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Training

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Aftersales Service Manual


VOITH Retarder 120 with Digiprop Control

Content

Table of Contents

1.

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

2.

General....................................................................................................2/1
2.1 Assembly Overview ..........................................................................2.1/1
2.2 Function and Operation Scheme .........................................................2.2/1
2.3 Retarder Data ..................................................................................2.3/1

3.

Maintenance............................................................................................3/1
3.1 Maintenance Work .............................................................................3.1/1
3.2 Oil Change .......................................................................................3.2/1
With Stainless-Steel Heat Exchanger ....................................................3.2/1
With Aluminium Heat Exchanger ..........................................................3.2/5
3.3 Checking Oil Level .............................................................................3.3/1
3.4 Cleaning Line Filter (Optional extra) ......................................................3.4/1

4.

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

5.

Removing, Installing Retarder .................................................................5/1


5.1 Removing, Installing Retarder (Free Mount Installation)............................5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment) ...............................5.2/1

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Content

6.

Table of Contents
(Continue)

Retarder Basic Group Repair (Gearbox Attachment)..............................6/1


6.1 Assembly Overview ...........................................................................6.1/1
6.2 Removing, Checking and Installing Casing Ventilation .............................6.2/1
6.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......6.3/1
6.4 Removing, Checking and Installing Non-Return Valve
(Stainless-Steel Heat Exchanger) .........................................................6.4/1
6.5 Removing, Cleaning 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 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) ..........................7/1


7.1 Assembly Overview ...........................................................................7.1/1
7.2 Removing, Checking and Installing Casing Ventilation .............................7.2/1
7.3 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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Content

Table of Contents
(Continue)

Removing, Cleaning and Installing Silencer ............................................7.5/1


Removing and Installing Bottom Cover ..................................................7.6/1
Removing and Installing Prop Shaft Flanges ..........................................7.7/1
Checking, Removing and Installing Closing Cover of Retarder Housing ......7.8/1
Removing and Installing Labyrinth Ring (Output Side),
Renewing Radial Shaft Sealing Ring .....................................................7.9/1
7.10 Removing and Installing Centering Cover (Input Side),
Renewing Radial Shaft Sealing Ring ...................................................7.10/1
7.5
7.6
7.7
7.8
7.9

8.

Removing, Checking and Installing Heat Exchanger ..............................8/1


8.1 Stainless-steel Heat Exchanger ...........................................................8.1/1
8.2 Aluminium Heat Exchanger .................................................................8.2/1

9.

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

10.

Annex ....................................................................................................10/1
Data Sheet
Miscellaneous Conversions

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Preface

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 for
appropriate 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.

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Preface

Preface
(Continue)

Caution!
The switched-on retarder will not secure the parked vehicle.
At a failure of the retarder, or while the temperature limitation is effective the vehicle speed must be
settled with the service brake.
Notice
Only genuine spare parts may be used for repairs. For inquiries and orders, please provide the following
information (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 not
available. Items or components with two-digit item numbers are no spare parts and therefore not
available in the spare part lists.

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Preface

Preface
(Continue)

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 lubricants
professionally.
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 the
retarder as a result of inexpert workmanship, the information and instructions must be read carefully and
complied with in their entirety.

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Preface

Preface
(Continue)

Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situations
which might entail the risk of injury for the person carrying out the work. It is therefore imperative that
any person carrying out repair work on VOITH retarders uses his professional knowledge to make sure
that his own safety is not endangered and that the retarder suffers no negative effects, in particular
safety-wise, through the chosen working procedure. For these reasons, no liability can be assumed for
damage incurred.
It is therefore expressly pointed out that all working procedures described must be carried out only in
compliance with the valid general directions and regulations of the locally responsible authorities, of the
health protection, accident prevention and environmental protection organisations.
The technical status of the present instructions can be seen from the updating index. There may be
discrepancies 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 without
prior notification.
Should you have queries about the descriptions, please contact the responsible person in the
appropriate organisation of the country involved or:
VOITH TURBO GmbH & Co. KG
D-74564 Crailsheim
Department cb; Voithstrae 1
Telephone (07951) 32-0
Telefax (07951) 32-756
Extensions:
Customer telephone and Spare Parts Service
32-401 / 32-422

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General

General

2.1

Assembly Overview ....................................................................................2.1/1


With Stainless-Steel Heat Exchanger .................................................................2.1/1
With 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

2.1

Assembly Overview

Illustration VOITH Retarder R 120


with Digiprop control system
basic group with stainless-steel
heat exchanger
100/1
100/2
100/3
1000
1900

100/3

Retarder data
Constant-air pressure
connection p y A
Ventilation connection R
Heat exchanger
Oil filler/check plug (M 30 x 1,5)

100/2

100/1
1900

1000
16001

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General

2.1

Assembly Overview
(Continue)

Illustration VOITH Retarder R 120


with Digiprop control system
basic group with stainless-steel
heat exchanger
(Continue)
1000
1000/1
1000/5
1700

Heat exchanger
Leakage oil drain plug
(M 14 x 1,5)
Cooling water drain plug
(M 18 x 1,5)
Retarder oil drain plug
(M 22 x 1,5)

1700

1000/1

1000/5

1000
16002

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General

2.1

Assembly Overview
(Continue)

Illustration VOITH Retarder R 120


with Digiprop control system
basic group with aluminium heat exchanger
100/1
100/2
100/3
1000
1000/5
1900

100/3

Retarder data
Constant-air pressure
connection p y A
Ventilation connection R
Heat exchanger
Cooling water drain plug
(M 12 x 1,5)
Oil filler/check plug (M 30 x 1,5)

100/2

1900
100/1

1000
1000/5

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16003

General

2.1

Assembly Overview
(Continue)

Illustration VOITH Retarder R 120


with Digiprop control system
basic group with aluminium heat exchanger
(Continue)
1000
1000/1
1000/3
1000/5
1700

Heat exchanger
Leakage oil drain plug
(M 10 x 1)
Heat exchanger oil drain plug
(M 12 x 1,5)
Cooling water drain plug
(M 12 x 1,5)
Retarder oil drain plug
(M 22 x 1,5)

1700

1000/3

1000/1

1000/5

1000
16004

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2.2

General

Function and Operation Scheme

Illustration of VOITH Retarder 120 with Digiprop control system

25

21
44

12

50

A R

67

46

16

26

37

69

23

52

20
2

19

45

18

53

43

56

66

17

15

47

70

1
Oil sump

Coolant (water)

Supply-air pressure p V
Constant-air pressure p y

Pump pressure p P

16005e

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

1
2
4
5
7
8
12
15
16
17
18
19
20
21
23
25
26
37

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Heat exchanger
Control unit
Connection terminal 15
Connection terminal 30
Fuses (5A)
Connection ground
Pump pressure test connection
ABS-Signal
Retarder stage switch
Retarder pilot light
Stop light relay
Temperature pick-up cooling water
Oil temperature pick-up
Proportional valve
Casing ventilation
Constant-air pressure line p y A
Supply-air pressure line p v P
Ventilation line R

43
44
45
46
47
50
52
53
56
66
67
69
70

Oil sump
Stator
Stator pin
Rotor
Speedometer signal
Output restrictor D1
Filling restrictor D2
Filling duct
Leakage oil return line
Check valve
(stainless-steel heat exchanger)
Check valve
(casing ventilation cover)
ISO interface plug
Extra operations plug

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General

2.2

Function and Control System


(Continue)

Description of the function


The VOITH Retarder 120 is a powerful hydrodynamic continous brake of compact design for buses and
commercial vehicles of the medium range. The VOITH Retarder 120 is mounted between the gearbox
and 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 be
used to regulate the vehicle speed.
A retarder stage switch (16) with a maximum of 5 switching stages is used to control the
VOITH 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 limit
of the maximum braking torque.
If the retarder is switched off (0 position), or switched to braking stage (position 2 to 5), the memorized
constant speed is deleted. If the constant speed function is re-activated, the new present speed
is 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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General

2.2

Function and Control System


(Continue)

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 holds
the vehicle speed downhill constant within the limits of the maximum braking torque. Another push on
the 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 of
the maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting to
braking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle accelerates
to the speed previously transferred to memory.
The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank for
auxiliary 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 the
proportional valve (21).
The proportional valve (21), depending on the magnitude of the control current, provides a
constant-air pressure p y on the oil sump (43).

16006

The hydrodynamic principle


a Rotor (46)
b Stator (44)
c
Oil flow

The constant-air pressure p y in 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).

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General

2.2

Function and Control System


(Continue)

The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarder
housing.
The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between
the 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, part
of the circulating oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and via
filling 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 vehicle
and dissipated via the vehicle radiator to the ambient air.

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General

2.2

Function and Control System


(Continue)

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


The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from the
retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and
oil temperature to the control unit (2).
To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarder
braking torque is limited to protect the vehicle cooling system and the retarder.
The constant-air pressure p y is limited.
The braking torque and consequently the heat generated are reduced until a balance is obtained
between the braking energy of the retarder and the amount of heat which can be dissipated by
the 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 the
temperature 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 to
control the vehicle.
The control unit (2) also cuts back braking torque if oil temperature rises too rapidly, irrespective of actual
oil temperature.

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General

2.2

Function and Control System


(Continue)

Casing ventilation (23)


During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) and
the 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 of
the stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent the
build-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back on
their 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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General

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 queries
or ordering spare parts.

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16007

Maintenance

Maintenance

3.1

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

3.2

Oil Change .................................................................................................3.2/1


Stainless-steel Heat Exchanger ........................................................................3.2/1
Aluminium 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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Maintenance

3.1

Maintenance Work

Overview of maintenance work


Carry out the following maintenance work at each oil change:
l

Clean the cleaning line filter (optional extra)

Carry out visual inspection on leaks at the complete retarder

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


Observe guidelines and instructions!

Tighten all screw plugs of the retarder basic groups and the heat exchanger with the appropriate
torque (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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Maintenance

3.2

Oil Change

Illustration oil change R 120


with stainless-steel heat exchanger
1000/1
1000/2
1000/5
1000/6
1600
1700
1800
1900

Leakage oil drain plug


(M 10 x 1), 13 Nm
Sealing ring (A 10 x 13,5), renew
Cooling water drain plug
(M12 x 1,5), 25 Nm
Sealing ring (A12 x 18), renew
Sealing ring (A 22 x 29), renew
Retarder oil drain plug
(M 22 x 1,5), 66 Nm
Sealing ring (A 30 x 36), renew
Oil filler/check plug
(M 30 x 1,5), 150 Nm

1900

1800

1000/6 1000/5

1000/2
1000/1
1600
1700

16008

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Maintenance

3.2

Oil Change
(Continue)

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) for
operating the retarder in the relevant application.

Heat exchanger

Service filling

Stainless-steel
heat exchanger
(L+R)

4,5 l

After complete
After exchange of
taking apart and cle- heat exchanger
aning, as well as
emptied heat
exchanger
5,8 l

6,5 l

The retarder oil temperature must be higher than 60 o C (operating temperature) for the oil
to be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressure is acting in the retarder.
The retarder and the ignition must have been switched off!

