asm_r115e

153.00009711 I 2007-09
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Table of Contents
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1.1 Purpose of this Document 6
1.2 Target Groups 6
1.5 Item Numbers 7
2.1 Product Safety 9
2.2 Staff Qualification 9
2.3 Safety-Conscious Working 9
2.4 Environmental Protection 9
2.5 Special Tools 9
2.8 Driving Mode 10
3.1 Overview of the Modules 12
3.2 Retarder Identification 14
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3.5 Function and Control Scheme 17
3.6 Function Description 19
4.1 Maintenance Intervals 22
4.2 Oil Change 23
4.4 Draining the Coolant 29
5 Diagnosis and Troubleshooting 31
5.1 Overview of the Possible Complaints 32
5.2 Checking the Constant-Air Pressure Control Loop 42 5.3 Checking the Pump Pressure pdyn 47
5.4 Checking the Proportional Valve Current 52
6 Removing and Installing the Retarder 54
7 Repair 62
7.5 Casing Ventilation 77
7.6 Retarder Ventilation 81
7.7 Basic Retarder 82
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7.17 Pressure Sensor 105
8 Overview of the Tools 108
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I About this Document
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1.2 Target Groups 6
1.5 Item Numbers 7
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Purpose of this DocumentVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I About this Document
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This Aftersales Service Manual provides information
and instructions on the maintenance and repair of the
Voith Retarder VR 115 E – 153.000188xx.
1.2 Target Groups
personnel for maintenance and diagnostics and may
not be reproduced or given to third parties.
1.3 Other Applicable Documents
Documents Information Voith item no.
Voith Retarder Oil change intervals/Oil selection list Oil change intervals and approved oil types 153.000900xx
Cooling water quality list Approved coolants H67.2224xx
ECU specifications Instructions on diagnosis for the VERA™ controller on request
Operating instructions for retarder tester Measured values for constant-air pressure and pump pressure 153.001508xx
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 control loop
Included in the scope of delivery of the "DIANA Lite"
(153.000776xx)
Operating instructions for the "WinDia ® " diagnostic software
Instructions on PC diagnosis for the Digiprop and VERA™ controllers 3623-020900
Conversion instructions for the basic retarder VR 115 E
Instructions for removing and installing the basic retarder and returning the basic retarder
153.002778xx
Instructions for converting the retarder ventilation 153.002005xx
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Symbols and IdentificationsVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I About this Document
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danger:
Notes
Distinctions
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
part lists.
1.6 Imprint
these documents, contact the respective organization
for your area.
Fax: 00 49 79 51 / 32-756
[email protected]
www.voith.com
Measures for the prevention of danger and its
consequences.
age to property if not prevented.
Possible imminent danger that could lead to slight
injury if not prevented.
or serious injury if not prevented.
Immediate danger that leads to death or serious in-
jury if not prevented.
tarder.
Measures for easier and safer work with the retarder.
WARNING
DANGER
NOTE
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Basic Safety Information
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2.8 Driving Mode 10
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Product SafetyVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Basic Safety Information
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the art in technology and acknowledged safety regu-
lations.
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
and maintenance work.
2.3 Safety-Conscious Working
and/or property damage caused by improper and un-
professional work.
tions and occupational health
2.4 Environmental Protection
must be disposed of properly.
2.5 Special Tools
spective action instructions.
view of the special tools.
In the case of special tools that may only be used
from a specific version on, the version number is contained in the last two digits of the Voith item no.
Example: H53.942811.
sion on.
Take the last two digits of the Voith item no. into
account in the diagram of the special tools.
2.6 Diagnosis and Troubleshooting
tive parts only.
Danger of accidents if the retarder tester is used
improperly!
uncontrollable operating state of the vehicle.
Carry out diagnosis only while the vehicle is stand-
ing still.
Work carefully.
The coolant may be hot.
Work carefully.
Parts of the retarder may be hot.
Work carefully.
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Driving ModeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Basic Safety Information
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Considerable damage or malfunctions may occur due
to soiling.
Ensure cleanliness.
