacity again. 40 km/h. Ö Engage the lowest possible gear to achieve a high engine speed. 2 Retarder Identification 14 3.3 VERA™ Controller Identification 15 3.4 Digiprop Controller Identification 16 3.6 Function Description 19 Voith Turbo I 153.1 Overview of the Modules 12 3. Page 11 .Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.5 Function and Control Scheme 17 3.000188xx I Design and Function Design and Function 3.00009711 I arrtd I 2007-09 © 2007 3. 000188xx I Design and Function 3.00009711 I arrtd I 2007-09 © 2007 1900 1600 100 28003 Page 12 . 100 Name 3700 Retarder housing 1600 Valve cover for non-return valve (outlet) 1900 Non-return valve (inlet) 2810 Air and vent filter 3700 Proportional valve 4100 Screw plug/oil filler plug 4100 Voith Turbo I 153.1 Overview of the Modules Overview of the Modules 2810 Item No.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Name 103 Screw plug 107 Screw plug/oil drain plug 3500 Screw plug of the pressure control valve 4200 Screw plug/oil drain plug 5200b 5500 Coolant temperature sensor 5500 Retarder ventilation "R" 6400 Heat exchanger 20000 Overview of the Modules 6400 Water neck 3500 20000 103 5200b Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 20000 107 4200 28004 Page 13 .Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Design and Function Item No. Nr. hac r.03 KW/Jahr Voith-Sach-Nr. er . 28001 Page 14 .00009711 I arrtd I 2007-09 © 2007 5E /Jah R11 KW pV Ty 2. -S N ith hVo ac -S Kd.2 Retarder Identification Retarder Identification NOTE Ö Specify the following data in case you have questions or are ordering spare parts: - Serien-Nr. S ien- Voith Turbo I 153.-Sach-Nr.03 = et iR Nr. Serien-Nr. r Kd. (Serial number) - Voith-Sach-Nr. i Ret.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. (Voith item number) Typ VR115E.000188xx I Design and Function 3. = 2. (Voith item number) Voith Turbo - VOITH Voith Turbo I 153.D. o.H X it 6 / 3 -E J V 3 J E 1 0 J R 5 2 J A / . (Voith item number) 084 - 022 Serial-No.000188xx I Design and Function 3.l-N r M N C -N o.2 0 Part-No.1 -M TM E 0 M v -H o 6 -T X B 7 2 u .3 VERA™ Controller Identification NOTE Ö Specify the following data in case you have questions or are ordering spare parts: Retarder Control Unit VERATM Serial-No. 0004463315 / EvoBus X1 X2 3 e1 022084 Voith-Sach-Nr.H-E02.10-H67.2866.00009711 I arrtd I 2007-09 © 2007 Serien-Nr. o n o V XX t r . VERA.VERA™ Controller Identification Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. (Serial number) e1 - X3 28138 Page 15 . XXXXXX / JJJJ-MM-TT Part-No.2 T s 8 6 6 . (Serial number) Voit h Tu rbo - VOI TH Ö Specify the following data of the retarder (see page 14): X R S et P er ar O ar ia de E t.20 OEM-No. E 0 R X ol 0 A X U 0 X .D X n 4 1 4 . : Serien-Nr.: Code-Nr.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. (Voith item number) Ba s Co is-N Se de-N r.r.00009711 I arrtd I 2007-09 © 2007 Ö Specify the following data of the retarder (see page 14): - Serien-Nr.000188xx I Design and Function 3. (Voith item number) Voith Turbo I 153. (Serial number) - Voith-Sach-Nr. (Serial number) - Serien-Nr.: VOITH 28002 Page 16 .: IT Nr. H : 53 .4 Digiprop Controller Identification Digiprop Controller Identification NOTE Ö Specify the following data in case you have questions or are ordering spare parts: - Basis-Nr.12 xx xx / Basis-Nr.: r VO ien. xx xxxx x . Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Design and Function 3. Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 Function and Control Scheme A Four-circuit protection valve B Air tank (auxiliary equipment) C Supply-air pressure pv "P" D Ventilation line "R" E Air and vent line "A" constant-air pressure py F Oil tank G Rising duct 107 Oil drain plug 200 Stator 300 Rotor 1900 Non-return valve (inlet) 2100 Non-return valve (outlet) 2200 Pressure control valve B A Name 2810 C 9000 2300 3700 P A R D E 5200a 1900 F 6400 Vehicleelectronics 5200b 300 200 2200 5500 2100 107 4200 G Oil sump Coolant Supply-air pressure pv Pump pressure pdyn Constant-air pressure py 28005 Page 17 .5 Function and Control Scheme Item No. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 300 200 2200 5500 2100 107 4200 G Oil sump Coolant Supply-air pressure pv Pump pressure pdyn Constant-air pressure py 28005 Page 18 . Function and Control Scheme Name 2300 Casing ventilation 2810 Air and vent filter 3700 Proportional valve 4200 Oil drain plug 5200a Oil temperature sensor 5200b Coolant temperature sensor 5500 Retarder ventilation "R" 6400 Heat exchanger 9000 Pressure sensor B A 2810 C 9000 2300 3700 P A R D E 5200a 1900 F 6400 Vehicleelectronics 5200b Voith Turbo I 153.000188xx I Design and Function Item No. Rotor (300) The rotor (300) must include the oil in its rotation and accelerate it. Page 19 . it issues a pneumatic constant-air pressure py which depends on the intensity of the electrical input signal and which acts on the oil tank (F) of the retarder.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Aerates and ventilates the retarder circuit via the casing ventilation (2300). This opens the non-return valve (input) (1900) and lets oil into the working chamber via the rising duct (G). Once the system circuit is free of air. A torque limiting valve is integrated in the non-return valve (outlet) (2100). When switched off. is cooled down and is fed back into the system circuit or the oil tank. the braking torque is adjusted via the constant-air pressure py until an equilibrium is achieved between the produced braking energy and the heat dissipated via the vehicle cooling system. the oil expels the air located in the system circuit from the retarder via the casing ventilation (2300) and the air and vent filter (2810). Function Description In braking mode. Limiting points and maximum values for the coolant and oil temperature are set in the controller to protect the cooling system and the retarder. the oil reaches the heat exchanger (6400) from the working chamber via the non-return valve (outlet) (2100). If one of the temperature limiting points is exceeded during braking. the oil sump is pressurized with compressed air. Rising duct (G) Connection between oil tank.000188xx I Design and Function 3. the oil coming from the heat exchanger (6400) flows via the rising duct back into the oil tank (F). Proportional valve (3700) The proportional valve (3700) is connected to the compressed-air system of the vehicle (auxiliary equipment circuit).6 Function Description Ventilation line "R" (D) Ventilation line for constant-air pressure py between the proportional valve (3700) and the retarder ventilation "R" (5500). The temperature sensors pass on information on the temperature of the oil and coolant to the retarder controller in the vehicle. Connects the retarder circuit with the atmosphere. Pressure control valve (2200) Temperature sensors for oil (5200a) and coolant (5200b) The pressure control valve (2200) regulates the lubrication in no-load operation (non-braking mode) of the retarder. Casing ventilation (2300) At the beginning of the braking process. retarder circuit and heat exchanger (6400).00009711 I arrtd I 2007-09 © 2007 Stator (200) In the stator (200) the oil is re-directed and is returned to the rotor (300) at the internal diameter of the working chamber. During braking oil flows from the oil tank (F) via the rising duct (G) to the non-return valve (inlet) (1900) in the retarder circuit. The torque limiting valve is a safety valve and limits the braking torque of the retarder. Non-return valve (inlet) (1900) Air and vent filter (2810) When the retarder is switched on. As soon as the proportional valve (3700) receives an electrical input signal from the retarder controller. Non-return valve (outlet) (2100) Air and vent line "A" constant-air pressure py (E) Air and vent line for constant-air pressure py between the proportional valve (3700) and oil tank (F). the casing ventilation (2300) closes. Voith Turbo I 153. the braking torque is adjusted if the oil temperature rises rapidly (gradient). the compressed air in the oil tank (F) is emitted to the atmosphere via the retarder ventilation "R" (5500). In addition.00009711 I arrtd I 2007-09 © 2007 Stainless steel heat exchanger 3 in 1 (three heat exchangers in one) • Large retarder oil circuit (active in braking mode) • Small retarder oil circuit (active in braking and noload operation) • Transmission oil cooling (always active) Page 20 . the braking torque is no longer actuated (corresponds to a reduction to 0). Heat exchanger (6400) Voith Turbo I 153. Pressure sensor (9000) The pressure sensor (9000) measures the pneumatic constant-air pressure py. regardless of the actual oil temperature. Function Description The three sections of the heat exchanger (6400) are not interconnected. A deviation from the permissible pressure tolerance (nominal/actual value comparison is carried out) is recognized as a fault and displayed by the controller. The vehicle speed has to be adjusted with the service brake while the adjustment is active. Retarder ventilation "R" (5500) When the retarder is switched off.000188xx I Design and Function If one of the maximum values is exceeded.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. The heat exchanger (6400) dissipates the generated heat to the vehicle cooling system. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.4 Draining the Coolant 29 Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 4.2 Oil Change 23 4.1 Maintenance Intervals 22 4.000188xx I Maintenance and Service Maintenance and Service 4.3 Checking the Oil Level 26 4. Page 21 . Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Checking the oil level – Page 26 Draining the coolant ÖObserve the specifications of the vehicle manufacturer. CAUTION Exceeding of the maintenance intervals/incorrect oil sort! Damage to/failure of the retarder. Activity Interval See Change oil ÖObserve the specifications of the vehicle manufacturer.00009711 I arrtd I 2007-09 © 2007 ÖIf no specifications available: Observe Voith Retarder Oil change intervals/Oil selection list.000188xx I Maintenance and Service 4. Page 29 Page 22 .1 Maintenance Intervals Maintenance Intervals The maintenance intervals depend on the stress put on the retarder and the oil sorts used. Ö Use only approved oils. Page 23 Voith Turbo I 153. Ö Observe the maintenance intervals. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service 4.2 Oil Change Item No. Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 Oil Change 4100 Name 107 Screw plug M 24 x 1.5; hexagon socket head, w.a.f. 12; with copper sealing ring (108): 80 Nm with integrated sealing ring: 47 Nm 108 Sealing ring A 24 x 29; replace 3500 Screw plug M 30 x 1.5; hexagon socket head, w.a.f. 17; with copper sealing ring (3550): 130 Nm with integrated sealing ring: 100 Nm 3550 Sealing ring A 30 x 36; replace 4100 Screw plug M 30 x 1.5; hexagon socket head, w.a.f. 17; with copper sealing ring (4150): 130 Nm with integrated sealing ring: 100 Nm 4150 Sealing ring A 30 x 36; replace 4200 Screw plug M 24 x 1.5; hexagon socket head, w.a.f. 12; with copper sealing ring (4250): 80 Nm with integrated sealing ring: 47 Nm 4250 Sealing ring A 24 x 29; replace NOTE Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. 4150 . Nr h. ac Nr .-S hKd ac -S ith Vo 3550 3500 108 107 4250 4200 4250 4200 28009 Page 23 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service Draining the oil Oil filling level Service filling (checking of the oil level, oil change) 7.0 l After replacement of the heat exchanger 7.5 l Refilling after complete disassembly, cleaning and emptied heat exchanger 7.8 l 1. Place oil collecting pan below the retarder. manufacturer). Ö Tighten the hex.