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Maintenance

3.2

Oil Change
(Continue)

Job scope
1.

Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and
switch it off after approx. 5 sec.
Repeat this procedure twice.
Switch off the retarder and ignition and wait 5 minutes (control function).
Caution! Risk of injury!

The oil filler/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).
Caution! Risk of injury!

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


4.

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

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Maintenance

5.

3.2

Oil Change
(Continue)

Screw out the leakage oil drain plug (1000/1) and remove sealing ring (1000/2) and drain the
accumulated oil.
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 the
vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two
radial 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 side
completely (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):
Leakage oil drain plug (1000/1):

Tightening torque 66 Nm
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).

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

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Maintenance

3.2

Oil Change
(Continue)

Illustration oil change R 120


with aluminium heat exchanger
1000/1
1000/2
1000/3
1000/4
1600
1700
1800
1900

Leakage oil drain plug


(M 10 x 1), 13 Nm
Sealing ring (A 10 x 13,5), renew
Heat exchanger oil drain plug
(M 12 x 1,5), 25 Nm
Sealing ring (A 12 x 15,5), renew
Sealing ring (A 22 x 29), renew
Retarder oil drain plug
(M 22 x 1,5), 66 Nm
Sealing ring (A 30 x 36), renew
Oil filler/check plug
(M 30 x 1,5), 150 Nm

1900

1000/4
1000/3
1800
1000/2
1000/1
1600

1700

16009

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Maintenance

3.2

Oil Change
(Continue)

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) for
operating the retarder in the relevant application.

Heat exchanger

Service filling

New filling

Aluminium heat exchanger (AKG)

5,5 l

6,0 l

The retarder oil temperature must be higher than 60 o C (operating temperature) for the oil
to be drained.

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

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Maintenance

3.2

Oil Change
(Continue)

Job scope
1.

Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and
switch it off after approx. 5 sec.
Repeat this procedure twice.
Switch off the retarder and ignition and wait 5 minutes (control function).
Caution! Risk of injury!

The oil filler/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).
Caution! Risk of injury!

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) and
remove 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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Page 3.2/7

Maintenance

3.2

Oil Change
(Continue)

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 the
vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two
radial 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, 1000/2
and 1000/4).
Retarder oil drain plug (1700):
Heat exchanger oil drain plug (1000/3):
Leakage oil drain plug (1000/1):

Tightening torque 66 Nm
Tightening torque 25 Nm
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).

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

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Page 3.2/8

Maintenance

3.3

Checking Oil Level

Illustration checking oil level

1900

Notice
The oil change intervals and operating
specifications have to be taken from the annex.
1800
1900

1800

Sealing ring (A 30 x 36), renew


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

Notice
The illustration shows a retarder 120 with
stainless-steel heat exchanger. A version with
aluminium heat exchanger is possible.

16010

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Page 3.3/1

Maintenance

3.3

Checking Oil Level


(Continue)

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 the
mounted heat exchanger.
For relevant application approved oils
Use only approved oils specified in the operating specifications (see Annex).

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Page 3.3/2

Maintenance

3.3

Checking Oil Level


(Continue)

Notice
For the oil level check, the temperature of the retarder oil must be higher
than 60C (operating temperature).
The oil level check must be carried out with the vehicle in a horizontal position.
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 and
switch 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 have
been 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).


Caution! Risk of injury!

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


3.

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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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Page 3.3/3

Maintenance

3.3

Checking Oil Level


(Continue)

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 slowly any 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

1900
Max
Min

16011

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Page 3.3/4

Maintenance

3.4

Cleaning Line Filter


(Optional Extra)

Illustration line filter


Complete line filter
Pressure spring
Intermediate plate
Cover
Holding plate
Pressure spring
Filter housing
Filter insert
O-ring (36,2 x 3), renew,
coat with silicone-free and
non-corossive grease
for installation

12000/1

12000/6
12111

12000/2
12000

12000
12000/1
12000/2
12000/3
12000/4
12000/5
12000/6
12111
12112

12000/5
Lubricants
O-ring

12112

Silicone-free and
non-corossive grease

12000/3

12000/4

16012

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Page 3.4/1

Maintenance

3.4

Cleaning Line Filter


(Continue)

Notice
Vehicle specific can be installed a line filter within the constant-air pressure line between air tank
for 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 valve
also when filter insert is badly soiled. In this case the compressed air will not be cleaned anymore.
Job scope

Caution! Risk of injury!


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 for
damages and renew if necessary.

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Maintenance

3.4

Cleaning Line Filter


(Continue)

5.

Insert the pressure spring (12000/1), the filter insert (12111), the intermediate plate (12000/2) and
the 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 to
the cover (12000/3).

7.

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

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

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Page 3.4/3

Diagnosis /
Troubleshooting

Diagnosis / Troubleshooting

4.1

Troubleshooting Diagram ...........................................................................4.1/1


Electrical 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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Page 4/1

4.1

Diagnosis /

Troubleshooting Diagram

Troubleshooting
Illustration troubleshooting diagram

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 non-return
valve

NOK

Contact
VOITH

OK

Check non-return
valve in cover of
casing ventilation
(Chapter
6.3)

Renew casing
ventilation

NOK

OK
Correct oil level of
retarder (*)

see chapter6.4

Check casing
ventilation
(Chapter6.2)

Check cooling system:


Check heat
exchanger
NO

YES

YES
OK

Water in the oil?


(emulsion)

NOK

-coolant level
-thermostat
-coolant pump
-radiator fan
-radiator grill for
dirtiness

NO

Water in the oil?


(emulsion)

Check oil level of


retarder

Retarder:
Check Temp.-Sens.
(oil/water)

Driver instruction!

Oil leak by
ventilation
OK
flashes

If the retarder is
still leaking, or the
chamber of
leakage oil is filled
again with oil after
1000 km,
renew radial shaft
seal

Empty chamber of
return of leakage oil
(at heat exchanger)
(Chapter3.3)

Check operation
(by braking with
retarder nominal
engine speed,
if possible

Complaint
Oil leak input side
or output side

NOK

Temperature limit!

Retarder pilot
light

R 120
Digiprop

Permanent
lighting
No respectively
too insufficient
retarder braking
effect

Activate flash code


and read out
trouble code
(Chapter4.2)

Clear faults and


delete fault memory
(Chapter4.2)

Check oil level of


retarder
Water in the oil?
(emulsion)
NO

OK

YES

YES

NO

Check heat
exchanger

Check yp(static)
(Chapterl 4.4
)
OK

Water in the oil?


(emulsion)

NOK

see chapter

Correct oil level of


retarder

6.4

NOK

Check p (dynamic)
(Kapitel4.3)
OK

NOK

Check voltage of
proportional valve
(Chapter4.4)
OK

Contact
VOITH

NOK

Contact
VOITH
Check control unit
(Chapter4.4)
OK

Contact
VOITH

Check compressed-air supply


(Chapter 4.4)
OK

NOK

Contact
VOITH

NOK

Check vehicle
compressed-air
supply

Mechanical fault of
proportional valve

OK

Contact
VOITH

* If you get oil leakage after a trail run again:


continue at Checking casing ventilation

NOK

Contact vehicle
manufacturer

FD 1601

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Page 4.1/1

4.1

Diagnosis /
Troubleshooting

Troubleshooting Diagram
(Continue)

Electrical Diagram Version 1

Connecting plug 4 pins


"ISO Interface"
3 1 2 4

Digiprop

X1.
18pins

X2.
9pins

X3.
12pins

3
2
1
6
5
4
9
8
7

CAN-high
CAN-Ground
CAN-low
Position 1
Position 2
Position 3
Position 4
Position 5
T 15 (Ignition lock)

Lead E-Box

T 30 (Battery)
Output / high side 1 `HS 1`
Output / low side 1 `LS 1`
Output / high side `HS 2`

pink
blue
orange
white
wei
grey
red
red
blue/white
orange/white
purple
purple
brown
brown
black
beige
yellow/green
black/white

Prop valve `+`


Prop valve `-`
Changeover valve `+`
Changeover valve `-`
Water temp.`+`
Water temp.`-`
Oil temp.`+`
Oil temp.`-`

pink
grey
orange
beige
yellow/green
blue
purple
white

12
11
10

ISO K
ISO L
Retarder Stage Switch`+`

15
14
13
18
17
16

T 31 (Ground)

3
2
1
6
5
4
9
8
7

Connecting plug 8 pins


"Retarder Stage Switch"

3
2
1
6
5
4
9
8
7
12

ABS
Speedometer signal
Input / pull-up `DIU 1`
Input / pull-up `DIU 2`
Input / pull-down `DID 1`
Input / pull-down `DID 2`
Input / pull-down `DID 3 `
Retarder pilot light
Input / (m 0...5V ) `INA-U `
Input / p.-down / PWM-in `DID 4 `

11
10

Stop light relay


Input / (0...20mA ) `INA-I

7
6
5
3
2
8
4

Position 1
Position 2
Position 3
Position 4
Position 5
Retarder Stage Switch`+`

T 15 (Ignition lock)
T 31 (Ground)
T 30 (Battery)

+
+

Lead Retarder
Pin 1
2
3
4

Prop valve `+`


Prop valve `-`
Changeover valve `+`
Changeover valve `-`
Water temp.`+`
Water temp.`-`
Oil temp.`+`
Oil temp.`-`

black/white
blue
white
pink
blue/white
brown/white
orange/white
yellow/green
grey/black
grey
grey
orange
red/white

ABS
Speedometer signal

Retarder pilot light

Stop light relay

1 9 5 8 4 3 2 7 6 1112101314
Connecting plug 14 ins
"Additional Functions"

16014e

Electrical Diagram Version 2

"ISO Interface"
3 1 2 4

Digiprop

X1.
18pins

X2.
9pins

X3.
12pins

3
2
1
6
5
4
9
8
7

CAN-high
CAN-Ground
CAN-low
Position 1
Position 2
Position 3
Position 4
Position 5
T 15 (Ignition lock)

Lead E-Box

T 30 (Battery)
Output / high side 1 `HS 1`
Output / low side 1 `LS 1`
Output / high side `HS 2`

pink
blue
orange
white
wei
grey
red
red
blue/white
orange/white
purple
purple
brown
brown
black
beige
yellow/green
black/white

Prop valve `+`


Prop valve `-`
Changeover valve `+`
Changeover valve `-`
Water temp.`+`
Water temp.`-`
Oil temp.`+`
Oil temp.`-`

pink
grey
orange
beige
yellow/green
blue
purple
white

12
11
10

ISO K
ISO L
Retarder Stage Switch`+`

15
14
13
18
17
16

T 31 (Ground)

3
2
1
6
5
4
9
8
7

Connecting plug 8 pins


"Retarder Stage Switch"

3
2
1
6
5
4
9
8
7
12

ABS
Speedometer signal
Input / pull-up `DIU 1`
Input / pull-up `DIU 2`
Input / pull-down `DID 1`
Input / pull-down `DID 2`
Input / pull-down `DID 3 `
Retarder pilot light
Input / (m 0...5V ) `INA-U `
Input / p.-down / PWM-in `DID 4 `

