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Training

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Aftersales Service Manual

VOITH Retarder 120 with Digiprop Control

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Content

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Table of Contents

1. Preface ....................................................................................................1/1

2. General....................................................................................................2/1

2.1 Assembly Overview ..........................................................................2.1/12.2 Function and Operation Scheme .........................................................2.2/12.3 Retarder Data ..................................................................................2.3/1

3. Maintenance............................................................................................3/13.1 Maintenance Work.............................................................................3.1/13.2 Oil Change .......................................................................................3.2/1

With Stainless-Steel Heat Exchanger ....................................................3.2/1With Aluminium Heat Exchanger ..........................................................3.2/53.3 Checking Oil Level.............................................................................3.3/13.4 Cleaning Line Filter (Optional extra) ......................................................3.4/1

4. Diagnosis/Troubleshooting......................................................................4/14.1 Troubleshooting Diagram ....................................................................4.1/1

Elektrical Connections Diagram ...........................................................4.1/24.2 Troubleshooting and Remedies............................................................4.2/14.3 Checking Pump Pressure ...................................................................4.3/14.4 Checking Control System....................................................................4.4/14.5 Operational Check .............................................................................4.5/1

5. Removing, Installing Retarder .................................................................5/15.1 Removing, Installing Retarder (Free Mount Installation)............................5.1/1

5.2 Removing, Installing Retarder (Gearbox Attachment)...............................5.2/1

Aftersales Service Manual VOITH Retarder 120 DigipropPage IHV/1

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6. Retarder Basic Group Repair (Gearbox Attachment)..............................6/16.1 Assembly Overview ...........................................................................6.1/16.2 Removing, Checking and Installing Casing Ventilation .............................6.2/16.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......6.3/16.4 Removing, Checking and Installing Non-Return Valve

(Stainless-Steel Heat Exchanger) .........................................................6.4/16.5 Removing, Cleaning and Installing Silencer............................................6.5/16.6 Removing and Installing Bottom Cover ..................................................6.6/16.7 Checking, Removing and Installing Closing Cover of Retarder Housing ......6.7/16.8 Removing and Installing Labyrinth Ring (Output Side),

Renewing Radial Shaft Sealing Ring.....................................................6.8/1

6.9 Removing and Installing Centering Cover (Input Side),Renewing Radial Shaft Sealing Ring.....................................................6.9/1

7. Retarder Basic Group Repair (Free Mount Installation) ..........................7/17.1 Assembly Overview ...........................................................................7.1/17.2 Removing, Checking and Installing Casing Ventilation .............................7.2/17.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......7.3/1

7.4 Removing, Checking and Installing Non-Return Valve(Stainless-Steel Heat Exchanger) .........................................................7.4/1


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7.5 Removing, Cleaning and Installing Silencer............................................7.5/17.6 Removing and Installing Bottom Cover ..................................................7.6/17.7 Removing and Installing Prop Shaft Flanges ..........................................7.7/17.8 Checking, Removing and Installing Closing Cover of Retarder Housing ......7.8/17.9 Removing and Installing Labyrinth Ring (Output Side),

Renewing Radial Shaft Sealing Ring.....................................................7.9/17.10 Removing and Installing Centering Cover (Input Side),

Renewing Radial Shaft Sealing Ring...................................................7.10/1

8. Removing, Checking and Installing Heat Exchanger ..............................8/18.1 Stainless-steel Heat Exchanger ...........................................................8.1/1

8.2 Aluminium Heat Exchanger .................................................................8.2/1

9. Control Parts ...........................................................................................9/1

10. Annex ....................................................................................................10/1Data SheetMiscellaneous Conversions


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Preface

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1 Preface

The present service manual serves as training material of the basics course.The information and instructions which is given to you furthermore provide the basis forappropriate and professional maintenance and repair at the VOITH Retarder 120 with Digiprop control.

We ask you firmly to notice the safety and warning notes which you will find in these instructions.

Caution!

is associated for safety instructions and for warning notes at dangerous situations for persons,at reduction of quality of workmanship and the possibility of damage to property.

Notice

is associated for general notices for a better handling during maintenance of the retarder.

Aftersales Service Manual VOITH Retarder 120 DigipropPage 1/1

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Preface

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1 Preface

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Caution!

The switched-on retarder will not secure the parked vehicle.

At a fa ilure of the retarder, or while the temperature limitation is effective the vehicle speed must besettled with the service brake.

Notice

Only genuine spare parts may be used for repairs. For inquiries and orders, please provide the followinginformation (see also Section 2.3):

Serial-Number Code-Number

Notice

The used three- or four-digit item numbers in these instructions are corresponding to the item numbers

in the spare part lists in the annex. Items or components shown with an oblique-number are notavailable. Items or components with two-digit item numbers are no spare parts and therefore notavailable in the spare part lists.


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Caution!

Pay attention to absolute cleanliness in maintenance work. Dirt on bearing and sealing surfaces and

electrical contacts may cause considerable damage or operational malfunctions.

Notice

To observe environmental protection you should dispose of drained fuels, coolants and lubricantsprofessionally.

Notice

Shield retarder proportional valve from direct jet of high-pressure cleaner (steam jet cleaner)!

Notice

In troubleshooting you must not replace parts on suspicion. Warranty work or goodwill work can only be

offered, if the parts involved are demonstrably defective.

To exclude injuries and to avoid impairment of the operational reliability of the retarder or damage to theretarder as a result of inexpert workmanship, the information and instructions must be read carefully andcomplied with in their entirety.


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Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situationswhich might entail the risk of injury for the person carrying out the work. It is therefore imperative thatany person carrying out repair work on VOITH retarders uses his professional knowledge to make surethat his own safety is not endangered and that the retarder suffers no negative effects, in particularsafety-wise, through the chosen working procedure. For these reasons, no liability can be assumed fordamage incurred.

It is therefore expressly pointed out that all working procedures described must be carried out only incompliance with the valid general directions and regulations of the locally responsible authorities, of thehealth protection, accident prevention and environmental protection organisations.

The technical status of the present instructions can be seen from the updating index. There may bediscrepancies between the actual technical status of the retarders and the descriptions owing to

continuous development and improvement of the retarders.VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and withoutprior notification.

Should you have queries about the descriptions, please contact the responsible person in theappropriate organisation of the country involved or:

VOITH TURBO GmbH & Co. KGD-74564 Crailsheim

Department cb; Voithstrae 1Telephone (07951) 32-0Telefax (07951) 32-756Extensions:Customer telephone and Spare Parts Service32-401 / 32-422


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General

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2 General

2.1 Assembly Overview....................................................................................2.1/1With Stainless-Steel Heat Exchanger .................................................................2.1/1With Aluminium Heat Exchanger .......................................................................2.1/3

2.2 Function and Operation Scheme................................................................2.2/1

2.3 Retarder Data.............................................................................................2.3/1


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General

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2.1 Assembly Overview

Illustration VOITH Retarder R 120

with Digiprop control system

basic group with stainless-steel

heat exchanger

100/1 Retarder data100/2 Constant-air pressure

connection py A100/3 Ventilation connection R1000 Heat exchanger1900 Oil filler/check plug (M 30 x 1,5)

Aftersales Service Manual VOITH Retarder 120 DigipropPage 2.1/1

1900100/1

1000

100/2

100/3

16001

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basic group with stainless-steel

heat exchanger

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1000 Heat exchanger1000/1 Leakage oil drain plug