-head screws (6600) at the heat Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 exchanger (see page 88). Lubricate the new sealing ring (108) with silicone-free and non-corrosive grease. - Screw in the screw plug (107) with sealing ring (108) and tighten it to 80 Nm. Face and hands could be burned. switched off. ter the oil change. tighten, if necessary (see specifications of vehicle - Hot exiting oil! Ö Visual inspection of retarder for leaks before and af- Ö Check prop shaft screws for proper seating and 5. For screw plug (107) with copper sealing ring (108): WARNING Ö Ensure that the retarder and ignition are Maintenance work during each oil change Oil Change CAUTION For screw plug (107) with integrated sealing ring: - Check the sealing ring for damage. If necessary, replace the screw plug (107). - Screw in the screw plug (107) and tighten it to 47 Nm. Hot screw plugs! Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths, if neces- 6. For screw plugs (4200) with copper sealing ring (4250): - Lubricate the new sealing rings (4250) with silicone-free and non-corrosive grease. - Screw in the screw plugs (4200) with sealing rings (4250) and tighten them to 80 Nm. sary. Requirements 2. Unscrew the screw plug (4100). • Vehicle is horizontal 3. Unscrew the screw plugs (107 and 4200). • Oil is at operating temperature (> 60 °C) 4. Drain oil into an oil collecting pan. • Retarder is switched off • Ignition is switched off NOTE Ö If the oil contains water: Check the heat exchanger (see page 88). For screw plugs (4200) with integrated sealing ring: - Check the sealing rings for damage. If necessary, replace the screw plugs (4200). - Screw in the screw plugs (4200) and tighten them to 47 Nm. Page 24 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service Servicing pressure control valve Filling in the oil NOTE Ventilating the retarder CAUTION CAUTION 2 variants of the pressure control valve are possible: Wrong oil type! Air is mixed in the oil! • Pressure control valve with integrated sieve Damage to/failure of the retarder. Oil loss through retarder ventilation. • Pressure control valve without sieve. Sieve is located at the screw plug (3500) Ö Fill in only approved oil (see Voith Retarder Oil Ö Ventilate the retarder. change intervals/Oil selection list). Ö Do not combine individual parts. 1. Unscrew the screw plug (3500). 1. Fill in the oil slowly via the bore of the screw plug (4100). 2. For pressure control valve (2200) with integrated sieve: Drain any oil that has accumulated. 2. For screw plug (4100) with copper sealing ring (4150): For pressure control valve (2200) without sieve: Clean the sieve at the screw plug (3500). 3. For screw plug (3500) with copper sealing ring (3550): Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 Oil Change - Lubricate the new sealing ring (3550) with silicone-free and non-corrosive grease. - Screw in the screw plug (3500) with sealing ring (3550) and tighten it to 130 Nm. For screw plug (3500) with integrated sealing ring: - Check the sealing ring for damage. If necessary, replace the screw plug (3500). - Screw in the screw plug (3500) and tighten it to 100 Nm. - Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease. - Screw in the screw plug (4100) with sealing ring (4150) and tighten to 130 Nm. 1. If it exists and if possible: Switch off the retarder foot operation. 2. Move the vehicle with 50 km/h. 3. Activate the retarder in the first braking stage 5 times for approx. 5 s each. For screw plug (4100) with integrated sealing ring: - Check the sealing ring for damage. If necessary, replace the screw plug (4100). - Screw in the screw plug (4100) and tighten it to 100 Nm. Page 25 5.f. 4100 Name 107 Screw plug M 24 x 1. with copper sealing ring (4250): 80 Nm with integrated sealing ring: 47 Nm 4250 Sealing ring A 24 x 29. with copper sealing ring (4150): 130 Nm with integrated sealing ring: 100 Nm 4150 Sealing ring A 30 x 36. 12.f. 4150 . ac Nr . Nr h. w. replace 4100 Screw plug M 30 x 1. replace NOTE Voith Turbo I 153.5.5.3 Checking the Oil Level Item No.00009711 I arrtd I 2007-09 © 2007 Checking the Oil Level Ö Lubricate sealing rings. w. 17.a. replace 4200 Screw plug M 24 x 1. with copper sealing ring (108): 80 Nm with integrated sealing ring: 47 Nm 108 Sealing ring A 24 x 29. 12. hexagon socket head. hexagon socket head.f.-S hKd ac -S ith Vo 108 107 4250 4200 4250 4200 28154 Page 26 . O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. w.000188xx I Maintenance and Service 4.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. hexagon socket head.a.a. replace the screw plugs (4200). 5. WARNING Hot exiting oil! Face and hands could be burned. if necessary. Place oil collecting pan below the retarder. - Check the sealing rings for damage. For screw plugs (4200) with copper sealing ring (4250): - Lubricate the new sealing rings (4250) with silicone-free and non-corrosive grease.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Page 27 . For screw plug (107) with copper sealing ring (108): For screw plugs (4200) with integrated sealing ring: - Lubricate the new sealing ring (108) with silicone-free and non-corrosive grease.000188xx I Maintenance and Service CAUTION Oil filling level Service filling (checking of the oil level. Unscrew the screw plugs (107 and 4200). 6. Drain oil into an oil collecting pan. - Screw in the screw plugs (4200) with sealing rings (4250) and tighten them to 80 Nm. - Screw in the screw plug (107) with sealing ring (108) and tighten it to 80 Nm. Unscrew the screw plug (4100). Ö Work carefully. 3. replace the screw plug (107). If necessary. Draining the oil 1. If necessary. Requirements • Vehicle is horizontal • Oil is at operating temperature (> 60 °C) • Retarder is switched off • Ignition is switched off Ö Wear protective gloves or use cloths.00009711 I arrtd I 2007-09 © 2007 Ö Ensure that the retarder and ignition are switched off. Voith Turbo I 153. 4. - Screw in the screw plug (107) and tighten it to 47 Nm.0 l Hot screw plugs! Checking the Oil Level For screw plug (107) with integrated sealing ring: - Check the sealing ring for damage. - Screw in the screw plugs (4200) and tighten them to 47 Nm. Hands could be burned. 2. oil change) 7. 3. For screw plug (4100) with copper sealing ring (4150): - Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease. 2. 1. Move the vehicle with 50 km/h.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 1. Measure the volume of the drained oil. Activate the retarder in the first braking stage 5 times for approx. CAUTION 2. replace the screw plug (4100). If necessary correct the oil volume. Fill in the oil slowly via the bore of the screw plug (4100). Wrong oil type! Damage to/failure of the retarder.00009711 I arrtd I 2007-09 © 2007 2. Page 28 . - Screw in the screw plug (4100) and tighten it to 100 Nm. - Screw in the screw plug (4100) with sealing ring (4150) and tighten to 130 Nm. Checking the Oil Level Ventilating the retarder CAUTION Air is mixed in the oil! Oil loss through retarder ventilation. Ö Ventilate the retarder. 5 s each. Ö Fill in only approved oil (see Voith Retarder Oil change intervals/Oil selection list). For screw plug (4100) with integrated sealing ring: - Check the sealing ring for damage. Voith Turbo I 153. NOTE Ö If oil is missing: Check the retarder valve for leaks.000188xx I Maintenance and Service Measuring the volume Filling in oil 1. If it exists and if possible: Switch off the retarder foot operation. If necessary. 4 Draining the Coolant Draining the Coolant NOTE Depending on the vehicle manufacturer. Ö If the screw plug (20300) does not exist: Drain the coolant at the vehicle (see specifications of vehicle manufacturer). O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.-S hKd ac -S ith Vo 20000 20400 20300 28155 Page 29 . w.000188xx I Maintenance and Service 4.a. Requirements • Retarder is switched off • Ignition is switched off . Item No. Name 20000 Water neck 20300 Screw plug M 14 x 1. Nr h. replace Voith Turbo I 153. 13.f.00009711 I arrtd I 2007-09 © 2007 NOTE Ö Lubricate sealing rings. the design of the water neck can differ. 32 Nm 20400 Sealing ring A 14 x 20.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. ac Nr . hexagon insert bit.5. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service 1. non-corrosive grease. Lubricate the new sealing ring (20400) with silicone-free. Fill the vehicle and retarder cooling circuit (see specifications of vehicle manufacturer). Ö Work carefully. 2. Screw in the screw plug (20300) with sealing ring (20400) and tighten it to 32 Nm. Page 30 . 4. Unscrew the screw plug (20300) and drain the coolant. 3. Ö Observe the specifications of the vehicle manufacturer or those of Voith Turbo cooling water quality list. Draining the Coolant 5.00009711 I arrtd I 2007-09 © 2007 Wrong coolant type! Damage to the vehicle and retarder cooling circuit. CAUTION Voith Turbo I 153. Place a clean coolant collecting pan under the retarder. CAUTION Hot parts and coolant! Burns and scalding could occur. Ö Wear protective gloves or use cloths if necessary. 2 Checking the Constant-Air Pressure Control Loop 42 5.4 Page 31 .1 Overview of the Possible Complaints 32 5.00009711 I arrtd I 2007-09 © 2007 5. Diagnosis and Troubleshooting 5.3 Checking the Pump Pressure pdyn Checking the Proportional Valve Current 47 52 Voith Turbo I 153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Diagnosis and Troubleshooting 5. 1 Overview of the Possible Complaints Overview of the Possible Complaints No. ÖObserve the specifications of the vehicle manufacturer. Complaint See A Retarder pilot light flashes (standard type) Page 33 On-board diagnosis is possible at some vehicle manufacturers (display).Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Diagnosis and Troubleshooting 5. B Oil loss via retarder ventilation (5500) or air and vent filter (2810) Page 34 C No or insufficient brake efficiency Page 36 D Other external leak Page 38 Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 ÖEnsure that there are no leaks at the screw plugs or sealing rings. Page 32 . Activity 1. observe the operating conditions. 2. OK 3. nominal speed of the engine. NOK = does not work correctly OK = works correctly Page 33 . No.00009711 I arrtd I 2007-09 © 2007 4. Result Continue with No. – – NOK 4. ÖInstruct the driver. ÖCheck cooling system of the vehicle (see specifications of vehicle manufacturer). if possible). OK 5. –and/or– ÖReplace coolant temperature sensor (see page 103). ÖReplace oil temperature sensor (see page 101). ÖCheck the operation (for retarder braking. – – – – ÖCheck coolant temperature sensor (see page 103). Ö Observe the specifications of the vehicle manufacturer. 3. ÖCheck oil temperature sensor (see page 101).000188xx I Diagnosis and Troubleshooting A Overview of the Possible Complaints Retarder pilot light flashes (standard type) NOTE On-board diagnosis is possible at some vehicle manufacturers (display). In doing so. NOK 2. 5.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Voith Turbo I 153. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Problem occurs again? NOK = does not work correctly OK = works correctly Page 34 . ÖCheck the retarder oil level and correct it (see page 26). ÖReplace the heat exchanger (see page 88). ÖCheck the gearbox oil level and correct it (see specifications of vehicle manufacturer). Overview of the Possible Complaints Result Continue with No. Yes 2. Voith Turbo I 153. Yes 3. if necessary (see specifications of vehicle manufacturer). No 8. NOK 4. ÖCheck whether water is contained in the oil (emulsion). If the gearbox oil level is too low and the retarder oil level is too high: – – Yes 8. 3. 4. 6. 