Aftersales Service Manual Voith Retarder VR 123€¦ · Voith Turbo Aftersales Service Manual Voith...
Transcript of Aftersales Service Manual Voith Retarder VR 123€¦ · Voith Turbo Aftersales Service Manual Voith...
Voith Turbo
Aftersales Service Manual Voith Retarder VR 123
153.000182.10 I 2005-05
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Table of Contents
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Table of Contents
1 About this Document 5
1.1 Purpose of this Document 61.2 Target Groups 61.3 Other Applicable Documents 61.4 Symbols and Identifications 71.5 Item Numbers 71.6 Legal/Contact Information 7
2 Basic Safety Instructions 8
2.1 Product Safety 92.2 Staff Qualification 92.3 Safety-Conscious Working 92.4 Environmental Protection 92.5 Troubleshooting 92.6 Maintenance and Repair 92.7 Driving Mode 92.8 Warranty 10
3 Design and Function 11
3.1 Overview of the Modules 123.2 Retarder Identification 143.3 VERATM Controller Identification 153.4 Digiprop Controller Identification 16
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Table of Contents
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3.5 Function and Control Scheme 173.6 Function Description 18
4 Maintenance and Service 19
4.1 Maintenance Intervals 204.2 Oil Change 214.3 Checking the Oil Level 234.4 Draining the Coolant 254.5 Proportional Valve and Damping Plate 27
5 Diagnosis and Troubleshooting 28
5.1 Troubleshooting Chart 295.2 Electrical Connections Diagram and Pin Assignment (VERATM) 335.3 Troubleshooting (VERATM) 365.4 Electrical Connections Diagram and Pin Assignment (Digiprop) 465.5 Troubleshooting (Digiprop) 515.6 Constant-Air Pressure (py) 615.7 Pump Pressure (pdyn) 645.8 Proportional Valve Current 67
6 Removing and Installing the Retarder 69
7 Repair 70
7.1 Components Overview 717.2 Top Cover 757.3 Casing Ventilation 777.4 Retarder Ventilation 81
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Table of Contents
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7.5 Non-Return Valve 827.6 Heat Exchanger 847.7 Water Neck 877.8 Oil Temperature Sensor 897.9 Coolant Temperature Sensor 917.10 Pressure Sensor 937.11 Proportional Valve and Damping Plate 96
8 Appendix 98
8.1 Tightening Torques 99
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this Document
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1. About this Document
1.1 Purpose of this Document 6
1.2 Target Groups 6
1.3 Other Applicable Documents 6
1.4 Symbols and Identifications 7
1.5 Item Numbers 7
1.6 Legal/Contact Information 7
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Purpose of this DocumentVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this Document
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1.1 Purpose of this Document
This Aftersales Service Manual provides information and instructions on maintenance and repair of the Voith Retarder VR 123.
1.2 Target Groups
This Aftersales Service Manual is intended for service people for service and diagnoses only and may not be reproduced or given to third parties.
1.3 Other Applicable Documents
Documents Information Item number
Voith retarder oil change intervals/oil specification list Oil change intervals and approved oil types 153.000831xx
Operating instructions for Voith Retarder VR 123 Information on the safe, professional and economical operation of the Voith Retarder VR 123
153.00102710
Cooling water quality list Approved coolants H67.2224xx
Operating instructions for retarder tester Measured values for constant-air pressure and pump pressure Included in scope of delivery of the retarder tester (153.001085xx)
Operating instructions for Diana-Lite test software Information on the testing of:
• constant-air pressure (py)
• pump pressure (pdyn)
Included in the scope of delivery of the Diana-Lite test software (153.000776xx)
Operating instructions for the WinDia diagnostic soft-ware
Instructions on PC diagnosis for the Digiprop and VERATM controllers 3623-020900
Gearbox-specific documents on the retarder Information on safe, professional installation and removal of the retarder on request
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Symbols and IdentificationsVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this Document
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1.4 Symbols and Identifications
Structure of warnings
Levels of danger
The warnings are categorised into four levels of dan-ger:
Notes
Distinctions
One-step action instruction.
1. First step of an action instruction. Other steps fol-low and are numbered in sequence.
1.5 Item Numbers
The item numbers used are usually found in the spare parts lists.
Exceptions:
• one- or two-digit item numbers
• item numbers with a slash
1.6 Legal/Contact Information
For questions and work procedures not described in these documents, contact the respective organisation for your area.
Voith Turbo Produktgruppe Retarder
Postfach 1555 74555 Crailsheim Deutschland
Phone: 00 49 79 51 / 32-401, 32-422, 32-1860Fax: 00 49 79 51 / [email protected]
Type and source of danger!
Possible consequences if not heeded.
Measures for the prevention of danger and its
consequences.
Potentially hazardous situation which, if not avoided,
may result in property damage.
Potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
LEVEL OF DANGER
CAUTION
CAUTION
Potentially hazardous situation which, if not avoided,
could result in death or serious injury.
Imminently hazardous situation which, if not avoid-
ed, will result in death or serious injury.
Information on easier and safer work with the re-tarder.
Measures for easier and safer work with the re-tarder.
WARNING
DANGER
NOTE
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic Safety Instructions
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2. Basic Safety Instructions
2.1 Product Safety 9
2.2 Staff Qualification 9
2.3 Safety-Conscious Working 9
2.4 Environmental Protection 9
2.5 Troubleshooting 9
2.6 Maintenance and Repair 9
2.7 Driving Mode 9
2.8 Warranty 10
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Product SafetyVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic Safety Instructions
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2.1 Product Safety
The retarder is constructed according to state of the art technology and acknowledged safety regulations.
Nevertheless, hazardous situations and property damage may occur as a result of improper usage, maintenance and repair.
Observe safety and warning information.
2.2 Staff Qualification
Allow only qualified professionals to carry out repair
and maintenance work.
2.3 Safety-Conscious Working
Voith does not assume any liability for personal injury and/or property damage caused by improper and un-professional work.
Observe the following regulations:
- Accident-prevention regulations
- Other generally acknowledged safety regula-tions and occupational health
- Motor vehicle regulations
- Safety regulations for handling chemical sub-stances such as oils and greases
2.4 Environmental Protection
Drained fuels and fluids, consumables and old parts
must be disposed of properly.
2.5 Troubleshooting
Voith provides a warranty/goodwill service for defec-tive parts only.
Do not replace parts on mere speculation.
2.6 Maintenance and Repair
Danger of burning and scalding by squirting oil!
The oil in the retarder may be hot.
Switch off the retarder and ignition so that the oil is
not fed by impulse lubrication.
Danger of burning and scalding by hot coolant!
The coolant may be hot.
Work carefully.
Danger of burns by hot parts!
Parts of the retarder may be hot.
Work carefully.
Wear protective gloves or use cloths if necessary.
Damage to property by soiled parts!
Considerable damage or malfunctions may occur due to soiling.
Ensure cleanliness.
Damage to property by improper cleaning!
Do not aim the jet of a high-pressure cleaner
(steam-jet device) at valves, pressure sensors or
ventilators of the retarder.
2.7 Driving Mode
Ensure that the retarder is fully functional for all ve-
hicle manoeuvres, i.e.:
- Retarder properly filled with oil
- Retarder electronics connected and functional
- Pneumatic control connected and functional
Driving after repair/oil change
For proper ventilation of the retarder system, do not
activate the retarder until you are driving:
- Min. speed: 50 km/h
- Retarder braking stage 1
- Activate five times for 5 s each
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WarrantyVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic Safety Instructions
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Towing
Tow vehicle with retarder max. 100 km at max.
40 km/h.
Parking
Do not use retarder as a parking brake, as it does
not act as a brake when the vehicle is standing still.
Failure while driving
During failure of the retarder, or while temperature ad-aptation is active, only the service brake is functional.
Adjust the speed of the vehicle with the service
brake.
Engage the lowest possible gear to achieve a high
engine speed.
Continue driving in this way until the retarder is
available at full capacity again.
2.8 Warranty
Voith accepts no liability for damage caused by changes to the retarder or the use of spare parts, ac-cessories, attachments and special features not test-ed and approved by Voith.
Use only parts approved by Voith to ensure the
safety of the vehicle.
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
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3. Design and Function
3.1 Overview of the Modules 12
3.2 Retarder Identification 14
3.3 VERATM Controller Identification 15
3.4 Digiprop Controller Identification 16
3.5 Function and Control Scheme 17
3.6 Function Description 18
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Overview of the ModulesVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
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3.1 Overview of the Modules
Item No. Designation
100 Retarder housing
1500 Screw plug M14x1.5(test connection)
1900 Non-return valve
2000 Cover of retarder housing
2800 Oil filler plug M30x1.5
3000 Top cover
5000 Proportional valve
5100 Damping plate
7000 Pressure sensor
32002
1500
1900
7000
100
2800 3000
5000
5100
2000
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Overview of the ModulesVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
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Item No. Designation
1500 Screw plug M14x1.5
1700 Screw plug M24x1.5
8000 Oil temperature sensor
9000 Rating plate
20000 Water neck inlet
20100 Water neck outlet
20200 Coolant drain plug M14x1.5
20600 Coolant temperature sensor
Kd.-Sach-Nr.Voith-Sach-Nr.
TYP VR 123FABR.Nr.BaujahriRET = 1.00
20000
8000
9000
32003
20200
20600
1700
1500
20100
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Retarder IdentificationVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
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3.2 Retarder Identification
Specify the following data in case you have questions or are ordering spare parts:
- Serial number (FABR.Nr.)
- Voith part number (Voith-Sach-Nr.)
32004
Kd.-Sach-Nr.
Voith-Sach-Nr.
TYP VR 123
FABR.Nr.
Baujahr
iRET = 1.00
Kd.-Sach-Nr.
Voith-Sach-Nr.
TYP VR 123
FABR.Nr.
Baujahr
iRET = 1.00
NOTE
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VERATM Controller Identification Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
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3.3 VERATM Controller Identification
Specify the following data in case you have questions or are ordering spare parts:
- Serial number (Serial-No.)
- Part number (Part No.)
Specify the following data of the retarder (see page 14):
- Serial number (FABR.Nr.)
- Voith part number (Voith-Sach-Nr.)