(M 14 x 1,5)1000/5 Cooling water drain plug

(M 18 x 1,5)1700 Retarder oil drain plug

(M 22 x 1,5)


1000/1

1700

1000/5

1000

16002

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basic group with aluminium heat exchanger

100/1 Retarder data

100/2 Constant-air pressureconnection py A

100/3 Ventilation connection R1000 Heat exchanger

1000/5 Cooling water drain plug(M 12 x 1,5)

1900 Oil filler/check plug (M 30 x 1,5)


1900

100/1

1000/5

1000

100/2

100/3

16003

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basic group with aluminium heat exchanger(Continue)

1000 Heat exchanger1000/1 Leakage oil drain plug

(M 10 x 1)1000/3 Heat exchanger oil drain plug

(M 12 x 1,5)1000/5 Cooling water drain plug

(M 12 x 1,5)1700 Retarder oil drain plug

(M 22 x 1,5)


16004

1000/1

1700

1000/5

1000

1000/3

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General 2.2 Function and Operation Scheme

Illustration of VOITH Retarder 120 with Digiprop control system

Notice

The reference numbers indicated in Section 2.2 are not identical with the reference numbers of the spare parts lists.

1 Heat exchanger2 Control unit

4 Connectio n ter minal 155 Connectio n ter minal 307 Fuses (5A)

8 Connection ground12 Pump pressure test connection15 ABS-Signal16 Reta rder stage switch

43 Oil sump44 Stator

45 Stator pin46 Rotor47 Speedometer signal

50 Output restrictor D152 Fil ling restrictor D253 Filling duct56 Leakage o il re turn line

R

P

A

46

44 12 50

25

52

45

23

53

19

37

67

20

26

21

7

416 5 8

2

7015 47177418

69

43 156 66

Oil sump

Supply-air pressure pV

Constant-air pressure p y

Coolant (water)

Pump pressure pP

16005e

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Description of the function

The VOITH Retarder 120 is a powerful hydrodynamic continous brake of compact design for buses andcommercial vehicles of the medium range. The VOITH Retarder 120 is mounted between the gearboxand the rear axle of the vehicle.

The retarder braking torque is sustained even when gear changes are made.The switched-on retarder will not secure a parked vehicle.In the event of a retarder failure or when the temperature limit is effective, the service brake must beused to regulate the vehicle speed.

A retarder stage switch (16) with a maximum of 5 switching stages is used to control theVOITH Retarders 120. A special version combines the retarder stage switch (16) with ABS,a 3-stage pedal-operated brake valve or a service-brake pressure switch.

The following variaties in operation are available:

Operation with function ,,Constant speed"

The retarder is operated by a 5-stage retarder stage switch.

When the retarder stage switch (16) is shifted to position 1, the Constant Speed function is activated.The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limitof the maximum braking torque.

If the retarder is switched off (0 position), or switched to braking stage (position 2 to 5), the memorizedconstant speed is deleted. If the constant speed function is re-activated, the new present speedis memorized.

When the retarder stage switch is shifted to position 2 to 5, braking stage 1 to 4 is energized.

Maximum braking torque is obtained when the retarder stage switch is in the maximum position.


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Description of operation of retarder R 120 with digiprop control system

As a special version, the control system is available with push button operation for constant speed.The retarder is operated in this case by a 4-stage retarder stage switch.When the push button is pushed in any position of the retarder stage switch, the momentary speed is

transferred to memory. In the 0 braking stage, this transfer to memory takes effect and the retarder holdsthe vehicle speed downhill constant within the limits of the maximum braking torque. Another push onthe push button in any switch position will delete the speed data.

On a downhill run with constant speed operation, the vehicle can be slowed down within the limits ofthe maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting tobraking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle acceleratesto the speed previously transferred to memory.

The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank forauxiliary equipment on the vehicle.

When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2).From this input signal, the control unit (2) provides a control current which flows to theproportional valve (21).The proportional valve (21), depending on the magnitude of the control current, provides aconstant-air pressure pyon the oil sump (43).

The constant-air pressure pyin the oil sump (43), depending on the operating conditions(prop shaft speed), forces a certain quantity of oil into the working chamber between rotor (46)and stator (44).

c

a b

16006

The hydrodynamic principlea Rotor (46)b Stator (44)c Oil flow


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The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarderhousing.The rotation of the rotor sets the oil in motion and circulates it in a closed circuit betweenthe rotor (46) and stator (44).The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking of

the rotor (46) and consequently to braking of the vehicle.

During braking, the kinetic energy of a deceleration is transformed into heat. To dissipate this heat, partof the circulat ing oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and viafilling ducts to join the circulating flow again.In the heat exchanger (3300), the heat energy of the oil is transferred to the cooling water of the vehicleand dissipated via the vehicle radiator to the ambient air.


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Temperatur pick-ups, water (19), oil (20)

The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from theretarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water andoil temperature to the control unit (2).To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarderbraking torque is limited to protect the vehicle cooling system and the retarder.The constant-air pressure pyis l imited.

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

If the cooling water temperature rises into the temperature limit range, the consequence is a limitation of

the retarder braking torque to protect the vehicle cooling system. If the temperature rises above thetemperature limit range, there is no more braking torque output.

While the temperature limit is effective or if there is a retarder failure, the service brake must be used tocontrol the vehicle.The control unit (2) also cuts back braking torque if oil temperature rises too rapidly, irrespective of actualoil temperature.


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Casing ventilation (23)

During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) andthe ventilation system (22) out of the retarder.Once the working circuit is free of air, a float rises and closes the casing ventilation.

Stator pins (45)

When the working chamber is empty, the rotor (46) sets up in it an air flow, which is retarded by the stator(44). To minimize this loss, automatically operating stator pins have been installed in the outer zone ofthe stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent thebuild-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back ontheir seats against the force of the spring and the full space between the blades is available.

Check valve (66) stainless-steel heat exchanger

The check valve (66) prevents the airflow emptying the heat exchanger insert of oil when idling.


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2.3 Retarder Data

The retarder data (arrow) are punched on the left side on the retarder housing.

The retarder data plate (2) provides the following information:

1. Serial number:

Six-digit number

2. Code number:Eight-digit number

Notice

Please, always quote the retarder serial-No. and code-No. when submitting queriesor ordering spare parts.

16007


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Maintenance

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3 Maintenance

3.1 Maintenance Work .....................................................................................3.1/1

3.2 Oil Change .................................................................................................3.2/1Stainless-steel Heat Exchanger

........................................................................3.2/1Aluminium Heat Exchanger ..............................................................................3.2/5

3.3 Checking Oil Level .....................................................................................3.3/1

3.4 Cleaning Line Filter (Optional Extra) ..........................................................3.4/1


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3.1 Maintenance Work

Overview of maintenance work

Carry out the fo llowing maintenance work at eachoil change:

l Clean the cleaning line filter (optional extra)

l Carry out visual inspection on leaks at the complete retarder

l Check hex.-head screws of prop shaft on correct fitment, or tighten.

Observe guidelines and instructions!

l Tighten all screw plugs of the retarder basic groups and the heat exchanger with the appropriatetorque (see Annex) except all fastening nuts of the heat exchanger (see Annex).

