transmissão voith retarder 120-3 57 pag

8/11/2019 Transmisso Voith Retarder 120-3 57 Pag.

1/57

Operating Instructions

Voith Retarder 120-3

Status: December 1999

Voith Article Number 67.3787.10


2/57

2 VOITH TURBOOperating Instructions Retarder 120-3


3/57


4/57


1Preface

These operating instructions contain important informa-

tion for a safe, proper and economical operation of theVoith Retarder 120-3.

The use of the Voith Retarder as hydrodynamic perma-nent brake in commercial vehicles is considered as pro-per use.The directives for proper use of the retarder are to be ob-served strictly by the persons in charge, in particular, bythe staff in charge of operation and repair.The user is liable for any hazardous situation and dama-ges resulting from improper use.

Observe the information in particular, the safety infor-

mation for operation and perform the specified servicework in regular intervals and in time using the specifiedoperating fluids.

Only qualified staff is allowed to do the repair andmaintenance work. Enter the work performed in the ser-

vice check list provided for this purpose enabling you toclaim full warranty.

Use only original spare parts in the event of a repair, be-cause only this guarantees that your retarder meets thetraffic safety and the design standard on shipment.

If the retarder is installed subsequently, i.e. not directly

by the vehicle manufacturer, it is necessary to fill in themodification certificate attached to this instruction manu-al and to return it to Voith Turbo, cbqr Dept.

For the purpose of technical development of our pro-ducts and to keep up with the progress, we reserve theright for modification of the Voith Retarder 120-3 outlinedin these operating instructions and for the applicabletechnical information and form.

Copyright December 1999 - Voith Turbo


5/57

Contents

VOITH TURBOOperating Instructions Retarder 120-3 3

1. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3. System Identification

3.1 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Retarder Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4. Illustrations Voith Retarder 120-3

4.1 Illustrations with stainless steel Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 Illustrations with aluminium Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6. Operation

6.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.2 Temperature Adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.3 Functions and Indications of Retarder Stage Switch

(without push button for "Constant Speed" function), Retarder Piot Light . . . . . . . . . . . . . . . 23

6.4 Functions and Indications of Retarder Stage Switch

(with push button for "Constant Speed" function), Retarder Pilot Light . . . . . . . . . . . . . . . . . 27

6.5 Pedal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.6 Customer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37


6/57

Contents


7. Maintenance

7.1 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.2 Oil Change (stainless steel Heat Exchanger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.3 Oil Change (aluminium Heat Exchanger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8. Maintenance Work, Cooling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9. Oil Change Intervals, Operating Fluids Instructions. . . . . . . . . . . . . . . . . . . . . . . . 50

10. Data Sheet Voith Retarder 120-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

11. Service Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

12. Modification Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56


7/57


2 Safety Information

To guarantee sound operation of the Voith Retarder

120-3 and to exclude any risks due to improperhandling, please read and follow the safety informa-

tion mentioned on this and the next page as well as

in each chapter!

The safety symbols are explained below:

Warning!

Precautions and safety regulations protecting personsfrom injuries or danger to their life.

Caution!

Special information and precautions preventing damageto the retarder or vehicle.Non-observance leads to exclusion of warranty.

Note

Special information for better handling when operatingthe retarder and for maintenance work.


8/57

8 VOITH TURBOOperating Instructions Retarder 120 - 3


Warning!

Unauthorized modifications on the retarder and theuse of spare parts, accessories, attachments and speci-al equipment not tested and released by Voith, may havea negative effect on the safety of the complete vehicle,for which liability is excluded for any resulting damages.

When in contact with oils, greases and other chemicalsubstances, e.g. retarder oil, observe the safety regula-tions applicable to these products.

Be cautious when you are in contact with hot opera-

ting fluids! Danger of burning or scald!

In case of unsafe road conditions (slick ice, snow, gra-vel etc.) or risk of aquaplaning, operate the retarder ca-refully and gradually only. In an extreme case, leave theretarder switched off!

Observe these precautions, in particular, for vehicles wi-thout ABS!Switch off the reatarder main switch (if available - see ve-hicle operating instructions) for vehicles without ABS.

For empty running vehicles, single vehicles or vehic-

les without body (e.g. transfer) operate the retarder ca-refully!

The switched-on retarder will not secure the parkedvehicle!

In the event of retarder failure or when the tempera-ture adaptation is active (see chapter 6.2: TemperatureAdaptation), use the service brake to adapt the vehiclespeed.