Retarder Control Unit
Serial-No. XXXXX / JJJJ-MM-TT
Part No. VERA.E.X - XXX.XX-XXXXXXXXXXXX
OEM No. XXXXXXXXXXXXX
X1 X2 X3
e1 022084
VO
ITH
Reta
rder C
ontrol U
nit
Serial-N
o. XXXXX /
JJJJ-MM
-TT
Part N
o. V
ERA
.E.X
- XXX.X
X-XXXXXXXXXXXX
OEM
No.
XXXXXXXXXXXXX
VOITH
VOITH
X1
X2
X3
e1 022084
Vo
ith
Tu
rbo
Voith Turbo
Voith Turbo
32006
NOTE
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Digiprop Controller IdentificationVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
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3.4 Digiprop Controller Identification
Specify the following data in case you have questions or are ordering spare parts:
- Basic number (Basis-Nr.:)
- Serial number (Serien-Nr.:)
Specify the following data of the retarder (see page 14):
- Serial number (FABR.Nr.)
- Voith part number (Voith-Sach-Nr.)
Basis-Nr.:
53.xxxx.12
Code-Nr.:
xxx
Serien-Nr.: xxxx/
VOITH
Basis-Nr.:
Code-Nr.:
Serien-Nr.:
VOITH
32084
NOTE
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Function and Control SchemeVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
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3.5 Function and Control SchemeItem No. Designation
A Compressed-air line (pressure controller)B Four-circuit protection valveC Compressed-air line (brake circuit 2)D Compressed-air line (brake circuit 1)E Compressed-air line (parking brake)F Air tank for auxiliary equipmentG Supply-air pressure (pv) "P"
H Constant-air pressure (py) "A"
I Ventilation line "R"J Oil tankK Rising duct
300 Stator1500 Oil drain plug1700 Oil drain plugs1900 Non-return valve2300 Casing ventilation2800 Oil filler plug (measuring point Py)
3300 Retarder ventilation4000 Rotor5000 Proportional valve6000 Heat exchanger7000 Pressure sensor8000 Oil temperature sensor
20600 Coolant temperature sensor
A R
P
G
H7000
5000
20600
6000
J
28002300
3300
8000
1700
4000
300
K
1900
32007
I
FBA
E
D
C
1500
Vehicle electro-
Oil sump
Supply-air pressure pv
Constant-air pressure py
Coolant
Pump Pressure Pdyn
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Function DescriptionVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
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3.6 Function Description
Application and point of installation
The Voith Retarder VR 123 is a compact hydrodynam-ic sustained-action brake for mid-sized omnibuses and commercial vehicles up to 18 tonnes. By installing it between the gearbox and rear axle, the braking torque of the retarder also remains in tact while shifting gears.
Non-return valve (1900)
The non-return valve (1900) is located in the outlet duct and prevents the heat exchanger being emptied during idling.
Casing ventilation (2300)
At the beginning of the braking process, the oil expels the air located in the system circuit from the retarder via the casing ventilation (2300). Once the system circuit is free of air, a float will rise and seal the casing ventilation.
Proportional valve (5000)
Depending on the intensity of the electric input signal, the proportional valve (5000) issues a pneumatic con-stant-air pressure which acts on the oil tank of the re-tarder.
Pressure sensor (7000)
The pressure sensor (7000) measures the pneumatic constant-air pressure. A deviation from the allowed pressure tolerance is recognized as a fault and dis-played by the controller.
Temperature sensors for oil (8000) and coolant (20600)
The temperature sensors are screwed into the cooling system of the vehicle (return pipe from retarder to heat exchanger) and in the oil duct of the retarder. The temperature sensors pass on information on the tem-perature of the coolant and oil to the controller.
Maximum values for the temperature of coolant and oil are set in the controller for protection of the cooling system and the retarder. To prevent the values being exceeded, the controller adapts the braking torque of the retarder accordingly via the constant-air pressure py.
The braking torque and the heat produced regulate themselves until an equilibrium has been reached be-tween the braking force and the heat dissipated via the vehicle cooling system.
If the temperature limit is exceeded during braking, the braking torque is adapted to protect the cooling system and retarder.
If the critical temperature threshold has been exceed-ed, the braking torque is no longer active.
The controller also adjusts the braking torque if the temperature of the oil increases rapidly, regardless of the actual temperature of the oil.
During temperature adaptation or failure of the retard-er, you must use the service brake to slow down the vehicle.
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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4. Maintenance and Service
4.1 Maintenance Intervals 20
4.2 Oil Change 21
4.3 Checking the Oil Level 23
4.4 Draining the Coolant 25
4.5 Proportional Valve and Damping Plate 27
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Maintenance IntervalsVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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4.1 Maintenance Intervals
The maintenance intervals depend on the stress put on the retarder.
Activity Interval See
Change oil See document: Oil change intervals/oil specification list 153.000831xx
Page 21
Check oil level
– Page 23
Drain coolant Observe specifica-tions of vehicle manufacturer
Page 25
Replace pro-portional valve
For vehicles used in city traffic: 120,000 km
Page 27
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Oil ChangeVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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4.2 Oil Change
Item No. Designation
1400 Sealing ring A14x18, replace
1500 Screw plug M14x1.5,hexagon socket head, w.a.f. 6,25 Nm
1600 Sealing ring A24x29, replace
1700 Screw plug M24x1.5,hexagon socket head, w.a.f. 12,80 Nm
2800 Oil filler plug M30x1.5,hexagon socket head, w.a.f. 17,130 Nm
2900 Sealing ring A30x36, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
Oil quantity
Service filling (oil check, oil change) 6.0 l
After replacement of heat exchanger 6.5 l
32008
2800
2900
1700
1600
1500
1400
1700
1600
NOTE
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Oil ChangeVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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Maintenance work during each oil change
• Visual inspection of retarder for leaks before and after the oil change.
• Check prop shaft screws for proper seating and tighten if necessary (See specifications of vehicle manufacturer).
• Tighten screw plugs of retarder basic module to the specified tightening torque (see page 98).
Requirements
• Vehicle is horizontal
• Oil is at operating temperature (> 60 °C)
• Retarder switched off
• Ignition switched off
Draining the oil
1. Place oil pan below the retarder.
2. Unscrew the oil filler plug (2800).
3. Unscrew the screw plugs (1500 and 1700).
4. Drain oil into an oil collecting pan.
5. Lubricate the new sealing rings (1400 and 1600) with silicone-free, non-corrosive grease.
6. Screw in screw plugs (1500 and 1700) with sealing rings (1400 and 1600).
7. Tighten screw plug (1500) to 25 Nm.
8. Tighten screw plugs (1700) to 80 Nm.
Filling in the oil
1. Fill in oil via the hole of the oil filler plug (2800).
2. Lubricate the new sealing ring (2900) with sili-cone-free, non-corrosive grease.
3. Screw in the oil filler plug (2800) with sealing ring (2900) and tighten to 130 Nm.
Hot exiting oil!
Face and hands could be burned.
Ensure that the retarder and ignition are switched
off.
WARNING
Hot oil filler plug (2800) and screw plugs (1500
and 1700)!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
CAUTION
Wrong oil type!
Damage to/failure of the retarder.
Use only oil approved by Voith (see oil specifica-
tion list).
For proper ventilation of the retarder system, do not activate the retarder until you are driving:
- Min. speed: 50 km/h
- Retarder braking stage 1
- Activate five times for 5 s each
CAUTION
NOTE
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Checking the Oil LevelVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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4.3 Checking the Oil Level
Item No. Designation
1400 Sealing ring A14x18, replace
1500 Screw plug M14x1.5,hexagon socket head, w.a.f. 6,25 Nm
1600 Sealing ring A24x29, replace
1700 Screw plug M24x1.5,hexagon socket head, w.a.f. 12,80 Nm
2800 Oil filler plug M30x1.5,hexagon socket head, w.a.f. 17,130 Nm
2900 Sealing ring A30x36, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
Oil quantity
Service filling (oil check, oil change)
6.0 l
32008
2800
2900
1700
1600
1500
1400
1700
1600
NOTE
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Checking the Oil LevelVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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Requirements
• Vehicle is horizontal
• Oil is at operating temperature (> 60 °C)
• Retarder switched off
• Ignition switched off
Drain the oil
1. Place oil pan below the retarder.
2. Unscrew the oil filler plug (2800).
3. Unscrew the screw plugs (1500 and 1700).
4. Drain oil into an oil collecting pan.
5. Lubricate the new sealing rings (1400 and 1600) with silicone-free, non-corrosive grease.
6. Screw in screw plugs (1500 and 1700) with sealing rings (1400 and 1600).
7. Tighten screw plug (1500) to 25 Nm.
8. Tighten screw plugs (1700) to 80 Nm.
Measuring the volume
1. Measure the volume of the drained oil.
2. If oil is missing, top up oil.
Filling in the oil
1. Fill in oil via the hole of the oil filler plug (2800).
2. Lubricate the new sealing ring (2900) with sili-cone-free, non-corrosive grease.
3. Screw in the oil filler plug (2800) with sealing ring (2900) and tighten to 130 Nm.
Hot exiting oil!
Face and hands could be burned.
Ensure that the retarder and ignition are switched
off.
Hot oil filler plug (2800) and screw plugs (1500
and 1700)!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
WARNING
CAUTIONWrong oil type!
Damage to/failure of the retarder.
Use only oil approved by Voith (see oil specifica-
tion list).
CAUTION
If oil was missing, check the retarder for leaks.
For proper ventilation of the retarder system, do not activate the retarder until you are driving:
- Min. speed: 50 km/h
- Retarder braking stage 1
- Activate five times for 5 s each
NOTE
NOTE
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Draining the CoolantVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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4.4 Draining the Coolant
Requirements
• Retarder switched off
• Ignition switched off
Item No. Designation
20100 Water neck outlet
20200 Screw plug M14x1.5,hexagon socket head, w.a.f. 6,25 Nm
20300 Sealing ring A14x18, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
Hot parts and coolant!
Burns and scalding could occur.
Work carefully.
Wear protective gloves or use cloths if necessary.
32085
20200
Kd.-Sach-Nr.
Voith-Sach-Nr.
TYP R 123
FABR.Nr.