Caution!

Tighten fastening nuts of heat exchanger only in case of leakage. Tightening torque: 23 Nm

The oil change intervals and operating specifications have to be taken from the annex!


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3.2 Oil Change

Illustration oil change R 120

with stainless-steel heat exchanger

1000/1 Leakage oil drain plug(M 10 x 1), 13 Nm

1000/2 Sealing ring (A 10 x 13,5), renew1000/5 Cooling water drain plug

(M12 x 1,5), 25 Nm1000/6 Sealing ring (A12 x 18), renew

1600 Sealing ring (A 22 x 29), renew1700 Retarder oil drain plug

(M 22 x 1,5), 66 Nm1800 Sealing ring (A 30 x 36), renew1900 Oil filler/check plug

(M 30 x 1,5), 150 Nm


1900

18001000/2

1000/6 1000/5

1000/1

1700

1600

16008

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Notice

For satisfactory retarder operation, it is important to adhere to the specified service filling(see table below) and to use only oils specified in the operating specifications (see Annex) foroperating the retarder in the relevant application.

The retarder oil temperature must be higher than 60 oC(operating temperature) for the oilto be drained.

Caution!

While the oil is being changed, make sure that no constant-air pressureis acting in the retarder.The retarder and the ignition must have been switched off!

Heat exchanger Service fill ing After complete

taking apart and cle-aning, as well as

emptied heatexchanger

After exchange of

heat exchanger

Stainless-steelheat exchanger

(L+R)4,5 l 5,8 l 6,5 l


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Job scope

1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec.Repeat this procedure twice.Switch off the retarder andignition and wait 5 minutes (control function).

Caution! Risk of injury!

The oil f iller/check plug is heated up (oil temperature)!

2. Push an oil collecting pan under retarder.

3. Screw out the oil check plug (1900) and remove sealing ring (1800).


The retarder oil drain plug is heated up (oil temperature)!

4. Screw out the retarder oil drain plug (1700) and remove sealing ring (1600) and drain oil.


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3.2 Oil Change

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5. Screw out the leakage oil drain plug (1000/1) and remove sealing ring (1000/2) and drain theaccumulated oil.

Notice

If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening theleakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with thevehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the tworadial shaft sealing rings at the Retarder and renew those, if necessary(see Section 6.8, 6.9, 7.9, 7.10).

If it is necessary to drain the cooling water during the service, remove and empty the retarder on oil sidecompletely (see Section 8.1, 8.2).

This process also must be enforced with strongly spent oil.

6. Screw the oil drain plugs (1700 and 1000/1) tight with new sealing rings (1600 and 1000/2).

Retarder oil drain plug (1700): Tightening torque 66 NmLeakage oil drain plug (1000/1): Tightening torque 13 Nm

7. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified(see page 3.2/2) in accordance with the operating specifications (see Annex).

8. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm

9. Check the oil level (see Section 3.3).



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3.2 Oil Change

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Illustration oil change R 120

with aluminium heat exchanger

1000/1 Leakage oil drain plug(M 10 x 1), 13 Nm

1000/2 Sealing ring (A 10 x 13,5), renew1000/3 Heat exchanger oil drain plug

(M 12 x 1,5), 25 Nm1000/4 Sealing ring (A 12 x 15,5), renew

1600 Sealing ring (A 22 x 29), renew1700 Retarder oil drain plug

(M 22 x 1,5), 66 Nm1800 Sealing ring (A 30 x 36), renew1900 Oil filler/check plug

(M 30 x 1,5), 150 Nm


1000/3

1000/4

1000/2

1000/1

17001600

1900

1800

16009

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Notice

For satisfactory retarder operation, it is important to adhere to the specified service filling(see table below) and to use only oils specified in the operating specifications (see Annex) foroperating the retarder in the relevant application.

The retarder oil temperature must be higher than 60 oC(operating temperature) for the oilto be drained.

Caution!

While the oil is being changed, make sure that no constant-air pressureis acting in the retarder.The retarder and the ignition must have been switched off!

Heat exchanger Service filling New filling

Aluminium heat exchanger (AKG) 5,5 l 6,0 l


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Job scope

1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec.Repeat this procedure twice.Switch off the retarder andignition and wait 5 minutes (control function).


The oil f iller/check plug is heated up (oil temperature)!

2. Push an oil collecting pan under retarder.

3. Screw out the oil filler/check plug (1900) and remove sealing ring (1800).


The retarder oil drain plug is heated up (oil temperature)!

4. Screw out the retarder oil drain plug (1700) and the heat exchanger oil drain plug (1000/3) andremove the sealing rings (1600 and 1000/4) and drain oil.

5. Screw out the leakage oil drain plug (1000/1) and drain the accumulated oil.


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3.2 Oil Change

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Notice

If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening the

leakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with thevehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the tworadial shaft sealing rings at the Retarder and renew those, if necessary(see Section 6.8, 6.9, 7.9, 7.10).

6. Screw the oil drain plugs (1700, 1000/3 and 1000/1) tight with new sealing rings (1600, 1000/2and 1000/4).

Retarder oil drain plug (1700): Tightening torque 66 NmHeat exchanger oil drain plug (1000/3): Tightening torque 25 NmLeakage oil drain p lug (1000/1): Tightening torque 13 Nm

7. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified(see page 3.2/2) in accordance with the operating specifications (see Annex).

8. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm

9. Check the oil level (see Section 3.3).



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3.3 Checking Oil Level

Illustration checking oil level

Notice

The oil change intervals and operatingspecifications have to be taken from the annex.

1800 Sealing ring (A 30 x 36), renew1900 Oil filler/check plug (M 30 x 1,5),

150 Nm

Notice

The illustration shows a retarder 120 withstainless-steel heat exchanger. A version withaluminium heat exchanger is possible.


1900

1800

16010

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Notice

For satisfactory retarder operation, it is important to use only oils specified in the operating specifications(see Annex) for operating the retarder in the relevant application.

Service filling

The service filling for the complete retarder system depends on the version of themounted heat exchanger.

For relevant application approved oils

Use only approved oils specified in the operating specifications (see Annex).


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Notice

For the oil level check, the temperature of the retarder oil must be higherthan 60C (operating temperature).

The oil level check must be carried out with the vehicle in a horizontalposition.Difference between min. and max. mark on oil filler/check plug is approx. 0,5 l.

Job scope

1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec.Repeat this procedure twice.

Caution!

While the oil level is being checked, make sure that retarder and ignition system must havebeen switched off!

Risk of injury exists at nonobservance, by hot leaving oil when screw out oil filler/check plug!

2. Switch off the retarder and wait 5 minutes (control function).


The oil filler/check plug (1900) is heated up (oil temperature)!

3. Screw out the oil filler/check plug (1900) and remove sealing ring (1800).Wipe off oil of the oil filler/check plug.


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4. Position oil filler/check plug (1900) plane at the thread.

Do not screw in the oil filler/check plug!

5. Pull out again the oil filler/check plug (1900).Oil level is correct bewteen min. and max. mark of the oil filler/check plug.