9/57



Caution!The Voith Retarder 120-3 is manufactured to the latestdesign standards and approved safety regulations. Ne-vertheless, hazards and damage to property may occurin case of improper use.

The user/owner has the obligation to always operatethe retarder in sound condition.

In case of malfunctions, observe the relevant informa-tion.

Voith will not assume liability for injuries and/or dama-ge to property resulting from non-observance of the

safety information, instruction manual or violation of theduty of care in handling, operation, maintenance and re-pair of the retarder.

Voith is not in the position to give explicit warning eve-

rywhere in this instruction manual, in case of any think-able situation, which may lead to a risk of injury for theoperator and/or damage to the retarder. It is thereforeabsolutely necessary that everyone in charge of operati-on and maintenance of the Voith Retarder 120-3 doesnot put its own safety at risk by the selected mode ofoperation and that it has no negative effect on the retar-der, in particular, with regard to safety.Voith is not liable for personal injury and/or damage toproperty caused by improper or unprofessional operati-on.


10/57

10 VOITH TURBOOperating Instructions Retarder 120 -3


Caution!Keep the operating instructions together with the ve-hicle operating instructions on hand in the vehicle. Re-place immediately any incomplete or i llegible instructionmanual.

Observe the relevant regulations for prevention of ac-cidents, any other generally accepted safety regulationsand industrial medical service and the Regulations Au-thorizing the Use of Vehicles for Road Traffic (StVZO).Voith is not liable for any damages resulting from non-observance of these regulations.

Do not start the vehicle without oil in the retarder.


11/57


3.1 System Identification: Retarder

Serial Number:

Voith Item Number:

You will find the retarder identification (nameplate) on

the output side of retarder housing (see arrow).

Information given on the nameplate:

1. Serial number, 6-digit number.

2. Voith i tem number, 8-digit number.

Please enter the serial and article number indicated onyour Voith retarder on the left-hand side nameplate.Please let us know these data in the event of any queriesor spare parts orders.

M+P-07A-1181

1501


12/57


3.2 System Identification: Retarder Control Unit

You will find the Digiprop control unit identification on the

control unit which is:

1. Voith item number, 8-digit numberThe last two digits identify the software version.Example: .12 = version 1.2

2. Code number, 3-digit number(adjustment of control unit)

3. Serial number, 5-digit numberalso indicating the coding date

4. Customer number

(optionally)

Please enter the identification data, indicated on yourcontrol unit, on the left-hand side nameplate.Please let us know these data in the event of any queriesor spare parts orders.

M+P-07A-1617

Voith-Nr.:

53.xxxx.12

Code-Nr.:

xxx

Serien-Nr.:

xxxx/Datum

Kunden-Nr.:

Voith-NoCode-No

Serial-No Date:

Customer-No

1522


13/57


4.1 Illustrations: Voith Retarder 120-3 with stainless steel Heat Exchanger

100/1 Retarder identification

1000 Heat exchanger

1900 Oil filler/check plug M 30x1.5

hex. head screw, w.a.f. 24

Note

The item numbers used in these operating instructionscorrespond to the item numbers in the spare parts l ists.Parts or components with item number anddash num-ber (e.g. 100/1) cannot be procured and are not mentio-ned in the spare parts lists.

1000

100/1

1900

1503


14/57


4.1 Illustrations: Voith Retarder 120-3 with stainless steel Heat Exchanger

1000 Heat exchanger

1001 Cooling water drain plug M18x1.5

hex. socket screw, SW 8

1700 Oil drain plug Retarder M22x1.5

hex. socket screw, w.a.f. 10

1588-3

10001001

1700

1504


15/57


4.2 Illustrations: Voith Retarder 120-3 with aluminium Heat Exchanger

100/1 Retarder identification

1000 Heat exchanger



1900 Oil filler/check plug M30x1.5


1585-3

1000100/1

1900

1001


16/57


4.2 Illustrations: Voith Retarder 120-3 with aluminium Heat Exchanger

1000 Heat exchanger



1002 Oil drain plug heat exchanger M12x1.5


1700 Oil drain plug - retarder M22x1.5


1586-3

1001

10001002

1700

1506


17/57


5 General Description

The Voith Retarder 120-3 is a powerful, hydrodynamicpermanent brake of compact design for commercial ve-hicles of medium range.

The retarder braking torque is also maintained on gearshifting.

Warning!

The switched-on retarder will not secure the parked ve-hicle.