5. ÖCheck the heat exchanger (see page 88).00009711 I arrtd I 2007-09 © 2007 ÖCheck gearbox ventilation and repair/clean. Activity 1. ÖCheck whether the retarder leaks oil via the retarder ventilation (5500). OK 8. No 5. OK 7.000188xx I Diagnosis and Troubleshooting B Oil loss via retarder ventilation (5500) or air and vent filter (2810) No. 2. – – NOK 6. Activity 7. if necessary (see VR 115 E 153. OK 13. 9. – – 13.387310 and higher (see page 98). – – 12. NOK 12. ÖCheck whether non-return valve (outlet) has a Voith item no. OK 10.00009711 I arrtd I 2007-09 © 2007 Through leaks in retarder housing. through steam-jet device or splash water. –or– • 8. Via retarder ventilation (5500) or air and vent filter (2810). e. Possible entry of water from outside into the retarder system: • Result Overview of the Possible Complaints Continue with No. ÖReplace non-return valve (outlet) (see page 98). Voith Turbo I 153. 11.001532xx ventilation conversion instructions). No 12. – – NOK 9.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. ÖInstall basic retarder (see page 82).g. Yes 11. ÖReplace casing ventilation (see page 77).255022 or H67. ÖConvert the retarder ventilation. – – NOK = does not work correctly OK = works correctly Page 35 . 10.000188xx I Diagnosis and Troubleshooting No. ÖCheck casing ventilation (see page 77). ÖCheck non-return valve (outlet) (see page 98). ÖRemove valve cover (1600). H67. ÖCheck retarder oil level (see page 26). Activity 1. ÖCheck proportional valve current as well as leads and plug connections (see page 52).Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. No. Yes 2. 3. – – 6. Page 34 4. ÖRepair retarder. NOK 5. ÖCheck coolant temperature sensor and supply line (see page 103). 2. Overview of the Possible Complaints NOK = does not work correctly OK = works correctly Page 36 . OK 6.000188xx I Diagnosis and Troubleshooting C No or insufficient brake efficiency No. OK 9. NOK 8. ÖCheck constant-air pressure control loop (see page 42). Continue with No. ÖCheck gearbox oil level (see specifications of vehicle manufacturer). – – NOK B.00009711 I arrtd I 2007-09 © 2007 Result OK 4. 6.. ÖCheck oil temperature sensor and supply line (see page 101). No 3. Voith Turbo I 153. ÖCheck whether an external leak is visible at retarder (except retarder ventilation). NOK 7. 7. OK 10. ÖRepair constant-air pressure control loop (see page 42). 5. ÖReplace casing ventilation (see page 77). ÖCheck constant-air pressure py (see page 42). NOK = does not work correctly OK = works correctly Page 37 . – – 13. NOK 11.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Use Voith ECU specification for this. Voith Turbo I 153. 10. ÖCheck casing ventilation (see page 77). Complaint mentioned above is not possible. –or– ÖCarry out off-board diagnosis (see specifications of vehicle manufacturer). Activity 8. ÖCarry out diagnosis with "WinDia®" (see "WinDia®" operating instructions).00009711 I arrtd I 2007-09 © 2007 11. ÖCheck pump pressure pdyn (see page 47). OK 14. – – – – –and/or– ÖReplace coolant temperature sensor or supply line (see page 103). ÖContact Voith. Result Overview of the Possible Complaints Continue with No.000188xx I Diagnosis and Troubleshooting No. OK 13. NOK 12. – – 14. ÖReplace oil temperature sensor or supply line (see page 101). – – ÖClarify the complaint again with the customer or perform the tests once again. 12. 9. No. No 3. Activity 1. ÖCheck whether the retarder leaks oil near the heat exchanger. contact Voith. 6. 5. NOK = does not work correctly OK = works correctly Page 38 .00009711 I arrtd I 2007-09 © 2007 4. – – NOK 7. If necessary. ÖCheck heat exchanger (see page 88). ÖReplace heat exchanger (see page 88). ÖCheck whether the retarder leaks water near the heat exchanger.000188xx I Diagnosis and Troubleshooting D Overview of the Possible Complaints Other external leak NOTE Ö Ensure that there are no leaks at the screw plugs or sealing rings.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. NOK 5. Voith Turbo I 153. Yes 4. OK 8. Yes 2. 2. No 13. ÖCheck retarder housing near the heat exchanger for leaking. – – 3. OK 6. Result Continue with No. ÖCheck hose connection between water neck at heat exchanger and water pipe in the vehicle (see specifications of vehicle manufacturer). No 17. OK 12. Result – Continue with No. – – 12.000188xx I Diagnosis and Troubleshooting No. ÖCheck whether the retarder leaks near the casing ventilation cover (see page 74). 10. 9. 11. ÖReplace hose connection (see specifications of vehicle manufacturer). NOK 9. OK 10. ÖCheck sealing. 14. No 15. ÖReplace gaskets (20100) (see page 86). NOK = does not work correctly OK = works correctly Page 39 . Activity 7. ÖContact Voith. – Overview of the Possible Complaints – Yes 16. ÖCheck whether the retarder leaks near the Oil tank cover top (see page 70) –or– Oil tank cover bottom (see page 72). ÖCheck sealing ring (5360) at the coolant temperature sensor (see page 103). ÖReplace sealing ring (5360) (see page 103). 15. replace. if necessary (see page 74). Yes 14. – NOK 11. ÖCheck gaskets (21000) at water necks (see page 86). – – 8.Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. – – 13. ÖCheck whether the retarder leaks near the non-return valve (inlet). – – ÖCheck the sealing ring. if necessary (see page 72). Version with integrated sealing ring: Yes 18. Bottom: ÖCheck gasket (2600). replace. Yes 20.-head screws (3100 and 3300) with thread seal (see page 70).Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Top: Result – Overview of the Possible Complaints Continue with No. ÖCheck whether the retarder leaks near the interstice retarder/gearbox. No 21. replace. 18.00009711 I arrtd I 2007-09 © 2007 ÖInsert non-return valve (inlet) with thread seal (see page 96). Activity 16. Voith Turbo I 153. if necessary (see page 96). – ÖCheck intermediate washer (8000). if necessary. ÖReplace non-return valve (inlet). ÖCheck sealing surface between gearbox and retarder. – – NOK = does not work correctly OK = works correctly Page 40 . 20. Version with copper sealing ring (1950): ÖReplace sealing ring (1950).000188xx I Diagnosis and Troubleshooting No. No 19. ÖInsert combined hex. 17. 19. – – NOK = does not work correctly Voith Turbo I 153. – – 23. 22.000188xx I Diagnosis and Troubleshooting No. No 23. ÖContact Voith. ÖCheck whether the retarder leaks at the gearbox flange near the radial shaft sealing ring.00009711 I arrtd I 2007-09 © 2007 OK = works correctly Page 41 .Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Activity 21. Result Overview of the Possible Complaints Continue with No. Yes 22. ÖReplace the radial shaft sealing ring (see specifications of vehicle manufacturer). Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 99/7 Name Pressure gauge 0–6 bar 50/56a Retarder tester 50/56b Cable 1: to the proportional valve 50/56c Cable 2: to the pressure sensor (9000) 50/56d Cable 3: to the temperature sensors 50/56e Cable 4: to the vehicle voltage supply/ PC interface 3700 99/7 50/56c 50/56a 50/56e 50/56d 50/56b 9000 3700 Proportional valve NOTE Ö Lubricate sealing rings. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.2 Checking the Constant-Air Pressure Control Loop Checking the Constant-Air Pressure Control Loop NOTE 4100 4150 The constant-air pressure control loop check provides information about • internal and external leaks of the retarder • proper functioning of the retarder • proper control of the retarder Item No. Voith Turbo I 153.000188xx I Diagnosis and Troubleshooting 5. 28173 Page 42 . 000188xx I Diagnosis and Troubleshooting Item No. w. hexagon socket head. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.5.00009711 I arrtd I 2007-09 © 2007 Ö Lubricate sealing rings. replace 4150 9000 Pressure sensor 50/56c 99/7 9000 NOTE Voith Turbo I 153. 50/56a 50/56e 50/56d 50/56b 3700 28173 Page 43 .f. 17.a.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. with copper sealing ring (4150): 130 Nm with integrated sealing ring: 100 Nm 4100 4150 Sealing ring A 30 x 36. 4100 Checking the Constant-Air Pressure Control Loop Name Screw plug M 30 x 1. measured values can be read out and stored via the PC in addition to the tests with the retarder tester.000188xx I Diagnosis and Troubleshooting Checking the Constant-Air Pressure Control Loop Requirements Special tools CAUTION • Ignition is switched off • Retarder is switched off Hands could be burned. Connecting the pressure gauge 4100 99/7 4150 DANGER Danger of accidents if the retarder tester is used improperly! Uncontrollable operating state of the vehicle. if necessary. Connect the pressure gauge (99/7) to the bore of the screw plug (4100). complete in a case Test software "DIANA Lite" 50/56 50/56i H53. Commercially available tools Ö Wear protective gloves or use cloths.000776xx Retarder tester. • Battery voltage: 18–32 V Ö Work carefully. The stored measured values can be transmitted to the Voith customer service for evaluation (see operating instructions on CD-ROM).00009711 I arrtd I 2007-09 © 2007 NOTE With the test software "DIANA Lite" (50/56i). 28081 1. Unscrew the screw plug (4100) with the sealing ring (4150). 2. • Supply-air pressure pv in auxiliary circuit 6–11 bar • Oil level is checked and in order (see page 26) • Electrical system of vehicle is checked and in order (see specifications of vehicle manufacturer) • Electrical connections of the retarder are completely disconnected from the vehicle Hot parts! 153.1403xx Pressure gauge 0–6 bar 99/7 Voith Turbo I 153. Ö Carry out diagnosis only while the vehicle is standing still. Multimeter Page 44 .Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.001085xx 153. the results of the following test are only valid during a testing period of 60 seconds maximum.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 11.55–1. Connect all the cables to the retarder tester (50/ 56a) (see also the operating instructions of the retarder tester). Switch the toggle switch to the position "EIN mit Regelkreis" (ON with control loop). 20 seconds: Position of "STELLDRUCK" (constant-air pressure) switch Setpoint Constant-air pressure py 0% 0 bar 25% 0.In "DIANA-Lite" read the "Stelldruck IST" (Constant-air pressure INST) measured value and the measured value at the pressure gauge (99/7): Setpoint after approx.00009711 I arrtd I 2007-09 © 2007 Checking the proportional valve 0 /56 00 Checking the Constant-Air Pressure Control Loop 3. 17.00 15 9000 08341 50 3.Read the measured value: Setpoint 0.Start the "DIANA-Lite" test software. Connect cable 3 (50/56d) to the oil temperature sensor (5200a) and to the coolant temperature sensor (5200b). 8. NOTE 9.725 V. 2.0 6. 16.Read the measured value: Setpoint 4.74 bar 75% 1. 10. To assess the operation of the proportional valve (3700).30 bar 100% 2.If the value deviates: Replace the pressure sensor (9000) (see page 105).000188xx I Diagnosis and Troubleshooting Connecting the retarder tester Checking the supply voltage of the pressure sensor VR 115 E 50/56b 83310 153.Load the template for the retarder tester (see operating instructions of "DIANA-Lite" test software). 18. Connect cable 4 (50/56e) to the vehicle voltage supply/PC interface. 5. Set the "RETARDER TYP" (Retarder type) switch at the retarder tester (50/56a) to "5". 153. Voith Turbo I 153.275–0.25 V.000 1 50/56a 50/56c 2 3 4 153.80–2. 14. 3700 d 83 51 0 50/56e 5200a 5200b 15.Set the "STELLDRUCK" (constant-air pressure) switch at the retarder tester to "25%". 4.75–5.Connect the multimeter to the "U_py IST" (U_py actual) socket (measuring type: V). Switch on the vehicle ignition.60–3.00083610 28082 1. Connect the multimeter to the "U_Versorgung" (U_Supply) socket (measuring type: V).If the value deviates: Replace the pressure sensor (9000) (see page 105).10 bar Page 45 . Checking the signal value of the pressure sensor 12. Connect cable 2 (50/56c) to the pressure sensor (9000). Connect cable 1 (50/56b) to the proportional valve (3700).24–1. 