Baujahr
iRET = 1.00
20300
20100
NOTE
CAUTION
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Draining the CoolantVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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1. Unscrew the screw plug (20200) and drain the coolant into a clean collecting vessel.
2. Replace the sealing ring (20300) and lubricate it with silicone-free, non-corrosive grease.
Observe the specifications of the vehicle manu-facturer or those of Voith Turbo cooling water quality list.
NOTE
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Proportional Valve and Damping PlateVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
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4.5 Proportional Valve and Damping Plate
For vehicles used in city traffic: Replace propor-tional valve at intervals of 120,000 km (see page 96).
NOTE
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5. Diagnosis and Troubleshooting
5.1 Troubleshooting Chart 29
5.2 Electrical Connections Diagram and Pin Assignment (VERATM) 33
5.3 Troubleshooting (VERATM) 36
5.4 Electrical Connections Diagram and Pin Assignment (Digiprop) 46
5.5 Troubleshooting (Digiprop) 51
5.6 Constant-Air Pressure (py) 61
5.7 Pump Pressure (pdyn) 64
5.8 Proportional Valve Current 67
Page 29
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5.1 Troubleshooting Chart
Complaint
Voith Retarder
VR 123
Retarder
pilot light
(standard type)
No or
insufficient
brake efficiency
*
Oil leak
on drive
or output side
Oil leaks via
retarder ventilation
(item 3300)
or holes in lid of
casing ventilation
**Contact
VOITH
A
B
C
On-board diagnosis is possible if the
OEM equipment allows it (display).
Observe the specifications of the
vehicle manufacturer.
*
** This fault may be due to a leak in
the transmission or in the retarder.
A thorough analysis is therefore necessary.32034_e
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On-board diagnosis is possible if the
OEM equipment allows it (display).
Observe the specifications of the
vehicle manufacturer.
Retarder on: Braking torque greater than 0Retarder off: Fault (fault code ?)
A
FLASHES
IO
NIOCheck theoperation
(for retarder braking,nominal speed of
the engine,if possible)
IO
NIOCheck
temperaturesensors
(oil/coolant)
Replacedefective part
Check the vehiclecooling system: - coolant level- thermostat- coolant pump- fan- radiator net for dirtIO = in order
NIO = not in order
*
Contact the vehiclemanufacturer
ON
No functionwith ignition ON
** Retarder
pilot light
(standard type)
Temperatureadaptation
Instructthe driver!
32035_e
(see page 89 onw.)
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32036_e
B
Replacedefective part
IO = in order
NIO = not in order
Check the dampingplate. Are/is there(an) outward leak?
Check thecasing ventilation
Replace thecasing ventilationIO NIO
p (dyn)
NIOp (static)
NIOy
Compressed-air lineto the proportionalvalve interrupted
or leaky
Repair compressed-airline according to
vehicle manufacturer
Check the proportionalvalve, replace if necessary
Contactthe vehicle
manufacturer
The retarderoil level must be
correct for checking!If the static and dynamic pressure are
in order, the complaint mentionedabove cannot be made.
Clarify the complaint again with thecustomer or perform the tests once again.
IO
NIO
Checkp (dyn) andp (static)
IO NIO
IO NIO
Check the prop.current as wellas leads and
plug connections
IO
NIOCheck the
temperature sensors(oil/coolant), pressure
sensor and leadsCheck the
control system
Check the supply-air pressure
IO NIO
Check the vehiclepneumatic
system
YesNo
External oil leak(except for retarder
ventilation item 3300)?
Repairthe retarder
Check theretarder oil level
Correct retarderoil level
If the problemoccurs again:continue with
NIO
IO
ContactVOITH
Replace thedamping plate
YesNo
Heavy air consumptionvia retarder ventilation
(item 3300)?
IONIO
Check thedamping plate
ContactVOITH
YesNo Replace the damping plate
No or
insufficient
brake efficiency
y
(see page 23)
(see page 77)
(see page 96)
(see page 89 onw.)
(see page 67)
(see page 96)
(see page 96)
(see page 61)
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32069_e
C
IO = in order
NIO = not in order
NIOIO
Check thecasing ventilation
Replacecasing ventilation
Retarderventilation(item 3300)
ContactVOITH
NIOIO
Check theretarder oil level
Is there waterin the oil?
YesNo
Correctoil level
Check heatexchanger
If the problemoccurs again:
Contact VOITH
Holes in coverof casingventilation
Oil leaks via
retarder ventilation
(item 3300) or
holes in lid of
casing ventilation
(see page 77)(see page 23)
(see page 84)
Page 33
Electrical Connections Diagram and Pin Assignment (VERATM)Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting
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5.2 Electrical Connections Diagram and Pin Assignment (VERATM)
Item No. Designation
2 Controller
4 Terminal 15
16 Actuating lever for engine control/sustained-action brake
17 Retarder pilot light (option)
19 Coolant temperature sensor
20 Oil temperature sensor
21 Proportional valve
72 Pressure sensor
83 ISO diagnosis
32010
4
2
X1
X2X3
8 94 56 13 23 2 16549 7 1210 118
21
18 1716 654 8 9 10 11 12 13 1415 7 3 12
7
-+
19
+ -
201 2 4
P U 72
17
4.
CAN
-+
16
83
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Plug X1 controller
Plug X3 controller
The diagrams show the plugs from the plug-in side.
Item No. Designation
1 CAN-LOW
2 CAN-GROUND
3 CAN-HIGH
4 Actuating lever for engine control/sustained-action brake, safety contact
5 Actuating lever for engine control/sustained-action brake, position 1
6 Actuating lever for engine control/sustained-action brake, position 2
NOTE
32041
147101316
258111417
369121518
7 Terminal 15 = battery voltage
8 Actuating lever for engine control/sustained-action brake, position 3
9 Actuating lever for engine control/sustained-action brake, position 4
10 Actuating lever for engine control/sustained-action brake +
11 not assigned
12 ISO interface, K-lead
13 not assigned
14 Terminal 31 = Ground
15 Retarder pilot light (option)
16 not assigned
17 not assigned
18 Actuating lever for engine control/sustained-action brake, position 5
Item No. Designation
Item No. Designation
1 Coolant temperature sensor –
2 Coolant temperature sensor +
3 Proportional valve +
4 Proportional valve –
5 Oil temperature sensor +
6 Oil temperature sensor –
7 Signal voltage pressure sensor
8 Ground pressure sensor
9 Supply voltage pressure sensor
10 not assigned
11 not assigned
12 not assigned
32043
14710
25811
36912
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Plug of coolant and oil temperature sensors Plug proportional valve Plug pressure sensor
Item No. Designation
1 Temperature sensor, any polarity
2 Temperature sensor, any polarity
32044
1
2
Item No. Designation
1 Proportional valve, any polarity
2 Proportional valve, any polarity
32045
1
2
Item No. Designation
1 Sensor supply
2 Signal
3 Core for pressure compensation
4 Ground
32066
1
2
3
4
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5.3 Troubleshooting (VERATM) Requirements
• Battery voltage: 18–32 V
• Compressed air: 6–11 bar
• Oil level checked and in order
• Electrical system of vehicle checked and in order (see specifications of vehicle manufacturer)
• Fuses for retarder controller tested and in order
Procedure
1. Read out the fault memory:
- with Win-Dia (see operating instructions of Win-Dia diagnostic software)
- on-board diagnosis (see specifications of vehi-cle manufacturer)
2. Evaluate fault code and remedy fault (see
“Troubleshooting with fault codes (VERATM)” on page 37).
3. Clear fault memory (see operating instructions of WinDia diagnostic software).
The fault memory can be read out in the following ways:
• with Win-Dia (see operating instructions of Win-Dia diagnostic software)
• on-board diagnosis (display) (see specifications of vehicle manufacturer)
Special tools
Connecting cable
PC interface
NOTE
H53.8206.12
PC Interface
VTVC Nr.:
53.8206.12
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Troubleshooting with fault codes (VERATM)
(type: Daimler Chrysler)
Requirements
• Ground (terminal 31) connected to pin 15 (plug X1)
• Battery voltage (terminal 15) connected to pins 13 and 7 (plug X1)
When performing measurements using a commer-cially available multimeter (without real r.m.s. value measurement), exact readout of these measured values is not possible (display jumps).
Commercially available tool
Multimeter (98/8) with real r.m.s. value measure-ment, e.g. Fluke 179
NOTEOnly if no fault is detected during complete check of the periphery:
Replace controller.
X1/10 Ω X1/18 in the "Measurement" column, for example, means the following:
• Pin 10 to plug X1 (retarder controller)
• Multimeter measuring type: ohms
• Pin 18 to plug X1 (retarder controller)
NOTE
NOTE
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Fault code
Fault text Cause Fault class
Detec-tion time
Remedy Test step
Requirement /Action
Measurement Setpoint
0 0512 GS/FR: perma-nently or tempo-rarily missing CAN telegram
– slight approx. 0.1 s
GS (EPS) or FR. – – – –
0 1105 Actuating lever for engine control/sustained-action brake: short-cir-cuit to battery
Short-circuit to Ubat in the signal path of the actuating lever for en-gine control/sustained-action brake
slight approx. 1 s
Check the lead, plug and actuating lever for engine control/sustained-action brake.
1 Ignition switched off
Pull plug X1.
Switch on ignition.
X1/14 V X1/4
X1/5
X1/6
X1/8
X1/9
X1/10
X1/18
< 2 V
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0 1140 Actuating lever for engine control/sustained-action brake: mechani-cal defect, im-plausible
Short-circuit to ground
–or–
Interruption in signal path of the actuating le-ver for engine control/sustained-action brake
slight approx. 1 s
Check the lead, plug and actuating lever for engine control/sustained-action brake.
1 Ignition switched off
Switch actuating lever for engine control/sus-tained-action brake to step 0.
X1/10 Ω X1/4 < 5 Ω
2 Switch actuating lever for engine control/sus-tained-action brake to highest step.
X1/10 Ω X1/5
X1/6
X1/8
X1/9
X1/18
< 5 Ω
3 X1/10 Ω X1/4 > 1 MΩ
infinite
4 Switch actuating lever for engine control/sus-tained-action brake to step 0.
X1/10 Ω X1/5
X1/6
X1/8
X1/9
X1/18
> 1 MΩ
infinite
Fault code
Fault text Cause Fault class
Detec-tion time
Remedy Test step
Requirement /Action
Measurement Setpoint
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0 1607 Oil temperature sensor: short-cir-cuit to ground
Short-circuit to ground in the signal path to the oil temperature sensor
slight 1 s Check lead, plug and oil temperature sen-sor.