Basically, there are two heat exchanger variants:

Retarder 120-3 with stainless steel heat exchanger Retarder 120-3 with aluminium heat exchanger


18/57


5 General Description

The following control system is installed:

Digiprop control system

Retarder stage switch with 5 switch stages and w ithconstant speed function in position 1 as well as 4brake stages in position 2 to 5.

The control system with push button for constant

speed function is available as special design:

Retarder stage switch with 4 switch stages, with pushbutton for constant speed function as well as 4 bra-ke stages in position 1 to 4.

NoteIn addition, as special version, the Digiprop control sy-stem may be combined with a 3-stage or 4-stage pedalactuation via the foot pedal of the vehicle service brake.

Warning!

This variant, however, is permissible only in vehiclesequipped with ABS!


19/57


6.1 Operation: Functional Description

The hydrodynamic principle

The Voith Retarder is controlled by a retarder stageswitch with 5 switch stages. In the maximum position ofthe retarder stage switch, the braking torque is at the ma-ximum. The control medium is compressed air which istaken from the vehicle air tank for auxiliary equipment .

A constant-air pressure depending on the set brake sta-ge is acting via a proportional valve on the oil sump of the

retarder. That means, according to the operating condi-tion (propshaft speed), a certain quantity of oil is forcedinto the working chamber of the retarder between rotor(1) and stator (2).

The rotor is connected with the propshaft of the vehicle,

the stator is fixed firmly to the retarder housing.

M+P-07A-1589

2

3

1

1507


20/57


6.1 Operation: Functional Description

The rotation of the rotor sets the oil in motion and circu-lates it in a closed circuit (3) between the rotor and thestator.The reduction of the velocity of the oil flow in the statorchambers leads to braking of the rotor and consequentlyto braking of the vehicle.

For Retarder 120-3 the impulse lubrication is activated

as soon as the vehicle ignition is switched on.

6 2


21/57


6.2 Operation: Temperature Adaptation

The energy generated by braking with the retarder isconverted into heat. In order to dissipate this heat, partof the oil in the working chamber is pumped constantlyby the rotor through the heat exchanger and fed backinto the ci rcuit.In the heat exchanger, the heat of the oil is passed on tothe cooling water of the vehicle and dissipated throughthe vehicles cooling system.

One temperature pick-up each monitors the cooling wa-ter oil temperature transmitting this information to thecontrol unit. This guarantees that the maximum permis-sible temperatures for cooling water and oil are not ex-ceeded.

The control unit includes vehicle-specific cooling waterand oil temperature limit settings.To prevent that these temperature limits are exceededduring retarder operation, the retarder braking torque isadapted optimally for protection and effective utilization

of vehicle cooling system and retarder.

With already significantly reduced braking torque, theretarder pilot light starts flashing.

Caution!Observe the following when the retarder pilot light isflashing or the temperature control is active:

Adjust the vehicle speed using the service brake andchange to the lowest possible gear (increase the engine

speed).Maintain this driving condition unti l the retarder regainedits full power.

6 2


22/57


6.2 Operation: Temperature Adaptation

By driving or operating the retarder properly, you canincrease and/or secure the vehicle cooling performanceand thus the availability of the retarder.

How?

On retarder braking, shift the gearbox down to reachrated engine speed!

Thus:

High delivery rate of water pump High fan speed

Result:

It is possible to make optimal use of the vehicle coo-

ling system performance!

Fuel consumption is not affected by the high enginespeed as the fuel injection system goes to zero deliveryin overrun condition.

M+P-07A-1624

1

2345

10

15

u/pm

20

25

30

1508

6 3


23/57


6.3 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light(without push button for Constant Speed function)

A Retarder pilot light(vehicle-specific installation s ite)

B Retarder stage switch

(vehicle-specific installation s ite)

0 Retarder OFF

1 Constant speed

2 Brake stage 1

3 Brake stage 24 Brake stage 3

5 Brake stage 4

Caution!

Operate the retarder stage switch only step-by-step toreach the required braking torque (do not just skip thegears)!In an emergency situation it is permitted to skip gearswhen operating the retarder stage switch.

To reduce the braking torque set at that moment, it ispossible to skip several stages at one time with the retar-der stage switch.

M+P-07A-1590

B

A

1509

0

1

2

34

5

6 3 O f S S ( f


24/57


6.3 Operation: Functions, Indications of Retarder Stage Switch (without push button forConstant Speed function), Retarder Pilot Light

Note

In case of very low outside temperatures, the braking ac-tion on first retarder braking starts with a response delayafter starting to drive.

For vehicles with zero gas switch, the constant speedfunction or the active brake stage is cleared on applica-tion of the gas pedal. After releasing the pedal, the newmomentary constant speed is stored or the previouslyapplied brake stage is reactivated.