Do not aim the jet of a high-pressure cleaner
(steam-jet device) at valves, sensors or the exhaust
of the retarder.
2.8 Driving Mode

Ensure that the retarder is fully functional for all vehicle maneuvers, i.e.:
- Retarder is properly filled with oil
- Retarder electronic equipment is connected
and is functional
functional
Air is mixed in the oil!
Oil loss through retarder ventilation.
Ventilating the retarder:
- If it exists and if possible: Switch off the retarder
foot operation.
- Activate the retarder in the first braking stage 5
times for approx. 5 s each.
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 or performance reduction while driving
During failure of the retarder, or while temperature ad-
aptation is active:
vice brake.
Engage the lowest possible gear to achieve a high engine speed.
During a temperature adaptation continue driving in
this way until the retarder is available at full capacity
again.
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 and functioning of the retarder.
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Design and Function
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3.2 Retarder Identification 14
3.5 Function and Control Scheme 17
3.6 Function Description 19
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Overview of the ModulesVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Design and Function
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Item No. Name
100 Retarder housing
1900 Non-return valve (inlet)
3700 Proportional valve
4100
1001600
3700
1900
2810
28003
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Overview of the ModulesVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Design and Function
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3500 Screw plug of the pressure control valve
4200 Screw plug/oil drain plug
5200b Coolant temperature sensor
5500 Retarder ventilation "R"
Retarder IdentificationVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx 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:
- Serien-Nr. (Serial number) - Voith-Sach-Nr. (Voith item number)
Kd.-Sach-Nr.
Voith-Sach-Nr.
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3.3 VERA™ Controller Identification
- Serial-No. (Serial number) - Part-No. (Voith item number)
Specify the following data of the retarder (see page 14):
- Serien-Nr. (Serial number)
Part-No. VERA.D.H-E02.10-H67.2866.20
V o i t h T u r b o
X1 X2 X3
TM
R e t a r d e r C o n t r o l U n i t V E
R A
S e r i a l - N o . X X X X
X X / J J J J - M M - T T
P a r t - N o . V E R
A . D . H - E 0 2
. 1 0 - H 6 7 . 2 8 6 6 . 2 0
O E M
- N o . 0 0 0
4 4 6 3 3 1 5 / E v o B u s
V O I T H V o i t h
T u r b o
X 1
X 2
X 3
T M
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3.4 Digiprop Controller Identification
- Basis-Nr. (Serial number) - Serien-Nr. (Voith item number)
Specify the following data of the retarder (see page 14):
- Serien-Nr. (Serial number)
Function and Control SchemeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Design and Function
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Item No. Name
"P"
F Oil tank
G Rising duct
Function and Control SchemeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Design and Function
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Function DescriptionVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Design and Function
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If one of the maximum values is exceeded, the brak-
ing torque is no longer actuated (corresponds to a re-
duction to 0).
In addition, the braking torque is adjusted if the oil
temperature rises rapidly (gradient), regardless of the
actual oil temperature.
The vehicle speed has to be adjusted with the service
brake while the adjustment is active.
Retarder ventilation "R" (5500)
When the retarder is switched off, the compressed air
in the oil tank (F) is emitted to the atmosphere via the
retarder ventilation "R" (5500).
Stainless steel heat exchanger 3 in 1 (three heat ex-
changers in one)
• Small retarder oil circuit (active in braking and no-
load operation)
The three sections of the heat exchanger (6400) are
not interconnected.
heat to the vehicle cooling system.
Pressure sensor (9000)
The pressure sensor (9000) measures the pneumatic constant-air pressure py. A deviation from the permis-
sible pressure tolerance (nominal/actual value com-
parison is carried out) is recognized as a fault and
displayed by the controller.
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service
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4.4 Draining the Coolant 29
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Maintenance IntervalsVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service
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Exceeding of the maintenance intervals/incor-
rect oil sort!
Observe the maintenance intervals.
Use only approved oils.
Change oil Observe the specifications of the vehicle manufacturer.
If no specifications available: Observe Voith Re- tarder Oil change intervals/Oil selection list.