11
10

Stop light relay


Input / (0...20mA ) `INA-I

7
6
5
3
2
8
4

Position 1
Position 2
Position 3
Position 4
Position 5
Retarder Stage Switch`+`

T 15 (Ignition lock)
T 31 (Ground)
T 30 (Battery)

+
+

Lead Retarder
Pin 1
2
3
4
Pin 1
2
3
4

black/white
blue
white
pink
blue/white
brown/white
orange/white
yellow/green
grey/black
grey
grey
orange
red/white

Prop valve `+`


Prop valve `-`
Changeover valve `+`
Changeover valve `-`
Water temp.`+`
Water temp.`-`
Oil temp.`+`
Oil temp.`-`

ABS
Speedometer signal

Retarder pilot light

Stop light relay

1 9 5 8 4 3 2 7 6 1112101314
Connecting plug 14 pins
"Additional Functions"

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Page 4.1/2

16015e

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies

Troubleshooting and remedies


Check requirements

Battery voltage 18 - 32 V
Vehicle electrical system checked in accordance with the Owners Manual for the vehicle
and found satisfactory.
Fuse for retarder control unit checked and found satisfactory.
Compressed-air pressure 6 - 11 bar
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 and
at 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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Page 4.2/1

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

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.
16016

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

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Page 4.2/2

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Connector arrangement and pin assignment

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

Plug X1 Control unit


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

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Not in use
Not in use
Not in use
Retarder stage switch, position 3 -(or)
Retarder stage switch, position 2 -(bl)
Retarder stage switch, position 1 -(pi)
Terminal 15 (rd)
Retarder stage switch, position 5 -(gr)
Retarder stage switch, position 4 -(wh)
Retarder stage switch + (vi)
ISO-interface, L-lead (or/wh)
ISO-interface, K-lead (bl/wh)
Terminal 30 (bl)
Not in use
Terminal 31 (br)
Output / high side 2 HS2 (bl/wh)
Output / low side 1 LS1 (ye/gr)
Output / high side 1 HS1 (be)

16

13

10

17

14

11

18

15

12

16017

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Page 4.2/3

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Plug X2 Control unit


1
2
3
4
5
6
7
8
9

Not operational/usable for applications (or)


Proportional valve - (gr)
Proportional valve + (pi)
Cooling water temperature pick-up - (bl)
Cooling water temperature pick-up + (ye/gr)
Not operational/ground (be)
Not in use
Oil temperature pick-up - (wh)
Oil temperature pick-up + (vi)

16018

Plug X3 Control unit


1
2
3
4
5
6
7
8
9
10
11
12

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Input / pull up DIU 1 (wh)


Speedometer signal (bl)
ABS-Signal (bl/wh)
Input / pull down DID 2 (br/wh)
Input / pull down DID 1 (bl/wh)
Input / pull up DIU 2 (pi)
Input / (0...5V) INA-U (gr/bl)
Retarder pilot light (ye/gr)
Input / pull down DID 3 (or/wh)
Input / (0...20 mA) INA-I (rd/wh)
Stop light relay (or)
Input / pull down / PWM-in DID4 (gr) / engine-speed signal

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Page 4.2/4

10

11

12

16019

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Extra operations plug


1
2
3
4
5
6
7
8
9
10
11
12
13
14

Retarder stage switch + (vi)


Input / pull down DID 1 (bl/wh)
Input / pull down DID 2 (br/wh)
Input / pull down DID 3 (or/wh)
Input / pull down / PWM -in DID 4 (gr)
Input / pull up DIU 1 (wh)
Input / pull up DIU 2 (pi)
Input / (0...5V) INA-U (gr/bl)
Input / (0...20 mA) INA-I (rd/wh)
Output / high side 1 HS1 (be)
Output / high side 2 HS2 (bl/wh)
Output / low side 1 LS1 (ye/gr)
Terminal 15 (rd)
Terminal 31 (br)

10

12

14

11

13

16020

ISO-Interface plug
1
2
3
4

K-lead (bl/wh)
K-lead (or/wh)
Terminal 15 (rd)
Terminal 31 (br)

16021

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Page 4.2/5

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Cooling water temperature pick-up plug


Oil temperature pick-up plug

16022

Proportional valve plug


1
2
3
4

Proportional valve + (pi)


Proportional valve + (gr)
Not operational (or)
Not operational (be)

4
1

2
3

16023

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Page 4.2/6

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Retarder stage switch plug


1
2
3
4
5
6
7
8

Not in use
Position 5 - (gr)
Position 4 - (wh)
Retarder stage switch + (vi)
Position 3 - (or)
Position 2 - (bl)
Position 1 - (pi)
Bridge to pin 4

16024

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Page 4.2/7

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

A. With fault code


Special tool

53.8224.10

Commercially available tool


Multimeter

recommended: Fluke 87

Notice
The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-out
from the fault memory.
Furthermore a diagnosis with the PC DigiDia software is possible. In this case please contact
VOITH TURBO or a responsible contracting party.

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Page 4.2/8

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Fault memory read-out via retarder pilot light blinking code

R
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.
16016

Fault memory read-out with service cable


(Digiprop-Version 0.2)
Requirements
-

1.

Retarder stage switch in position 0


Vehicle in parking position, Ignition ON
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
-

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long blinking signals (2 sec.) tens unit.


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

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Page 4.2/9

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Digiprop-Version 1.0
The blinking code can be triggered analogous to V 0.2, the conditions are the same. Additionally the
blinking code can be triggered with the help of the retarder stage switch during the service function:
1.
2.
3.
4.
5.

Shift RSS-Position 0
Shift RSS-Position 1 ( 2 Seconds)
Shift RSS-Position 0
Blinking code of first fault is indicated
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 retarder
pilot light is switched off.

16025

Display example: Fault code 23

Display example for fault code 23:


The number of tens will be indicated first as long ON-time:
The number of singles afterwards will be indicated as short ON-time:
Breaks between each ON-time:

each 2 seconds
each 0,5 seconds
each 1 second

E
A
t

If a relevant fault is indicated, the retarder pilot light is ON before triggering of the blinking code, the
retarder 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.

cbtd 98-01
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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/10

Retarder stage switch on


Retarder stage switch off
Time

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

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 of
service cable switch.

3.

Ignition: ON

4.

Disconnect after 2 seconds the L-lead of ground.

cbtd 98-01
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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/11

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

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

Code
01

Fault text

Fault
class

Trigger time

Requirement /
Operation

Measurement/
test
connection1 )

Result/
Set point

Cause/
Remedy 2)

Stop light relay/

slight

1s

- Ignition: OFF
- Pull plug X3 out of
control unit

X 3/11 W X 1/15

Relay is
installed:
250 - 350 W

Check lead, plugs


and relay
or consumers

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

0V

Check lead, plugs


and relay
or consumers

(Check)

Short circuit to
ground
02

LS 1 output
Short circuit to
battery

1)
2)

cbtd 98-01
53.2659.10

X 1/15 = ground control unit


Only, if no fault is recognizable after a complete check of the periphery: change control unit.

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/12

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 2:
Fault text
Fault
Code
03

Fault
class

Trigger time

slight

1s

Measurement/
test connection

Result/
Set point

Cause/
Remedy

- Ignition: OFF
- Pull plug X1 out of
control unit

X 1/18

W X 1/
15

With relay
installed:
250 - 350 W

Check lead, plugs


and relay
or consumers

slight

1s

- Ignition: OFF
- Pull plug X1 out of
control unit

X 1/16 W X 1/15

With relay
installed:
250 - 350 W

Check lead, plugs


and relay
or consumers

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, plugs


and fuses

serious

10 s

- Ignition: OFF
- Pull plug X1 out of
control unit
- Ignition: ON
- Start engine
(idle speed)

X 1/7

V X 1/15

32,5 V

Checking electrical
installation of vehicle
(see manufacturer
instructions)

Operation

(Check)
HS 1 output
Short circuit

04

HS 2 output
Short circuit

05

Terminal 15
Undervoltage

06

Terminal 15
Overvoltage

cbtd 98-01
53.2659.10

Requirement /

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/13

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 3:
Fault text
Fault
Code
08
09

Fault
class

Trigger time

Requirement /
Operation

Measurement/
test connection

Result/
Set point

(Check)
1s

Water temperature sensor


Discontinuity /
Short circuit to
battery

serious/
slight *

- 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 in
one temperature
range
normally is
sufficient.

cbtd 98-01
53.2659.10

Cause/
Remedy

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

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/14

Check lead and


sensor

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 4:
Fault text
Fault
Code
11
12

Fault
class

Trigger time

Requirement /
Operation

Measurement/
test connection

Result/
Set point

Cause/
Remedy

X 2/9 W X 2/8

20C 10 C =
1039 - 1117W

Check lead and


sensor

(Check)
Oil temperature
sensor

1s
serious/
slight *

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

60C 10 C =
1099 - 1271W

Discontinuity /
Short circuit to
battery

80C 10 C =
1271 - 1347W
Notice:
The measuring in
one temperature
range
normally is
sufficient.
*

cbtd 98-01
53.2659.10

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

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/15

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 5:
Fault text
Fault
Code

(Check)

13

13

13

Retarder stage
switch
Undefined
switch state

Fault
class

Trigger time

serious

100 ms

Requirement /

Measurement/
test connection

Result/
Set point

Cause/
Remedy

- Ignition: ON
- Retarder stage
switch:
Position 0

X 1/10 V X 1/15

17,5 V

Check lead, plug and


retarder stage switch

- Ignition: ON
- Retarder stage
switch:
Position 1

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

Operation

- Ignition: ON
- Retarder stage
switch:
Position 2

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

X 1/5
X 1/4
X 1/9
X 1/8

V
V
V
V

X 1/15
X 1/15
X 1/15
X 1/15
X 1/15

X 1/15
X 1/15
X 1/15
X 1/15

X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4
X 1/9
X 1/8

cbtd 98-01
53.2659.10

V
V
V
V
V

V X 1/15
V X 1/15
V X 1/15

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/16

0V
0V
0V
0V
0V
17,5 V
17,5 V

Check lead, plug and


retarder stage switch

0V
0V
0V
0V
17,5 V
17,5 V
17,5 V
0V
0V
0V

Check lead, plug and


retarder stage switch

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 6:
Fault text
Fault
Code

(Check)

13

Fault
class

Trigger time

Requirement /
Operation

Measurement/
test connection

Result/
Set point

Cause/
Remedy

- Ignition: ON
- Retarder stage
switch:
Position 3

X 1/10 V
X 1/6 V
X 1/5 V
X 1/4 V

Check lead, plug and


retarder stage switch

X 1/15
X 1/15
X 1/15
X 1/15

X 1/9 V X 1/15
X 1/8 V X 1/15
13

- Ignition: ON
- Retarder stage
switch:
Position 4

X
X
X
X
X

1/10 V
1/6 V
1/5 V
1/4 V
1/9 V

X
X
X
X
X

1/15
1/15
1/15
1/15
1/15

X 1/8 V X 1/15
13

cbtd 98-01
53.2659.10

- Ignition: ON
- Retarder stage
switch:
Position 5

X 1/10
X 1/6
X 1/5
X 1/4
X 1/9
X 1/8

V
V
V
V
V
V

X
X
X
X
X
X

1/15
1/15
1/15
1/15
1/15
1/15

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/17

17,5 V
17,5 V
17,5 V
17,5 V

0V
0V

17,5 V
17,5 V
17,5 V
17,5 V
17,5 V

Check lead, plug and


retarder stage switch

0V

17,5 V
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V

Check lead, plug and


retarder stage switch

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 7:
Fault text
Fault
Code

Fault
class

Trigger time

Requirement /
Operation

Measurement/
test connection

Result/
Set point

Cause/
Remedy

(Check)