For vehicles with cruise control, dependent on the equip-ment, it is possible to clear the cruise control automati-cally by actuating the constant speed function.

The retarder pilot light has the additional function of faultindication that enables to find the fault in the electronicsystem even without service unit. The indication of anfault can be realized by the flash code of the retarder pi-lot light.

Caution!

Only qualified staff is allowed to activate the flash codeand to perform any repair work which might be necessa-ry.

6 3 O ti F ti I di ti f R t d St S it h R t d Pil t Li ht


25/57


6.3 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light(without push button for Constant Speed function)

Off(symbol for retarder pilot light

may differ from vehicle to vehic-

le)

Ignition ON

Light test:

Retarder pilot light5 sec. steady light

Steady light:

constant speed

Steady light:

Brake stages 1-4

Flashing light:

Temperature adaptation

0

2

34

1

0

2

34

1

0

2

34

1

0

2

34

1

Steady lightin position 0 to 4

Minor fault:

Retarder braking may partlyoccur at reduced braking tor-que.

Consult a qualified workshop!

Major fault:

Retarder braking no longerpossiblethe retarder is swit-ched off.

Continue driving only withsubstantially reduced

speed - consult a qualified

workshop immediately!

0

2

34

1

6 3 O ti F ti I di ti f R t d St S it h


26/57


6.3 Operation: Functions, Indications of Retarder Stage Switch(without push button for Constant Speed function), Retarder Pilot Light

1 Adapt the speed.

2 Activate constant speed at the wanted speed.

The retarder keeps this vehicle speed constant withinthe maximum braking torque.Should the vehicle accelerate in spite of constantspeed, it is necessary to apply the service brake inaddition. Continued shifting to gear stage 4 does notincrease the braking action.

When leaving the constant speed lever position,automatic control is cleared immediately.

3 Switch off the retarder or adapt to the traffic situationusing a brake stage.

M+P-07A-1618

1

1

10 km

6%2

3

0

2

34

5

0

2

3

4

5

1

0

2

3

4

5

1

1510

6 4 Operation: Functions Indications of Retarder Stage Switch Retarder Pilot Light


27/57


6.4 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light(with push button for Constant Speed function)

A Retarder pilot light(vehicle-specific installation s ite)

B Retarder stage switch

(vehicle-specific installation s ite)

C Push button constant speed

0 Retarder OFF

1 Brake stage 1

2 Brake stage 23 Brake stage 3

4 Brake stage 4

Caution!

Operate the retarder stage switch only step-by-step toreach the required braking torque (do not just skip thegears)!In an emergency situation it is permitted to skip gearswhen operating the retarder stage switch.

To reduce the braking torque set at that moment, it ispossible to skip several stages at one time with the retar-der stage switch.

M+P-07A-1688

A

B

C0

1

2

34

1511



28/57


6.4 Operation:Functions, Indications of Retarder Stage Switch, Retarder Pilot Light(with push button for Constant Speed function)

Note

In case of very low outside temperatures, the braking ac-tion on first retarder braking starts with a response delayafter starting to drive.

For vehicles with zero gas switch, the constant speedfunction or the active brake stage is cleared on applica-tion of the gas pedal. After releasing the pedal, the newmomentary constant speed is stored or the previouslyapplied brake stage is reactivated.

For vehicles with cruise control, dependent on the equip-ment, it is possible to clear the cruise control automati-cally by actuating the constant speed function.

The retarder pilot light has the additional function of faultindication that enables to find the fault in the electronicsystem even without service unit. The indication of anfault can be realized by the flash code of the retarder pi-lot light.

Caution!




29/57



Off(symbol for retarder pilot light

may deviate, depending on the

vehicle manufacturer)

Ignition ONLight test:

Retarder pilot light5 sec. steady light

Steady light:

constant speed

Steady light:

Brake stages 1-4

Flashing light:Temperature adaptation

0

2

34

1

0

2

34

1

0

2

34

1

0

2

34

1

Steady lightin position 0 to 5

Minor fault:

Retarder braking may partlyoccur at reduced braking tor-que.

Consult a qualified workshop!

Major fault:

Retarder braking no longerpossiblethe retarder is swit-ched off.

Continue driving only withsubstantially reduced

speed - consult a qualified

workshop immediately!