6. Top up slowlyany lacking oil through the hole for the oil filler/check plug.

7. Screw the oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm


Max

Min

1900

16011

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Maintenance

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3.4 Cleaning Line Filter

(Optional Extra)

Illustration line filter

12000 Complete line filter12000/1 Pressure spring12000/2 Intermediate plate

12000/3 Cover12000/4 Holding plate12000/5 Pressure spring12000/6 Filter housing

12111 Filter insert12112 O-ring (36,2 x 3), renew,

coat with silicone-free andnon-corossive greasefor installation

Lubricants

O-ring Silicone-free andnon-corossive grease

12000/1

12111

12000/2

12000/5

12112

12000/3

12000/4

12000/6

12

000

16012


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Notice

Vehicle specific can be installed a line filter within the constant-air pressure line between air tankfor auxiliary equipment and the proportional valve of the retarder control system.

The line filter is designed and in the way installed, to ensure an optimum air flow to the proportional valvealso when filter insert is badly soiled. In this case the compressed air will not be cleaned anymore.

Job scope


Observe fall in pressure in the compressed air circuit for auxiliary equipment (e.g. air springs)!

1. Disconnect constant-air pressure line at the line filter for air tank of auxiliary equipment .

2. Press in the cover (12000/3) and pull out the holding plate (12000/4).

3. Pull out of the filter housing (12000/6) the cover (12000/3) with O-ring (12112),

the pressure spring (12000/5), the intermediate plate (12000/2), the filter insert (12111)and the pressure spring (12000/1) .

4. Blow out the filter insert (12111) with compressed air from inside out. Check filter insert fordamages and renew if necessary.


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5. Insert the pressure spring (12000/1), the filter insert (12111), the intermediate plate (12000/2) andthe pressure spring (12000/5) in filter housing (12000/6).

6. Coat new O-ring (12112) with silicone-free and non-corossive grease. Pull the new O-ring on tothe cover (12000/3).

7. Press in the cover (12000/3) into the filter housing (12000/6) and put in theholding plate (12000/4).

Notice

If complete filter (12000) has to be removed, observe the correct installing position.


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Diagnosis /

Troubleshooting

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4 Diagnosis / Troubleshooting

4.1 Troubleshooting Diagram...........................................................................4.1/1Electrical Connections Diagram ........................................................................4.1/2

4.2 Troubleshooting and Remedies .................................................................4.2/1

4.3 Checking Pump Pressure...........................................................................4.3/1

4.4 Checking Control System...........................................................................4.4/1

4.5 Operational Check......................................................................................4.5/1


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Diagnosis /

Troubleshooting

4.1 Troubleshooting Diagram

Illustration troubleshooting d iagram

Notice

Before starting troubleshooting the oil level of the retarder must be checked and corrected(see chapter 3.3 Checking oil level).It is important that the specific service filling is kept for a trouble-free operation of the retarder

(see chapter 3.2 Oil change and annex).

Renew casingventilation

Check oil level ofretarder

OK NOK

YESNO

Water in the oil?(emulsion)

Check casingventilation

(Chapter6.2)

NOK OK

YES NO

Water in the oil?(emulsion)

OK NOK

Check oil level ofretarder

YES NO

Water in the oil?

(emulsion)

NO YES

Water in the oil?

(emulsion)

OK NOK

Check py(static)

(Chapterl4.4)

Complaint

R 120Digiprop

Check p (dynamic)

(Kapitel4.3)

Activate flash codeand read outtrouble code

(Chapter4.2)

Temperature limit!

Permanentlighting

flashes

OK NOK

Check operation(by braking with

retarder nominalengine speed,

if possible

Check cooling system:

-coolant level

-thermostat-coolant pump-radiator fan-radiator grill fordirtiness

Retarder:

Check Temp.-Sens.(oil/water)

Driver instruction!

Clear faults anddelete fault memory

(Chapter4.2)

Check heatexchanger

see chapter 6.4

Check heatexchanger

see chapter 6.4

Retarder pilotlight

No respectivelytoo insufficient

retarder brakingeffect

Oil leak byventilation

Oil leak input sideor output side

Empty chamber ofreturn of leakage oil(at heat exchanger)

(Chapter3.3)

If the retarder isstill leaking, or the

chamber ofleakage oil is filled

again with oil after1000 km,

renew radial shaftseal

Correct oil level ofretarder (*)

Correct oil level ofretarder

Check non-returnvalve in cover ofcasing ventilation

(Chapter6.3)

NOK OK

Contact

VOITH

Renew non-return

valve

i i

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Diagnosis /

Troubleshooting

4.1 Troubleshooting Diagram

(Continue)

Electrical Diagram Version 1

Electrical Diagram Version 2

Input / (0...20mA ) ÌNA-I Stop light relay Stop light relay

Speedometer signal Speedometer signal

Prop valve +`

Output / low side 1 `LS 1Òutput / high side `HS 2`

Output / high side 1 `HS 1`

Prop valve -`

T 30 (Battery) T 30 (Battery)

T 31 (Ground)T 31 (Ground)

Retarder Stage Switch`+`

ISO LISO K

Position 5Position 4Position 3Position 2Position 1


CAN-lowCAN-GroundCAN-high

T 15 (Ignition lock)


Changeover valve -`Changeover valve +`

Water temp.`-`Water temp.`+`

Oil temp.`+Òil temp.`-`

Prop valve +`Prop valve -`

Changeover valve -`Changeover valve +`

Water temp.`-`Water temp.`+`

Oil temp.`+Òil temp.`-`

ABS ABSblue

white

white

weiwhite

black

pink

pink

blue/white

blue/white

brown/whiteorange/white

orange/white

orange

orangeorange

orange

yellow/green

yellow/green

grey/black

red/white

grey

bluepurple

32

3

1211

10

151413181716

21654987

7

32165498

1654987

12

12pinsX3.

9pinsX2.

18pinsX1.

Digiprop

1110

grey

brownbrown

beige

beige

redred

grey

grey

pinkblue

black/white

black/whiteyellow/green

Input / p.-down / PWM-in `DID 4 Ìnput / (m 0...5V ) ÌNA-U `

Input / pull-down `DID 3 `

Input / pull-up `DIU 1Ìnput / pull-up `DIU 2Ìnput / pull-down DID 1Ìnput / pull-down DID 2`

Retarder pilot light Retarder pilot light

purplepurple

9 5 4 3 2 7 6 101112 131481

Connecting plug 14 ins"Additional Functions"

"ISO Interface"Connecting plug 4 pins

7653284

3 21 4


"Retarder Stage Switch"Connecting plug 8 pins

+

+

+

Lead Retarder

Lead E-Box

3

4

2

1Pin

16014e

Prop valve `+`

Output / low side 1 `LS 1Òutput / high side `HS 2`

Output / high side 1 `HS 1`

Prop valve ` `

T 30 (Battery) T 30 (Battery)

T 31 (Ground)T 31 (Ground)

Retarder Stage Switch`+ÌSO LISO K



CAN-lowCAN-GroundCAN-high



Prop valve `+`Prop valve ` `

weiwhite

black

pink

blue/whiteorange/white

orangeorange

3

121110

151413181716

2

7

32165498

18pinsX1.

Digiprop

brownbrown

beige

redred

grey

grey

pinkblue

black/whiteyellow/green

purplepurple

"ISO Interface"

7653284

3 21 4


"Retarder Stage Switch"Connecting plug 8 pins

+

+

Lead Retarder

Lead E-Box

21Pin

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Diagnosis /

Troubleshooting

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4.2 Troubleshooting and Remedies

Troubleshooting and remedies

Check requirements

Batter y voltage 18 - 32 V

Vehicle electrical system checked in accordance with the Owner s Manual for the vehicleand found satisfactory.