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Checking the oil level – Page 26
Draining the coolant Observe the specifications of the vehicle manufacturer.
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Oil ChangeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service
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4.2 Oil Change
Item No. Name
107 Screw plug M 24 x 1.5; hexagon socket head, w.a.f. 12; with copper sealing ring (108): 80 Nm with integrated sealing ring: 47 Nm
108 Sealing ring A 2 4 x 2 9; replace
4100 Screw plug M 30 x 1.5;hexagon socket head, w.a.f. 17; with copper sealing ring (4150): 130 Nm with integrated sealing ring: 100 Nm
4200 Screw plug M 24 x 1.5; hexagon socket head, w.a.f. 12; with copper sealing ring (4250): 80 Nm
with integrated sealing ring: 47 Nm
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
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Visual inspection of retarder for leaks before and af-
ter the oil change.
tighten, if necessary (see specifications of vehicle
manufacturer).
exchanger (see page 88).
• Retarder is switched off
• Ignition is switched off
2. Unscrew the screw plug (4100).
3. Unscrew the screw plugs (107 and 4200).
4. Drain oil into an oil collecting pan.
5. For screw plug (107) with copper sealing ring
(108):
cone-free and non-corrosive grease.
(108) and tighten it to 80 Nm.
For screw plug (107) with integrated sealing ring:
- Check the sealing ring for damage. If neces-
sary, replace the screw plug (107).
- Screw in the screw plug (107) and tighten it to
47 Nm.
(4250):
icone-free and non-corrosive grease.
For screw plugs (4200) with integrated sealing
ring:
sary, replace the screw plugs (4200).
- Screw in the screw plugs (4200) and tighten
them to 47 Nm.
7.0 l
Refilling after complete disassembly, cleaning and emptied heat exchanger
7.8 l Hot exiting oil!
Face and hands could be burned.
Ensure that the retarder and ignition are
switched off.
Wear protective gloves or use cloths, if neces-
sary.
If the oil contains water: Check the heat exchanger (see page 88).
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2. For pressure control valve (2200) with integra-
ted sieve: Drain any oil that has accumulated.
For pressure control valve (2200) without sieve: Clean the sieve at the screw plug (3500).
(3550):
For screw plug (3500) with integrated sealing
ring:
- Screw in the screw plug (3500) and tighten it
to 100 Nm.
Filling in the oil
1. Fill in the oil slowly via the bore of the screw plug
(4100).
(4150):
ring (4150) and tighten to 130 Nm.
ring:
to 100 Nm.
Ventilating the retarder
1. If it exists and if possible: Switch off the retarder
foot operation.
3. Activate the retarder in the first braking stage 5
2 variants of the pressure control valve are possible:
• Pressure control valve with integrated sieve
• Pressure control valve without sieve. Sieve is lo-
cated at the screw plug (3500) Do not combine individual parts.
NOTE
Fill in only approved oil (see Voith Retarder Oil
change intervals/Oil selection list).
Ventilate the retarder.
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Checking the Oil LevelVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service
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Item No. Name
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive grease before installation.
Kd .-S
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• Retarder is switched off
• Ignition is switched off
2. Unscrew the screw plug (4100).
3. Unscrew the screw plugs (107 and 4200).
4. Drain oil into an oil collecting pan.
(108):
ring:
47 Nm.
6. For screw plugs (4200) with copper sealing ring (4250):
- Lubricate the new sealing rings (4250) with sil-
icone-free and non-corrosive grease.
For screw plugs (4200) with integrated sealing
ring:
sary, replace the screw plugs (4200).
- Screw in the screw plugs (4200) and tighten
them to 47 Nm.
7.0 l
Ensure that the retarder and ignition are
switched off.
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2. If necessary correct the oil volume.
Filling in oil
1. Fill in the oil slowly via the bore of the screw plug
(4100).
(4150):
ring (4150) and tighten to 130 Nm.
ring:
- Check the sealing ring for damage. If necessary, replace the screw plug (4100).
to 100 Nm.