14

Retarder stage
switch
Short circuit to
battery

serious

10 s

- Ignition: OFF
- Pull plug X1 out of
control unit
- Ignition: ON
- Retarder stage
switch:
Position 0

X 1/10 V X 1/15

0V

Check lead and plug

15

Retarder stage
switch
Short circuit to
battery

serious

1s

- Ignition: OFF
- Pull plug X1 out of
control unit
- Retarder stage
switch:
Position 5

X 1/10 W X 1/15

Resistor
infinite

Single check of
stages for
short circuit

cbtd 98-01
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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/18

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 8:
Fault text
Fault
Code
16

Fault
class

Trigger time

serious

Requirement /
Operation

Measurement/
test connection

Result/
Set point

Cause/
Remedy

2s

- Ignition: ON

X 3/2 V X 1/15

==1 V

Check lead and


speedometer

serious

2s

- Ignition: OFF
- Pull plug X3 out of
control unit
- Ignition: ON

X 3/2 V X 1/15

==9 V

Check lead and


speedometer

serious

60 s

- Ignition: ON

X 3/3 V X 1/15

3,5 V

Check lead,
relay and ABS-control unit

(Check)
Speedometer
signal
Discontinuity

18

Speedometer signal
Short circuit to
battery

19

cbtd 98-01
53.2659.10

ABS
Short circuit to
ground

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/19

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 9:
Fault text
Fault
Code

Fault
class

Trigger time

Requirement /
Operation

Measurement/
test connection

Result/
Set point

Cause/
Remedy

X 3/3 V X 1/15

16,5 V

Check lead,
relay and ABScontrol unit

Replace control
unit

==10 V

Check lead

(Check)

21

ABS-Signal undefined

serious

60 s

- Ignition: ON

22

Internal fault
ABS-current path

serious

1s

23

Proportional valve
Fault No. 1:
Short circuit to battery

serious

1s

- Ignition: OFF
- Pull plug X2 out of
control unit
- Ignition: ON

cbtd 98-01
53.2659.10

X 2/3 V X 1/15

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/20

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 10:
Fault text
Fault
Code

(Check)

24

24

cbtd 98-01
53.2659.10

Proportional valve
Fault No. 2:
- Short circuit proportional
valve magnetic
- Short circuit connection
lead proportional valve
- Discontinuity proportional valve magnetic
Valve magnetic
- Discontinuity connection lead proportional
valve
- Short circuit to ground at
proportional valve
- Prop.- and shift valve
interchanged

Fault
class

Trigger time

serious

1s

Requirement /

Measurement/
test connection

Result/
Set point

Cause/
Remedy

- Ignition: ON
- Pull plug X2 out
of control unit

X 2/2 W X 2/3

18-25 W

Check lead and


proportional
valve (valve
block)

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

X 2/3 W X 1/15

Resistor
infinite

Check lead and


proportional
valve (valve
block)

Operation

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/21

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 11:
Fault text
Fault
Code

(Check)

24

Fault
class

Trigger time

Requirement /
Operation

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

Measurement/
test connection

Result/
Set point

Cause/
Remedy

X 2/2 W X 1/15

Resistor
infinite

Check lead and


proportional
valve (valve
block)

25

Proportional valve
Fault No. 3:
defective control unit

serious

10 s

Replace
control unit

27

Proportional valve
Fault No. 5:
defective control unit

serious

2s

Replace
control unit

28

Terminal 30

serious

60 s

Undervoltage

cbtd 98-01
53.2659.10

- Ignition: OFF
- Pull plug X1 out of
control unit
- Ignition: ON

X 1/13 V X 1/15

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/22

17,5 V

Check lead,
plug and fuse

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 12:
Fault text
Fault
Code

Fault
class

Trigger time

Requirement /
Operation

Measurement/
test connection

Result/
Set point

Cause/
Remedy

(Check)

29

Fault control unit

serious

180 ms

Replace
control unit

31

Control unit:
Coding fault

serious

100 ms

Provide new
parameters for
control unit

32

Retarder pilot light:


Discontinuity /
Short circuit to ground

serious

3s

- Ignition: OFF
- Pull plug X3 out of
control unit
- Ignition: ON

X 3/8 V X 1/15

17,5 V

Check lead,
retarder pilot
light and fuse

33

Retarder pilot light:


Short circuit to battery

serious

3s

- Ignition: ON
- Retarder stage
switch:
Position 1

X 3/8 V X 1/15

==2 V

Check lead and


retarder pilot
light

cbtd 98-01
53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/23

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

Table 13:
Fault text
Fault
Code

Fault
class

Trigger time

Requirement /
Operation

Measurement/
test connection

Result/
Set point

Cause/
Remedy

(Check)

35

Fault control unit

serious

500 ms / 123 s

Replace
control unit

37

Fault pedal operation

slight

100 ms / 1 s

Check installation relating to


OEMrespectively
VOITHinstructions

cbtd 98-01
53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/24

Diagnosis /
Troubleshooting

4.2

Troubleshooting and Remedies


(Continue)

B. Without fault code


Notice
Retarder faults without fault code are not recognized electronically.

cbtd 98-01
53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.2/25

Diagnosis /
Troubleshooting

4.3

Checking Pump Pressure

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

101
102

Notice
The pump-pressure check provides information
on the mechanical condition of rotating parts,
on internal leaks and on the operation
of the retarder.
Special tool

53.4788.10
16026

Pressure gauge
0 - 25 bar
cbtd 98-01
53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.3/1

Diagnosis /
Troubleshooting

4.3

Checking Pump Pressure


(Continue)
99/1

Caution! Risk of injury!


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 and
read-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).

16027

99/1 Pressure gauge 53.4788.10

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

cbtd 98-01
53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.3/2

Diagnosis /
Troubleshooting

Setting [Nm]

4.3

Code Number

3)

Checking Pump Pressure


(Continue)

Pump pressure static


Setpoint [bar]

Pump pressure dynamic 1 )


v p s = 1000 r.p.m.
Minimum value [bar]

1)
2)
3)

1000

027

1,15 1,45

1250

028

1,45 1,75

1500

029

1,75 2,05

12

1750

030

2,05 2,35

14

2000

031

2,35 2,65

16

Retarder stage switch in highest position


Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure)
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 make
further modifications.

cbtd 98-01
53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.3/3

Diagnosis /
Troubleshooting

4.3

Checking Pump Pressure


(Continue)

Job scope dynamic


1.

Drive the vehicle with a prop-shaft speed of v p 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. and
read-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 the
dynamic check, please contact VOITH TURBO!

Caution! Risk of injury!


The screw of the pressure gauge and the retarder are heated up!
4.

cbtd 98-01
53.2659.10

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

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.3/4

4.4

Diagnosis /

Checking Control System

Troubleshooting
Illustration checking control system

25

Notice
The reference numbers indicated in Section 4.4
are not identical with the reference numbers of
the spare parts lists.

33

71
32

21

61

A R
P

37
1
2
11
19

20
21
25
26
31

32

33
34
35
37
39

40
61
71

cbtd 98-01
53.2659.10

Heat exchanger
Control unit
Proportional valve
current connection
Temperatur pick-up cooling water
alternative: positions 19 and 20
joining in the central-plug (see electrical diagram Version 2)
Temperature pick-up oil
Proportional valve
Constant-air pressure line p y
(Connection A)
Supply-air pressure line p v
(Connection P)
Compressed air line
(pressure regulator - four-circuit
protection valve)
Compressed-air pressure line
(four-circuit protection valve air tank for auxiliary equipment
with test connection
Compressed-air line
(brake circuit No. 1)
Compressed-air line
(brake circuit No. 2)
Compressed-air line
(parking brake)
Ventilation line R
Electrical lead (cooling-water
temperature pick-up to control unit,
2 wires)
Electrical lead (oil temperature
pick-up to control unit, 2 wires)
Four-circuit protection valve
Air tank for auxiliary equipment

31

1
35

26

34

40
2

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.4/1

20

39
19

16028

4.4

Diagnosis /
Troubleshooting

Checking Control System


(Continue)

Check requirements

Battery voltage 18 - 32 V
Electrical system checked in accordance with the Owners Manual for the vehicle
and found satisfactory.
Fuse for retarder control unit checked and found satisfactory.
Retarder stage switch in Position 0
Ignition OFF

Special tools

Wasser

53.4788.10

53.8207.10

53.8279.10

53.8198.10

Pressure gauge
0 -25 bar
The adapter lead 53.8279.10 (98/5) has to be used only to connect the temperature simulator
53.8207.10 (99/2), if the temperature sensor for oil and water are using one central plug.
Commercially available tool
Multimeter

cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

recommended: Fluke 87

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.4/2

Diagnosis /
Troubleshooting

4.4

Checking Control System


(Continue)

Checking supply-air pressure pv


1.

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

6 bar

Maximum pressure:

11 bar

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

32
16029

Pressure gauge 53.1403.10

Test set-up job scope


1.

57

98/5

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

99/2

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

16030

99/2 Temperature simulator 53.8207.10

cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.4/3

Diagnosis /
Troubleshooting

2.

4.4

Checking Control System


(Continue)

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

1900

1800

16031

3.

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

99/7

16032

99/7 Pressure gauge 53.1403.10

cbtd 98-01
53.2659.10

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Page 4.4/4

Diagnosis /
Troubleshooting

4.4

Checking Control System


(Continue)

4.

Connect up Propstrom measuring adapter (99/3).

Disconnect plug from proportional valve (21) and connect it up


to Propstrom measuring adapter (99/3).

21

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.

98/8

99/3
16033

99/3 Propstrom measuring adapter 53.8198.10


99/8 Multimeter

cbtd 98-01
53.2659.10

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.4/5

Diagnosis /
Troubleshooting

4.4

Checking Control System


(Continue)

Job scope test

57

98/5

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 p y and the control current must reach the values given in table on the
next page (page 4.4/7).

2.

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

16030

99/2 Temperature simulator 53.8207.10

3.

Set the rotary switch of the temperature simulator (99/2) to 185 C oil temperature.
The constant-air pressure must drop to at approx. 4% below the set maximum pressure. Set the
rotary switch of the temperature simulator (99/2) to 225 oC oil temperature. There must be no more
output of constant-air pressure p y .

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 for
cooling water and oil.

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.4/6

Diagnosis /
Troubleshooting

4.4

Checking Control System


(Continue)

Notice
If the control current is reached but the constant-air pressure is not, either the retarder is leaking or the
proportional valve is defective and must be renewed.
If both values are not reached, please see Section 4.2 Troubleshooting and Remedies.
Setting [Nm]

1)
2)

3)

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Code Number1 )

Control current
[mA] 2 )

Constant-air pressure p y
[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

The Code Number is to be found on the control unit.