Fuse for retarder control unit checked and found satisfactory. Compressed-air pressure 6 - 11 bar

l For check with the multimeter, pin 15 (plug X1) on the control unit (2)must be connected to pin 15 ground (terminal 31),at pin 7 (plug X1) must be connected terminal 15 andat pin 13 (terminal X1) terminal 30.

Notice

Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary(see Section 3.3 Checking Oil Level ).

For trouble-free retarder operation, it is important that the filling quantity specified is adhered to(see table, Section 3.2, page 3.2/2).


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Diagnosis /

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Notice

The retarder pilot light (arrow) has additionally the function of a fault code:

- slight fault

Permanent lighting in position 0 - 5 of retarder stage switch, braking is still possible to limited extent.

- serious fault

Permanent lighting in position 0 - 5 of retarder stage switch, braking no longer possible- retarder is switched off.

Notice

If the ignition is switched off and on, the retarder is in operation again and the retarder pilot lightgoes off. If a serious fault remains present or reoccurs, the retarder switches off again and the retarderpilot light comes on permanently in position 0 to 5 of the retarder stage switch.

R

16016


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16017

147101316

258111417

369121518


(Continue)

Connector arrangement and pin assignment

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

Plug X1 Control unit

1 Not in use2 Not in use

3 Not in use4 Retarder stage switch, position 3 -(or)5 Retarder stage switch, position 2 -(bl)6 Retarder stage switch, position 1 -(pi)7 Terminal 15 (rd)8 Retarder stage switch, position 5 -(gr)9 Retarder stage switch, position 4 -(wh)10 Retarder stage switch + (vi)11 ISO-interface, L-lead (or/wh)12 ISO-interface, K-lead (bl/wh)13 Terminal 30 (bl )14 Not in use15 Terminal 31 (br )16 Output / high side 2 HS2 (bl/wh)17 Output / low side 1 LS1 (ye/gr)18 Output / high side 1 HS1 (be)


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1 Not operational/usable for applications (or)2 Proport ional valve - (gr)3 Proportional valve + (pi)4 Cooling water temperature pick-up - (bl)

5 Cooling water temperature pick-up + (ye/gr)6 Not operational/ground (be)7 Not in use8 Oil temperature pick-up - (wh)9 Oil temperature pick-up + (vi)


1 Input / pull up DIU 1 (wh)2 Speedometer signal (b l)3 ABS-Signal (bl/wh)4 Input / pull down DID 2 (br/wh)5 Input / pull down DID 1 (bl/wh)6 Input / pull up DIU 2 (p i)7 Input / (0.. .5V) INA-U (gr/bl)8 Retarder pilot light (ye/gr)9 Input / pull down DID 3 (or/wh)10 Input / (0...20 mA) INA-I (rd/wh)11 Stop l ight relay (or)12 Input / pull down / PWM-in DID4 (gr) / engine-speed signal

16018

147

258

369

16019

14710

25811

36912


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Diagnosis /

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Extra o perations plug

1 Retarder stage switch + (vi)2 Input / pull down DID 1 (bl/wh)3 Input / pull down DID 2 (br/wh)4 Input / pull down DID 3 (or/wh)

5 Input / pull down / PWM -in DID 4 (gr)6 Input / pull up DIU 1 (wh)7 Input / pull up DIU 2 (p i)8 Input / (0.. .5V) INA-U (gr/bl)9 Input / (0...20 mA) INA-I (rd/wh)10 Output / high side 1 HS1 (be)11 Output / high side 2 HS2 (bl/wh)12 Output / low side 1 LS1 (ye/gr)13 Terminal 15 (rd)

14 Terminal 31 (br)

ISO-Interface plug

1 K-lead (bl/wh)2 K-lead (or/wh)3 Terminal 15 (rd)4 Terminal 31 (br)

2

1

4

3

6

5

8

7

10

9

12

11

14

13

16020

2 1

4 3

16021


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Cooling water temperature pick-up plug

Oil temperature pick-up plug

Proportional valve p lug

1 Proportional valve + (pi )2 Proportional valve + (gr)3 Not operational (or )4 Not operational (be)

16022


1

2

3

4

16023

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Diagnosis /

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Retarder stage switch plug

1 Not in use2 Position 5 - (gr)3 Position 4 - (wh)4 Retarder stage switch + (vi)

5 Position 3 - (or)6 Position 2 - (bl)7 Position 1 - (pi)8 Bridge to pin 4

16024

1 2 3 4

5 6 7 8


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Diagnosis /

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A. With fault code

Special tool

Commercially available tool

Notice

The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-outfrom the fault memory.

Furthermore a diagnosis with the PC DigiDia software is possible. In this case please contactVOITH TURBO or a responsible contracting party.

Multimeter recommended: Fluke 87

53.8224.10


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Diagnosis /

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Fault memory read-out via retarder pilot light blinking code

Notice

If several faults have been stored in the memory, they are indicated in the sequence of their occurance,but always only one fault per triggering.

Exception:

The fault Coding fault is not held in the memory but is indicated via the blinking code.

The blinking code can be read-out of the control unit with service cable or retarder stage switch.

Fault memory read-out with service cable

(Digiprop-Version 0.2)

Requirements

- Retarder stage switch in position 0

- Vehicle in parking position, Ignition ON1. Service interface L-lead connected to ground for 2 s. For this purpose, press push-button of

service cable switch.

2. First fault as blinking code output.

3. Repeat from step 2 and 3 for more blinking code outputs.

Meaning

- long blinking signals (2 sec.) tens unit.

- short blinking signals (0,5 sec.) single unit.


R

16016

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Diagnosis /

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Digiprop-Version 1.0

The blinking code can be triggered analogous to V 0.2, the conditions are the same. Additionally theblinking code can be triggered with the help of the retarder stage switch during the service function:

1. Shift RSS-Position 0

2. Shift RSS-Position 1 ( 2 Seconds)3. Shift RSS-Position 04. Blinking code of first fault is indicated5. Repeat from step 2 to 3 for more blinking code outputs

Addition for versions as of V 1.1

There is a break of 3 seconds before and after each blinking code output, during this time the retarderpilot light is switched off.

Display example for fault code 23:

The number of tens will be indicated first as long ON-time: each 2 secondsThe number of singles afterwards will be indicated as short ON-time: each 0,5 secondsBreaks between each ON-time: each 1 second

If a relevant fault is indicated, the retarder pilot light is ON before tr iggering of the blinking code, theretarder pilot light switches to permanent lighting again after the blinking code.If there is only one fault in the memory, the retarder pilot light stays OFF after the output.


16025

Display example: Fault code 23

E Retarder stage switch on

A Retarder stage switch o ff

t Time

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Diagnosis /

Troubleshooting

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Delete fault memory

No marginal conditions in accordance with read-out of fault memory.

1. Ignition: OFF

2. Service interface L-lead connected to ground. For this purpose, press push-button ofservice cable switch.

3. Ignition: ON

4. Disconnect a fter 2 seconds the L-lead of ground.


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Diagnosis /

Troubleshooting

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Notice

Meaning of entries in Measurement/test connection column: X 1/15 W X 3/11Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3

Table 1:

1) X 1/15 = ground control unit2) Only, if no fault is recognizable after a complete check of the periphery: change control unit.