13.05 bar 50% 1. 7. 000188xx I Diagnosis and Troubleshooting 19. 24. replace the screw plug (4100). 27. Disconnecting the retarder tester Checking the Constant-Air Pressure Control Loop For screw plug (4100) with integrated sealing ring: - Check the sealing ring for damage.Switch off the vehicle ignition. Page 46 .Complete the retarder and vehicle. 21.Disconnect the pressure gauge (99/7).Switch the toggle switch to the "AUS" (off) position.Repeat the test in the switch positions "50%". - Screw in the screw plug (4100) and tighten it to 100 Nm. if necessary (see page 106). Voith Turbo I 153.Disconnect the retarder tester (50/56a) and all cables.Set the "STELLDRUCK" (constant-air pressure) switch at the retarder tester to "0%". If necessary. 23.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 20. 22. "75%" and "100%". - Screw in the screw plug (4100) with sealing ring (4150) and tighten it to 130 Nm.For screw plug (4100) with copper sealing ring (4150): - Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease.If one of the values deviates: Check the proportional valve (3700) and damping plate (3800) and replace. 25.00009711 I arrtd I 2007-09 © 2007 26. Nr .Checking the Pump Pressure pdyn Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.-S hKd ac -S ith Vo NOTE Ö Lubricate sealing rings. Name 50/56a Retarder tester 50/56b Cable 1: to the proportional valve 50/56c Cable 2: to the pressure sensor (9000) and to the pressure sensor (50/56g) 50/56d Cable 3: to the temperature sensors 50/56e Cable 4: to the vehicle voltage supply/ PC interface 50/56g Pressure sensor pdyn 0–30 bar 9000 3700 50/56d . Nr hac .000188xx I Diagnosis and Troubleshooting 5.00009711 I arrtd I 2007-09 © 2007 Item No.3 Checking the Pump Pressure pdyn NOTE 50/56c Checking the pump pressure pdyn provides information about • the mechanical status of the rotor parts • internal leaks of the retarder • proper functioning of the retarder 50/56b 50/56a 50/56e Voith Turbo I 153. 50/56g 104 103 28025 Page 47 . 00009711 I arrtd I 2007-09 © 2007 Ö Lubricate sealing rings. replace 3700 Proportional valve 9000 Pressure sensor 50/56b 50/56a NOTE 50/56e 3700 50/56d Voith Turbo I 153.-S hKd ac -S ith Vo 50/56g 104 103 28025 Page 48 .000188xx I Diagnosis and Troubleshooting Item No.a.5. 103 104 Name Screw plug M 12 x 1. w. hexagon socket head. with copper sealing ring (104): 20 Nm with integrated sealing ring: 13 Nm 50/56c 9000 Sealing ring A12 x 15.Checking the Pump Pressure pdyn Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.5.f. Nr hac . O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. 6. Nr . . if necessary. Page 49 . NOTE • Constant-air pressure control loop is checked and in order (see page 42) • No external leaks are detected at retarder • Vehicle is secured • Prop shaft is removed from flanges and is secured (see specifications of vehicle manufacturer) Ö Secure the prop shaft screws. Ö Carry out diagnosis only while the vehicle is standing still.00009711 I arrtd I 2007-09 © 2007 Ignition is switched off • Retarder is switched off If the prop shaft screws are screwed in from the transmission side: • Supply-air pressure pv in auxiliary circuit 6–11 bar Ö Ensure that the prop shaft screws are screwed out at the drive-side flange. Ö Wear protective gloves or use cloths. DANGER Danger of accidents if the retarder tester is used improperly! Uncontrollable operating state of the vehicle. Ö Work carefully. measured values can be read out and stored via the PC in addition to the tests with the retarder tester. complete in a case Test software "DIANA Lite" 50/56 50/56i Voith Turbo I 153.Checking the Pump Pressure pdyn Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.001085xx 153.000188xx I Diagnosis and Troubleshooting Requirements Special tools 153. • Oil level is checked and in order (see page 26) –or– • Electrical system of vehicle is checked and in order (see specifications of vehicle manufacturer) • Electrical connections of the retarder are completely disconnected from the vehicle • NOTE With the test software "DIANA Lite" (50/56i). CAUTION Hot parts and oil! Hands can be burned and scalded. The stored measured values can be transmitted to the Voith customer service for evaluation (see operating instructions on CD-ROM).000776xx Retarder tester. 00083610 28083 3.0 0 /56 00 2.000 1 153.Checking the Pump Pressure pdyn Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Voith Turbo I 153. Connect the pressure sensor (50/56g) with sealing ring (104). Connect all the cables to the retarder tester (50/ 56a) (see also the operating instructions of the retarder tester). 6. Connect cable 4 (50/56e) to the vehicle voltage supply/PC interface. a small amount of oil may leak out. 4. Connect cable 2 (50/56c) to the pressure sensor (9000) and to the pressure sensor (50/56g) . 7.00 15 08341 50 3. not affect retarder operation. 9000 50/56g 83 d 51 0 50/56e 28027 3700 5200a 5200b 153. however. Connect cable 1 (50/56b) to the proportional valve (3700).000188xx I Diagnosis and Troubleshooting Connecting the pressure sensor Connecting the retarder tester 50/56g 104 NOTE VR 115 E Due to construction. this does. Unscrew screw plug (103) and remove sealing ring (104). Page 50 . Connect cable 3 (50/56d) to the oil temperature sensor (5200a) and to the coolant temperature sensor (5200b).00009711 I arrtd I 2007-09 © 2007 28026 1. 50/56a 83310 104 50/56c 2 3 4 103 50/56b 153. 5. - Screw in the screw plug (103) with sealing ring (108) and tighten it to 20 Nm. 20.For screw plug (103) with copper sealing ring (108): - Lubricate the new sealing ring (104) with silicone-free and non-corrosive grease.Complete the retarder and vehicle.Adjust the engine speed to 1000 min-1. 17.Switch the toggle switch to the position "EIN mit Regelkreis" (ON with control loop). 22. Disconnecting the pressure sensor and retarder tester 19. NOTE Ö Shift in direct gear (ratio 1:1). NOTE Test when the "STELLDRUCK" (constant-air pressure) switch is set to "100%": "Gehäusedruck Ist" (Housing pressure actual) setpoint > 12 bar. If the setpoint of the constant-air pressure py is reached. 12. Voith Turbo I 153. read the "Gehäusedruck Ist" (Housing pressure actual) measured value in "DIANA Lite": Setpoint > 9 bar.00009711 I arrtd I 2007-09 © 2007 18.Checking the Pump Pressure pdyn Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.When the engine speed is 1000 min-1 . - Screw in the screw plug (103) and tighten it to 13 Nm.000188xx I Diagnosis and Troubleshooting Checking the pump pressure pdyn 8. the retarder has an internal defect.Start the "DIANA-Lite" test software Ö Install the basic retarder (see page 82). replace the screw plug (103). but the pump pressure pdyn is undershot. Set the "RETARDER TYP" (Retarder Type) switch at the retarder tester to "5". 9.Set the "STELLDRUCK" (constant-air pressure) switch at the retarder tester to "0%".Set the "STELLDRUCK" (constant-air pressure) switch at the retarder tester to "25%". For screw plug (103) with integrated sealing ring: - Check the sealing ring for damage.Load the template for the retarder tester (see operating instructions of "DIANA-Lite" test software). 23. 11.Adjust the engine speed back to 1000 min-1 .Start the engine and warm it up to operating temperature. Is normally not possible with the retarder tester when the vehicle is standing still. Switch on the vehicle ignition. If necessary. 21.Disconnect the pressure sensor (50/56g). 14. 15. The engine speed 1000 min-1 then corresponds to the prop shaft speed of 1000 min-1.Disconnect the retarder tester (50/56a) and all cables. 16. Page 51 . 13. NOTE 10.Set the"STELLDRUCK" (constant-air pressure) switch at the retarder tester to "50%". e. 3700 98/8 99/3 H53. Shift the retarder to the highest gear. Disconnect the plug from the proportional valve (3700) and connect it to the measuring adapter (99/3).m. Fluke 179 Page 52 . exact readout of these measured values is not possible (display jumps). Turn the "Prop valve" switch at the measuring adapter to Position "I".Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Multimeter (98/8) with real r.m.000188xx I Diagnosis and Troubleshooting 5. Connect the multimeter (98/8) (measuring type: mA).00009711 I arrtd I 2007-09 © 2007 Electrical lead and plug connections are checked (visual inspection) and in order 28019 When performing measurements using a commercially available multimeter (without real r. 5.g. 3.s.4 Checking the Proportional Valve Current Special tools Checking the Proportional Valve Current Requirements • Ignition is switched off • Retarder is switched off • Battery voltage: 24–28 V • Electrical system of vehicle is checked and in order (see specifications of vehicle manufacturer) • Fuse for retarder controller is checked and in order • Male and female plug connectors at proportional valve are checked for damage or wear (notch scratches). NOTE Voith Turbo I 153. Commercially available tools 6.8198xx Measuring adapter • 99/3 1. Connect the plug of the measuring adapter to the proportional valve (3700).s. Switch on the vehicle ignition. 4. 2. value measurement. value measurement). 00009711 I arrtd I 2007-09 © 2007 9. if necessary. 504.2866xx H67. 152.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 512.3449xx H67. If the value deviates: Check the leads. H67. 10. (Code-No. 508. the measured values may not be constant. (Part-No. Read the measured value at the multimeter (98/8) and compare it to the specified setpoint: 153 423–623 mA 157.Pull the plug from the measuring adapter (99/3) and connect it to the proportional valve (3700). but are within the specified range. 502.2763xx 440–640 mA 179. 180.3457xx H67.) Setpoint 159 534–546 mA H67. Voith Turbo I 153.3658xx 153.) Setpoint Digiprop 138. Disconnect the multimeter (98/8). 155 396–596 mA 150 365–565 mA 151 379–579 mA 7. Page 53 .000188xx I Diagnosis and Troubleshooting NOTE Controller Voith item no.000586xx Checking the Proportional Valve Current 8. connectors and retarder controller and replace them. 514 440–640 mA VERA™ 510 430–630 mA Due to continuous readjustment in the control loop. 158 409–609 mA Controller Voith item no. CAUTION Hot parts! Hands could be burned. Removing and Installing the Retarder DANGER Retarder can fall! Your body can be crushed severely.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Page 54 .00009711 I arrtd I 2007-09 © 2007 necessary.000188xx I Removing and Installing the Retarder 6. Ö Wear protective gloves or use cloths if Voith Turbo I 153. Ö Use a suitable lifting device. Ö Work carefully. Ö Secure retarder and gearbox against falling. 25200 800 28046 Page 55 . replace 25200 Hex.000188xx I Removing and Installing the Retarder Item No. hexagon insert bit.00009711 I arrtd I 2007-09 © 2007 Ö Lubricate sealing rings. 16.f. Name 800 Inside part 850 Outer race. w.a. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. hexagon insert bit. 58 Nm 25200 NOTE 25100 Voith Turbo I 153. w.-head screw M 10 x 70. when the inside part (800) is replaced 25300 25000 25300 850 25000 Shim 25100 O-ring 14 x 4. 16.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.a. 58 Nm 25300 Hex.f. replace.-head screw M 10 x 60. Unscrew the hex. Page 56 .80) 1.3320xx Puller 98/3 H67. DIN 17100 (1.-head screws (25200) and (25300).Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. CAUTION Unprotected inside part (800)! Damage to the inside part (800). Use a suitable lifting device to remove the retarder from the gearbox.3319xx Measuring device Marking punch 98/1 98/4 • Retarder is switched off • Ignition is switched off • Supply-air pressure pv is drained • Electrical connecting leads are disconnected • Supply-air pressure line py is removed • Retarder oil is drained (see page 23) • Oil is drained from the gearbox (see specifications of vehicle manufacturer) • Coolant is drained (see page 29) • Prop shaft at the gearbox flange is removed from the flanges (see specifications of vehicle manufacturer) 25200 28029 M 10 Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 Tools for self-fabrication 15 80 28028 • Output flange is removed (see specifications of vehicle manufacturer) • Tacho-sensor and output speed sensor are removed (see specifications of vehicle manufacturer) 2 x Threaded bolt Material: St 37-2. Ö Ensure that the inside part (800) is not damaged when it is put down. 2.3224xx H67.000188xx I Removing and Installing the Retarder • Aids Special tools Thread seal Loctite 5203 for sealing surface gearbox housing/retarder housing Requirements Retarder with gearbox is removed from vehicle (see specifications of vehicle manufacturer) Removing the retarder 25200 25300 0 80 62 265 FJ 6 48 H67. A digital depth gauge is included in the measuring device (98/1) scope of delivery. H is noted in the factory by Voith on the measuring device. 80 °C in the area of the outer race (850). - The distance from the top edge of the measuring device to the measuring panel in the measuring device is measured for dimension C. Removing the outer race (850) and shim (25000) 1. Remove the shim (25000). Pull off the outer race (850) using the puller (98/3). The thickness D of the shim is calculated in accordance with the following equation: Thickness D = Dimension B – Dimension A – 0. if necessary.000188xx I Removing and Installing the Retarder CAUTION Determining the shim NOTE Hot parts! Hands could be burned. heat the gearbox housing to approx. 25100 28036 3.00009711 I arrtd I 2007-09 © 2007 25000 850 28181 Page 57 . Remove the O-rings (25100) from the gearbox. Ö Wear protective gloves or use cloths. 98/3 00 628 265 FJ 486 Voith Turbo I 153. 2.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.02 mm • The distance of the gearbox housing sealing surface to the outer race contact surface (850) in the gearbox housing is measured for dimension B. Ö Work carefully. • Dimension A is the distance between the retarder housing sealing surface and the outer race ring and is calculated in accordance with the following equation: Dimension A = H – Dimension C NOTE Ö In order to facilitate the removal. -head screws with 10 Nm. Place the outer ring (850) onto the inside part (800). Place the measuring device (98/1) on the retarder housing and fasten with 4 hex. NOTE Ö Carry out measurements at the gearbox and the retarder at room temperature in a vertical position. Voith Turbo I 153. Page 58 . 1. Note dimension C. 98/1 28031 7. B 6.000188xx I Removing and Installing the Retarder 4. Tighten the hex.-head screws M 10 x 40. Ö Ensure that the gearbox and retarder have cooled down.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 28086 28084 3. Turn the pinion manually 15 times clockwise and then 15 times counter-clockwise. Measure dimension C with the digital depth gauge: From the top edge of the measuring device to the measuring panel in the measuring device (98/1). 850 800 98/1 28032 2. Measure dimension B and note the value. 5. 3439xx 0. Installing the outer race (850) and shim (25000) 850 25000 98/4 28135 NOTE Ö If two shims are used: Insert the thicker shim first into the gearbox housing.3442xx NOTE Ö If necessary.3433xx 0.3432xx 0.76 67. 9.58 67.55 67.82 67.Remove the outer ring (850). Read dimension H from the measuring device (98/1) (see arrow/diagram). 1. 0.3430xx 0.79 67.61 67. Calculate dimension A: Dimension A = H – Dimension C.3437xx 0.91 67.94 67.85 67.3435xx 0.3436xx 0.3427xx Thickness D [mm] Voith item no.88 67.97 67.67 67.73 67.Calculate thickness D of the shim: Thickness D = Dimension B – Dimension A – 0.3426xx 0.3431xx 0.3438xx 0.Remove the measuring device (98/1). Insert the shim (25000) into the gearbox housing.3440xx 0.3434xx 0.00009711 I arrtd I 2007-09 © 2007 10. Shims with the following thicknesses D can be ordered from Voith Turbo GmbH & Co.02 mm 11.xx 98/1 28085 8. Page 59 .00 67.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.70 67. KG: Thickness D [mm] Voith item no. NOTE If the inside part (800) was replaced: Ö Replace the outer ring (850).3441xx 1.000188xx I Removing and Installing the Retarder H = xxx. 12.64 67. Voith Turbo I 153. Ö If the calculated compensation dimension cannot be achieved exactly with the shims: Use the next smaller compensation dimension.52 67.3428xx 0.3429xx 0. 0. use two shims in order to realize the compensation dimension. Ö Wear protective gloves or use cloths. 28038 Page 60 . 28037 1.00009711 I arrtd I 2007-09 © 2007 3. 2. Place the gearbox so that the sealing surface faces upwards. Knock in the outer race (850) until it stops using the marking punch (98/4).000188xx I Removing and Installing the Retarder CAUTION Hot parts! Installing the retarder 25100 1 Hands could be burned. Voith Turbo I 153. if necessary. NOTE Ö In order to facilitate installation heat the gearbox housing to approx. 80 °C in the area of the outer race (850). Ö Work carefully. Screw the two threaded bolts into the gearing housing (see arrows/diagram). 4. Clean the sealing surface of the retarder housing (1). 3. 5. Clean the sealing surface of the gearbox housing and apply Loctite 5203. Lubricate the new O-rings (25100) with siliconefree and non-corrosive grease and insert them into the gearbox housing.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 2. Insert the outer ring (850) into the gearbox housing. 000188xx I Removing and Installing the Retarder 25200 25200 25200 25300 28039 6.Tighten the hex. Unscrew the threaded bolts. Screw in the two hex.-head screws (25200). Page 61 . Screw in the three hex. 9.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 8.Screw in the hex. 11.-head screws (25300) and tighten it with 58 Nm.-head screws (25200) with 58 Nm.-head screws (25200). 7.00009711 I arrtd I 2007-09 © 2007 10. Voith Turbo I 153. Place the retarder on the gearing housing. 13 Non-Return Valve (inlet) 96 7.8 Inside Part (800) 83 7.9 Pipe (5900) 85 7.6 Retarder Ventilation 81 7.10 Water Neck 86 7.1 Components Overview 63 7.16 Coolant Temperature Sensor 103 7.7 Basic Retarder 82 7.Voith Turbo I 153.2 Top Oil Tank Cover 70 7.14 Non-Return Valve (outlet) 98 7.18 Proportional Valve and Damping Plate 106 Page 62 . Repair 7.11 Heat Exchanger 88 7.3 Bottom Oil Tank Cover 72 7.12 Pressure Control Valve 93 7.00009711 I arrtd I 2007-09 © 2007 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.4 Cover for Casing Ventilation 74 7.000188xx I Repair 7.17 Pressure Sensor 105 7.15 Oil Temperature Sensor 101 7.5 Casing Ventilation 77 7. 55.f. if necessary 2105 2100 2106 1700 1600 4250 1900 4250 4200 4200 3100 6700 6600 20100 20200 5200b 5300 20200 20000 20400 20300 28047 Page 63 . Retarder housing 107 Screw plug M 24 x 1.a. 12. w. hexagon socket head. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.000188xx I Repair 7.00009711 I arrtd I 2007-09 © 2007 Components Overview 2000 8000 6600 100 2300 6700 5300 3850 5200a 3800 3850 3900 6600 6700 7600 7500 7300 7300 7300 7500 6400 6700 6600 2600 20100 1950 20000 2900 5600 2206 5500 4000 108 5400 3700 3500 107 3550 2200 2500 3100 Replace component Check component according to specifications and replace. 4100 4150 3300 3100 9000 5901 6100 6101 2810 2800 2801 6101 2301 3300 Sealing ring A 24 x 29 1600 1950 5901 5900 Name 100 108 Voith Turbo I 153. with copper sealing ring (108): 80 Nm with integrated sealing ring: 47 Nm Valve cover 1700 O-ring 60 x 3 1900 Non-return valve (inlet) M 48 x 1. if necessary Perform visual inspection and replace. hexagon insert bit.a.f. with copper sealing ring (1950): 280 Nm with integrated sealing ring: 280 Nm Sealing ring A 48 x 55 NOTE Ö Lubricate sealing rings.5.5. w.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.1 Components Overview Item No. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.5 2300 Casing ventilation 2301 O-ring 55 x 3 2500 Bottom oil tank cover 2600 Gasket 5901 5900 4100 4150 3300 3100 9000 5901 6100 6101 2810 2301 3300 2800 2801 6101 2000 8000 6600 100 2300 6700 5300 3850 5200a 3800 3850 3900 6600 6700 7600 7500 7300 7300 7300 7500 6400 6700 6600 2600 20100 1950 20000 2900 NOTE Voith Turbo I 153. Sieve at the screw plug (3500) 2206 O-ring 21. 5600 2206 5500 4000 108 5400 3700 3500 107 3550 2200 2500 3100 Replace component Check component according to specifications and replace. with integrated sieve without sieve. if necessary Perform visual inspection and replace.000188xx I Repair Item No.00009711 I arrtd I 2007-09 © 2007 Components Overview Ö Lubricate sealing rings.5 x 2. complete. if necessary 2105 2100 2106 1700 1600 4250 1900 4250 4200 4200 3100 6700 6600 20100 20200 5200b 5300 20200 20000 20400 20300 28047 Page 64 . Name 2000 Top oil tank cover 2100 Non-return valve (outlet) 2105 O-ring 34 x 3 2106 O-ring 54 x 3 2200 Pressure control valve. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 30 Nm Combined hex. if necessary Perform visual inspection and replace.-head screw M 8 x 30.a. w. 13. 10 Nm 3100 3300 3500 3550 Voith Turbo I 153. 17.-head screw M 8 x 80. hexagon insert bit. 13. w.a.a. 3300 6100 6101 3300 Combined hex.00009711 I arrtd I 2007-09 © 2007 Name 2800 2900 Components Overview 5900 Screw plug M 30 x 1.000188xx I Repair Item No. if necessary 2105 2100 2106 1700 1600 4250 1900 4250 4200 4200 3100 6700 6600 20100 20200 5200b 5300 20200 20000 20400 20300 28047 Page 65 .a. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. 30 Nm 4100 4150 9000 5901 Gasket 5901 2200 2500 3100 Replace component Check component according to specifications and replace. hexagon insert bit. with copper sealing ring (3550): 130 Nm with integrated sealing ring: 100 Nm Sealing ring A 30 x 36 2810 3100 2800 2801 6101 2301 2000 8000 6600 100 2300 6700 5300 3850 5200a 3800 3850 3900 6600 6700 7600 7500 7300 7300 7300 7500 6400 6700 6600 2600 20100 1950 20000 2900 5600 2206 5500 4000 108 5400 3700 3500 107 3550 NOTE Ö Lubricate sealing rings. 17. Cover for casing ventilation 2801 Cover 2810 Air and vent filter M 12 x 1.f.f. w.5. hexagon socket head.5. w.f.f. hexagon insert bit. hexagon socket head. w.f. 13.a. 17.a. w. hexagon insert bit.a.5.-head nut M 8. 30 Nm 4000 4100 4150 Screw plug M 30 x 1. 18 Nm NOTE Voith Turbo I 153. if necessary 2105 2100 2106 1700 1600 4250 1900 4250 4200 4200 3100 6700 6600 20100 20200 5200b 5300 20200 20000 20400 20300 28047 Page 66 . Name 3700 Proportional valve 3800 Damping plate 3850 O-ring 16 x 3 3900 Combined hex. if necessary Perform visual inspection and replace. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. w.000188xx I Repair Item No.00009711 I arrtd I 2007-09 © 2007 Components Overview 2000 8000 6600 100 2300 6700 5300 3850 5200a 3800 3850 3900 6600 6700 7600 7500 7300 7300 7300 7500 6400 6700 6600 2600 20100 1950 20000 2900 5600 2206 5500 4000 108 5400 3700 3500 107 3550 2200 2500 3100 Replace component Check component according to specifications and replace. 13.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 5901 5900 4100 4150 3300 3100 9000 5901 6100 6101 2810 2800 2801 6101 2301 3300 Hex.-head screw M 8 x 20.f.f. hexagon insert bit. with copper sealing ring (4150): 130 Nm with integrated sealing ring: 100 Nm Sealing ring A 30 x 36 Ö Lubricate sealing rings. 30 Nm 4100 4150 2000 8000 6600 100 2300 6700 5300 3850 5200a 3800 3850 3900 6600 6700 7600 7500 7300 7300 7300 7500 6400 6700 6600 2600 20100 1950 20000 2900 5600 2206 5500 4000 108 5400 3700 3500 107 3550 2200 NOTE Ö Lubricate sealing rings.f.