If a commercially available multimeter is used for measurements (without real effective measuring)
exact readings cannot be made (indication jumps!).
Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.4/7

Diagnosis /
Troubleshooting

4.5

Operational Check

Requirements for check

Battery voltage 18 - 32 V
Electrical system checked in accordance with the Owners 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):

16016

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 or
Constant Speed operation has been selected with the retarder stage switch.
The retarder pilot light additionally has the function of a fault indicator.
-

slight fault
The 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 fault
The 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.

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.5/1

Diagnosis /
Troubleshooting

4.5

Operational Check
(Continue)

Notice
If the ignition is switched off and on again, the retarder is in operation and the retarder pilot light
is going off.
If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on in
position 0 to 5 of the retarder stage switch.
Retarder pilot light flashes
-

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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!

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.5/2

Diagnosis /
Troubleshooting

4.5

Operational Check
(Continue)

Troubleshooting
Test step
1

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Scope of check
Retarder pilot light

Retarder

Requirement /
Operation
Ignition: ON

Vehicle on move
- Shift retarder stage
switch
to stage 1 to 5.

Result / Set point

Note, Cause / Remedy

Retarder pilot light comes on and


goes off after approx. 5 sec.

Retarder pilot light trouble-free

Retarder pilot light does not come


on, or does not go off.

Troubleshooting as on page 4.1/1

Retarder pilot light comes on,


retarder brakes in stages 1 to 5.

Retarder operates trouble-free.

Retarder pilot light does not come


on, or retarder does not brake
properly.

Troubleshooting as on page 4.1/1

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 4.5/3

Retarder Removing, Installing

Removing, Installing Retarder

5.1

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

5.2

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

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 5/1

Retarder Removing, Installing

5.1

Removing, Installing Retarder


(Free Mount Installation)

Illustration Retarder (Free mount installation)

1300
1300
1400
1400

1200

1200

94

92

95

36

92

25
1100
96

93
97

1000
96

57
1000/6
1200
1000-5
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 cooling water
Retarder stage switch in switch position 0
Ignition OFF
Notice

When stainless-steel heat exchanger is installed, oil can not be drained from the heat exchanger.
25
36
57
92
93
94
95
96
97
1000

Constant-air pressure line p y A


Ventilation line R
Plug temperature pick-up
Prop-shaft
Hex.-head screw
Spring washer
Hex.-head screw
Hose clamp
Hose connection
Heat exchanger

1000/5
1000/6
1100
1200
1200/1
1300
1400
1500

Drain plug cooling water (M 18 x 1,5), 50 Nm


Sealing ring (A 18 x 22), renew
Suspension complete
Megi-pads, check, renew if necessary
Spacer tube
Hex.-head screw (M 16 x 90)
Washer (B 16)
Hex.-head nut (M 16) self-locking, renew, 110 Nm

Note for installation


The universal joints for both prop-shafts must be installed aligned with one another.
Max. permissible offset 5 .
Tightening torques, see manufacturers data.
Renew spring washer.
Caution!
Observe VOITH-Installation instructions. These have to be requested from VOITH TURBO.
Should these installation instructions be disregarded, the retarder may be completely wrecked!

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 5.1/1

Retarder Removing, Installing

5.2

Removing, Installing Retarder


(Gearbox Attachment)

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-Installation 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!

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 5.2/1

Repair Gearbox
Attachment

Repair (Gearbox Attachment)

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 .........................................................6.8/1

6.9

Removing and Installing Centering Cover (input side)


Renewing Radial Shaft Sealing Ring .........................................................6.9/1

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6/1

6.1

Repair Gearbox

Assembly Overview

Attachment
Illustration assembly overview (retarder basic group)

3200
3100

2800
2700

2900

2500
2902
2901
2903

4600
4400
4500

2600
2300/1

3000

2301

4300

101

2300
2300/2

102

2300/3
2400

1900
1800
700

850
800
900

104
103
103
104

1200
1300

1100

1400

1600

1500

1000

1700
16035

101
102
103
104
700
800
850
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2300
2300/1
2300/2
2300/3

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


Sealing ring (A 12 x 15,5)
Silencer-ventilation (30 x 4)
Circlip (JL 30 x 1,2)
Raduial shaft sealing ring (80 x 100 x 10)
Labyrinth cover
O-ring (125 x 2,5)
Hex.-head screw (M 8 x 25)
Cover
O-ring (82 x 4)
Gasket
Bottom cover
Washer (B 8,4)
Cap screw (M 6 x 20)
Sealing ring (A 22 x 29)
Screw plug (M 22 x 1,5)
Sealing ring (A 30 x 36)
Oil filler/check plug (M 30 x 1,5)
Casing ventilation (D 30 x 38)
contents Position 2301
Valve insert
Float
Float cage

2301
2400
2500
2600
2700
2800
2900
2901
2902
2903
3000
3100
3200
4300
4400
4500
4600

O-ring (55 x 3)
Sieve (D 60 x 23)
Cover sheet metal
Spacer (D 50/42 x 15,5)
Washer (B 6,4)
Cap screw (M 6 x 12)
Top cover
with 7 threads for M 6
Valve internal part
Spring
Connector
Gasket
for 7 fixing screws M 6
Washer (B 6,4)
Cap screw (M 6 x 30)
Radial shaft sealing ring (85 x 105 x 13)
Centering cover (D 180 x 70)
O-ring (130 x 4)
Hex.-head screw (M 8 x 20)

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.1/1

Repair Gearbox
Attachment

6.2

Removing, Checking and Installing


Casing Ventilation

Illustration casing ventilation


Preconditions for job

Retarder removed (see Section 5.1).


Retarder stage switch in position 0
Ignition OFF

2800
2700

3200

2500

3100

2600
2300
2300/1
2300/2
2300/3
2301

2400
2500
2600
2700
2800
2900
3000
3100
3200

Casing ventilation
Valve insert
Float checking, renew if necessary
Float cage
O-ring (55 x 3), renew,
coat of silicone-free and noncorrosive grease for installation
Mesh strainer clean with benzine
Cover plate
Spacer
Washer (B 6,4)
Hex.-head screw (M 6 x 12), 10 Nm
Cover
Gasket, renew
Washer (B 6,4)
Cap screw (M 6 x 30), 10 Nm

2900
2300/1
2300

3000

2301
2300/2
2300/3

2400

16036

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.2/1

6.2

Repair Gearbox
Attachment

Removing, Checking and Installing


Casing Ventilation (Continue)

Lubricants and cleaning agents


Mesh strainer

Benzine

O-ring

Silicone-free and
non-corrosive grease

Float

Methylated Spirit

Special tools

53.7712.10

53.9428.10

To remove
1.

Screw out hex.-head screws (3200).

2.

Remove washer (3100).

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Page 6.2/2

Repair Gearbox
Attachment

6.2

Removing, Checking and Installing


Casing Ventilation (Continue)

3.

Remove the cover (2900) from the retarder housing.

4.

Remove gasket (3000) and clean the sealing surface.

5.

Screw out hex.-head screws (2800) and remove Washer (2700).

98/7

6.

Remove cover plate (2500).

2300

7.

Remove spacer (2600).

8.

Use the impact tool (99/5) and adapter (98/9) to extract the casing ventilation (2300).

99/5

16037

98/7 Adapter 53.9428.10


99/5 Impact tool 53.7712.10
9.

Extract the valve insert (2300/1) from float cage (2300/3).

10.

Lever O-ring (2301) out of the groove of the valve insert (2300/1).

11.

Remove the mesh strainer (2400), check and wash with benzine, if necessary.

2300/1
2301

2300/3
16038

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Page 6.2/3

Repair Gearbox
Attachment

6.2

Removing, Checking and Installing


Casing Ventilation (Continue)

To check
1.

Check the float (2300/2) for damage to the surface and to the sealing surfaces (arrow).

2.

Weight the float (2300/2).


Specified weight 11g 1 Gramm. If the weight is more than the specified weight, renew the
complete casing ventilation.
2300/2
Notice

Oil has penetrated into the float, the retarder is impaired in its operation.
16039

3.

Check sealing edge of shaft sealing ring (arrow) in valve insert (2300/1).
Set the valve insert (2300/1) down on the float (2300/2) and fill up the cavity between float (2300/2)
and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not
damaged, the fluid level must not change within 1 minute. If necessary, renew the
complete casing ventilation.

2300/2

2300/1

16040

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Page 6.2/4

Repair Gearbox
Attachment

6.2

Removing, Checking and Installing


Casing Ventilation (Continue)

To install
1.

Install the mesh strainer (2400).

2.

Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on
to the valve insert (2300/1).

3.

Fit the float (2300/2) into float cage (2300/3).

2300/1

2301

Notice
If the float only has one polished surface fit float with this surface on top.

16041

4.

Fit the float cage (2300/3) into the valve insert (2300/1).

5.

Fit the casing ventilation (2300) into the retarder housing.

6.

Use the impact tool (99/5) and adapter (98/9) to knock in carefully the casing ventilation (2300).

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Page 6.2/5

Repair Gearbox
Attachment

6.2

Removing, Checking and Installing


Casing Ventilation (Continue)

7.

Place the spacer (2600) on the casing ventilation (2300)

8.

Position cover plate (2500).

9.

Screw new hex.-head screws (2800) with washer (2700) tight. Tightening torque 10 Nm

10.

Position new gasket (3000) and the cover (2900) at the retarder housing.

Caution!
Make sure the gasket (3000) is properly located.

11.

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Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.2/6

Repair Gearbox
Attachment

6.3

Removing and Installing Non-Return Valve


(Casing Ventilation)

Illustration non-return valve


(casing ventilation)
2901

2902

2903

2902

Valve internal components,


check for damage, renew complete
non-return valve, if necessary
Spring,
check for damage, renew complete
non-return valve, if necessary
Connector,
install with Loctite 270 locking
agent, 100 Nm
check valve seat, renew complete
non-return valve, if necessary

2901

2903

Locking agent
Connector

Loctite 270

16042

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Page 6.3/1

Repair Gearbox
Attachment

6.4

Removing, Checking and Installing Non-Return


Valve (Stainless-Steel Heat Exchanger

Illustration non-return valve


(stainless-steel heat exchanger)
1400
1200
1200/1
1200/2
1200/3

1200/4

1200/5

1300
1400

Non-return valve (stainless-steel


heat exchanger)
Valve cover
Valve housing
O-ring , renew,
coat of silicone-free and noncorrosive grease for installation
Spring, check for fatigue, renew
complete non-return valve (1200),
if necessary
Valve piston, check valve seat in
heat exchanger and vulcanization,
renew complete non-return valve
(1200), if necessary.
Spring washer, renew
Cap screw (M 8 x 20), 25 Nm

1300
1200/1
1200/2
1200/3
1200
1200/4

1200/5

Lubricants
O-ring

Silicone-free and
non-corrosive grease
16043

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Page 6.4/1

6.5

Repair Gearbox
Attachment

Removing, Checking and Installing Silencer

Illustration Silencer
Preconditions for job

Retarder stage switch in position 0


Ignition OFF
Notice

This step can be performed with the retarder


removed or installed.
103

104

Silencer (30 x 4)
clean with Benzine and blow out
with compresse-air
Circlip (JL 30 x 1,2),
concave side must face silencer

104

103

Cleaning agents
Silencer

Benzine
103
104
16044

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Page 6.5/1

Repair Gearbox
Attachment

6.6

Removing and Installing Bottom Cover

Illustration bottom cover


Preconditions for job

Oil drained from retarder (see Section 3.2)


Retarder stage switch in position 0
Ignition OFF
1200
1300
1400
1500

Gasket, renew
Bottom cover
Washer (B 6,4)
Cap screw (M 6 x 20), 10 Nm
1200

1300

1400
1500

16045

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.6/1

Repair Gearbox
Attachment

6.7

Checking, Removing and Installing Closing


Cover of Retarder Housing

Special tool

1000

53.7712.10

99/5

To check
1.