Ventilating the retarder
1. If it exists and if possible: Switch off the retarder
foot operation.
3. Activate the retarder in the first braking stage 5
If oil is missing: Check the retarder valve for leaks.
Wrong oil type!
Fill in only approved oil (see Voith Retarder Oil
change intervals/Oil selection list).
Ventilate the retarder.
Draining the CoolantVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service
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of the water neck can differ.
If the screw plug (20300) does not exist: Drain the coolant at the vehicle (see specifications of vehicle manufacturer).
Item No. Name
20000 Water neck
Lubricate sealing rings, O-rings and shaft seal-
ing rings with silicone-free and non-corrosivegrease before installation.
Kd .-S
ac h-N
Draining the CoolantVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Maintenance and Service
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retarder.
coolant.
cone-free, non-corrosive grease.
4. Screw in the screw plug (20300) with sealing ring
5. Fill the vehicle and retarder cooling circuit (see
specifications of vehicle manufacturer).
Hot parts and coolant!
Work carefully.
sary.
Wrong coolant type!
Damage to the vehicle and retarder cooling circuit. Observe the specifications of the vehicle manu-
facturer or those of Voith Turbo cooling water
quality list.
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Diagnosis and Troubleshooting
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5.2 Checking the Constant-Air Pressure Control Loop 42
5.3 Checking the Pump Pressure pdyn 47
5.4 Checking the Proportional Valve Current 52
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Overview of the Possible ComplaintsVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Diagnosis and Troubleshooting
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No. Complaint See
On-board diagnosis is possible at some vehicle manufacturers (display).
Observe the specifications of the vehicle manufacturer.
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B Oil loss via retarder ventilation (5500) or air and vent filter (2810)
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D Other external leak
Ensure that there are no leaks at the screw plugs or sealing rings.
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B Oil loss via retarder ventilation (5500) or air and vent filter (2810)
No. Activity Result Continue with No.
1. Check whether the retarder leaks oil via the retarder ventilation (5500).
Yes 2.
No 8.
2. Check whether water is contained in the oil (emul-
sion).
3. Check the heat exchanger (see page 88). NOK 4.
OK 7.
5. Check the retarder oil level and correct it (see
page 26). Check the gearbox oil level and correct it (see speci-
fications of vehicle manufacturer).
NOK 6.
OK 8.
6. If the gearbox oil level is too low and the retarder oil level is too high:
– –
OK = works correctly
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7. Possible entry of water from outside into the retarder system:
• Via retarder ventilation (5500) or air and vent filter (2810), e.g. through steam-jet device or splash water.
Convert the retarder ventilation, if necessary (see
VR 115 E 153.001532xx ventilation conversion instructions).
–or–
– –
OK 10.
10. Remove valve cover (1600).
Check whether non-return valve (outlet) has a Voith item no. H67.255022 or H67.387310 and higher (see page 98).
Yes 11.
No 12.
11. Check non-return valve (outlet) (see page 98). NOK 12.
OK 13.
13. Install basic retarder (see page 82). – –
NOK = does not work correctly
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C No or insufficient brake efficiency
1. Check whether an external leak is visible at retarder (except retarder ventilation).
Yes 2.
No 3.
Check gearbox oil level (see specifications of vehicle manufacturer).
NOK B, No. 6., Page 34
OK 4.
NOK 5.
OK 6.
– –
6. Check proportional valve current as well as leads and plug connections (see page 52).
NOK 7.
OK 10.
7. Check oil temperature sensor and supply line (see page 101).
NOK 8.
(see page 103).
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8. Replace oil temperature sensor or supply line (see page 101).
–and/or–
Replace coolant temperature sensor or supply line (see page 103).
9. Carry out diagnosis with "WinDia ®
" (see "WinDia ®
–or–
– –
Check constant-air pressure py (see page 42).
NOK 11.
OK 14.
OK 13.
13. Contact Voith. – –
14. Complaint mentioned above is not possible.
– –
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D Other external leak
Ensure that there are no leaks at the screw plugs or sealing rings.