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.f.5.4 6100 6101 2810 3100 2800 2801 6101 2301 3300 Coolant temperature sensor M 14 x 1.000188xx I Repair Item No. w. with copper sealing ring (4250): 80 Nm with integrated sealing ring: 47 Nm 5901 5900 5901 Sealing ring A 14 x 20 5400 Wave spring 5500 Washer silencer 5600 Circlip JL 30 x 1. 4200 4250 5200a Voith Turbo I 153. hexagon insert bit.5. 30 Nm 5300 3300 9000 Sealing ring A 24 x 29 Oil temperature sensor M 14 x 1. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. 2500 3100 Replace component Check component according to specifications and replace. if necessary 2105 2100 2106 1700 1600 4250 1900 4250 4200 4200 3100 6700 6600 20100 20200 5200b 5300 20200 20000 20400 20300 28047 Page 67 .f.a.5. w. hexagon insert bit.3 x 2.a.a. 27. 12. hexagon socket head. w.00009711 I arrtd I 2007-09 © 2007 5200b Components Overview Name Screw plug M 24 x 1. with union nuts. 27. 60 Nm 5901 O-ring 15.2 5900 Pipe. if necessary Perform visual inspection and replace. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 Item No.3 x 2. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.a. hexagon insert bit.4 6400 Heat exchanger 6600 Hex. if necessary 2105 2100 2106 1700 1600 4250 1900 4250 4200 4200 3100 6700 6600 20100 20200 5200b 5300 20200 20000 20400 20300 28047 Page 68 . 22. in case of mounting with angle measuring tool: Initial torque: 50 Nm Final torque: 30° in case of mounting with torque wrench: Initial torque: 50 Nm Final torque: 130 Nm 5901 5900 6700 Washer A 14 7300 O-ring 15 x 4 7500 O-ring 45 x 5 7600 O-ring 25 x 4 8000 Intermediate washer 196 x 144 x 2 3300 3100 9000 5901 6100 6101 2810 3300 2800 2801 6101 2301 2000 8000 6600 100 2300 6700 5300 3850 5200a 3800 3850 3900 6600 6700 7600 7500 7300 7300 7300 7500 6400 6700 6600 2600 20100 1950 20000 2900 5600 2206 5500 4000 108 5400 3700 3500 107 3550 2200 NOTE Ö Lubricate sealing rings. w. Components Overview Name 6100 Pipe 6101 O-ring 15.000188xx I Repair Voith Turbo I 153.f. 4100 4150 2500 3100 Replace component Check component according to specifications and replace. if necessary Perform visual inspection and replace.-head screw M 14 x 45. hexagon insert bit. hexagon insert bit.f.f.f.00009711 I arrtd I 2007-09 © 2007 Components Overview 2000 8000 6600 100 2300 6700 5300 3850 5200a 3800 3850 3900 6600 6700 7600 7500 7300 7300 7300 7500 6400 6700 6600 2600 20100 1950 20000 2900 5600 2206 5500 4000 108 5400 3700 3500 107 3550 2200 2500 3100 Replace component Check component according to specifications and replace. 30 Nm 20000 Water neck 20100 Gasket 20200 Combined hex.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.a. w.-head screw M 8 x 80.5. hexagon insert bit. 13.000188xx I Repair Item No.5. w. 13.a. w. 27. 32 Nm NOTE Voith Turbo I 153. 9000 Name Pressure sensor M 16 x 1. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. if necessary Perform visual inspection and replace.a. 30 Nm 20300 20400 Sealing ring A 14 x 20 Ö Lubricate sealing rings. 5901 5900 4100 4150 3300 3100 9000 5901 6100 6101 2810 2800 2801 6101 2301 3300 Screw plug M 14 x 1. if necessary 2105 2100 2106 1700 1600 4250 1900 4250 4200 4200 3100 6700 6600 20100 20200 5200b 5300 20200 20000 20400 20300 28047 Page 69 . f. hexagon insert bit. H67.00009711 I arrtd I 2007-09 © 2007 Top Oil Tank Cover 6101 2800 8000 Ö Lubricate sealing rings.2 Top Oil Tank Cover Item No.4.150030 upwards: 100 Aids Thread seal Loctite 572 for bores of the combined hex. In case of retarders from Voith item no.-head screw M 8 x 80. 13. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.f.a. 30 Nm 2000 3300 6100 Pipe. take installation position into account 6101 O-ring 15. 30 Nm 3100 Combined hex.-head screw M 8 x 30.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. replace 8000 Intermediate washer 196 x 144 x 2. 6101 Name 3300 6100 100 Retarder housing 2000 Top oil tank cover 2800 Cover for casing ventilation 3100 Combined hex. 13.000188xx I Repair 7.-head screws 28072 Page 70 .3 x 2.a. w. replace NOTE Voith Turbo I 153. w. hexagon insert bit. Lubricate bore for the pipe (6100) into the casing ventilation cover (2800) with silicone-free and noncorrosive grease. Screw on the oil tank cover (2000) with the combined hex. Ö Work carefully.150030 upwards: Apply thread seal Loctite 572 to the bores of the combined hex. In doing so.-head screws (3100 and 3300). Clean the sealing surfaces at the retarder housing and at the oil tank cover (2000). H67. if necessary. Remove the pipe (6100) with the O-rings (6101). Page 71 . 4. 4. Voith Turbo I 153. 8. 6. observe the installation position. Remove the intermediate washer (8000). Top Oil Tank Cover 2. Lubricate the new O-rings (6101) with siliconefree and non-corrosive grease and pull them onto the pipe (6100).Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Removing 1. Tighten the combined hex. In case of retarders from Voith item no. Ö Wear protective gloves or use cloths. CAUTION Hot parts! Hands could be burned. Insert the pipe (6100) in the oil tank cover (2000) and casing ventilation cover (2800). 2.00009711 I arrtd I 2007-09 © 2007 3. 3. Insert a new intermediate washer (8000). Unscrew the combined hex.-head screws (3100 and 3300) crosswise with 30 Nm.000188xx I Repair Requirements Installing • Retarder is switched off • Ignition is switched off 1. 5.-head screws (3100 and 3300). Remove the oil tank cover (2000).-head screws (3100 and 3300). 7. w. hexagon insert bit. 30 Nm NOTE Ö Lubricate sealing rings. 2600 2500 Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 3100 28073 Page 72 . 13.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.3 Bottom Oil Tank Cover Bottom Oil Tank Cover Item No. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. Name 2500 Bottom oil tank cover 2600 Gasket. replace 3100 Combined hex.f.-head screw M 8 x 30.000188xx I Repair 7.a. -head screws (3100) tight in the prescribed sequence with 30 Nm.-head screws! • Retarder oil is drained (see page 23) Cover can buckle. 1. Incorrect sequence when tightening the com- Ö Screw the combined hex.00009711 I arrtd I 2007-09 © 2007 3. Remove the oil tank cover (2500).Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Repair Requirements Bottom Oil Tank Cover CAUTION • Retarder is switched off • Ignition is switched off bined hex. Clean the sealing surfaces at the retarder housing and at the oil tank cover (2500). Page 73 . Insert new gasket (2600). 2. Remove the gasket (2600). Screw the combined hex. 6 Ö Wear protective gloves or use cloths. 2. CAUTION Hot parts! Hands could be burned.-head screws tight in the prescribed sequence. Installing 1 8 9 16 10 15 11 14 12 13 28074 4. if neces- 5 3 4 sary. Unscrew the combined hex. 7 2 17 Removing 1. Screw on the oil tank cover (2500) with the combined hex. Ö Work carefully.-head screws (3100). Voith Turbo I 153. 3.-head screws (3100). 4 Cover for Casing Ventilation Cover for Casing Ventilation 3300 Item No.00009711 I arrtd I 2007-09 © 2007 Ö Lubricate sealing rings.a. 13. NOTE If the casing ventilation cover (2800) is replaced: Ö Order the sealing cover (2801) as well.-head screw M 8 x 80. hexagon insert bit.000188xx I Repair 7. w. Name 2800 Cover for casing ventilation 2801 Cover 2900 Gasket.4. 28180 Page 74 . replace NOTE 2800 6101 6100 2801 6101 2900 Voith Turbo I 153.f. take installation position into account 6101 O-ring 15. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.3 x 2. replace 3300 Combined hex. 30 Nm 6100 Pipe. Remove the pipe (6100). Remove the casing ventilation cover (2800). 28050 Ö Work carefully. 5. Ö Wear protective gloves or use cloths. sary. Unscrew the combined hex.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Pull off the O-rings (6101).-head screws (3300).000188xx I Repair Cover for Casing Ventilation Removing Requirements • Retarder is switched off • Ignition is switched off 6101 6100 6101 3300 • Proportional valve and damping plate are removed (see page 106) CAUTION Hot parts! 28052 Hands could be burned. 2800 Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 2900 28051 2. if neces- 4. 1. Page 75 . Remove the gasket (2900). 3. -head screws (3300) crosswise to 30 Nm. Insert the pipe (6100) into the oil tank cover top (2000).Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Lubricate the new O-rings (6101) with siliconefree and non-corrosive grease and pull them onto the pipe (6100). Screw on the casing ventilation cover (2800) with the combined hex. 28136 28060 3. Voith Turbo I 153.-head screws (3300). observe the installation position. 6100 3300 2800 28061 4. 2900 6101 7. Installing 2000 6100 6.00009711 I arrtd I 2007-09 © 2007 2. 1. Page 76 . In doing so. Tighten the combined hex.000188xx I Repair Cover for Casing Ventilation 5. Put the casing ventilation cover (2800) onto the pipe (6100). Lubricate bore for the pipe (6100) into the casing ventilation cover (2800) with silicone-free and noncorrosive grease. Insert new gasket (2900). 2300 Name Casing ventilation 2300/1 Valve insert 2300/2 Float.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Repair 7. 12 g.00009711 I arrtd I 2007-09 © 2007 Aids Ethyl alcohol for float 28048 Page 77 . O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.5 Casing Ventilation Casing Ventilation Item No. 2301 2300/2 2300/3 Voith Turbo I 153. H53. for casing ventilation from Voith item no. replace 2300 NOTE Ö Lubricate sealing rings. specified weight max.133214 upwards take installation position into account: the side marked "O" faces upwards 2300/3 Float cage 2301 2300/1 O-ring 55 x 3. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Repair CAUTION Casing Ventilation CAUTION Tools for self-fabrication Hot parts! Damage to components. Hands could be burned. Ö Only use special tools in the specified version. Ö Work carefully. Ö Take the last two digits of the Voith item no. into Ø 40.5 mm Ø 60 mm account in the diagram of the special tools. 7 mm False special tools! H67.2757xx Ö Wear protective gloves or use cloths, if necessary. Removing Special tools Test ring 99/4 99/5 Material: St 37 Weight: 0.085 kg Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 98/9 H53.7712xx H53.942811 Impact puller Adapter 99/5 98/9 The test ring (99/4) can be ordered from Voith Turbo GmbH & Co. KG: Voith item no. H67.2757xx. Requirements 28053 • Retarder is switched off • Ignition is switched off 1. Screw the impact puller (99/5) to the adapter (98/9). • Proportional valve and damping plate are removed (see page 106) 2. Use the impact puller (99/5) including the adapter (98/9) to pull the valve insert (2300/1) upwards and out. • Casing ventilation cover is removed (see page 74) Page 78 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Repair Casing Ventilation Checking 2300/2 1. Check the casing ventilation (2300) for soiling and sludge and clean it. 99/4 2300/2 2300/3 2300/1 2300/2 28054 28057 3. If necessary, remove the float (2300/2) and the float cage (2300/3). 28056 2300/1 2. Check the float (2300/2) for damaged surfaces and sealing areas (see arrow/diagram). Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 3. Weigh the float (2300/2): Specified weight: max. 12 g. 4. For exceeded specified weight: Replace the entire casing ventilation (2300). 2301 5. Check the sealing edge of the radial shaft sealing ring in the valve insert (2300/1) (see arrow/diagram): - Place the float (2300/2) on a suitable object, e.g. hex.-head nut. - Place the valve insert (2300/1) on the float and weigh it down using the test ring (99/4). - Fill the empty space between the float (2300/2) and upper edge of the valve insert with ethyl alcohol. NOTE 28055 4. Remove O-ring (2301) of the groove in the valve insert (2300/1). The sealing edge is damaged, if the fluid level drops within 1 minute. 