Fault Fault text Fault

class

Trigger time Requirement /

Operation

Measurement/

test

connection1 )

Result/

Set point

Cause/

Remedy 2)

C ode (Check)

01 Stop light relay/

Short circuit toground

slight 1 s - Ignition: OFF- Pull plug X3 out of

control unit

X 3/11 W X 1/15 Relay isinstalled:250 - 350 W

Check lead, plugsand relayor consumers

02 LS 1 output

Short circuit tobattery

slight 400 ms - Ignition: OFF- Pull plug X1 out of

control unit- Disconnect plug

for extra operation(e.g. lamp or

relay)- Ignition: ON

X 1/17 V X 1/15 0 V Check lead, plugsand relayor consumers


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Diagnosis /

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Table 2:

Fault

Fault text Fault

class


Operation

Measurement/

test connection

Result/

Set point

Cause/

Remedy

C ode (Check)

03 HS 1 output

Short circuit


control unit

X 1/18 W X 1/15

With relayinstalled:250 - 350 W

Check lead, plugsand relayor consumers

04 HS 2 output

Short circuit


control unit

X 1/16 W X 1/15 With relayinstalled:

250 - 350 W

Check lead, plugsand relay

or consumers

05 Terminal 15

Undervoltage

serious 60 s - Ignition: OFF- Pull plug X1 out of

control unit- Ignition: ON

X 1/7 V X 1/15 17,5 V Check lead, plugsand fuses

06 Terminal 15

Overvoltage


control unit- Ignition: ON- Start engine

(idle speed)

X 1/7 V X 1/15 32,5 V Checking electricalinstallation of vehicle

(see manufacturerinstructions)


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Table 3:

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

Fault

Fault text Fault

class


Operation

Measurement/

test connec-

tion

Result/

Set point

Cause/

Remedy

Code (Check)

08

09

Water tempera-ture sensor

Discontinuity /Short circuit tobattery

serious/slight *

1 s - Ignition: OFF- Pull plug X2 out of

control unit

X 2/5 W X 2/4 20C 10 C =1039 - 1117W

60C 10 C =1099 - 1271W

80C 10 C =

1271 - 1347W

Notice:

The measuring inone temperaturerangenormally issufficient.

Check lead andsensor


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Diagnosis /

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Table 4:

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

Fault

Fault text Fault

class


Operation

Measurement/

test connec-

tion

Result/

Set point

Cause/

Remedy

C ode (Check)

11

12

Oil temperaturesensor

Discontinuity /Short circuit tobattery

serious/slight *

1 s - Ignition: OFF- Pull plug X2 out of

control unit

X 2/9 W X 2/8 20C 10 C =1039 - 1117W

60C 10 C =1099 - 1271W

80C 10 C =

1271 - 1347W

Notice:

The measuring inone temperaturerangenormally issufficient.

Check lead andsensor


4 2 T bl h i d R di

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Diagnosis /

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Table 5:

Fault

Fault text Fault

class


Operation

Measurement/

test connection

Result/

Set point

Cause/

Remedy

Code (Check)

13 1 Retarder stageswitchUndefinedswitch state

serious 100 ms - Ignition: ON- Retarder stage switch:

Position 0

X 1/10 V X 1/15

X 1/6 V X 1/15X 1/5 V X 1/15X 1/4 V X 1/15X 1/9 V X 1/15X 1/8 V X 1/15

17,5 V

0 V0 V0 V0 V0 V

Check lead, plug andretarder stage switch

13 2 - Ignition: ON- Retarder stage switch:

Position 1

X 1/10 V X 1/15X 1/6 VX 1/15

X 1/5 V X 1/15X 1/4 V X 1/15X 1/9 V X 1/15X 1/8 V X 1/15

17,5 V

17,5 V

0 V0 V0 V0 V



Position 2

X 1/10 V X 1/15X 1/6 VX 1/15X 1/5 VX 1/15

X 1/4 V X 1/15X 1/9 V X 1/15X 1/8 VX 1/15

17,5 V17,5 V

17,5 V

0 V0 V0 V



4 2 T bl h ti d R di

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Table 6:

Fault

Fault text Fault

class


Operation

Measurement/

test connection

Result/

Set point

Cause/

Remedy

C ode (Check)


Position 3

X 1/10 VX 1/15X 1/6 VX 1/15

X 1/5 V X 1/15X 1/4 VX 1/15

X 1/9 VX 1/15X 1/8 VX 1/15

17,5 V

17,5 V

17,5 V

17,5 V

0 V0 V



Position 4

X 1/10VX 1/15X 1/6 VX 1/15X 1/5 VX 1/15X 1/4 VX 1/15X 1/9 VX 1/15

X 1/8 VX 1/15

17,5 V17,5 V

17,5 V

17,5 V

17,5 V

0 V


13 6 - Ignition: ON

- Retarder stage switch:

Position 5

X 1/10 VX 1/15

X 1/6 VX 1/15X 1/5 VX 1/15X 1/4 VX 1/15X 1/9 VX 1/15X 1/8 VX 1/15

17,5 V

17,5 V17,5 V

17,5 V17,5 V17,5 V

Check lead, plug and

retarder stage switch


4 2 Tro bleshooting and Remedies

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Diagnosis /

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Table 7:

Fault

Fault text Fault

class


Operation

Measurement/

test connection

Result/

Set point

Cause/

Remedy

C ode (Check)

14 Retarder stageswitchShort circuit tobattery


control unit- Ignition: ON- Retarder stageswitch:

Position 0

X 1/10 V X 1/15 0 V Check lead and plug

15 Retarder stageswitchShort circuit tobattery


control unit- Retarder stageswitch:

Position 5

X 1/10 W X 1/15 Resistorinfinite

Single check ofstages forshort circuit


Di i / 4 2 Troubleshooting and Remedies

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Table 8:

Fault

Fault text Fault

class


Operation

Measurement/

test connec-

tion

Result/

Set point

Cause/

Remedy

C ode (Check)

16 Speedometersignal

Discontinuity

serious 2 s - Ignition: ON X 3/2 VX 1/15 1 V Check lead andspeedometer

18 Speedometer si-gnal

Short circuit tobattery



X 3/2 VX 1/15 9 V Check lead andspeedometer

19 ABSShort circuit toground

serious 60 s - Ignition: ON X 3/3 VX 1/15 3,5 V Check lead,relay and ABS-con-trol unit


Di i / 4 2 Troubleshooting and Remedies

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Table 9:

Fault

Fault text Fault

class


Operation

Measurement/

test connec-

tion

Result/

Set point

Cause/

Remedy

C ode (Check)

21 ABS-Signal undefined serious 60 s - Ignition: ON X 3/3 V X 1/15 16,5 V Check lead,relay and ABS-control unit

22 Internal faultABS-current path

serious 1 s - - Replace controlunit

23 Proportional valveFault No. 1:Short circuit to battery



X 2/3 V X 1/15 10 V Check lead


Diagnosis / 4 2 Troubleshooting and Remedies

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Table 10:

Fault

Fault text Fault

class

Trigger t ime Requirement /

Operation

Measurement/

test connec-

tion

Result/

Set point

Cause/

Remedy

C ode (Check)