1 Ignition switched off
Pull plug X3.
X3/5 Ω X1/14 > 1 MΩ
infinite
0 1641 Oil temperature sensor: short-cir-cuit to battery or interruption
Short-circuit to Ubat
–or–
Interruption in signal path to oil temperature sensor
slight 1 s Check leads, plugs and oil temperature sensor.
1 Ignition switched off
Pull plug X3.
X3/5 Ω X3/6 Note:Measure-ment in one tempera-ture range is usually sufficient.
10 °C to 30 °C = 1,039 Ω to 1,117 Ω
50 °C to 70 °C = 1,194 Ω to 1,271 Ω
70 °C to 90 °C = 1,271 Ω to 1,347 Ω
0 1808 Pressure sensor:battery short-cir-cuit signal
Short-circuit to Ubatin signal path
slight 1 s Check lead and pres-sure sensor.
1 Ignition switched on
Switch actuating lever for engine control/sus-tained-action brake to step 0.
X3/7 V X3/8 0.3–0.7 V
Fault code
Fault text Cause Fault class
Detec-tion time
Remedy Test step
Requirement /Action
Measurement Setpoint
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0 1840 Pressure sensor: signal implausible
– slight 10 s Check lead and pres-sure sensor.
1 Ignition switched on
Switch actuating lever for engine control/sus-tained-action brake to step 0.
X3/7 V X3/8 0.3–0.7 V
0 1842 Pressure sensor: signal interruption or short-circuit to ground
– slight 1 s Check lead and pres-sure sensor.
1 Ignition switched off
Pull plugs X1 and X3.
X3/7 Ω X1/14 > 1 MΩ
infinite
0 1843 Pressure sensor: Supply voltage outside admitted range
– slight 0.5 s Check lead and pres-sure sensor.
1 Ignition switched on X3/9 V X3/8 4.75–5.25 V
0 2012 FR: permanently or temporarily missing CAN tele-gram
– slight approx. 0.1 s
Check the FR. – – – –
1 0110 CAN connection to retarder con-troller or CAN-starpoint commu-nication faulted (Bus Off)
Retarder controller does not receive any data telegrams from the vehicle CAN bus
serious – Check CAN bus. – – – –
1 0113 CAN connection to retarder con-troller
Communication fault between controller and vehicle CAN-bus star-point
serious – Check plug connec-tions, leads and vehi-cle CAN-bus starpoint.
– – – –
Fault code
Fault text Cause Fault class
Detec-tion time
Remedy Test step
Requirement /Action
Measurement Setpoint
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1 0212 ABS/BS: perma-nently or tempo-rarily missing CAN telegram
– serious approx. 0.1 s
Check ABS or BS. – – – –
1 0820 Retarder control-ler: Internal error
– serious – Replace controller. – – – –
1 0821 Parameterisation faulty
– serious – Contact Voith. – – – –
1 1001 Terminal 15: overvoltage
Overvoltage (> 33 V) at terminal 15
serious 10 s Check the controller and generator.
1 Ignition switched off
Pull plug X1.
Switch on ignition.
Start engine and run in medium r.p.m. range.
X1/14 V X1/7 < 33 V
1 1002 Terminal 15: undervoltage
Undervoltage (< 17.5 V) at terminal 15 or inter-ruption in the signal path to the basic mod-ule
serious 60 s Check the battery voltage, leads and plugs.
1 Ignition switched off
Pull plug X1.
Switch on ignition.
X1/14 V X1/7 > 17.5 V
1 1330 Proportional valve outlets: short-circuit to battery
Short-circuit to Ubat in signal path to propor-tional valve
–or–
Short-circuit of both out-puts to proportional valve
serious max. 1 s Check the leads, plugs and proportion-al valve.
1 Ignition switched off
Pull plugs X1 and X3.
Switch on ignition.
X1/14 V X3/4 < 2 V
2 Ignition switched off
Pull plug X3.
X3/4 Ω X3/3 18–25 Ω
Fault code
Fault text Cause Fault class
Detec-tion time
Remedy Test step
Requirement /Action
Measurement Setpoint
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1 1331 Proportional valve outlets: short-circuit to ground
Short-circuit to ground
–or–
Interruption in signal path to proportional valve
serious max. 60 s Check the leads, plugs and proportion-al valve.
1 Ignition switched off
Pull plug X3.
X3/4 Ω X3/3 18–25 Ω
2 Pull plug X1. X1/14 Ω X3/3
X3/4
> 1 MΩinfinite
1 1332 Proportional valve outputs
Controller defective serious max. 60 s Replace controller. – – – –
1 1507 Coolant tempera-ture sensor: short-circuit to ground
Short-circuit to ground in the signal path to the coolant temperature sensor
serious 1 s Check leads, plugs and coolant tempera-ture sensor.
1 Ignition switched off
Pull plug X3.
X3/2 Ω X1/14 > 1 MΩinfinite
Fault code
Fault text Cause Fault class
Detec-tion time
Remedy Test step
Requirement /Action
Measurement Setpoint
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1 1541 Coolant tempera-ture sensor: short-circuit to battery
Short-circuit to Ubat or interruption in the signal path to the coolant tem-perature sensor
serious 1 s Check leads, plugs and coolant tempera-ture sensor.
1 Ignition switched off
Pull plug X3.
X3/2 Ω X3/1 Note:Measure-ment in one tempera-ture range is usually sufficient.
10 °C to 30 °C = 1,039 Ω to 1,117 Ω
50 °C to 70 °C = 1,194 Ω to 1,271 Ω
70 °C to 90 °C = 1,271 Ω to 1,347 Ω
1 1705 Retarder pilot light: short-circuit to battery
– serious 3 s Check lead and re-tarder pilot light.
1 Ignition switched on
Switch actuating lever for engine control/sus-tained-action brake to step 1.
X 1/15 V X 1/14 ≤ 2 V
Fault code
Fault text Cause Fault class
Detec-tion time
Remedy Test step
Requirement /Action
Measurement Setpoint
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1 1742 Retarder pilot light: Short-circuit to ground or inter-ruption
– serious 1 s Check lead, retarder pilot light and fuse.
1 Ignition switched off
Pull plug X1.
Switch on ignition.
X 1/15 V X 1/14 ≥ 17.5 V
Fault code
Fault text Cause Fault class
Detec-tion time
Remedy Test step
Requirement /Action
Measurement Setpoint
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5.4 Electrical Connections Diagram and Pin Assignment (Digiprop)
Item No. Designation
2 Controller
4 Terminal 15
15 ABS signal
16 Actuating lever for engine control/sustained-action brake
17 Retarder pilot light
18 Stop light relays
19 Coolant temperature sensor
20 Oil temperature sensor
21 Proportional valve
47 Speedometer signal
69 ISO interface plug
70 Additional functions plug
72 Pressure sensor
18
70 47 15 21
-
- +
+
+ -
19 20
17
4
16
69
4
2
X1
X2X389456132321654971210118
14
8787
a30
13 11 12 10 1 9 5 8 4 3 2 7 6
18 17 16 6 5 4 89 10 11 12 13 14 15 7
43 2 1 4
832567
3 12
7
32086
1 2 4
..
.
P U 72
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Plug X1 controller
Plug X2 controller
The diagrams show the plugs from the plug-in side.
Item No. Designation
1 not assigned
2 not assigned
3 not assigned
4 Actuating lever for engine control/sustained-action brake, position 3
5 Actuating lever for engine control/sustained-action brake, position 2
6 Actuating lever for engine control/sustained-action brake, position 1
NOTE
32041
147101316
258111417
369121518
7 Terminal 15 = battery voltage
8 Actuating lever for engine control/sustained-action brake, position 5
9 Actuating lever for engine control/sustained-action brake, position 4
10 Actuating lever for engine control/sustained-action brake +
11 ISO-interface, L-lead
12 ISO interface, K-lead
13 connected to terminal 15
14 not assigned
15 Terminal 31 = Ground
16 Universal output
17 not assigned
18 Universal output
Item No. Designation
Item No. Designation
1 No function
2 Proportional valve –
3 Proportional valve +
4 Coolant temperature sensor –
5 Coolant temperature sensor +
6 No function
7 not assigned
8 Oil temperature sensor –
9 Oil temperature sensor +
32087
147
258
369
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Plug X3 controller Plug of coolant and oil temperature sensors
Item No. Designation
1 Universal input
2 Speedometer signal
3 ABS signal
4 Universal input
5 Universal input
6 Ground pressure sensor
7 Signal voltage pressure sensor
8 Retarder pilot light
9 Universal input
10 Supply voltage pressure sensor
11 Stop light relays
32043
14710
25811
36912
12 Universal input
Item No. Designation
Item No. Designation
1 Temperature sensor, any polarity
2 Temperature sensor, any polarity
32044
1
2
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Plug proportional valve Plug pressure sensor Plug ISO interface cable
Item No. Designation
1 Proportional valve, any polarity
2 Proportional valve, any polarity
32045
1
2
Item No. Designation
1 Sensor supply
2 Signal
3 Core for pressure compensation
4 Ground
32066
1
2
3
4
Item No. Designation
1 K-line
2 L-line
3 Terminal 15
4 Terminal 31
32088
2 1
4 3
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Plug additional functions cable
Item No. Designation
1 Actuating lever for engine control/sustained-action brake +
2 Universal input
3 Universal input
4 Universal input
5 Universal input
6 Universal input
7 Ground pressure sensor
8 Signal voltage pressure sensor
9 Supply voltage pressure sensor
10 Universal output
11 Universal output
32089
2
1
4
3
6
5
8
7
10
9
12
11
14
13
12 No function
13 Terminal 15
14 Terminal 31
Item No. Designation
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5.5 Troubleshooting (Digiprop) Requirements
• Battery voltage: 18–32 V
• Compressed air: 6–11 bar
• Oil level checked and in order
• Electrical system of vehicle checked and in order (see specifications of vehicle manufacturer)
• Fuses for retarder controller tested and in order
Procedure
1. Read out the fault memory:
- with a service cable (see page 52)
- via the actuating lever for engine control/sustained-action brake (see page 52)
- with Win-Dia (see operating instructions of Win-Dia diagnostic software)
2. Evaluate fault code and remedy fault (see page 53).
3. Clear fault memory:
- with a service cable (see page 52)
- with Win-Dia (see operating instructions of Win-Dia diagnostic software)
Display example of fault code 23
Meanings:
• long signal (2 s): steps of ten
• short signal (0.5 s): steps of one
• Pause (1.0 s) between the signals
Faults are output in the sequence in which they occur. There is a pause of 3 seconds after each fault code. The OFF signal remains if there is only one fault in memory.