0

2

34

1

6.4 Operation: Functions Indications of Retarder Stage Switch Retarder Pilot Light


30/57



1 Adapt the speed.M+P-07A-1689

1

0

2

3

4

1

1512

6.4 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light


31/57



2 Switching on constant speed at the wanted speed: Press the push buttonThe present speed is stored, the retarder pilot lightl ights steadily.

Retarder stage switch in position 0:

The constant speed function is stored.

Retarder stage switch in position 1-4:

Switch retarder stage switch to position 0. Constant speed function is reactivated.

The retarder keeps this vehicle speed constant within

the maximum braking torque.Should the vehicle accelerate in spite of constantspeed , it is necessary to apply the service brake inaddition. Continued shifting to gear stage 4 does notincrease the braking action.

M+P-07A-1690

10 km

6%2

0

2

3

4

1

1513

6.4 Operation: Functions, Indications of Retarder Stage Switch, Retarder Pilot Light


32/57



3 During downhill run with constant speed, a brake sta-ge (retarder stage switch position 1 to 4) can be swit-ched on additionally to reduce the vehicle speed.When switching the retarder stage switch afterwardsagain to position 0, the vehicle accelerates to the pre-viously stored speed and keeps it constant within themaximum braking torque.

4 Switching off constant speed :Press the push button again.

The retarder pilot light extinguishes when the retarderstage switch is in position 0.

M+P-07A-1691

3

4

0

2

3

4

1

1514

6.5 Operation: Pedal Operation


33/57


p p

A Retarder

B Retarder and service brake

1 Brake stage 1 *2 Brake stage 2 *

3 Brake stage 3 *

* The brake stages operated with the pedal are normally iden-

tical with the brake stages of the hand operation.

M+P-07A-1591

3

B

A2 1

1515

6.5 Operation:Pedal Operation


34/57


p p

NoteThe illustration shows the 3-stage variant, a 4-stage va-riant also is offered.

The main switch pedal operation ON-OFF is located inthe dashboard.

ON: retarder is ready for operationOFF: e.g. in case of unsafe road conditions

For combined hand and pedal operation, the respectivehigher braking torque applies.

In case of very low outside temperatures, the braking ac-tion on first retarder braking starts with a response delay.

The constant speed function cannot be selected viathe foot pedal.

The retarder is operated via the 3 or 4-stage foot pedalof the service brake. The maximum braking torque is re-

ached in the maximum position.

Foot pedal in position 0:

Retader is switched off no indication on the retarder pilot light.

Foot pedal in position 1 to 3 or 1 to 4:The brake stages 1 to 3 or 1 to 4 are selected accordin-gly the retarder pilot light lights steadily.

6.5 Operation: Pedal Operation


35/57


Special functions

with combined hand and pedal operation

(without push button for constant speed function)

Retarder stage switch in position 1

constant speed,

foot pedal in position 1:

Constant speed function is cleared when selecting

constant speed while the retarder stage switch is in po-sition 1 and the retarder is then operated via the foot pe-dal. After releasing the foot pedal, the new momentaryspeed is stored, provided the retarder stage switchremains in position 1 the retarder pilot l ight l ights steadily.

Special functions

with combined hand and pedal operation

(with push button for constant speed function)

Constant speed function active,

foot pedal in position 1:

Constant speed is cleared when selecting constantspeed by pressing the push button and the retarder is

then operated via the foot pedal. After releasing the footpedal, the retarder pilot light extinguishes.

6.5 Operation:Pedal Operation


36/57


The retarder pilot light can indicate additionally the follo-wing operating conditions:

Without indication:

The retarder is switched off; no fault.

Flashing light

- during retarder braking:

Temperature adaptation is active - the retarder adapts itsbraking torque. Please see Chapter 6.2: TemperatureAdaptation!

Steady light

- on electronic check:

when turning on the vehicle ignition for about 5 seconds

in position 0 to 3 or 0 to 4

a) Minor fault:

Retarder brakings may partly occur at reducedbraking torque.Consult a qualified workshop!

b) Major fault:

Retarder brakings are no longer possibleretarder is switched off.

Continue driving only with substantially reduced

speed - consult a qualified workshop immediately!

The retarder pilot light has the additional function that en-ables to find the fault in the electronic system even wit-hout service unit. The indication of a fault can be realizedby the flash code of th retarder pilot light.

Caution!


6.6 Operation: Customer options


37/57


The following descriptions of hand operation, foot operation as well as of retarder pilot light are stored in a softwaredata record in customer-specific form for MAN; in such cases there are differences of certain functions to the Voith

standard data record. The descriptions refer exclusively to the current software version of the control unit.