NOTE
1. Check whether the retarder leaks oil near the heat exchanger.
Yes 2.
No 3.
– –
heat exchanger.
Yes 4.
No 13.
OK 6.
5. Replace heat exchanger (see page 88). – –
6. Check hose connection between water neck at heat exchanger and water pipe in the vehicle (see specifications of vehicle manufacturer).
NOK 7.
OK 8.
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Check intermediate washer (8000), replace, if necessary.
Insert combined hex.-head screws (3100 and 3300) with thread seal (see page 70).
Bottom: Check gasket (2600), replace, if necessary (see
page 72).
– –
17. Check whether the retarder leaks near the non-return valve (inlet).
Yes 18.
No 19.
Check the sealing ring.
Version with copper sealing ring (1950):
Replace sealing ring (1950).
– –
19. Check whether the retarder leaks near the interstice retarder/gearbox.
Yes 20. No 21.
– –
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21. Check whether the retarder leaks at the gearbox flange near the radial shaft sealing ring.
Yes 22.
No 23.
tions of vehicle manufacturer).
Checking the Constant-Air Pressure Control LoopVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Diagnosis and Troubleshooting
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The constant-air pressure control loop check pro-
vides information about
• proper functioning of the retarder
• proper control of the retarder
Item No. Name
50/56a Retarder tester
50/56c Cable 2: to the pressure sensor (9000)
50/56d Cable 3: to the temperature sensors
50/56e Cable 4: to the vehicle voltage supply/ PC interface
50/56c
50/56e
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Item No. Name
9000 Pressure sensor
50/56c
50/56e
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• Supply-air pressure pv in auxiliary circuit 6–11 bar
• Oil level is checked and in order (see page 26)
• Electrical system of vehicle is checked and in order
(see specifications of vehicle manufacturer)
• Electrical connections of the retarder are com-
pletely disconnected from the vehicle
Connecting the pressure gauge
ring (4150).
2. Connect the pressure gauge (99/7) to the bore of
the screw plug (4100).
With the test software "DIANA Lite" (50/56i), mea-
sured values can be read out and stored 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).
used improperly!
Carry out diagnosis only while the vehicle is
standing still.
sary.
CAUTION
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1. Connect cable 1 (50/56b) to the proportional valve (3700).
2. Connect cable 2 (50/56c) to the pressure sensor
(9000).
sensor (5200a) and to the coolant temperature
sensor (5200b).
supply/PC interface.
5. Connect all the cables to the retarder tester (50/
56a) (see also the operating instructions of the
retarder tester).
6. Switch on the vehicle ignition.
7. Set the "RETARDER TYP" (Retarder type) switch
at the retarder tester (50/56a) to "5".
8. Switch the toggle switch to the position "EIN mit
Regelkreis" (ON with control loop).
9. Connect the multimeter to the "U_Versorgung"
(U_Supply) socket (measuring type: V).
10.Read the measured value: Setpoint 4.75–5.25 V.
11.If the value deviates: Replace the pressure sensor
(9000) (see page 105).
12.Connect the multimeter to the "U_py IST"
(U_py actual) socket (measuring type: V).
13.Read the measured value: Setpoint 0.275–0.725 V.
14.If the value deviates: Replace the pressure sensor
(9000) (see page 105).
Checking the proportional valve
16.Load the template for the retarder tester (see
operating instructions of "DIANA-Lite" test soft-
ware).
switch at the retarder tester to "25%".
18.In "DIANA-Lite" read the "Stelldruck IST" (Con-
stant-air pressure INST) measured value and the
measured value at the pressure gauge (99/7):
Setpoint after approx. 20 seconds:
3700
5200a
5200b
9000
15 3. 0 0 0 8 3 31
0
50/56e 153.00083610
5 0 / 5 6 c 15 3 .0 0 0 8 3 4 10 5 0 / 5 6 d
1 5 3 .0
1
2
3
4
50/56a
28082
(3700), the results of the following test are only val-
id during a testing period of 60 seconds maximum.