The fault memory can be read out in the following ways:
• with a service cable
• via the actuating lever for engine control/sustained-action brake
• with Win-Dia (see operating instructions of Win-Dia diagnostic software)
Faults are saved in the sequence in which they oc-cur.Exception:Fault code 31 "Controller coding fault" is not saved, but it is output.
NOTE
NOTE
Item No. Designation
E ON signal
A OFF signal
t Time
32047_e
2 s
1 s
0.5
s
1 s
1 s
1 s
0.5
s
0.5
s
2 s
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Reading out the fault memory via the service cable
Requirements
• Retarder switched off
• Vehicle not running
• Ignition switched on
1. Connect service interface L-lead to ground for ≥ 2 s. For this purpose, press "L-pushbutton" on service cable.The fault code of the first fault is output via the retarder pilot light.
2. Repeat Step 1 for additional fault code output.
Clearing the fault memory
1. Turn ignition off.
2. Connect service interface L-lead to ground. For this purpose, press "L-pushbutton" on service cable.
3. Switch on ignition.
4. Disconnect the L-lead from ground after ≥ 2 s.
Reading out fault memory via actuating lever for engine control/sustained-action brake
Requirements
• Service mode activated:
- Vehicle not running
- Ignition switched on
1. Switch actuating lever for engine control/sustained-action brake to position 0.
2. Switch actuating lever for engine control/sustained-action brake to position 1.
3. Switch actuating lever for engine control/sustained-action brake to position 0.The fault code of the first fault is output via the retarder pilot light.
4. Repeat Steps 1–3 for additional fault code output.
Special tools
Service cable Connecting cable
PC interface
99/53
H53.8224xx H53.8206.12
PC Interface
VTVC Nr.:
53.8206.12
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Troubleshooting with fault code
(type: Daimler Chrysler)
Requirements
• Ground (terminal 31) connected to pin 15 (plug X1)
• Battery voltage (terminal 15) connected to pin 7 (plug X1)
Commercially available tool
Multimeter (98/8) with real r.m.s. value measure-ment, e.g. Fluke 179
When performing measurements using a commer-cially available multimeter (without real r.m.s. value measurement), exact readout of these measured values is not possible (display jumps).
Only if no fault is detected during complete check of the periphery:
Replace controller.
NOTE
NOTE
X1/15 Ω X3/11 in the "Measurement" column, for example, means the following:
• Pin 15 to plug X1
• Multimeter measuring type: ohms
• Pin 11 to plug X3
NOTE
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Fault code
Fault text Fault class
Detection time
Remedy Test step
Requirement /Action
Measurement Setpoint
01 Stop light relays, short-circuit to ground
slight 1 s Check lead, plug and re-lays or consumers.
1 Ignition switched off
Pull plugs X1 and X3.
X3/11 Ω X1/15 Relays is installed: 250–350 Ω
03 Output HS 1, short-cir-cuit to ground
slight 1 s Check lead, plug and re-lays or consumers.
1 Ignition switched off
Pull plug X1.
X1/18 Ω X1/15 Relays is installed: 250–350 Ω
04 Output HS 2, short-cir-cuit to ground
slight 1 s Check lead, plug and re-lays or consumers.
1 Ignition switched off
Pull plug X1.
X1/16 Ω X 1/15 Relays is installed: 250–350 Ω
05 Terminal 15 undervolt-age
serious 60 s Check lead, plugs and fuse.
1 Ignition switched off
Pull plug X1.
Switch on ignition.
X1/7 V X1/15 ≥ 17.5 V
06 Terminal 15 overvoltage serious 10 s Check electrical system of vehicle (see specifica-tions of vehicle manu-facturer)
1 Ignition switched off
Pull plug X1.
Switch on ignition.
Start engine (idle).
X1/7 V X1/15 ≤ 32.5 V
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Fault code
Fault text Fault class
Detection time
Remedy Test step
Requirement /Action
Measurement Setpoint
0809
Coolant temp. sensor short-circuit to battery or ground or interruption
serious/
slight a)1 s Check lead and sensor. 1 Ignition switched off
Pull plug X2.
X2/5 Ω X2/4 Note:Measurement in one temperature range is usually sufficient.
10 °C to 30 °C = 1,039 Ω to 1,117 Ω
50 °C to 70 °C = 1,194 Ω to 1,271 Ω
70 °C to 90 °C = 1,271 Ω to 1,347 Ω
1112
Oil temperature sensor, short-circuit to battery or ground or interruption
serious/
slight a)1 s Check lead and sensor. 1 Ignition switched off
Pull plug X2.
X2/9 Ω X2/8 Note:Measurement in one temperature range is usually sufficient.
10 °C to 30 °C = 1,039 Ω to 1,117 Ω
50 °C to 70 °C = 1,194 Ω to 1,271 Ω
70 °C to 90 °C = 1,271 Ω to 1,347 Ω
a) If oil and coolant temperature sensors are simultaneously defective, this is considered a serious fault.
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Fault code
Fault text Fault class
Detection time
Remedy Test step
Requirement /Action
Measurement Setpoint
13 Actuating lever for engine control/sustained-action brake in undefined state
serious 1 s Check the lead, plug and actuating lever for en-gine control/sustained-action brake.
1 Ignition switched on
Switch actuating lever for engine control/sus-tained-action brake to position 0.
X1/10 V X1/15
X1/6 V X1/15
X1/5 V X1/15
X1/4 V X1/15
X1/9 V X1/15
X1/8 V X1/15
≥ 17.5 V
0 V
0 V
0 V
0 V
0 V
2 Switch actuating lever for engine control/sus-tained-action brake to position 1.
X1/10 V X1/15
X1/6 V X1/15
X1/5 V X1/15
X1/4 V X1/15
X1/9 V X1/15
X1/8 V X1/15
≥ 17.5 V
≥ 17.5 V
0 V
0 V
0 V
0 V
3 Switch actuating lever for engine control/sus-tained-action brake to position 2.
X1/10 V X1/15
X1/6 V X1/15
X1/5 V X1/15
X1/4 V X1/15
X1/9 V X1/15
X1/8 V X1/15
≥ 17.5 V
≥ 17.5 V
≥ 17.5 V
0 V
0 V
0 V
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14 Actuating lever for engine control/sustained-action brake, battery short-cir-cuit
serious 10 s Check lead and plugs. – Ignition switched off
Pull plug X1.
Switch on ignition.
Switch actuating lever for engine control/sus-tained-action brake to position 0.
X1/10 V X1/15 0 V
15 Actuating lever for engine control/sustained-action brake, short-circuit to ground
serious 1 s Check each stage for short-circuit to ground.
– Ignition switched off
Pull plug X1.
Switch actuating lever for engine control/sus-tained-action brake to position 5.
X1/10 Ω X1/15 > 1 MΩ
infinite
16 Speedometer signal inter-rupted
serious 2 s Check lead and speed-ometer.
– Ignition switched on X3/2 V X1/15 ≤ 1 V
18 Speedometer battery short-circuit/undefined signal
serious 2 s Check lead and speed-ometer.
– Ignition switched off
Pull plugs X1 and X3.
Switch on ignition.
X3/2 V X1/15 ≤ 9 V
19 ABS Short-circuit to ground
serious 60 s Check lead, relays and ABS controller.
– Ignition switched on X3/3 V X1/15 ≥ 3.5 V
21 ABS signal undefined serious 1 s Check lead, relays and ABS controller.
– Ignition switched on X3/3 V X1/15 ≥ 16.5 V
22 Internal fault ABS current path
serious 1 s Replace controller. – – – –
Fault code
Fault text Fault class
Detection time
Remedy Test step
Requirement /Action
Measurement Setpoint
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23 Proportional valve fault 1: short-circuit to battery
serious 1 s Check lead. – Ignition switched off
Pull plugs X1 and X2.
Switch on ignition.
X2/3 V X1/15 < 2 V
24 Proportional valve fault 2:
• Short-circuit to prop. valve magnet
• Short-circuit to con-necting cable, prop. valve interruption
• Prop. valve magnet
• Interruption of con-necting cable, prop. valve ground short-cir-cuit at prop. valve
serious 1 s Check lead and propor-tional valve (valve block).
1 Ignition switched on
Pull plug X2.
X2/2 Ω X2/3 18–25 Ω
2 Turn ignition off.
Pull plug X1.
X2/3 Ω X1/15 Resistance infinite
3 – X2/2 Ω X1/15 Resistance infinite
Fault code
Fault text Fault class
Detection time
Remedy Test step
Requirement /Action
Measurement Setpoint
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25 Proportional valve fault 3: Controller defective
serious 60 s Replace controller. – – – –
27 Proportional valve fault 5: Controller defective
serious 3 s Replace controller. – – – –
28 Terminal 30 Undervolt-age
serious 60 s Check lead, plug and fuse.
– Ignition switched off
Pull plugs X1 and X3.
Switch on ignition.
X1/13 V X1/15 ≥ 17.5 V
29 Fault in controller serious approx. 0.2 s Replace controller. – – – –
31 Controller: coding incor-rect
serious approx. 0.1 s Code controller proper-ly.
– – – –
32 Retarder pilot light: Inter-ruption or short-circuit to ground
serious 1 s Check lead, retarder pi-lot light and fuse.
– Ignition switched off
Pull plugs X1 and X3.
Switch on ignition.