MAN bus

Hand operation Function is as the Voith standard (see chapters 6.3, 6.4: Functions and Indications)

Foot operation Option: 3-stage foot operation

Retarder pilot

light

Steady light: if retarder braking torque is > 0(no steady light if the hand or foot operation is in a switch stage > 0 and the retarder brakingtorque is 0)

LED in the

handle of theretarder stage

switch

Steady light: if constant speed function is activated

7.1 Maintenance: Oil Level Check


38/57


1800 Sealing ringA30x36, DIN 7603 Cu......renew


hex. head screw, w.a.f. 24 ..................MA= 150 Nm

1592-3

1900

1800

1516

Max

Min



39/57


Caution!

For a sound operation of the retarder it is important to ob-serve the specified oil fill level, chapter 10: Data Sheet.Use only oils released in the specification for operatingfluids, chapter 9.

Note

The illustration on page 38 shows a retarder 120-3 withstainless steel heat exchanger. Oil level check is identi-cal for aluminium heat exchangers.

Check the oil level with the vehicle in horizontal position!

The temperature of the retarder oil must be above 60 C(operating temperature)!

1. Operate the retarder at the highest stage (highestbrake stage) while the vehicle is at standstill and

switch it off after about 5 seconds.Repeat this procedure twice.

2. Switch off vehicle ignition.

Warning!

Oil filler/check plug (1900) is hot (oil temperature)!

The retarder andthe vehicle ignition must be switchedoff during oil level check!If the vehicle ignition remains switched on from workingstep 3, with oil filler/check plug removed, there is a high-er risk of injury due to hot leaking oil (increased pressu-re)!



40/57


3. Unscrew the oil dipstick after about 5 minutes, remo-ve sealing ring (1800) and wipe off the oil filler/check

plug.

4. Insert the oil filler/check plug flush with the counter-sunk taphole - do not screw in.

5. Pull out again the oil filler/check plug.

Oil level is correct between min. and max. mark of the oilfiller/check plug.The difference between min. and max. mark is about0.5 l oil.

6. Fill in any lacking oil via the bore for the oil filler/checkplug according to specification for operating fluidsand oil fillings.

7. Re-insert the oil filler/check plug with new sealing ringand tighten it.Oil filler/check plug (1900), 150 Nm.

7.2 Maintenance: Oil Change (stainless steel Heat Exchanger)


41/57


1800 Sealing ring A30x36, DIN 7603 Cu.....renew



1595-31800

1900

1517



42/57


1700 Oil drain plug Retarder M22x1.5

hex. socket screw, w.a.f. 10 ...............MA= 66 Nm

1596-3

1700

1518



43/57


Caution!

For a sound operation of the retarder it is important to ob-serve the specified oil fill level, chapter 10: Data Sheet.Use only oils released in the specification for operatingfluids, chapter 9!

Note

For draining the oil, the temperature of the retarder oilmust be higher than 60 C (operating temperature)!

1. Place the oil collecting pan under the retarder.

2. Operate the retarder at the highest stage (highestbrake stage) while the vehicle ist at standstill andswitch it off after about 5 seconds.Repeat this procedure twice.

3. Switch off vehicle ignition.

Warning!

Oil drain plug (1700) and oil filler/check plug (1900) arehot (oil temperature)!

The retarder andthe vehicle ignition must be switchedoff during oil level check!If the vehicle ignition remains switched on from workingstep 4, with oil drain plug (1700) and oil filler/check plug(1900) removed, there is a higher risk of injury due to hotleaking oil (increased pressure)!



44/57


4. For faster draining of the retarder, unscrew the oil fil-ler/check plug (ventilation) and remove the sealing

ring (1800).

5. Unscrew the retarder oil dain plug and drain the oil.Waste disposal of drained oil according to regu-

lations!

6. Check the sealing ring of the oil drain plug for dama-ges; replace the oil drain plug, if necessary.

7. Insert and tighten the oil drain plug.Retarder oil drain plug (1700), 66 Nm.

Note

When the retarder is in inclined position up toapprox. 4 - reduce the oil filling by 0.25lapprox. 8 - reduce the oil filling by 0.5l .