Position of "STELL-
Checking the Pump Pressure pdynVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Diagnosis and Troubleshooting
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Item No. Name
104 Sealing ring A12 x 15.5; replace
9000 Pressure sensor
Kd .-S
ach -Nr.
Voi th-
NOTE
Ch ki h P PV i h T b I Af l S i M l V i h R d VR 115 E 153 000188 I Di i d T bl h i
V o i t h T u r b o I 1 5 3 . 0
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• Oil level is checked and in order (see page 26)
• Electrical connections of the retarder are com-
pletely disconnected from the vehicle
• Constant-air pressure control loop is checked and
in order (see page 42)
• No external leaks are detected at retarder
• Vehicle is secured
Special tools
Retarder tester,
With the test software "DIANA Lite" (50/56i), mea-
sured values can be read out and stored 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).
used improperly!
Carry out diagnosis only while the vehicle is
standing still.
If the prop shaft screws are screwed in from the
transmission side:
Ensure that the prop shaft screws are screwed out at the drive-side flange.
–or–
Hot parts and oil!

Work carefully. Wear protective gloves or use cloths, if neces-
sary.
NOTE
CAUTION
Checking the Pump Pressure pVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153 000188xx I Diagnosis and Troubleshooting
V o i t h T u r b o I 1 5 3 . 0
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ring (104).
ing ring (104).
3. Connect cable 1 (50/56b) to the proportional valve (3700).
4. Connect cable 2 (50/56c) to the pressure sensor
(9000) and to the pressure sensor (50/56g) .
5. Connect cable 3 (50/56d) to the oil temperature
sensor (5200a) and to the coolant temperature sen-
sor (5200b).
supply/PC interface.
7. Connect all the cables to the retarder tester (50/
56a) (see also the operating instructions of the
retarder tester).
Due to construction, a small amount of oil may leak
out; this does, however, not affect retarder opera-
tion.
NOTE
15 3. 0 0 0 8 3 31
0
50/56e 153.00083610
5 0 / 5 6 c 15 3 .0 0 0 8 3 4 10 5 0 / 5 6 d
1 5 3 .0 0 0 8 3 5 1 0
1
2
3
4
50/56a
28083
Checking the Pump Pressure pdVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153 000188xx I Diagnosis and Troubleshooting
V o i t h T u r b o I 1 5 3 . 0
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9. Set the "RETARDER TYP" (Retarder Type) switch
at the retarder tester to "5".
10.Switch the toggle switch to the position "EIN mit
Regelkreis" (ON with control loop).
11.Start the "DIANA-Lite" test software
12.Load the template for the retarder tester (see
operating instructions of "DIANA-Lite" test soft-
ware).
13.Start the engine and warm it up to operating tem-
perature.
15.Set the "STELLDRUCK" (constant-air pressure)
16.Adjust the engine speed back to 1000 min-1 .
17.Set the"STELLDRUCK" (constant-air pressure)
18.When the engine speed is 1000 min-1 , read the "Gehäusedruck Ist" (Housing pressure actual)
measured value in "DIANA Lite": Setpoint > 9 bar.
Disconnecting the pressure sensor and retarder
tester
20.Disconnect the retarder tester (50/56a) and all
cables.
22.For screw plug (103) with copper sealing ring (108):
- Lubricate the new sealing ring (104) with sili-
ring:
13 Nm.
Shift in direct gear (ratio 1:1).
The engine speed 1000 min-1 then corresponds to
the prop shaft speed of 1000 min-1.
NOTE
reached, but the pump pressure pdyn is undershot,
the retarder has an internal defect.
Install the basic retarder (see page 82).
Test when the "STELLDRUCK" (constant-air pres-
sure) switch is set to "100%":
"Gehäusedruck Ist" (Housing pressure actual)
setpoint > 12 bar.
when the vehicle is standing still.
NOTE
NOTE
Checking the Proportional Valve CurrentVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153 000188xx I Diagnosis and Troubleshooting
Checking the Proportional Valve CurrentVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
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Requirements
• Fuse for retarder controller is checked and in order
• Male and female plug connectors at proportional
valve are checked for damage or wear (notch
scratches).