X3/8 V X1/15 ≥ 17.5 V
Fault code
Fault text Fault class
Detection time
Remedy Test step
Requirement /Action
Measurement Setpoint
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33 Retarder pilot light: short-circuit to battery
serious 3 s Check lead and retarder pilot light.
– Ignition switched on
Switch actuating lever for engine control/sus-tained-action brake to position 1.
X3/8 V X1/15 ≤ 2 V
35 Fault in controller serious max. 9 min. Replace controller. – – – –
37 Fault in pedal operation slight 1 s Check system according to specifications of OEM or VOITH.
– – – –
38 Constant-air pressure fault
slight max. 10 s Check the pressure sen-sor cable harness.
In case of deviation: Test Step 2.
1 Ignition switched on
Switch actuating lever for engine control/sus-tained-action brake to position 0.
X3/7 V X1/15
and
X3/10 V X1/15
0.3–0.7 V
4.75–5.25 V
Troubleshoot in cable harness, pressure sen-sor, proportional valve, supply air, ECU (contact Voith).
2 – – –
Fault code
Fault text Fault class
Detection time
Remedy Test step
Requirement /Action
Measurement Setpoint
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Constant-Air Pressure (py)Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting
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5.6 Constant-Air Pressure (py)
Item No. Designation
5000 Proportional valve
7000 Pressure sensor
99/30 Retarder tester
99/31 Cable 1 (to the proportional valve)
99/32 Cable 2 (to the pressure sensor)
99/33 Cable 3 (to temperature sensors)
99/34 Cable 4 (to the vehicle voltage supply/PC interface)
The constant-air pressure py measurement pro-vides information on
• internal and external leaks
• proper functioning
• proper control of the retarder
32091
7000
5000
99/32
99/34
99/30
99/31
99/33
NOTE
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Requirements
• Ignition switched off
• Retarder switched off
• Battery voltage: 18–32 V
• Supply-air pressure in auxiliary circuit: 8–11 bar
• Oil level checked and in order
• Electrical system of vehicle checked and in order (see specifications of vehicle manufacturer)
• Electrical connections of the retarder are com-pletely disconnected from the vehicle.
Test scope
1. Connect the retarder tester (99/30) (see Test set-up diagram Page 61 and operating instructions of the retarder tester):
- Connect cable 1 (99/31) to proportional valve (5000).
- Connect cable 2 (99/32) to pressure sensor (7000).
- Connect cable 3 (99/33) to oil temperature sen-sor (8000) and coolant sensor (20600).
- Connect cable 4 (99/34) to the vehicle voltage supply/PC interface.
2. Select the retarder type at the retarder tester.
3. Check constant-air pressure (see operating instructions of retarder tester).
4. Compare measured values (see operating instruc-tions of retarder tester).
Special tools
Retarder tester in a case compl.
Test softwareDiana-Lite
Air pressure gauge
0–6 bar
99/29 99/40 99/7
comprising:99/30–99/35
50/35 a. 50/36
With the test software "Diana-Lite" (99/40), meas-ured values can be read out and stored comfortably via the PC in addition to the tests with the retarder tester.The stored measured values can be transmitted to the Voith customer service for evaluation (see op-erating instructions on CD-ROM).
153.001085xx 153.000776xx H53.1403xx
NOTE
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
CAUTION
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5. Disconnect the retarder tester (99/30) and all cables.
6. Restore connections between vehicle electronics and retarder.
If the measured constant-air pressure value (py) is below the required setpoint, either the retarder is leaking or the control system is defective (see trou-bleshooting diagram Page 29).
NOTE
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Pump Pressure (pdyn)Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting
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5.7 Pump Pressure (pdyn)
Item No. Designation
100 Retarder housing
5000 Proportional valve
50/36 Pressure sensor: 0–30 bar
99/30 Retarder tester
99/31 Cable 1 (to the proportional valve)
99/32 Cable 2 (to the pressure sensor)
99/33 Cable 3 (to temperature sensors)
99/34 Cable 4 (to the vehicle voltage supply/PC interface)
Checking the pump pressure pdyn provides infor-mation on
• the mechanical status of the rotor parts
• internal leaks
• proper functioning of the retarder
32092
5000100
99/32
99/34
99/30
99/31
99/33
50/36
NOTE
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Requirements
• Ignition switched off
• Retarder switched off
• Compressed air: 6–11 bar
• Oil level checked and in order
• Electrical system of vehicle checked and in order (see specifications of vehicle manufacturer)
• Electrical connections of the retarder are com-pletely disconnected from the vehicle.
• No external leaks detected at retarder
• Vehicle secured
• Prop shaft at the retarder removed from the flang-es (see specifications of vehicle manufacturer)
Test scopeSpecial tools
Pressure sensor0–30 bar
Retarder testerin case compl.
Test softwareDiana-Lite
50/36 99/29 comprising:99/30–99/35
50/35 a. 50/36
99/40
With the test software "Diana-Lite" (99/40), meas-ured values can be read out and stored comfortably via the PC in addition to the tests with the retarder tester.The stored measured values can be transmitted to the Voith customer service for evaluation (see op-erating instructions on CD-ROM).
--- 153.001085xx 153.000776xx
NOTE
Hot parts and oil!
Hands can be burned and scalded.
Work carefully.
Wear protective gloves or use cloths if necessary.
Due to construction, a small amount of oil may leak out; this does, however, not affect retarder opera-tion.
CAUTION
NOTE
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1. Unscrew screw plug (1500) and remove sealing ring (1400).
2. Connect pressure sensor (50/36) to retarder hous-ing (100) with sealing ring (1400).
3. Connect the retarder tester (99/30) (see Test set-up diagram Page 64 and operating instructions of the retarder tester):
- Connect cable 1 (99/31) to proportional valve (5000).
- Connect cable 2 (99/32) to pressure sensor (50/36).
- Connect cable 3 (99/33) to oil temperature sen-sor (8000) and coolant (20600).
- Connect cable 4 (99/34) to the vehicle voltage supply/PC interface.
4. Select the retarder type at the retarder tester.
5. Switch on ignition.
6. Drive the vehicle with a prop shaft speed of nps = 1,000 r.p.m..
7. Check pump pressure (see operating instructions of retarder tester).
8. Compare measured values (see operating instruc-tions of retarder tester).
9. Disconnect the retarder tester (99/30) and all cables.
10.Disconnect the pressure sensor (50/36) and remove the sealing ring (1400).
11.Lubricate the new sealing ring (1400) with sili-cone-free, non-corrosive grease.
12.Screw in the screw plug (1500) with the sealing ring (1400).
13.Tighten the screw plug (1500) to 25 Nm.
14.Remove prop shaft at the retarder from the flanges (see specifications of vehicle manufacturer).
32078
1500
1400
32093
100
50/361400
Shift in direct gear (ratio 1:1). The engine speed 1,000 min-1 then corresponds to the prop shaft speed of 1,000 r.p.m.
NOTE
If the setpoint of the constant-air pressure (py) is reached, but the pump pressure (pdyn) is under-shot, the retarder has an internal defect.
Check rotor parts.
NOTE
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5.8 Proportional Valve Current Requirements
• Ignition switched off
• Retarder switched off
• Battery voltage: 18–32 V
• Electrical system of vehicle checked and in order (see specifications of vehicle manufacturer)
• Fuse for retarder controller tested and in order
• Male and female plug connectors at proportional valve checked for damage or wear (notch scratch-es).
• Electrical lead and plug connections checked (vis-ual inspection) and in order
Test scope
1. Disconnect the plug from the proportional valve (21) and connect it to the measuring adapter (99/3).
2. Connect the plug of the measuring adapter to the proportional valve (21).
3. Connect the multimeter (98/8). Measuring type: mA.
4. Turn the "Propventil" (prop valve) switch at the measuring adapter to position "I".
5. Switch on ignition.
6. Shift the retarder to the highest gear.
Special tools
Measuring adapter
99/3
When performing measurements using a commer-cially available multimeter (without real r.m.s. value measurement), exact readout of these measured values is not possible (display jumps).
Commercially available tool
Multimeter (98/8) with real r.m.s. value measure-ment, e.g. Fluke 179
---
NOTE
32059
98/8
99/3
21
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7. Read measured value and compare to the speci-fied values:
8. Disconnect multimeter.
9. Pull the plug from the measuring adapter (99/3) and connect it to the proportional valve (21).
Due to continuous readjustment in the control loop, the measured values may not be constant, but are within the specified range.
Controller Item number/Code number
Measured value
Digiprop 117/153.000863xx 440–640 mA
118/153.000967xx
119/153.000976xx
120/153.000999xx
VERATM 153.000107xx 440–640 mA
NOTE
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Removing and Installing the Retarder
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6. Removing and Installing the Retarder
Retarder can fall!
Your body can be crushed severely.
Secure retarder against falling.
Use a suitabe device for hanging it up.
Improper removal/installation!
Damage to/failure of the retarder.
Warranty is voided.
Request and use gearbox-specific documents
and special tools from VOITH.