8. Fill in the oil quantity specified in the specification foroperating fluids through the bore for the oil filler/check

plug.Oil fi lling = 4.5 litres (service fill ing)

9. Insert and tighten the oil filler/check plug with newsealing ring.Oil filler/check plug (1900), 150 Nm.

7.3 Maintenance: Oil Change (aluminium Heat Exchanger)


45/57


1800 Sealing ring A30x36, DIN 7603 Cu.....renew1900 Oil filler/check plug M30x1.5


M+P-07A-1593

1800

1900

1521



46/57


1002 Oil drain plug WAT M12x1.5hex. socket screw, w.a.f. 6 .................MA= 25 Nm

1700 Retarder oil drain plug M22x1.5hex. socket screw, w.a.f. 10 ...............MA= 66 Nm

1594-3

1700

1002

1520



47/57


Caution!

For a sound operation of the retarder it is important to ob-serve the specified oil fill level, chapter 10: Data Sheet.Use only oils released in the specification for operatingfluids, chapter 9!

Note

For draining the oil, the temperature of the retarder oilmust be higher than 60 C (operating temperature)!

1. Place the oil collecting pan under the retarder.

Warning!

Oil drain plugs (1002, 1700) and oil filler/check plug(1900) are hot (oil temperature)!

The retarder andthe vehicle ignition must be switchedoff during oil level check!If the vehicle ignition remains switched on from workingstep 2, with oil drain plugs and oil filler/check plug remo-ved, there is a higher risk of injury due to hot leaking oil(increased pressure)!

2. For faster draining of retarder, unscrew the oil filler/check plug (ventilation) and remove the sealing ring(1800).

3. Unscrew the oil drain plugs on retarder and heat ex-

changer and drain the oil.Waste disposal of drained oil according to regu-

lations!



48/57


4. Check the sealing rings of oil drain plugs for possibledamages; replace the oil drain plugs, if necessary.

5. Insert and tighten the oil drain plugs.Retarder oil drain plug (1700), 66 Nm.Heat exchanger oil drain plug (1002), 25 Nm.

Note

When the retarder is in inclined position up toapprox. 4 - reduce the oil filling by 0.25lapprox. 8 - reduce the oil filling by 0.5l

6. Fill in the oil quantity specified in the specificaion foroperating fluids through the bore for the oil filler/checkplug.Oil filling = 5.5 litres (service fil ling)

7. Insert and tighten the oil dipstick with new sealing

ring.Oil dipstick (1900), 150 Nm.

8 Maintenance Work, Cooling Water Quality


49/57


Maintenance work

on every oil change Retighten the propshaft screws Retighten all screw plugs (retarder basic group and

heat exchanger). Fastening nuts and bolts of the heatexchanger are excluded.

For oil changing intervals and specification for ope-rating fluids, please see chapter 9.

Cooling water quality

The vehicle manufacturers specifications apply. If thereare no specifications, observe Voiths cooling water listor the service manual - Retarder 120-3.

Cooling water l ist; Voith Article Number 67.2224.10Service manual; Voith Article Number 53.2676.10

9 Oil Changing Intervals, Operating Fluids Instructions


50/57


1) according to specification on the next page

2) if the specified mileage is not reached within 2 years, it is necessary to change the oil!

Single-grade

mineral oil1 )Multi-grade

mineral oil 1)Synth./

part-synthetic oil

1 )

Truck

normal duty90,000 km 2 ) 135,000 km 2 )

Truck

heavy duty45,000 km 2 ) 90,000 km 2 )

Bus

normal duty135,000 km 2 ) 90,000 km 2 ) 180,000 km 2 )

Bus

heavy duty60,000 km 2 ) 45,000 km 2 ) 90,000 km 2 )



51/57


1. Normal duty

Example: long-distance travel

2. Heavy duty

Duties exceeding the normal limit.

Examples: Applications in regions with high outside temperatures

(e.g. Saudi Arabia) Construction-site and timber vehicles High permissible total weight at low rated engine po-

wer (< 8 PS/ton) Frequent uphill/downhill roads Extremely short distances with many road downgra-

des

It is possible to fall below the specified maximum values,if this results in an improvement of operating sequences

relative to the overall maintenance of the vehicle.

When the total service life of the retarder passed morethan 10 %, relative to the vehicle mileage as well as toother factors not mentioned here, but also affecting theaging of retarder oil, it is necessary to shorten the speci-

fied oil-changing intervals individually.

In case of application in extremely cold zones, use oils ofcorresponding low viscosity (Transmax Z or SAE 5W40).

In case of doubt, please consult our Service Department.



52/57


Oil types permitted for use must meet the following specification:

The vehicle manufacturers specifications apply as to the selection of oil types. If there are no specifications, observeVoiths list of recommended oils which you may obtain from Voith Turbo under Voith Article Number 67.2246.10.