6. If the sealing edge is damaged: Replace the casing ventilation (2300). Page 79 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Repair Casing Ventilation Installing CAUTION 99/5 2300/1 Grease at the radial shaft sealing ring! Malfunction of the retarder. 98/9 2300/2 Ö Do not lubricate the radial shaft sealing ring. 2300/3 28059 2300/1 2. Clean the float with ethyl alcohol. NOTE For casing ventilation from Voith item no. H53.133214 upwards: 2301 Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 28058 1. Lubricate the new O-ring (2301) with silicone-free and non-corrosive grease and pull it on the valve insert (2300/1). 28053 7. Use the impact puller (99/5) including the adapter (98/9) to press the casing ventilation (2300) carefully in. 8. Complete the retarder. Ö Observe the installation position of the float: The side marked "O" upwards. 3. Insert the float (2300/2) into the float cage (2300/3). 4. Place valve insert (2300/1) on float cage (2300/3). 5. Clean the sealing surfaces at the retarder housing and at the casing ventilation cover (2800). 6. Lubricate the bore of the casing ventilation (2300) in the retarder housing with silicone-free and noncorrosive grease. Page 80 5400 5500 Ö Replace retarder ventilation.000188xx I Repair 7.00009711 I arrtd I 2007-09 © 2007 28062 Aids Benzine for disc silencer Page 81 .Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Retarder Ventilation Requirements • Retarder is switched off • Ignition is switched off Name 5400 Corrugated spring. replace 5500 Disc silencer.6 Retarder Ventilation Item No. CAUTION 5600 Mechanically damaged retarder ventilation! Malfunction of the retarder. clean and blow out with compressed air 5600 Circlip DANGER Heavily soiled or painted-over retarder ventilation! Retarder reduces braking power after a delay. r. ach h-S Voit Voith Turbo I 153. ch-N -Sa -Nr. Kd. check. Ö Replace retarder ventilation. hexagon insert bit. 33 Name Basic retarder 850 Outer race. 58 Nm 25300 Hex. w.-head screw M 10 x 60. hexagon insert bit.a.000188xx I Repair 7. 58 Nm NOTE Instructions are enclosed with the basic retarder (spare part).f. w.00009711 I arrtd I 2007-09 © 2007 Basic Retarder Oil temperature sensor 6400 Heat exchanger 9000 Pressure sensor 25000 Shim 25100 O-ring 14 x 4. 16.a.f.7 Basic Retarder Item No. replace 25200 Hex. replace 3700 Proportional valve 3800 Damping plate 5200a Voith Turbo I 153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.-head screw M 10 x 70. 25000 25300 850 5200a 25200 3700 9000 3800 25100 25200 6400 33 28182 Page 82 . 16. These describe the removal/installation and return of the defective basic retarder (see conversion instructions for basic retarder VR 115 E). 000188xx I Repair 7.00009711 I arrtd I 2007-09 © 2007 from the retarder shaft.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 800 Name Inside part 800 Commercially available tools Hot plate Requirements • Retarder is removed (see page 54) Removing Ö Use a suitable puller to pull the inside part (800) Voith Turbo I 153.8 Inside Part (800) Inside Part (800) Item No. 28184 Page 83 . Ö Wear protective gloves or use cloths. 1. Ö Work carefully.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Press the inside part (800) onto the retarder shaft until it stops.000188xx I Repair Inside Part (800) Installing CAUTION Hot parts! Hands could be burned. 100 °C.00009711 I arrtd I 2007-09 © 2007 2. Voith Turbo I 153. Page 84 . Use a hot plate to heat the inside part (800) to approx. if necessary. Name 5900 Pipe.9 Pipe (5900) Pipe (5900) Item No.4. with union nuts.00009711 I arrtd I 2007-09 © 2007 5901 28183 Page 85 .000188xx I Repair 7. replace 5900 Requirements • 5901 Retarder is removed (see page 54) Voith Turbo I 153.3 x 2.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 60 Nm 5901 O-ring 15. -head screw M 8 x 80.f.000188xx I Repair 7. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. 30 Nm 20100 20000 20200 NOTE Voith Turbo I 153. 13.a.-S hKd ac -S ith Vo 20100 20000 20200 28063 Page 86 .00009711 I arrtd I 2007-09 © 2007 Ö Lubricate sealing rings. hexagon insert bit. . ac Nr . Item No. the design of the water neck can differ (see specifications of vehicle manufacturer). w. Name 20000 Water neck 20100 Gasket.10 Water Neck Water Neck NOTE Depending on the vehicle manufacturer.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Nr h. replace 20200 Combined hex. 000188xx I Repair Water Neck Requirements • Retarder is switched off • Ignition is switched off • Coolant is drained (see page 29) CAUTION Hot parts! Hands could be burned. if neces- Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 sary.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Page 87 . Ö Wear protective gloves or use cloths. Ö Work carefully. 22. w.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.a.-head screw M 14 x 45. in case of mounting with angle measuring tool: Initial torque: 50 Nm Final torque: 30° in case of mounting with torque wrench: Initial torque: 50 Nm Final torque: 130 Nm 6700 Washer A 14 7300 O-ring 15 x 4. hexagon insert bit.11 Heat Exchanger Item No. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. replace 7600 O-ring 25 x 4. Name 6400 Heat exchanger 6600 Hex. replace 7500 O-ring 45 x 5.000188xx I Repair 7. 6700 6600 7600 7500 7300 7300 6400 7300 7500 6700 6600 6700 6600 28064 Page 88 . NOTE Ö Please procure any connecting pieces that are not listed here by yourself.00009711 I arrtd I 2007-09 © 2007 Heat Exchanger Ö Lubricate sealing rings. replace NOTE Voith Turbo I 153.f. + 250 °C • Voith item no. Ö Secure the heat exchanger against falling. Page 89 . Remove the heat exchanger (6400).000188xx I Repair Heat Exchanger Removing Requirements Special tools • Retarder is switched off • Ignition is switched off • Supply-air pressure pv is drained • Retarder oil is drained (see page 24) • Coolant is drained (see page 29) • Water neck is removed (see page 86) 6400 H67... Ö Use a suitable lifting device. Unscrew the hex.001697xx For sealing surface heat exchanger/ retarder housing 6700 6700 6600 6700 6600 28066 1. if necessary. Aids Elring sealing compound Dirko-S Profi press HT: 6600 CAUTION Hot parts! Hands could be burned.00009711 I arrtd I 2007-09 © 2007 • Color black • Temperature-resistant –50 °C . Ö Wear protective gloves or use cloths.1948xx Pressure test equipment DANGER 50/22 Heat exchanger can fall! Commercially available tools Rotation angle measuring tool 3/4" Voith Turbo I 153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 190. 2.-head screws (6600) with washers (6700). Your body can be crushed severely. Ö Work carefully. 00009711 I arrtd I 2007-09 © 2007 Ö If air bubbles occur in the water or if an external leak is found: Replace the heat exchanger. if necessary. Remove the O-rings (7300. A B 28068 1. Ö Work carefully. 4. Connect the compressed-air line with pressure reducer to connection (A). Install the pressure-test equipment (50/22) using O-rings to the heat exchanger (6400). 70 °C). Repeat the test at the connections (B and C). Checking 50/22 7600 7500 7300 7300 CAUTION 6400 Heat exchanger leaks! Malfunction of the retarder. Installing NOTE The water and oil section of new heat exchangers are coated with anti-corrosion oil. Fill the water section of the heat exchanger (6400) with hot water (approx. of 10 bars overpressure. C 5.000188xx I Repair Heat Exchanger 2. 7300 7500 28067 3. 1. 7500 and 7600) with silicone-free and non-corrosive grease and insert into the retarder housing. CAUTION 7600 Hot water! 7500 7300 7300 Hands could be burned. 100 3. 7300 7500 28070 Voith Turbo I 153. Slowly pressurize the heat exchanger (6400) with a max. Ö Wear protective gloves or use cloths. Ö Before installation drain any anti-corrosion oil and rinse the water section with hot water. Lubricate the new O-rings (7300. Page 90 .Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 7500 and 7600). 28066 3. In case of water in the retarder! 6.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.0 liters engine oil or flush oil. Ö Repeat the process 2 or 3 times. Fill the vehicle and retarder cooling circuit (see specifications of vehicle manufacturer). Malfunction of the retarder.-head screws (6600) crosswise with 130 Nm. Ö De-oil the cooling and heating system (see specifications of vehicle manufacturer). 6400 CAUTION 5. Place the heat exchanger (6400) on the retarder housing. Page 91 . Ö Observe the specifications of the vehicle manufacturer or those of Voith Turbo cooling water quality list. Screw on the hex. Ö Flush the retarder system by braking several times lightly.-head screws (6600) with washers (6700). In case of mounting with torque wrench: Tighten the hex. CAUTION Wrong coolant type! Damage to the vehicle and retarder cooling circuit. Ö Drain the oil. Voith Turbo I 153.-head screws (6600) crosswise with 30°. Tighten the hex. 7. Ö Fill the retarder with 7. Complete the retarder. In case of mounting with angle measuring tool: Tighten the hex.000188xx I Repair Heat Exchanger 4. 28174 2. Oil emission through retarder ventilation. Apply sealing compound to the two sealing surfaces (see dashed lines/figure).-head screws (6600) crosswise with 50 Nm.00009711 I arrtd I 2007-09 © 2007 6600 6700 6700 6600 6700 6600 8. Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Seal the gap between the heat exchanger and the retarder housing (see dashed line/figure). Page 92 .00009711 I arrtd I 2007-09 © 2007 9.000188xx I Repair Heat Exchanger 6400 28175 Voith Turbo I 153. 5.12 Pressure Control Valve Pressure Control Valve Item No. . w. with copper sealing ring (3550): 130 Nm with integrated sealing ring: 100 Nm 3550 Sealing ring A 30 x 36. 2206 Voith Turbo I 153. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. hexagon socket head. Sieve at the screw plug (3500) 2206 O-ring 21. 17.f.000188xx I Repair 7. replace r.-S h-N Kd ac -S ith Vo NOTE Ö Lubricate sealing rings.5. with integrated sieve without sieve.00009711 I arrtd I 2007-09 © 2007 3550 3500 2200 28075 Page 93 .5 x 2.a. complete. Name 2200 Pressure control valve. replace 3500 Screw plug M 30 x 1. h-N ac r. hac Nr.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.5 Adapter 50/43 3500 3550 28076 1. 3.7712xx Impact puller 99/5 99/5 Hot parts! Hands could be burned. Unscrew the screw plug (3500) with the sealing ring (3550). For pressure control valve (2200) with integrated sieve: Removing 2. if necessary. ac th-S Voi M 20 x 1. -S hKd. Page 94 . Ö Wear protective gloves or use cloths.00009711 I arrtd I 2007-09 © 2007 M8 Nr. . Use the impact puller (99/5) to knock out the complete pressure control valve (2200) out of the retarder housing. hac Nr. 28077 Ö Work carefully.000188xx I Repair Special tools Pressure Control Valve Requirements • Retarder is switched off • Ignition is switched off • Retarder oil is drained (see page 23) Nr.-S hKd ac -S ith Vo CAUTION H53. Tools for self-fabrication Voith Turbo I 153. For pressure control valve (2200) with integrated sieve: Screw the impact puller (99/5) to the screw plug (50/43). -S h-N Kd ac -S th Voi - Check the sealing ring for damage. Lubricate the new O-ring (2206) with silicone-free and non-corrosive grease and pull it onto the pressure control valve (2200). If necessary.00009711 I arrtd I 2007-09 © 2007 2200 28078 1. Use the impact puller (99/5) to press the complete pressure control valve (2200) carefully in. 2206 Voith Turbo I 153. Page 95 . For screw plug (3500) with copper sealing ring (3550): • Pressure control valve with integrated sieve - • Pressure control valve without sieve. h-N . replace the screw plug (3500). Ö Do not combine individual parts. Sieve is located at the screw plug (3500) Lubricate the new sealing ring (3550) with silicone-free and non-corrosive grease. For pressure control valve (2200) with integrated sieve: If necessary. ac r . screw the impact puller (99/5) to the screw plug (50/43). - Screw in the screw plug (3500) and tighten it to 100 Nm. 2.000188xx I Repair Installing Pressure Control Valve 3. - Screw in the screw plug (3500) with sealing ring (3550) and tighten it to 130 Nm. NOTE 2 variants of the pressure control valve are possible: 4.