• Electrical lead and plug connections are checked (visual inspection) and in order
1. Disconnect the plug from the proportional valve
(3700) and connect it to the measuring adapter
(99/3).
2. Connect the plug of the measuring adapter to the
proportional valve (3700).
mA).
4. Turn the "Prop valve" switch at the measuring adapter to Position "I".
6. Shift the retarder to the highest gear.
Special tools
cially available multimeter (without real r.m.s. value
measurement), exact readout of these measured
values is not possible (display jumps).
Commercially available tools
Multimeter (98/8) with real r.m.s. value measurement, e.g. Fluke 179
H53.8198xx
NOTE
98/8
99/3
3700
28019
Checking the Proportional Valve CurrentVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Diagnosis and Troubleshooting
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and compare it to the specified setpoint:
8. If the value deviates: Check the leads, connectors
and retarder controller and replace them, if neces-
sary.
10.Pull the plug from the measuring adapter (99/3)
and connect it to the proportional valve (3700).
Due to continuous readjustment in the control loop,
the measured values may not be constant, but are
within the specified range.
Controller Voith item no.
H67.2866xx
H67.3449xx
H67.3457xx
H67.3658xx
153.000586xx
(Code-No.)
Setpoint
150 365–565 mA
151 379–579 mA
153 423–623 mA
159 534–546 mA
440–640 mA
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Removing and Installing the Retarder
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Item No. Name
800 Inside part
850 Outer race; replace, when the inside part (800) is replaced
25000 Shim
25100 O-ring 14 x 4; replace 25200 Hex.-head screw M 1 0 x 7 0;
hexagon insert bit, w.a.f. 16; 58 Nm
25300 Hex.-head screw M 1 0 x 6 0; hexagon insert bit, w.a.f. 16; 58 Nm
25200
25200
25100
25000
850
25300
25300
800
28046
NOTE
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• Supply-air pressure line py is removed
• Retarder oil is drained (see page 23)
• Oil is drained from the gearbox (see specifications
of vehicle manufacturer)
• Prop shaft at the gearbox flange is removed from
the flanges (see specifications of vehicle manufacturer)
• Output flange is removed (see specifications of ve-
hicle manufacturer)
moved (see specifications of vehicle manufactur-
er)
• Retarder with gearbox is removed from vehicle (see specifications of vehicle manufacturer)
Removing the retarder
(25300).
2. Use a suitable lifting device to remove the retarder
from the gearbox.
0
H67.3320xx H67.3224xx H67.3319xx
Unprotected inside part (800)!
Damage to the inside part (800). Ensure that the inside part (800) is not damaged
when it is put down.
25200
28029
CAUTION
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3. Remove the O-rings (25100) from the gearbox.
Removing the outer race (850) and shim (25000) 1. Pull off the outer race (850) using the puller (98/3).
2. Remove the shim (25000).
Determining the shim
4 8 6
sary.
In order to facilitate the removal, heat the gearbox housing to approx. 80 °C in the area of the outer race (850).
CAUTION
NOTE
The thickness D of the shim is calculated in accor-
dance with the following equation:
Thickness D = Dimension B – Dimension A – 0.02
mm
• The distance of the gearbox housing sealing surface to the outer race contact surface (850) in the gearbox housing is measured for dimension B.
• Dimension A is the distance between the retarder housing sealing surface and the outer race ring and is calculated in accordance with the following equation:
Dimension A = H – Dimension C - H is noted in the factory by Voith on the mea-
suring device.
suring device is measured for dimension C.
A digital depth gauge is included in the
measuring device (98/1) scope of delivery.
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(see arrow/diagram).
10.Calculate thickness D of the shim:
Thickness D = Dimension B – Dimension A –
0.02 mm
Shims with the following thicknesses D can be or-
dered from Voith Turbo GmbH & Co. KG:
Installing the outer race (850) and shim (25000)
1. Insert the shim (25000) into the gearbox housing.
Thickness D [mm] Voith item no.