24 1 Proportional valveFault No. 2:- Short circuit proportional

valve magnetic- Short circuit connection

lead proportional valve- Discontinuity proportio-

nal valve magneticValve magnetic

- Discontinuity connection lead proportional

valve- Short circuit to ground at proportional valve- Prop.- and shift valve

interchanged

serious 1 s - Ignition: ON- Pull plug X2 out of control unit

X 2/2 W X 2/3 18-25 W Check lead andproportionalvalve (valveblock)

24 2 - Ignition: OFF- Pull plug X2 out of control unit

X 2/3W X 1/15 Resistorinfinite

Check lead andproportionalvalve (valveblock)


Diagnosis / 4.2 Troubleshooting and Remedies

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Table 11:

Fault

Fault text Fault

class


Operation

Measurement/

test connec-

tion

Result/

Set point

Cause/

Remedy

C ode (Check)

24 3 - Ignition: OFF- Pull plug X2 out of

control unit

X 2/2 W X 1/15 Resistorinfinite

Check lead andproportionalvalve (valveblock)

25 Proportional valveFault No. 3:

defective control unit

serious 10 s Replacecontrol unit

27 Proportional valveFault No. 5:defective control unit

serious 2 s Replacecontrol unit

28 Terminal 30

Undervoltage



X 1/13VX 1/15 17,5 V Check lead,plug and fuse



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Table 12:

Fault

Fault text Fault

class


Operation

Measurement/

test connec-

tion

Result/

Set point

Cause/

Remedy

C ode (Check)

29 Fault control unit serious 180 ms Replacecontrol unit

31 Control unit:Coding fault

serious 100 ms Provide newparameters forcontrol unit

32 Retarder pilot light:Discontinuity /Short circuit to ground



X 3/8 V X 1/15 17,5 V Check lead,retarder pilotlight and fuse

33 Retarder pilot light:Short circuit to battery

serious 3 s - Ignition: ON- Retarder stage

switch:Position 1

X 3/8 V X 1/15 2 V Check lead andretarder pilotlight



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Table 13:

Fault

Fault text Fault

class


Operation

Measurement/

test connec-

tion

Result/

Set point

Cause/

Remedy

C ode (Check)

35 Fault control unit serious 500 ms / 123 s Replacecontrol unit

37 Fault pedal operation slight 100 ms / 1 s Check installati-on relating toOEM-respectively

VOITH-instructions



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B. Without fault code

Notice

Retarder faults without fault code are not recognized electronically.


Diagnosis / 4.3 Checking Pump Pressure

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Illustration checking pump pressure

Preconditions for checking

Ignition OFF Retarder stage switch in position 0

101 Hex.-head screw (M 12 x 1,5),

(Pump pressure measuring point)25 Nm

102 Sealing ring (A 12 x 15,5), renew

Notice

The pump-pressure check provides informationon the mechanical condition of rotating parts,

on internal leaks and on the operationof the retarder.

Special tool

Pressure gauge 0 - 25 bar

53.4788.10


102

101

16026


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The screw plug is heated up!

Job scope

1. Screw out screw plug (101) with sealing ring (102) at the retarder housing.

2. Connect up pressure gauge (99/1) to retarder housing.

3. Shift retarder stage switch (16) to the highest braking stage with the vehicle in parking position andread-off after 30 sec. the pump pressure from the pressure gauge (99/1).

4. Compare read-off pump pressure with the setpoint of the static pump pressure(see following table page 4.3/3).

Caution!

If the measurement of the static pump pressure falls short of the setpoint, either the retarder is leaking orthe control system is defective (see troubleshooting diagram).


99/1

16027

99/1 Pressure gauge 53.4788.10


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1) Retarder stage switch in highest position2) Decisive is the pressure which has built up i tself after 30 seconds (stabilized, constant pressure)3) The code number is to be found at the control unit

Notice

The data represent the state of the art at the time of going to print.

Control units with different values are still in circulation. The manufacturer reserves the right to makefurther modifications.

Setting [Nm] Code Number 3 ) Pump pressure static

Setpoint [bar]Pump pressure dynamic 1 )

vps= 1000 r.p.m.

Minimum value [bar]

1000 027 1,15 1,45 7

1250 028 1,45 1,75 9

1500 029 1,75 2,05 12

1750 030 2,05 2,35 14

2000 031 2,35 2,65 16



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Job scope dynamic

1. Drive the vehicle with a prop-shaft speed of vp s= 1000 r.p.m.

2. Shift the retarder stage switch (16) to position 5 while on the move at vps= 1000 r.p.m. andread-off pump pressure at pressure gauge (99/1).

3. Compare read-off pump pressure with the value of dynamic pump pressure(see table page 4.3/3).

Caution!

If the setpoint is obtained in the check at parking position but the minimum value is not reached in thedynamic check, please contact VOITH TURBO!


The screw of the pressure gauge and the retarder are heated up!

4. Disconnect the pressure gauge (99/1). Screw in screw plug (101) with new sealing ring.Tightening torque 25 Nm


Diagnosis /

Troubleshooting

4.4 Checking Control System

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Illustration checking control system

Notice

The reference numbers indicated in Section 4.4are not identical with the reference numbers ofthe spare parts li sts.

1 Heat exchanger

2 Con tro l un it11 Proportional valve

current connection

19 Temperatur pick-up cooling wateralternative: positions 19 and 20joining in the central-plug (see elec-trical diagram Version 2)

20 Temperature pick-up oil21 Proportional valve25 Constant-air pressure line py

(Connection A)

26 Supply-air pressure line pv(Connection P)

31 Compressed air line

(pressure regulator - four-circuitprotection valve)

32 Compressed-air pressure line(four-circuit protection valve -

air tank for auxiliary equipmentwith test connection

33 Compressed-air line

(brake circuit No. 1)34 Compressed-air line

(brake circuit No. 2)35 Compressed-air line

(parking brake)

37 Ventilation line R39 Electrical lead (cooling-water

temperature pick-up to control unit,

2 wires)40 Electrical lead (oil temperature

pick-up to control unit, 2 wires)

61 Four-circuit protection valve71 Air tank for auxiliary equipment

R

P

A

71

32

33

31

3435

61

39

19

1

40

202

25

1

37

21

26

16028

Diagnosis /

T bl h ti


(C ti )

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Check requirements

Battery voltage 18 - 32 V Electrical system checked in accordance with the Owner s Manual for the vehicle

and found satisfactory. Fuse for retarder control unit checked and found satisfactory. Retarder stage switch in Position 0 Igni ti on OFF

Special tools

Pressure gauge 0 -25 bar

The adapter lead 53.8279.10 (98/5) has to be used only to connect the temperature simulator53.8207.10 (99/2), if the temperature sensor for oil and water are using one central plug.

Commercially available tool

Multimeter recommended: Fluke 87

53.4788.10

Wasser l

53.8207.10 53.8279.10 53.8198.10


Diagnosis /

Troubleshooting


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Checking supply-air pressure pv

1. Connect pressure gauge to test connection of compressed-air line (32) (four-circuit protectionvalve - air tank for auxiliary equipment) and check supply-air pressure pv.

Notice

If the pressure is not within the specified range, the service brake must be checkedto the manufacturers data.