DANGER
CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
CAUTION
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7. Repair
7.1 Components Overview 71
7.2 Top Cover 75
7.3 Casing Ventilation 77
7.4 Retarder Ventilation 81
7.5 Non-Return Valve 82
7.6 Heat Exchanger 84
7.7 Water Neck 87
7.8 Oil Temperature Sensor 89
7.9 Coolant Temperature Sensor 91
7.10 Pressure Sensor 93
7.11 Proportional Valve and Damping Plate 96
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Components OverviewVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.1 Components Overview
Item No. Designation
100 Retarder housing
1000 O-ring 158.34x3.53, replace
1400 Sealing ring A14x18, replace
1500 Screw plug M14x1.5,hexagon socket head, w.a.f. 6, 25 Nm
1600 Sealing ring A24x29, replace
1700 Screw plug M24x1.5,hexagon socket head, w.a.f. 12, 80 Nm
1900 Non-return valve M48x1.5,hexagon insert bit, w.a.f. 55, 280 Nm
1950 Sealing ring A48x55, replace
2000 Cover of retarder housing
2100 O-ring 228.2x3.53, replace
2300 Casing ventilation
2301 O-ring 55x3, replace
2800 Oil filler plug M30x1.5,hexagon socket head, w.a.f. 17, 130 Nm
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
3300
3400
3500 3200
7000
8000 6100
100
5000
5400
5200 5200
5300 5100
3000
2300
3600
2800 2900
32012
6150 2000 3600
6000
6150 6300
6100
1000 2100
6200
4800
4800 1600
1700
1500 1400
1400
20600
20500
20500
20400
20400
20200 20300
20000
20100
1900 1500
20700
8100 2301
6150
6150 1950
4703 4702
NOTE
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Item No. Designation
2900 Sealing ring A30x36, replace
3000 Top cover
3200 Sealing top cover, replace
3300 Disc silencer
3400 Corrugated spring
3500 Circlip JL30x1.2
3600 Hex head screw M8x45,hexagon insert bit, w.a.f. 13,Initial torque: 17 Nm,Final torque: 30 Nm
4702 Sealing ring A8x12, replace
4703 Screw plug M8x1, hexagon socket head, w.a.f. 5, 10 Nm
4800 Hex head screw M8x70,hexagon insert bit, w.a.f. 13,Initial torque: 17 Nm,Final torque: 30 Nm
5000 Proportional valve
5100 Damping plate
5200 O-ring 16x3, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
3300
3400
3500 3200
7000
8000 6100
100
5000
5400
5200 5200
5300 5100
3000
2300
3600
2800 2900
32012
6150 2000 3600
6000
6150 6300
6100
1000 2100
6200
4800
4800 1600
1700
1500 1400
1400
20600
20500
20500
20400
20400
20200 20300
20000
20100
1900 1500
20700
8100 2301
6150
6150 1950
4703 4702
NOTE
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Item No. Designation
5300 Hex head screw M8x20, replacehexagon insert bit, w.a.f. 13, 30 Nm
5400 Hex head nut M8, replacehexagon insert bit, w.a.f. 13, 18 Nm
6000 Heat exchanger
6100 O-ring 25x2.5 (brown), replace
6150 O-ring 25x2.5 (black), replace
6200 Hex head screw with flange M10x40,hexagon insert bit, w.a.f. 15, 46 Nm
6300 Hex head screw with flange M10x70,hexagon insert bit, w.a.f. 15, 46 Nm
7000 Pressure sensor M16x1.5,hexagon insert bit, w.a.f. 27, 30 Nm
8000 Oil temperature sensor M14x1.5,hexagon insert bit, w.a.f. 27, 28 Nm
8100 Sealing ring A14x20, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
3300
3400
3500 3200
7000
8000 6100
100
5000
5400
5200 5200
5300 5100
3000
2300
3600
2800 2900
32012
6150 2000 3600
6000
6150 6300
6100
1000 2100
6200
4800
4800 1600
1700
1500 1400
1400
20600
20500
20500
20400
20400
20200 20300
20000
20100
1900 1500
20700
8100 2301
6150
6150 1950
4703 4702
NOTE
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Item No. Designation
20000 Water neck inlet
20100 Water neck outlet
20200 Screw plug M14x1.5,hexagon socket head, w.a.f. 6,25 Nm
20300 Sealing ring A14x18, replace
20400 Hex head screw M8x45,hexagon insert bit, w.a.f. 13,30 Nm
20500 O-ring 55.56x3.53, replace
20600 Coolant temperature sensor M14x1.5,hexagon insert bit, w.a.f. 27,28 Nm
20700 Sealing ring A14x20, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
3300
3400
3500 3200
7000
8000 6100
100
5000
5400
5200 5200
5300 5100
3000
2300
3600
2800 2900
32012
6150 2000 3600
6000
6150 6300
6100
1000 2100
6200
4800
4800 1600
1700
1500 1400
1400
20600
20500
20500
20400
20400
20200 20300
20000
20100
1900 1500
20700
8100 2301
6150
6150 1950
4703 4702
NOTE
Page 75
Top CoverVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.2 Top Cover
Requirements
• Retarder switched off
• Ignition switched off
Item No. Designation
100 Retarder housing
3000 Top cover
3200 Sealing top cover, replace
3600 Hex head screw M8x45,hexagon insert bit, w.a.f. 13,Initial torque: 17 Nm,Final torque: 30 Nm
32013
100
3200
3000 3600
Page 76
Top CoverVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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Removal
1. Unscrew the hex head screw (3600).
2. Remove the cover (3000).
Checking
1. Check the holes in the cover (3000) for accessibil-ity with compressed air.
Installation
1. Insert new seal (3200).
2. Screw on cover (3000) with the hex head screws (3600).
3. Tighten hex head screws (3600) in the sequence 1 to 13 (see diagram) with an initial torque of 17 Nm.
4. Tighten hex head screws in the same sequence with a final torque of 30 Nm.
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
CAUTIONIncorrect sequence when tightening the hex
head screws!
Cover can buckle.
Tighten hex head screws in the prescribed se-
quence.
CAUTION
12
3
4
56
78
9101112
13
32014
Page 77
Casing VentilationVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.3 Casing Ventilation
Item No. Designation
2300 Casing ventilation
2301 O-ring 55x3, replace
2300/1 Valve insert
2300/2 Float, specified weight max. 12 g, clean
2300/3 Float cage
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
Cleaning agent
Float Methylated spirit
32015
2300/1
23012300
2300/2
2300/3
NOTE
Page 78
Casing VentilationVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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The test ring (99/4) can be ordered from Voith Turbo GmbH & Co. KG: Item number H67.2757xx.
Requirements
• Retarder switched off
• Ignition switched off
• Top cover removed and checked (see page 75)
Removal
1. Knock valve insert (2300/1) with the impact puller (99/5) and the adapter (98/9) upward from the retarder housing.
Use only the adapter (98/9) as from item number H53.942811.
Special tools
Impact puller Adapter
99/5 98/9
NOTE
H53.7712xx H53.9428xx
Tools for self-fabrication
Test ring
99/4
Material: St 37
Weight: 0.085 kg
Ø 40.5 mm
7 m
m Ø 60 mm
32016e
Material: St 37Weight: 0.085 kg
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
CAUTION
32017
99/5
98/9
2300/1
Page 79
Casing VentilationVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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2. Float (2300/2) and float cage (2300/3) are to be removed from retarder housing.
3. Take O-ring (2301) out of the groove in the valve insert (2300/1).
Checking
1. Check the casing ventilation (2300) for dirt/sludge and clean it.
2. Check the float (2300/2) for damaged surfaces and sealing areas (arrow).
3. Weight float (2300/2): Specified weight: max. 12 g.
4. For exceeded specified weight: replace the entire casing ventilation (2300).
5. Check the sealing edge of the radial shaft sealing ring (arrow) in the valve insert (2300/1):
- For this purpose, place the float (2300/2) on a suitable object (e.g. hex head nut).
- Place the valve insert (2300/1) on the float (2300/2) and weigh it down using the test ring (99/4).
- Fill empty space between float (2300/2) and up-per edge of valve insert with methylated spirit.
If the sealing edge is undamaged, the fluid level re-mains constant over 1 minute.
32018
2300/3
2300/2
2300/1
2301
32019
2300/2
32020
2300/2
2300/1
99/4
32021
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Casing VentilationVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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6. Replace casing ventilation (2300) if sealing edge is damaged.
Installation
1. Apply silicone-free and non-corrosive grease to a new O-ring (2301) and pull it on the valve insert (2300/1).
2. Clean float with methylated spirit.
3. Insert float (2300/2) into the float cage (2300/3).
4. Place valve insert (2300/1) on float cage (2300/3).
5. Coat bore of casing ventilation in the retarder housing with silicone-free and non-corrosive grease.
6. Press valve insert (2300/1) carefully into the retarder housing with the impact puller (99/5) and the adapter (98/9).
7. Assemble retarder.
Changing the radial shaft sealing ring leads to mal-functions of the retarder.
If the radial shaft sealing ring is damaged: re-place the entire casing ventilation (2300).
Do not replace the radial shaft sealing ring.
Lubricating the radial shaft sealing ring leads to malfunctions of the retarder.
Do not lubricate the radial shaft sealing ring.
NOTE
NOTE
2300/1
2301
32022
2300/1
2300/2
2300/3
32023
32024
99/5
98/9
2300/1
Page 81
Retarder VentilationVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.4 Retarder Ventilation
Requirements
• Retarder switched off
• Ignition switched off
Item No. Designation
3300 Check, clean and blow out disc silenc-er with compressed air
3400 Corrugated spring
3500 Circlip
Cleaning agent
Retarder ventilation Benzine
Heavily soiled or painted-over retarder ventila-
tion!
Retarder reduces braking power after a delay.
Replace retarder ventilation.
Replace retarder ventilation in case of mechan-ical damage.
32025
3400
3300
3500
DANGER
NOTE
Page 82
Non-Return ValveVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.5 Non-Return Valve
Item No. Designation
1900 Non-return valve
1900/1 Guide M48x1.5,hexagon insert bit, w.a.f. 55,280 Nm
1900/2 Spring
1900/3 Check spool for damage and soiling and replace entire non-return valve if necessary.
1950 Sealing ring A48x55, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
32027
1900
1900/3
1900/1
1900/2
1950
NOTE
Page 83
Non-Return ValveVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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Requirements
• Retarder switched off
• Ignition switched off
• Oil drained (see page 22)
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
CAUTION
Page 84
Heat ExchangerVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.6 Heat Exchanger
Item No. Designation
1000 O-ring 158.34x3.53, replace
2000 Cover of retarder housing
2100 O-ring 228.2x3.53, replace
3600 Hex head screw M8x45,hexagon insert bit, w.a.f. 13,Initial torque: 17 Nm,Final torque: 30 Nm
4800 Hex head screw M8x70,hexagon insert bit, w.a.f. 13,Initial torque: 17 Nm,Final torque: 30 Nm
6000 Heat exchanger
6100 O-ring 25x2.5 (brown), replace
6150 O-ring 25x2.5 (black), replace
6200 Hex head screw M10x40, hexagon insert bit, w.a.f. 15, 46 Nm
6300 Hex head screw M10x70,hexagon insert bit, w.a.f. 15, 46 Nm
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
32028
6150
6150 1000 2100
6000
2000 6200
3600
6300
4800
4800
6100
6100
NOTE
Page 85
Heat ExchangerVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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Requirements
• Retarder switched off
• Ignition switched off
• Supply-air pressure discharged
• Oil drained (see page 22)
• Coolant drained (see page 25)
Removal
1. Unscrew hex head screws (3600, 4800, 6200 and 6300).
2. Remove the cover (2000).
3. Remove heat exchanger (6000).
Checking
1. Attach pressure test equipment (50/22) to heat exchanger (6000) with O-rings and attach the compressed-air line to the connection.