1100 1000

Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.

99/5 Impact tool 53.7712.10

To remove
1.

Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).

To install
1.

cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease
and install together with closing covers (1000).

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.7/1

16046

Repair Gearbox
Attachment

6.8

Removing and Installing Labyrinth Cover (Output


Side), Renewing Radial Shaft Sealing Ring

Illustration labyrinth cover (output side)


Prior jobs

Prop shaft removed from flange


(see vehicle manufacturer instructions)
Prop shaft flange removed
(see VOITH-installation schemes)
Retarder stage switch in position 0
Ignition OFF

700

850
800

Notice

900

This job can be performed with the retarder


removed or installed.
700

800

850

900

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Radial shaft sealing ring


(80 x 100 x 10), renew,
coat with silicone-free and
non-corossive grease
for installation
Labyrinth cover, coat with Hylomar
sealant around leakage oil return
bore
O-ring (125 x 2,5), renew,
coat with silicone-free and
non-corossive grease
for installation
Hex.-head screw (M 8 x 25)
self-locking, renew, 23 Nm

16047

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.8/1

Repair Gearbox
Attachment

6.8

Removing and Installing Labyrinth Cover (Output


Side), Renewing Radial Shaft Sealing Ring (Cont.)

Sealants and locking agents


Housing sealing surfaces
O-ring

Hylomar
Silicone-free and
non-corossive grease

Special tool

53.0742.10

Job scope
1.

Screw out hex.-head screw (900).

2.

Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the
rotor housing.

800

16048

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.8/2

Repair Gearbox
Attachment

6.8

Removing and Installing Labyrinth Cover (Output


Side), Renewing Radial Shaft Sealing Ring (Cont.)

3.

Place the labyrinth cover (800) on a piece of pipe.

4.

Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes
(arrows) out of the labyrinth cover (800).
Notice

Check race of radial shaft sealing ring for scores and uneven surface. If a sealing function is no longer
guaranteed, please contact VOITH TURBO.
5.

800

700

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (700).
16049

6.

Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into
the labyrinth cover (800).
Position for installation: Sealing lip at top.

94/4

700

800

16050

94/4 Press-in equipment 53.0742.10


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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.8/3

Repair Gearbox
Attachment

6.8

Removing and Installing Labyrinth Cover (Output


Side), Renewing Radial Shaft Sealing Ring (Cont.)

7.

Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in
the labyrinth cover.

8.

Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800).
Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow)
are in alignment.

9.

Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm

850
800

16051

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.8/4

Repair Gearbox
Attachment

6.9

Removing and Installing Centering Cover (Input


Side), Renewing Radial Shaft Sealing Ring

Illustration centering cover (input side)


Prior job

Retarder removed (see Section 5)


4300

4400
4500

4600

Radial shaft sealing ring


(85 x 105 x 13), renew,
coat with silicone-free and
non-corossive grease
for installation
Centering cover
O-ring (130 x 4), renew,
coat with silicone-free and
non-corossive grease
for installation
Hex.-head screw (M 8 x 20),
self-locking, renew, 23 Nm

4600

Lubricants
O-ring

Silicone-free and
non-corossive grease

4500

4300

4400
16052

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.9/1

Repair Gearbox
Attachment

6.9

Removing and Installing Centering Cover (Input


Side), Renewing Radial Shaft Sealing Ring (Cont.)

Special tool

53.0742.10

Job scope
1.

Screw out hex.-head screws (4600).

2.

Use two hex.-head screws (M 8 x 30) (arrows) to press centering cover (4400) off
retarder housing.

3.

Remove O-ring (4500) of centering cover (4400).

4.

Use an appropriate punch to knock the radial shaft sealing ring (4300) out of
the centering cover (4400).
Notice

4400

4400

Check race of radial shaft sealing ring for scores and uneven surface. If a sealing function is no longer
guaranteed, please contact VOITH TURBO.

cbtd 98-01
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4500

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.9/2

16053

Repair Gearbox
Attachment

5.

6.9

Removing and Installing Centering Cover (Input


Side), Renewing Radial Shaft Sealing Ring (Cont.)

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (4300).
94/4

6.

Use a press-in equipment (94/4) to press the radial shaft sealing ring (4300) as far as it will go into
the centering cover (4400).
Position for installation: Sealing lip at top.

4300

4400
16054

94/4 Press-in equipment 53.0742.10

7.

Apply thin coat of silicone-free and non-corossive grease to new O-ring (4500) and fit in
the centering cover.

8.

Apply thin coat of Hylomar sealant around leakage-oil return bore in centering cover (4400).
Install so that the leakage-oil return bores in the rotor housing and in the centering cover (arrow)
are in alignment.

9.

4600

4500

Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
4400
16055

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 6.9/3

Repair Free Mount


Installation

Repair (Free Mount Installation)

7.1

Assembly Overview ....................................................................................7.1/1

7.2

Removing, Checking and Installation Casing Ventilation ...........................7.2/1

7.3

Removing, Installing Non-Return Valve (Casing Ventilation) .....................7.3/1

7.4

Removing, Checking and Installing Non-Return Valve


(Stainless-Steel Heat Exchanger) ..............................................................7.4/1

7.5

Removing, Checking and Installing Silencer ..............................................7.5/1

7.6

Removing and Installing Bottom Cover ......................................................7.6/1

7.7

Removing and Installing Prop Shaft Flanges ............................................7.7/1

7.8

Checking, Removing and Installing Closing Cover of Retarder Housing ...7.8/1

7.9

Removing and Installing Labyrinth Cover (output side)


Renewing Radial Shaft Sealing Ring .........................................................7.9/1

7.10

Removing and Installing Labyrinth Cover (input side)


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

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 7/1

Repair Free Mount


Installation

7.1

Assembly Overview

Illustration assembly overview (retarder basic group)


3200

2800
2700

2900

3100
2500
4700

2902
2901
2903

800
3000

850

700

2600
2300/1
2301

2300

101
102

2300/2
2300/3

5400
5500

2400

1900
1800
5500
5400

700

850
800

104
900

103
103
104

1200
1300
1400
1500

1100
1600

1000

1700
16056

101
102
103
104
700
800
850
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2300
2300/1
2300/2
2300/3

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


Sealing ring (A 12 x 15,5)
Silencer-ventilation (30 x 4)
Circlip (JL 30 x 1,2)
Raduial shaft sealing ring (80 x 100 x 10)
Labyrinth cover
O-ring (125 x 2,5)
Hex.-head screw (M 8 x 25)
Cover
O-ring (82 x 4)
Gasket
Bottom cover
Washer (B 8,4)
Cap screw (M 6 x 20)
Sealing ring (A 22 x 29)
Screw plug (M 22 x 1,5)
Sealing ring (A 30 x 36)
Oil filler/check plug (M 30 x 1,5)
Casing ventilation (D 30 x 38)
contents Position 2301
Valve insert
Float
Float cage

2301
2400
2500
2600
2700
2800
2900
2901
2902
2903
3000
3100
3200
4300
4700
5400
5500
5600

O-ring (55 x 3)
Sieve (D 60 x 23)
Cover sheet metal
Spacer (D 50/42 x 15,5)
Washer (B 6,4)
Cap screw (M 6 x 12)
Top cover
with 7 threads for M 6
Valve internal part
Spring
Connector
Gasket
for 7 fixing screws M 6
Washer (B 6,4)
Cap screw (M 6 x 30)
Radial shaft sealing ring
(95 x 115 x 10)
Hex.-head screw (M 8 x 30),
self-locking
Race
O-ring (80 x 3)
O-ring (125 x 2,5)

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Page 7.1/1

Repair Free Mount7.2


Installation

Removing, Checking and Installing


Casing Ventilation

Illustration casing ventilation

2800

3200

2700

Preconditions for job


The job in this section can be performed with
the retarder removed or installed.

Retarder stage switch in position 0

Ignition OFF
2300
2300/1
2300/2
2300/3
2301

2400
2500
2600
2700
2800
2900
3000
3100
3200

Casing ventilation
Valve insert
Float checking, renew if necessary
Float cage
O-ring (55 x 3), renew,
coat of silicone-free and noncorrosive grease for installation
Mesh strainer clean with benzine
Cover plate
Spacer
Washer (B 6,4)
Hex.-head screw (M 6 x 12), 10 Nm
Cover
Gasket, renew
Washer (B 6,4)
Hex.-head screw (M 6 x 30), 10 Nm

3100

2500
2600

2900

2300/1
2300

3000

2301
2300/2
2300/3
2400

16057

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Page 7.2/1

Repair Free Mount 7.2


Installation

Removing, Checking and Installing


Casing Ventilation (Continue)

Lubricants and cleaning agents


Mesh strainer

Benzine

O-ring

Silicone-free and
non-corrosive grease

Float

Methylated Spirit

Special tools

53.7712.10

53.9428.10

To remove
1.

Screw out hex.-head screws (3200).

2.

Remove washer (3100).

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Page 7.2/2

Repair Free Mount 7.2


Installation

Removing, Checking and Installing


Casing Ventilation (Continue)

3.

Remove the cover (2900) from the retarder housing.

4.

Remove gasket (3000) and clean the sealing surface.

5.

Screw out hex.-head screws (2800) and remove Washer (2700).

99/5

99/9
6.

Remove cover plate (2500).

7.

Remove spacer (2600).

8.

Use the impact tool (99/5) and adapter (98/9) to extract the casing ventilation (2300).

16058

99/9 Adapter 53.9428.10


99/5 Impact tool 53.7712.10
9.

Extract the valve insert (2300/1) from float cage (2300/3).

10.

Lever O-ring (2301) out of the groove of the valve insert (2300/1).

11.

Remove the mesh strainer (2400), check and wash with benzine, if necessary.

2300/1
2301

2300/3
16038

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Page 7.2/3

Repair Free Mount 7.2


Installation

Removing, Checking and Installing


Casing Ventilation (Continue)

To check
1.

Check the float (2300/2) for damage to the surface and to the sealing surfaces (arrow).

2.

Weight the float (2300/2).


Specified weight 11g 1 Gramm. If the weight is more than the specified weight, renew the
complete casing ventilation.
2300/2
Notice

Oil has penetrated into the float, the retarder is impaired in its operation.
16039

3.