0.52 67.3426xx
0.55 67.3427xx
H = xxx,xx
0.58 67.3428xx
0.61 67.3429xx
0.64 67.3430xx
0.67 67.3431xx
0.70 67.3432xx
0.73 67.3433xx
0.76 67.3434xx
0.79 67.3435xx
0.82 67.3436xx
0.85 67.3437xx
0.88 67.3438xx
0.91 67.3439xx
0.94 67.3440xx
0.97 67.3441xx
1.00 67.3442xx
If necessary, use two shims in order to realize the compensation dimension.
If the calculated compensation dimension can- not be achieved exactly with the shims: Use the next smaller compensation dimension.
Thickness D [mm] Voith item no.
NOTE
If two shims are used: Insert the thicker shim first into the gearbox housing.
If the inside part (800) was replaced:
Replace the outer ring (850).
850
25000
98/4
28135
NOTE
NOTE
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2 0 0 7
2. Insert the outer r ing (850) into the gearbox housing.
3. Knock in the outer race (850) until it stops using
the marking punch (98/4).
(1).
faces upwards.
and apply Loctite 5203.
4. Lubricate the new O-rings (25100) with silicone- free and non-corrosive grease and insert them
into the gearbox housing.
housing (see arrows/diagram).
sary.
In order to facilitate installation heat the gearbox housing to approx. 80 °C in the area of the outer race (850).
CAUTION
NOTE
1
28037
25100
28038
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8. Unscrew the threaded bolts.
9. Screw in the two hex.-head screws (25200).
10.Tighten the hex.-head screws (25200) with
58 Nm.
tighten it with 58 Nm.
25200 25200
25200
25300
28039
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Repair
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7.5 Casing Ventilation 77
7.6 Retarder Ventilation 81
7.7 Basic Retarder 82
7.9 Pipe (5900) 85
7.10 Water Neck 86
7.11 Heat Exchanger 88
7.17 Pressure Sensor 105
7.18 Proportional Valve and Damping Plate 106
Components OverviewVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E – 153.000188xx I Repair
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7.1 Components Overview
Item No. Name
100 Retarder housing
107 Screw plug M 24 x 1.5; hexagon socket head, w.a.f. 12; with copper sealing ring (108): 80 Nm
108 Sealing ring A 2 4 x 2 9
1600 Valve cover
1700 O-ring 60 x 3
1900 Non-return valve (inlet) M 48 x 1.5; hexagon insert bit, w.a.f. 55; with copper sealing ring (1950): 280 Nm
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
NOTE
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2100 Non-return valve (outlet)
2105 O-ring 34 x 3
2106 O-ring 54 x 3
2200 Pressure control valve, complete;
with integrated sieve without sieve. Sieve at the screw plug (3500)
2206 O-ring 21.5 x 2.5
2300 Casing ventilation
2600 Gasket
4100
NOTE
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2801 Cover
2810 Air and vent filter M 12 x 1.5; hexagon insert bit, w.a.f. 17; 10 Nm
2900 Gasket
3100 Combined hex.-head screw M 8 x 30; hexagon insert bit, w.a.f. 13; 30 Nm
3500 Screw plug M 30 x 1.5;
hexagon socket head, w.a.f. 17; with copper sealing ring (3550): 130 Nm with integrated sealing ring: 100 Nm
4100
NOTE
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3850 O-ring 16 x 3
4000 Hex.-head nut M 8; hexagon insert bit, w.a.f. 13; 18 Nm
4100
NOTE
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Item No. Name
5200a Oil temperature sensor M 14 x 1.5;
hexagon insert bit, w.a.f. 27; 30 Nm
5200b Coolant temperature sensor M 14 x 1.5; hexagon insert bit, w.a.f. 27; 30 Nm
5400 Wave spring
5500 Washer silencer
5900 Pipe; with union nuts; 60 Nm
5901 O-ring 15.3 x 2.4
4100
NOTE
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6400 Heat exchanger
6600 Hex.-head screw M 1 4 x 4 5; hexagon insert bit, w.a.f. 22; in case of mounting with angle measuring tool: Init