Test set-up job scope

1. Connect temperature simulator (99/2) with the adapter lead (98/5) at the temperature pick-up (57).

Notice

Pay attention to the correct connection of the plugs for cooling water and oil.

Minimum pressure: 6 bar

Maximum pressure: 11 bar


Pressure gauge 53.1403.10

16029

32

5798/5

99/2

16030

99/2 Temperature simulator 53.8207.10

Diagnosis /

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2. Screw out oil filler/check plug (1900) with sealing ring (1800).

3. Connect pressure gauge (99/7) to retarder housing.


1900

1800

16031

99/7

16032

99/7 Pressure gauge 53.1403.10

Diagnosis /

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4. Connect up Propstrom measuring adapter (99/3).

Disconnect plug from proportional valve (21) and connect it upto Propstrom measuring adapter (99/3).

Connect plug of Propstrom measuring adapter (99/3) to proportional valve (21).

Connect up multimeter (98/8) to measure mA.

Set switch Propvalve on Propstrom measuring adapter (99/3) to position I.

99/3 Propstrom measuring adapter 53.8198.1099/8 Multimeter


16033

98/8

99/3

21

Diagnosis /

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Job scope test

Preconditions for checking

Ignition ON

1. Set the rotary switch of the temperature simulator (99/2) to 95C cooling water temperature and

165C oil temperature operate the retarder at the highest stage.The constant-air pressure pyand the control current must reach the values given in table on thenext page (page 4.4/7).

2. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. Theconstant-air pressure pymust drop to at approx. 7% bar below the set maximum pressure. Setrotary switch of the temperature simulator (99/2) to 125oC cooling water temperature. There mustbe no more output of constant-air pressure p y.Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature.

3. Set the rotary switch of the temperature simulator (99/2) to 185oC oil temperature.The constant-air pressure must drop to at approx. 4% below the set maximum pressure. Set therotary switch of the temperature simulator (99/2) to 225oC oil temperature. There must be no moreoutput of constant-air pressure py.

4. Carry out measurements for current and constant-air pressure regarding the following table(see page 4.4/7).

5. Screw oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm

6. Reconnect electrical lead (57) for cooling water and oil to temperature pick-ups forcooling water and oil.


5798/5

99/2

16030

99/2 Temperature simulator 53.8207.10

Diagnosis /

Troubleshooting


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Notice

If the control current is reached but the constant-air pressure is not, either the retarder is leaking or theproportional valve is defective and must be renewed.

If both values are not reached, please see Section 4.2 Troubleshooting and Remedies.

1) The Code Number is to be found on the control unit.2) If a commercially available multimeter is used for measurements (without real effective measuring)

exact readings cannot be made (indication jumps!).3) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).

Setting [Nm] Code Number1 ) Control current

[mA] 2 )Constant-air pressure py

[bar] 3 )

1000 027 429 441 1,15 1,45

1250 028 449 461 1,45 1,75

1500 029 470 482 1,75 2,05

1750 030 490 502 2,05 2,35

2000 031 510 522 2,35 2,65


Diagnosis /

Troubleshooting

4.5 Operational Check

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Requirements for check

Battery voltage 18 - 32 V Electrical system checked in accordance with the Owner s Manual for the vehicle

and found satisfactory. Constant-air pressure 6 -11 bar Retarder oil level satisfactory

The following operational states are indicated by the retarder pilot light (arrow):

Retarder pilot light without indication

The retarder is switched off. There is no fault in the memory.

Retarder pilot light permanently on

The retarder is switched on, i.e., one of the four possible retarder braking stages orConstant Speed operation has been selected with the retarder stage switch.

The retarder pilot light additionally has the function of a fault indicator.

- slight faultThe retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch, braking

operations are possible (the retarder operates with limited braking torque).

- serious faultThe retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch.There are no more braking operations possible - the retarder is switched off.


R

16016

Diagnosis /

Troubleshooting


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Notice

If the ignition is switched off and on again, the retarder is in operation and the retarder pilot lightis going off.If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on inposition 0 to 5 of the retarder stage switch.

Retarder pilot light f lashes

- while the retarder is braking

The temperature limitation is functioning, the retarder cuts back its braking torque.This flashing function only is realized at defined control variants!


Diagnosis /

Troubleshooting


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Troubleshooting

Test step Scope of check Requirement /

Operation

Result / Set point Note, Cause / Remedy

1 Retarder pilot l ight Ignition: ON Retarder pilot light comes on and

goes off after approx. 5 sec.

Retarder pilot light does not comeon, or does not go off.

Retarder pilot light trouble-free

Troubleshooting as on page 4.1/1

2 Retarder Vehicle on move- Shift retarder stage

switchto stage 1 to 5.

Retarder pilot light comes on,retarder brakes in stages 1 to 5.

Retarder pilot light does not come

on, or retarder does not brakeproperly.

Retarder operates trouble-free.

Troubleshooting as on page 4.1/1


Retarder Remo-

ving, Installing

5 Removing, Installing Retarder

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5.1 Removing, Installing Retarder (Free Mount Installation) ............................5.1/1

5.2 Removing, Installing Retarder (Gearbox Attachment)................................5.2/1


Retarder Remo-

ving, Installing

5.1 Removing, Installing Retarder

(Free Mount Installation)

Illustration Retarder (Free mount installation)

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1000-5

1000/6

1300

93

96

97

96

92

1000

9294

95

36

25

1100

1400

1200

1300

1400

1200

1200

57

1200/1

1500

16034

Preconditions for job

Drain oil from retarder (see Section 3.2) Drain oil from heat exchanger (see Section 8.1 and 8.2) Drain cool ing water Retarder stage switch in switch position 0

Igni ti on OFF

Notice

When stainless-steel heat exchanger is installed, oil can notbe drained from the heat exchanger.

25 Constant-air pressure line py A36 Ventilation line R

57 Plug temperature pick-up92 Prop-shaf t93 Hex head screw

1000/5 Drain plug cooling water (M 18 x 1,5), 50 Nm1000/6 Sealing ring (A 18 x 22), renew

1100 Suspension complete1200 Megi-pads, check, renew if necessary

1200/1 Spacer tube

Retarder Remo-

ving, Installing

5.2 Removing, Installing Retarder

(Gearbox Attachment)

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To install the retarder 120 according to regulations to the gearbox or to remove from the gearbox,specific working steps requiring special tools have to be carried out.

Caution!

Observe VOITH-Installat ion instructions and gear-box specific installation instructions.These have to be requested from VOITH TURBO.Should these installation instructions be disregarded, the retarder may be completely wrecked!


Repair Gearbox

Attachment

6 Repair (Gearbox Attachment)

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6.1 Assembly Overview....................................................................................6.1/1

6.2 Removing, Checking and Installing Casing Ventilation ..............................6.2/1

6.3 Removing, Installing Non-Return Valve (Casing Ventilation) .....................6.3/1

6.4 Removing, Checking and Installing Non-Return Valve(Stainless-Steel Heat Exchanger) ..............................................................6.4/1

6.5 Removing, Checking and Installing Silencer ..............................................6.5/1

6.6 Removing and Installing Bottom Cover ......................................................6.6/1

6.7 Checking, Removing and Installing Closing Cover of Retarder Housing ...6.7.1

6.8 Removing and Installing Labyrinth Cover (output side)

Renewing Radial Shaft Sealing Ring ......................

retardador 120 (of 1721 )

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