Oil type Code

to DIN 51502

Viscosity class to

DIN 51511

Performance

class

Single-grade

mineral oil

HD SAE 10W

SAE 20W 20

SAE 30

API - CC/SF

and better

Multi-grademineral oil

HD all classes API - CC/SFand better

Synthetic oil /

part-synthetic oil

HC SAE 0W 40

SAE 5W 30

SAE 5W 40

SAE 5W 50

SAE 10W 30

SAE 10W 40

API - CC/SF

and better

10 Data Sheet Voith Retarder 120-3


53/57


* When the retarder is in inclined position up to

approx. 4 - reduce the oil filling by 0.25lapprox. 8 - reduce the oil filling by 0.5l

** Dependent on the attachment, the total weight may deviate.

Max. possible braking torque at propshaft M(Br) max.= 2000 Nm

Working medium Oil type indicated in the operating fluids instruc-

tions

Oil filling quantity: *

service filling (oil change, oil level check)

initial filling/re-filling

With stainless steel With aluminium

heat exchanger: heat exchanger:

4.5 l itres 5.5 litres

6.5 l itres 6.0 litres

Control medium Compressed air

Supply-air pressure 710 bar

Total weight (incl. flange, heat exchanger, without oil filling) approx. 70 kg ** approx. 65 kg **

11 Service Check List


54/57


Kilometer reading ....... ......... ......... .....

oil change

line filter cleaned

propshaft screws checked

all screw plugs checked

visual check performed

Firm stamp / Signature

Date: ........... ......... ......... .... ..... ..

Kilometer reading . ......... ......... .... ..... ..

oil change

line filter cleaned





Date: ........................................

Kilometer reading ....... ......... ......... ..... oil change

line filter cleaned





Date: ........... ......... ......... .... ..... ..

Kilometer reading . ......... ......... .... ..... .. oil change

line filter cleaned

propshaft checked




Date: ........................................

11 Service Check List


55/57


Kilometer reading ........... .... ..... ......... .

oil change

line filter cleaned





Date: . ......... ......... ..... ......... .......

Kilometer reading .............. .... ..... .......

oil change

line filter cleaned





Date: ........................................

Kilometer reading ........... .... ..... ......... . oil change

line filter cleaned





Date: . ......... ......... ..... ......... .......

Kilometer reading .............. .... ..... ....... oil change

line filter cleaned





Date: ........................................

12 Modification Certificate

If the retarder is installed subsequently i e not directly by the vehicle manufacturer it is necessary to fill in the modification cer

to be filled in by the installation


56/57

56 VOITH TURBOInstruction Manual Retarder 120-3

If the retarder is installed subsequently, i.e. not directly by the vehicle manufacturer, it is necessary to fill in the modification cer-

tificate and to return a copy of the filled in certificate to Voith Turbo, cbqr Dept.!

Retarder data

Retarder type:

Voith Retarder 120-3

Control systems

Pedal operation yes q/ noq

Serial No.: . . . . . . . . . . . . . . . . . . . . . . .

Voith Article Number: . . . . . . . . . . . . . . . . . . . . . . .

Set max. braking torque: . . . . . . . . . . . . . . . . . . . . . . .

Set temperature limit: . . . . . . . . . . . . . . . . . . . . . . .

Parts List No. - basic group: . . . . . . . . . . . . . . . . . . . . . . .

Parts List No. - attaching parts: . . . . . . . . . . . . . . . . . . . . . . .

Parts List No. - heat exchanger: . . . . . . . . . . . . . . . . . . . . . . .

Parts List No. - cooling circuit: . . . . . . . . . . . . . . . . . . . . . . .

Parts List No. - control: . . . . . . . . . . . . . . . . . . . . . . .

Installation workshop:

(stamp)

Installation date /

Signature: . . . . . . . . . . . . . . . . . . . . . . .

Vehicle data

Vehicle type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Ident. No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List No. - gearbox: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propshaft length

(after retarder installation)

Gearbox installation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

Special equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modification Certificate 12

Deviating from the standard the following parts were replaced or modified on installation of the retarder in the afore mentioned

to be filled in by the installat ion


57/57

VOITH T URBOInstruction Manual Retarder 120-3 57

Deviating from the standard, the following parts were replaced or modified on installation of the retarder in the afore-mentioned

vehicle:

Parts designation Part number (if available) Parts designat ion Part number (if available)

If you have any further questions, please contact the installation workshop in charge or

Voith Turbo, Customer Service, telephone: 07951 / 32-401, 32-694 or 32-422.

transmissão voith retarder 120-3 57 pag

Documents