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. For screw plug (3500) with integrated sealing ring: r. 000188xx I Repair 7.a. replace NOTE 1950 Ö Lubricate sealing rings. 1900 Name Non-return valve (inlet). ac th-S Voi 1900 28079 Page 96 . 55. H67. with copper sealing ring (1950): 280 Nm with integrated sealing ring: 280 Nm 1900/2 Spring 1900/3 Piston 1950 Sealing ring A 48 x 55. 1900/3 1900/2 1900/1 Voith Turbo I 153. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.00009711 I arrtd I 2007-09 © 2007 In case of retarders from Voith item no.5 hexagon insert bit.13 Non-Return Valve (inlet) Non-Return Valve (inlet) Item No. w. complete 1900/1 Guide M 48 x 1. hac Nr.f.150030 upwards and copper sealing ring (1950): Aids Thread seal Loctite 572 for the guide thread Nr. -S hKd.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Removing 1.000188xx I Repair Non-Return Valve (inlet) Requirements Checking Installing • Retarder is switched off Ö In case of retarders from Voith item no. If necessary. replace the complete nonreturn valve (inlet) (1900). - Tighten the non-return valve (inlet) (1900) with 280 Nm. Check the rubber coating of the piston (1900/3) for damage. Ö Wear protective gloves or use cloths. • Ignition is switched off 1. 1900/2 28179 2. Ö Work carefully.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. If necessary. 1900/3 For guide (1900/1) with integrated sealing ring: Screw in the non-return valve (inlet) (1900) and tighten it with 280 Nm. Check the guide (1900/1) and spring (1900/2) for wear.00009711 I arrtd I 2007-09 © 2007 2. replace the complete nonreturn valve (inlet) (1900). CAUTION H67. - Screw in the non-return valve (inlet) (1900) with sealing ring (1950). Remove the spring (1900/2) and piston (1900/3) from the retarder housing. 3. If necessary. For guide (1900/1) with integrated sealing ring: Check the sealing ring for damage. 1900/1 Hot parts! Hands could be burned. - Lubricate the new sealing ring (1950) with silicone-free and non-corrosive grease. Page 97 . replace the complete non-return valve (inlet) (1900). Unscrew the guide (1900/1).150030 upwards and copper sealing ring (1950): - Apply Loctite 572 to the thread of the guide (1900/1). Voith Turbo I 153. if necessary. 00009711 I arrtd I 2007-09 © 2007 Ö Lubricate sealing rings. 30 Nm NOTE Voith Turbo I 153. ac Nr .14 Non-Return Valve (outlet) Non-Return Valve (outlet) Item No.000188xx I Repair 7. replace 3100 Combined hex.a.-S hKd ac -S ith Vo 2105 2106 1700 2100 1600 3100 28080 Page 98 . Nr h. 13.-head screw M 8 x 30. w. Name 1600 Valve cover.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. . take installation position into account 2105 O-ring 34 x 3. complete. replace 2106 O-ring 54 x 3. take installation position into account 1700 O-ring 60 x 3. hexagon insert bit. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.f. replace 2100 Non-return valve (outlet). If necessary. Push the puller (50/1) onto the non-return valve (outlet) (2100) until it latches in.000052xx Puller 28158 50/1 Voith Turbo I 153. If necessary. 3. Unscrew the combined hex.000188xx I Repair Non-Return Valve (outlet) Checking Removing Special tools 1. Remove the valve cover (1600). Ö Work carefully. Check the bore or sleeve for wear and eccentricity (see arrow/diagram). Pull the non-return valve (outlet) (2100) out of the retarder housing. replace the complete non-return valve (outlet) (2100). 2100 1 2. 2 153. Check the rubber coating of the valve disk (1) for damage. 5. 2105 and 2106).Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 Requirements 50/1 • Retarder is switched off • Ignition is switched off • Retarder oil is drained (see page 23) CAUTION Hot parts! 28153 3.-head screws (3100). Hands could be burned. replace the complete non-return valve (outlet) (2100). 1. Remove the O-rings (1700. Page 99 . 2. 4. If necessary. if necessary. replace the complete nonreturn valve (outlet) (2100). Press the valve disk (1) until it stops and check the guide piston (2) for wear. Ö Wear protective gloves or use cloths. 5. Tighten the combined hex. 4. observe the installation position. In doing so.-head screws (3100) crosswise to 30 Nm.-head screws (3100). 3.000188xx I Repair Non-Return Valve (outlet) Installing 1. 2100 28178 Voith Turbo I 153.00009711 I arrtd I 2007-09 © 2007 2. Page 100 . observe the installation position (see arrow/ diagram). Lubricate the O-ring (1700) with silicone-free and non-corrosive grease and pull it onto the valve cover (1600). Use a suitable tool to press the non-return valve (outlet) (2100) into the retarder housing.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. Screw on the valve cover (1700) with the combined hex. Lubricate the new O-rings (2105 and 2106) with silicone-free and non-corrosive grease and pull them onto the non-return valve (outlet) (2100). In doing so. w.00009711 I arrtd I 2007-09 © 2007 Requirements • Retarder is switched off • Ignition is switched off • Electrical connecting leads are disconnected 5300 5200a CAUTION Hot parts! Hands could be burned.5.f. if necessary. 5200a 5300 Name Oil temperature sensor M 14 x 1. Voith Turbo I 153.a. Ö Work carefully.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. replace NOTE Ö Lubricate sealing rings.000188xx I Repair 7. 27. 28115 Page 101 . hexagon insert bit. Ö Wear protective gloves or use cloths. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.15 Oil Temperature Sensor Oil Temperature Sensor Item No. 30 Nm Sealing ring A 14 x 20. Resistance 20 °C ± 10 °C 1039–1117 Ω 60 °C ± 10 °C 1194–1271 Ω 80 °C ± 10 °C 1271–1347 Ω Voith Turbo I 153.000188xx I Repair Oil Temperature Sensor Checking the internal resistance NOTE Measuring in one temperature range is usually sufficient. Polarity irrelevant.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 Temperature Page 102 . 30 Nm Sealing ring A 14 x 20. 5200b 5300 Name Coolant temperature sensor M 14 x 1.000188xx I Repair 7. hexagon insert bit. w.f.16 Coolant Temperature Sensor Coolant Temperature Sensor Item No.a.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. replace NOTE 5200b Ö Lubricate sealing rings.5.00009711 I arrtd I 2007-09 © 2007 Requirements • Retarder is switched off • Ignition is switched off • Coolant is drained (see page 29) • Electrical connecting leads are disconnected 28114 Page 103 . O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. 5300 Voith Turbo I 153. 27. Ö Wear protective gloves or use cloths. Checking the internal resistance NOTE Measuring in one temperature range is usually sufficient. Polarity irrelevant.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 Temperature Page 104 . if necessary.000188xx I Repair Coolant Temperature Sensor CAUTION Hot parts! Hands could be burned. Ö Work carefully. Resistance 20 °C ± 10 °C 1039–1117 Ω 60 °C ± 10 °C 1194–271 Ω 80 °C ± 10 °C 1271–347 Ω Voith Turbo I 153. f. w. Ö Wear protective gloves or use cloths. 28116 Page 105 .a.000188xx I Repair 7. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 Requirements • Retarder is switched off • Ignition is switched off • Electrical connecting leads are disconnected CAUTION Hot parts! Hands could be burned. 9000 Name Pressure sensor M 16 x 1. hexagon insert bit. Ö Work carefully.5. if necessary. 27.17 Pressure Sensor Pressure Sensor Item No. 30 Nm NOTE 9000 Ö Lubricate sealing rings. Voith Turbo I 153. hexagon insert bit.a. O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation. 3850 Name C Supply-air pressure pv "P" H Electrical connecting lead 3700 Proportional valve 3800 Damping plate. 28113 Page 106 . hexagon insert bit.00009711 I arrtd I 2007-09 © 2007 NOTE C 3900 4000 Ö Lubricate sealing rings. 13. w. 30 Nm.f.a.f.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 18 Nm. replace 4000 Hex.-head screw M 8 x 20. replace if damaged 3850 O-ring 16 x 3. w.18 Proportional Valve and Damping Plate Proportional Valve and Damping Plate Item No.-head nut M 8. replace 3800 3850 3900 4000 H 3700 Voith Turbo I 153.000188xx I Repair 7. replace 3900 Combined hex. 13. Page 107 . (H) Male and female connector are checked for damage or wear (notch scratches) NOTE Voith Turbo I 153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 Ö Check damping plate (3800) for mechanical and aging damage and replace.000188xx I Repair Proportional Valve and Damping Plate Requirements • Retarder is switched off • Ignition is switched off • Supply-air pressure pv is drained • Supply-air pressure line py (C) is removed • Electrical connecting lead is disconnected from proportional valve. if necessary. 2 Removing and Installing the Retarder 111 8.1 Diagnosis 109 8. into Voith Turbo I 153. Overview of the Tools 8. Ö Take the last two digits of the Voith item no.3 Repair 112 CAUTION False special tools! Damage to components.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 account in the diagram of the special tools. Ö Only use special tools from the specified version on. Page 108 .000188xx I Overview of the Tools 8. 001085xx 153.1 Diagnosis Activity Special tools Tools for self-fabrication Checking the constantair pressure control loop – 153.000776xx H53.1403xx Retarder tester.001085xx 153. complete in a case Test software "DIANA Lite" 50/56 50/56i Page 109 . complete in a case Test software "DIANA Lite" Pressure gauge 0–6 bar 50/56 50/56i 99/7 Voith Turbo I 153.000776xx Retarder tester.000188xx I Overview of the Tools 8.00009711 I arrtd I 2007-09 © 2007 Checking the pump pressure pdyn – 153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153. 8198xx Measuring adapter Voith Turbo I 153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Overview of the Tools Activity Special tools Checking the proportional valve current Tools for self-fabrication – H53.00009711 I arrtd I 2007-09 © 2007 99/3 Page 110 . Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.3320xx 15 Page 111 .00009711 I arrtd I 2007-09 © 2007 H67. DIN 17100 (1.000188xx I Overview of the Tools 8.3224xx H67.2 Removing and Installing the Retarder Activity Special tools Tools for self-fabrication 0 80 62 265 FJ 6 48 M 10 Removing and installing the retarder H67.80) Voith Turbo I 153.3319xx Puller Measuring device Marking punch 98/3 98/1 98/4 80 28028 2 x Threaded bolt Material: St 37-2. 1948xx Pressure test equipment 50/22 Page 112 .085 kg Voith Turbo I 153.5 mm Ø 60 mm H53.3 Repair Activity Special tools Tools for self-fabrication Ø 40.942811 H67.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.7712xx H53.00009711 I arrtd I 2007-09 © 2007 Heat exchanger – H67.2757xx Impact puller Adapter Test ring 99/5 98/9 99/4 7 mm Casing ventilation Material: St 37 Weight: 0.000188xx I Overview of the Tools 8. 7712xx M 20 x 1.000052xx Puller 50/1 Page 113 .5 Impact puller Adapter 99/5 50/43 – Non-return valve (outlet) Voith Turbo I 153.Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.00009711 I arrtd I 2007-09 © 2007 153.000188xx I Overview of the Tools Activity Special tools Tools for self-fabrication Pressure control valve M8 H53. com Engineered reliability.Voith Turbo Produktgruppe Retarder Postfach 1555 74555 Crailsheim Deutschland Phone: 00 49 79 51 / 32-0 Fax: 00 49 79 51 / 32-756 service-retarder@voith. .voith.com www.
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