2. Place heat exchanger (6000) with pressure test equipment (50/22) in a water bath (approx. 40 °C).
3. Slowly pressurise heat exchanger (6000) with compressed air from 0 to max. 10 bar.
4. If air bubbles appear in the water, replace the heat exchanger.
Special tools
Pressure test equipment
50/22
153.000769xx
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
CAUTION
32094
6000
50/22
Page 86
Heat ExchangerVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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Installation
1. Apply silicone-free and non-corrosive grease to the new O-rings (6100) and (6150) and pull them on the heat exchanger (6000).
2. Lubricate the new O-ring (1000) with silicone-free, non-corrosive grease and pull it on.
3. Fit in heat exchanger (6000).
4. Lubricate the new O-ring (2100) with silicone-free, non-corrosive grease and pull it on.
5. Screw on cover (2000) with the hex head screws (3600, 4800).
6. Tighten hex head screws (3600, 4800) in the pre-scribed sequence 1 to 7 (see diagram) with an ini-tial torque of 17 Nm.
7. Tighten hex head screws (3600, 4800) in the same sequence to a final torque of 30 Nm.
8. Screw in hex head screws (6200 and 6300) and tighten to 46 Nm.
9. Fill in the oil (see “Oil Change” on page 21).
Ensure that the brown O-rings (6100) and the black O-rings (6150) are not inadvertently swapped.
32095
6150
6150 1000
6000
6100
6100
NOTE
When inserting the heat exchanger (6000), en-sure correct installation position (see arrow in the diagram).
Ensure that the sealing surfaces are not dam-aged.
NOTE
32064
1
2
3
45
6
7
6200
2000
48004800
6300
4800 4800
4800
36003600
Incorrect sequence when tightening the hex
head screws!
Cover can buckle.
Screw tight hex head screws in the prescribed se-
quence.
CAUTION
Page 87
Water NeckVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.7 Water Neck
Item No. Designation
20000 Water neck inlet
20100 Water neck outlet
20200 Screw plug M14x1.5,hexagon socket head, w.a.f. 6, 25 Nm
20300 Sealing ring A14x18, replace
20400 Hex head screw M8x45,hexagon insert bit, w.a.f. 13, 30 Nm
20500 O-ring 55.56x3.53, replace
20600 Coolant temperature sensor M14x1.5, hexagon insert bit, w.a.f. 27, 28 Nm
20700 Sealing ring A14x20, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
32029 20400
20400
20300
20400
20400
20000
20500
20500
2010020600
20200
Kd.-Sach-Nr.
Voith-Sach-Nr.
TYP R 123
FABR.Nr.
Baujahr
iRET = 1.00
20700
NOTE
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Water NeckVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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Requirements
• Retarder switched off
• Ignition switched off
• Coolant drained (see page 25)
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
CAUTION
Page 89
Oil Temperature SensorVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.8 Oil Temperature Sensor
Requirements
• Retarder switched off
• Ignition switched off
Item No. Designation
8000 Temperature sensor M14x1.5,hexagon insert bit, w.a.f. 27, 28 Nm
8100 Sealing ring A14x20, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
32032
8000 Kd.-Sach-Nr.
Voith-Sach-Nr.
TYP R 123
FABR.Nr.
Baujahr
iRET = 1.00
8100
NOTE
CAUTION
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Oil Temperature SensorVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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Measuring in one temperature range is usually suf-ficient.
Temperature Resistance
20 °C ± 10 °C 1,039–1,117 Ω
60 °C ± 10 °C 1,194–1,271 Ω
80 °C ± 10 °C 1,271–1,347 Ω
NOTE
Page 91
Coolant Temperature SensorVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.9 Coolant Temperature Sensor
Requirements
• Retarder switched off
• Ignition switched off
• Coolant drained (see page 25)
Item No. Designation
20600 Temperature sensor M14x1.5,hexagon insert bit, w.a.f. 27, 28 Nm
20700 Sealing ring A14x20, replace
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
32033
20600
Kd.-Sach-Nr.
Voith-Sach-Nr.
TYP R 123
FABR.Nr.
Baujahr
iRET = 1.00
20700
NOTE
CAUTION
Page 92
Coolant Temperature SensorVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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Observe the specifications of the vehicle manu-facturer on coolant quality or those of Voith Tur-bo cooling water quality list.
Measuring in one temperature range is usually suf-ficient.
Temperature Resistance
20 °C ± 10 °C 1,039–1,117 Ω
60 °C ± 10 °C 1,194–1,271 Ω
80 °C ± 10 °C 1,271–1,347 Ω
NOTE
NOTE
Page 93
Pressure SensorVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.10 Pressure Sensor
Item No. Designation
7000 Pressure sensor M16x1.5 with integrat-ed FPM sealing ring, hexagon insert bit, w.a.f. 27, 30 Nm
Lubricate FPM sealing ring on both sides with silicone-free, non-corrosive grease before in-stallation.
Special tools
Measuring adapter
99/3
32031
7000
NOTE
H53.8198xx
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Pressure SensorVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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Requirements
• Retarder switched off
• Ignition switched off
• Constant-air pressure gauge connected
• Electrical leads and plug connections checked (visual inspection) and in order
Test scope
1. Pull plug from pressure sensor (38).
2. Connect the plug of the measuring adapter (99/3) to the pressure sensor (38).
3. Connect the ground lead of the multimeter (98/8) to test socket 4 (ground) of the measuring adapter.
4. Turn the "Propventil" (prop valve) switch at the measuring adapter (99/3) to position "Propventil" (prop valve).
5. Switch on ignition.
6. Connect the positive lead of the multimeter (98/8) to test socket 1 (positive) of the measuring adapter.
7. Measure voltage: setpoint 4.75–5.25 V.
8. Connect the positive lead of the multimeter (98/8) to test socket 2 (positive).
9. Measure voltage.
When performing measurements using a commer-cially available multimeter (without real r.m.s. value measurement), exact readout of these measured values is not possible (display jumps).
Commercially available tool
Multimeter (98/8) with real r.m.s. value measure-ment, e.g. Fluke 179
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
NOTE
CAUTION
32060
98/8
99/3
38
In case of a fault (cable or sensor), the controller switches of the supply voltage.
Check cable or sensor and replace if necessary.
NOTE
Page 95
Pressure SensorVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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10.Compare measured values of constant-air pres-sure against the values (see diagram).
11.Turn ignition off.
12.Disconnect measuring adapter (99/3).
13.Connect electrical connection to pressure sensor.
Voltage measurement at pressure sensor
32062_e
0
1
2
3
4
5
0.5
1.5
2.5
3.5
4.5
00.5 1 1.5 2 2.5 3 3.5 4
[ BAR ]
[ V ]
Page 96
Proportional Valve and Damping PlateVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
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7.11 Proportional Valve and Damping Plate
Item No. Designation
5000 Proportional valve
5100 Damping plate, replace if damaged
5200 O-ring 16x3, replace
5300 Hex head screw M8x20, replacehexagon insert bit, w.a.f. 13, 30 Nm
5400 Hex head nut M8, replacehexagon insert bit, w.a.f. 13, 18 Nm
Lubricate sealing rings, O-rings and shaft seal-ing rings with silicone-free, non-corrosive grease before installation.
For vehicles used in city traffic: Replace propor-tional valve at intervals of 120,000 km.
32030
5200 5200 5000 5400
5300
5100
5400
NOTE
NOTE
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Requirements
• Retarder switched off
• Ignition switched off
• Supply-air pressure discharged
• Compressed-air line disconnected
• Electrical connection lead disconnected from pro-portional valve. Male and female connector checked for damage or wear (notch scratches)
Check damping plate (5100) for mechanical and aging damage and replace if necessary.
NOTE
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8. Appendix
8.1 Tightening Torques 99
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Tightening TorquesVoith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Appendix
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8.1 Tightening Torques
Item No. Designation Dimensions Tightening torque
1500 Screw plug M14x1.5, hexagon socket head, w.a.f. 6 25 Nm
1700 Oil drain plug M24x1.5, hexagon socket head, w.a.f. 12 80 Nm
1900 Non-return valve outlet M48x1.5, hexagon insert bit, w.a.f. 55 280 Nm
2800 Oil filler plug M30x1.5, hexagon socket head, w.a.f. 17 130 Nm
3600 Hex head screw M8x45, hexagon insert bit, w.a.f. 13 Observe tightening sequence:
Initial torque: 17 Nm
Final torque: 30 Nm
4703 Screw plug M8x1, hexagon socket head, w.a.f. 5 10 Nm
4800 Hex head screw M8x70, hexagon insert bit, w.a.f. 13 Observe tightening sequence:
Initial torque: 17 Nm
Final torque: 30 Nm
5300 Hex head screw M8x20, hexagon insert bit, w.a.f. 13 30 Nm
5400 Hex head nut M8, hexagon insert bit, w.a.f. 13 18 Nm
6200 Hex head screw with flange M10x40, hexagon insert bit, w.a.f. 15 46 Nm
6300 Hex head screw M10x70, hexagon insert bit, w.a.f. 15 46 Nm
7000 Pressure sensor M16x1.5, hexagon insert bit, w.a.f. 27 30 Nm
8000 Oil temperature sensor M14x1.5, hexagon insert bit, w.a.f. 27 28 Nm
20200 Screw plug M14x1.5, hexagon socket head, w.a.f. 6 25 Nm
20400 Hex head screw M8x45, hexagon insert bit, w.a.f. 13 30 Nm
20600 Coolant temperature sensor M14x1.5, hexagon insert bit, w.a.f. 27 28 Nm
Voith Turbo Produktgruppe Retarder
Postfach 1555 74555 Crailsheim Deutschland
Phone: 00 49 79 51 / 32-0 Fax: 00 49 79 51 / 32-756 [email protected] www.voith.com
Engineered reliability.