Check sealing edge of shaft sealing ring (arrow) in valve insert (2300/1).
Set the valve insert (2300/1) down on the float (2300/2) and fill up the cavity between float (2300/2)
and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not
damaged, the fluid level must not change within 1 minute. If necessary, renew the
complete casing ventilation.

2300/2

2300/1

16040

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Page 7.2/4

Repair Free Mount 7.2


Installation

Removing, Checking and Installing


Casing Ventilation (Continue)

To install
1.

Install the mesh strainer (2400).

2.

Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on
to the valve insert (2300/1).

3.

Fit the float (2300/2) into float cage (2300/3).

2300/1

2301

Notice
If the float only has one polished surface fit float with this surface on top.

16041

4.

Fit the float cage (2300/3) into the valve insert (2300/1).

5.

Fit the casing ventilation (2300) into the retarder housing.

6.

Use the impact tool (99/5) and adapter (98/9) to knock in carefully the casing ventilation (2300).

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Page 7.2/5

Repair Free Mount 7.2


Installation

Removing, Checking and Installing


Casing Ventilation (Continue)

7.

Place the spacer (2600) on the casing ventilation (2300)

8.

Position cover plate (2500).

9.

Screw new hex.-head screws (2800) with washer (2700) tight. Tightening torque 10 Nm

10.

Position new gasket (3000) and the cover (2900) at the retarder housing.

Caution!
Make sure the gasket (3000) is properly located.

11.

cbtd 98-01
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53.2659.10
53.2640.10

Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 7.2/6

Repair Free Mount7.3


Installation

Removing and Installing Non-Return Valve


(Casing Ventilation)

Illustration non-return valve


(casing ventilation)
2901

2902

2903

2902

Valve internal components,


check for damage, renew complete
non-return valve if necessary
Spring,
check for damage, renew complete
non-return valve if necessary
Connector,
install with Loctite 270 locking
agent, 100 Nm
check valve seat, renew complete
non-return valve if necessary

2901

2903

Locking agent
Connector

Loctite 270

16059

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Page 7.3/1

Repair Free Mount7.4


Installation

Removing, Checking and Installing Non-Return


Valve (Stainless-Steel Heat Exchanger

Illustration non-return valve


(stainless-steel heat exchanger)
1400
1200
1200/1
1200/2
1200/3

1200/4

1200/5

1300
1400

Non-return valve
(stainless-steel heat exchanger)
Valve cover
Valve housing
O-ring , renew,
coat of silicone-free and noncorrosive grease for installation
Spring, check for fatigue, renew
complete non-return valve (1200),
if necessary
Valve piston, check valve seat in
heat exchanger and vulcanization,
renew complete non-return valve
(1200), if necessary.
Spring washer, renew
Cap screw (M 8 x 20), 25 Nm

1300
1200/1
1200/2
1200/3
1200
1200/4

1200/5

Lubricants
O-ring

Silicone-free and
non-corrosive grease
16043

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Page 7.4/1

Repair Free Mount 7.5

Removing, Checking and Installing Silencer

Installation
Illustration Silencer
Preconditions for job

Retarder stage switch in position 0


Ignition OFF
Notice

This step can be performed with the retarder


removed or installed.
103

104

Silencer (30 x 4)
clean with Benzine and blow out
with compressed-air
Circlip (JL 30 x 1,2),
concave side must face silencer

104

103

Cleaning agents
Silencer

Benzine
103
104
16044

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Page 7.5/1

Repair Free Mount 7.6

Removing and Installing Bottom Cover

Installation
Illustration bottom cover
Preconditions for job

Oil drained from retarder (see Section 3.2)


Retarder stage switch in position 0
Ignition OFF
1200
1300
1400
1500

Gasket, renew
Bottom cover
Washer (B 6,4)
Cap screw (M 6 x 20), 10 Nm
1200

1300

1400
1500

16045

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Page 7.6/1

Repair Free Mount 7.7

Removing and Installing Prop Shafts Flanges

Installation
Illustration prop shafts flanges
Prior jobs

Prop shafts flanges removed


(see vehicle manufacturer instructions)
Notice

93/1

97/6

97/8

The jobs in this section can be performed with


the retarder removed or installed.
93/1
95/2
97/6
97/7
97/8
97/9
98

98

97/9

Hex.-head screw (M 20 x 180)


Hex.-head nut (M 20), 375 Nm
Prop shaft flange
(output side)
Prop shaft screw, renew
Guard ring (output side)
Guard ring (input side)
Prop shaft flange
(input side)

95/2

97/7

16060

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Page 7.7/1

Repair Free Mount 7.7


Installation

Removing and Installing Prop Shafts Flanges


(Continue)

Removing and installing


1.

Screw out hex.-head screw (95/2).


Note for installation
Screw hex.-head nut (95/2) tight. Tightening torque 375 Nm

2.

Pull out hex.-head screw (93/1) on output side.

3.

Pull both prop shaft flanges (97/6, 98) out of the retarder housing.

4.

Remove guard rings (97/8, 97/9).

97/7

97/8
97/9

Note for installation


Renew prop shaft screws (97/7).
Align hole patterns of both prop shaft flanges prior to installation.
Maximum permissible offset 5.
5.

Install the prop shafts in accordance to the vehicle manufacturer instructions.


16061

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 7.7/2

Repair Free Mount 7.8


Installation

Checking, Removing and Installing Closing


Cover of Retarder Housing

Special tool

99/5 1000 1100

53.7712.10

1000

To check
1.

16062

Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.

To remove
1.

Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).

To install
1.

cbtd 98-01
cbtd 98-01
53.2659.10
53.2640.10

Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease
and install together with closing covers (1000).

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 7.8/1

Repair Free Mount 7.9


Installation

Removing and Installing Labyrinth Cover (Output


Side), Renewing Radial Shaft Sealing Ring

Illustration labyrinth cover


Prior jobs

Prop shaft removed from flange


(see vehicle manufacturer instructions)
Prop shaft flange removed
(see VOITH-installation schemes)
Retarder stage switch in position 0
Ignition OFF

5500

5400

700

850
800
900

Notice
This job can be performed with the retarder
removed or installed.
700

800

850

900
5400
5500

cbtd 98-01
53.2659.10

Radial shaft sealing ring


(80 x 100 x 10), renew, coat with
silicone-free and non-corossive
grease for installation
Labyrinth cover, coat with Hylomar
sealant around leakage oil return
bore
O-ring (125 x 2,5), renew, coat with
silicone-free and non-corossive
grease for installation
Hex.-head screw (M 8 x 25)
self-locking, renew, 23 Nm
Race
O-ring (80 x 3), renew, coat with
silicone-free and non-corossive
grease for installation

16063

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 7.9/1

Repair Free Mount 7.9


Installation

Removing and Installing Labyrinth Cover (Output


Side), Renewing Radial Shaft Sealing Ring (Cont.)

Sealants and locking agents


Housing sealing surfaces
O-ring

900

Hylomar
Silicone-free and
non-corossive grease

Special tool

16064

53.0742.10

Job scope
1.

Screw out hex.-head screw (900).

2.

Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the
rotor housing.

800

16065

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 7.9/2

Repair Free Mount 7.9


Installation

Removing and Installing Labyrinth Cover (Output


Side), Renewing Radial Shaft Sealing Ring (Cont.)

3.

Place the labyrinth cover (800) on a piece of pipe.

4.

Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes
(arrows) out of the labyrinth cover (800).

5.

Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft.

6.

Remove O-ring (5500) of hollow shaft.

7.

Check race for scores and radial shaft sealing ring for uneven surface and renew
race if necessary.
Notice

800

700

16049

If a sealing function is no longer guaranteed, please contact VOITH TURBO.


Recommendation:
Always change radial shaft sealing ring and race together.
8.

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500)
and pull-on to the hollow shaft.

9.

Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it
will go.

10.

Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).

5400

16066

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Page 7.9/3

Repair Free Mount 7.9


Installation
11.

Removing and Installing Labyrinth Cover (Output


Side), Renewing Radial Shaft Sealing Ring (Cont.)

Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into
the labyrinth cover (800).
Position for installation: Sealing lip at top.

94/4

700

800

94/4 Press-in equipment 53.0742.10


12.

Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in
the labyrinth cover.

13.

Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800).
Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow)
are in alignment.

14.

Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm

850
800

16051

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 7.9/4

Repair Free Mount 7.10


Installation

Removing and Installing Labyrinth Cover (Input


Side), Renewing Radial Shaft Sealing Ring

Illustration labyrinth cover


Prior jobs

Prop shaft removed from flange


(see vehicle manufacturer instructions)
Prop shaft flange removed
(see Section 7.7)
5500
Notice

5400

700

850
800

This job can be performed with the retarder


removed or installed.
700

800

850

4700
5400
5500

cbtd 98-01
53.2659.10

Radial shaft sealing ring


(95 x 115 x 10), renew, coat with
silicone-free and non-corossive
grease for installation
Labyrinth cover, coat with Hylomar
sealant around leakage oil return
bore
O-ring (125 x 2,5), renew, coat with
silicone-free and non-corossive
grease for installation
Hex.-head screw (M 8 x 30)
self-locking, renew, 25 Nm
Race
O-ring (80 x 3), renew, coat with silicone-free and non-corossive grease for installation

4700

16067

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Page 7.10/1

Repair Free Mount 7.10


Installation

Removing and Installing Labyrinth Cover (Input


Side), Renewing Radial Shaft Sealing Ring (Cont.)

Sealants and locking agents


Housing sealing surfaces

Hylomar

O-ring

Silicone-free and
non-corossive grease

Special tool

53.0742.10

Job scope
1.

Screw out hex.-head screws (4700).

2.

Use two hex.-head screws (M 8 x 40) (arrows) to press labyrinth cover (4400) off
retarder housing.

3.

Place the labyrinth cover (800) on a piece of pipe.

800

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Page 7.10/2

16068

Repair Free Mount 7.10


Installation

Removing and Installing Labyrinth Cover (Input


Side), Renewing Radial Shaft Sealing Ring (Cont.)

4.

Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes
(arrows) out of the labyrinth cover (800).

5.

Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft.

6.

Remove O-ring (5500) of hollow shaft.

7.

Check race for scores and radial shaft sealing ring for uneven surface and renew
race if necessary.
800

700

Notice
If a sealing function is no longer guaranteed, please contact VOITH TURBO.

16049

Recommendation:
Always change radial shaft sealing ring and race together.
8.

Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500)
and pull-on to the hollow shaft.

9.

Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it
will go.

10.

Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).

16069

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Page 7.10/3

Repair Free Mount 7.10


Installation
11.

Removing and Installing Labyrinth Cover (Input


Side), Renewing Radial Shaft Sealing Ring (Cont.)

Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into
the labyrinth cover (800).
Position for installation: Sealing lip at top.

94/4

700

800

16050

94/4 Press-in equipment 53.0742.10


12.

Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in
the labyrinth cover.

13.

Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800).
Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow)
are in alignment.

14.

Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm

850
800

16051

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Page 7.10/4

Repair
Heat Exchanger

Removing, Checking and Installing


Heat Exchanger

8.1

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

8.2

Removing, Checking and Installing Aluminium Heat Exchanger ...............8.2/1

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Page 8/1

8.1

Repair
Heat Exchanger

Removing, Checking and Installing


Stainless-steel Heat Exchanger

Illustration stainless-steel heat exchanger

1000/6
1000/5

9500
3000
2000

1000/2

8000

1000/1

15000
9000

17000

1800

4000

7000
1700
4000

16000

4000

17000

5000

13000
14000

97

5000
96
1000

17000
16000
12000

14000
16070

Prior jobs

Retarder removed (Section 5.1)


This job sequence can also be performed with the retarder installed, if necesary.

Retarder stage switch on stage position 0

Ignition OFF
96
97
1000
1000/1
1000/2
1000/5
1000/6
1600
1700
2000
3000
4000

Hose clamp
Cooling water hose
Heat exchanger
Leaking oil drain plug (M 14 x 1,5), 32 Nm
Sealing ring (A 14 x 18), renew
Cooling water drain plug (M 18 x 1,5), 50 Nm
Sealing ring (A 18 x 22), renew
Sealing ring (A 22 x 29), renew
Retarder oil drain plug (M 22 x 1,5), 66 Nm
Throttle disc (outlet throttle)
O-ring (36 x 4), renew, coat with silicone-free and
non-corrosive grease
Washer (B 8,4)

5000
7000
8000
9000
9500
12000
13000
14000
15000
16000
17000

Hex.-head nut M 8, self-locking, renew, 23 Nm


Hex.-head screw (M 8 x 35), 23 Nm
Pin screw (M 10 x 50)
O-ring (45 x 4) renew, coat with silicone-free and
non-corrosive grease
O-ring (8 x 2) renew, coat with silicone-free and non-corrosive
grease
Connecting piece
Connecting piece
Sealing ring, renew
Hex.-head screw (M 10 x 65), 46 Nm
Hex.-head screw (M 10 x 35), 46 Nm
Washer (B 10,6)

Data
Pressure test (oil section) max.10 bar

Lubricants
O-ring

cbtd 98-01
53.2659.10

Silicone-free and
non-corrosive grease

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 8.1/1

Repair

8.1

Heat Exchanger

Removing, Checking and Installing


Stainless-steel Heat Exchanger (Continue)

Notice
If this job sequence will be performed with the retarder installed, the following prior jobs must be
performed prior to removal of the heat exchanger.
Caution! Risk of injury!
The coolant drain plug is heated up!
1.

Screw out coolant drain plug (1000/5) with sealing ring (1000/6) and drain the cooling water from
the heat exchanger. Remove the cooling water hoses (97) from the retarder.

2.

Push an oil collecting pan under retarder.


Caution! Risk of injury!

The oil drain plugs are heated up (oil temperature)!


3.

Screw out the oil drain plugs (1700, 1000/1) and remove the sealing rings (1600, 1000/2).
Drain the oil.

4.

Screw the coolant drain plug (1000/5) with new sealing ring (1000/6) and the oil drain plugs (1700,
1000/1) with new sealing rings (1600, 1000/2) tight.

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Page 8.1/2

Repair

8.1

Heat Exchanger

Removing, Checking and Installing


Stainless-steel Heat Exchanger (Continue)

To remove
1.

Screw out the four hex.-head nuts (5000) and remove the washers (4000).

2.

Screw out the two hex.-head screws (7000) remove the washers (4000)
and heat exchanger (1000).

3.

Remove the three O-rings (9000, 3000, 9500) and throttle disc (2000) from retarder housing.
Notice

Do not remove insert (93/8) with the throttle disc.


4.

Check closing cover (1000) for leaks, renew O-ring (1100), if necessary (see Section 6.7 and 7.8
Checking, removing and installing closing cover).

Caution!
Do not pressurize heat exchanger with pressure-test plate 53.4786.10.
An appropriate variant on the stainless-steel heat exchanger is in preperation.
Please, contact VOITH TURBO.

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 8.1/3

Repair
Heat Exchanger

8.1

Removing, Checking and Installing


Stainless-steel Heat Exchanger (Continue)

To install

Notice
New heat exchangers are wetted with preserving oil in the cooling water section and in the oil section.
Prior to installation of a new heat exchanger, drain any preserving oil which has collected and flush out
the cooling water section with hot water.
1.

Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (9000, 3000, 9500).
Fit them in the feed bores of the retarder housing.

2.

Apply thin coat of silicone-free and non-corrosive grease to the throttle disc (2000) and fit it in the
right bore.

3.

Install the heat exchanger (1000) to the retarder housing and use new
self-locking hex.-head nuts (5000) and washers (4000), hex.-head screws (7000) and
washers (4000) to screw it tight on the retarder housing. Tightening torque 23 Nm

4.

Install retarder, if necessary (see Section 5.1).

5.

Fill in cooling water and bleed coolant circuit according to the vehicle instructor manual.
Notice

Heed the statements of the vehicle-manufacturer respecting the cooling water-quality,


as well as the VOITH cooling water-list in the appendix.

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Page 8.1/4

Repair

8.1

Heat Exchanger
6.

Removing, Checking and Installing


Stainless-steel Heat Exchanger (Continue)

If the heat exchanger (1000) had been leaking in the oil section, splush the retarder:
While flushing, brake lightly several times to avoid the retarder oil overheating.
Caution! Risk of injury!

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


Fill retarder with 4,5 litres engine oil or flushing oil. Flush the retarder system by braking several
times and drain the oil through the oil drain plug (1700). Repeat the procedure two or three times
until no more oil is visible in the water.
Screw oil drain plug (1700) tight with new sealing ring.
Tightening torque 66 Nm
7.

Fill in retarder oil in accordance with the operating specifications (see Section 3.2 Oil change
and annex).
Notice

If retarder oil has entered the cooling-water system, the vehicle-cooling system must be cleaned
in accordance with the instructions of the vehicle manufacturer.
8.

cbtd 98-01
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If heat exchanger (1000) had been leaking, deoil vehicle cooling and heating system in
accordance with vehicle manufacturers data.

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 8.1/5

1700

16071

8.2

Repair
Heat Exchanger

Removing, Checking and Installing


Aluminium Heat Exchanger

Illustration aluminium heat exchanger

1000/4
9500

1000/3
1000/6

3000

1000/2

1000/5

2000
8000

1000/1
20

4000

93/9

4000

9000
7000
4000

1600
5000

1700

5000
1000
97
96

16072

Prior jobs

Retarder removed (Section 5.1)


This job sequence van also be performed with the retarder installed, if necessary.

Retarder stage switch in stage position 0

Ignition OFF

20
96
97
93/9
1000
1000/1
1000/2
1000/3
1000/4
1000/5
1000/6
1600

Oil temperature pick-up (M 14 x 1,5), 32 Nm


Hose clamp
Cooling water hose
Sealing ring (A 14 x 20), renew
Heat exchanger
Leaking oil drain plug (M 14 x 1,5), 32 Nm
Sealing ring (A14 x 18), renew
Oil drain plug heat exchanger (M 12 x 1,5), 25 Nm
Sealing ring (A 12 x 15,5), renew
Cooling water drain plug (M 18 x 1,5), 50 Nm
Sealing ring (A12 x 15,5), renew
Sealing ring (A 22 x 29), renew

1700
2000
3000
4000
5000
7000
8000
9000
9500

Heat exchanger oil drain plug (M 22 x 1,5), 66 Nm


Throttle disc (outlet throttle)
O-ring (36 x 4), renew, coat with silicone-free and non-corrosive
grease
Washer (B 8,4)
Hex.-head nut M 8, self-locking, renew, 23 Nm
Hex.-head screw (M 8 x 35), 23 Nm
Pin screw (M 10 x 50)
O-ring (45 x 4), renew, coat with silicone-free and non-corrosive
grease
O-ring (8 x 2), renew, coat with silicone-free and non-corrosive
grease

Data
Pressure test (oil section) max.10 bar
Special tool
Lubricants
O-ring

Silicone-free and
non-corrosive grease

53.4786.10

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Page 8.2/1

Repair

8.2

Heat Exchanger

Removing, Checking and Installing


Aluminium Heat Exchanger (Continue)

Notice
If this job sequence will be performed with the retarder installed, the following prior jobs must be
performed prior to removal of the heat exchanger.
Caution! Risk of injury!
The coolant drain plug is heated up!

1.

Screw out coolant drain plug (1000/5) with sealing ring (1000/6) and drain the cooling water from
the heat exchanger. Remove the cooling water hoses (97) from the retarder.

2.

Push an oil collecting pan under retarder.


Caution! Risk of injury!

The oil drain plugs are heated up (oil temperature)!


3.

Screw out the oil drain plugs (1700, 1000/1, 1000/3) and remove the sealing rings (1600, 1000/2,
1000/4).
Drain the oil.

4.

Screw the coolant drain plug (1000/5) with new sealing ring (1000/6) and the oil drain plugs (1700,
1000/1, 1000/3) with new sealing rings (1600, 1000/2, 1000/4) tight.

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Page 8.2/2

Repair

8.2

Heat Exchanger

Removing, Checking and Installing


Aluminium Heat Exchanger (Continue)

To remove
1.

Screw out the four hex.-head nuts (5000) and remove the washers (4000).

2.

Screw out the two hex.-head screws (7000) remove the washers (4000)
and heat exchanger (1000).

3.

Remove the three O-rings (9000, 3000, 9500) and throttle disc (2000) from retarder housing.
Notice

Do not remove insert (93/8) with the throttle disc.


4.

Check closing cover (1000) for leaks, renew O-ring (1100), if necessary (see Section 6.7 and 7.8
Checking, removing and installing closing cover).

To check
1.

Fit pressure-test plate (99/6) on heat exchanger (1000) and connect compressed-air line and
pressure minimizer.

2.

Fill the heat exchanger (1000) in water section with hot water (approx. 70C).

3.

Pressurize the heat exchanger (1000) slowly from 0 to max. 10 bar overpressure (oil section).

99/6

Notice
If air bubbles form in the hot water, the heat exchanger is leaking and must be renewed.

1000
16073

99/6 Pressure-test plate 53.4786.10


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Page 8.2/3

Repair

8.2

Heat Exchanger
4.

Removing, Checking and Installing


Aluminium Heat Exchanger (Continue)

Remove the pressure-test plate (99/6).

To install

Notice
New heat exchangers are wetted with preserving oil in the cooling water section and in the oil section.
Prior to installation of a new heat exchanger, drain any preserving oil which has collected and flush out
the cooling water section with hot water.

1.

Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (9000, 3000, 9500).
Fit them in the feed bores of the retarder housing.

2.

Apply thin coat of silicone-free and non-corrosive grease to the throttle disc (2000) and fit it in the
right bore.

3.

Install the heat exchanger (1000) to the retarder housing and use new
self-locking hex.-head nuts (5000) and washers (4000), hex.-head screws (7000) and
washers (4000) to screw it tight on the retarder housing. Tightening torque 23 Nm

4.

Install retarder, if necessary (see Section 5.1).

5.

Fill in cooling water and bleed coolant circuit according to the vehicle instructor manual.
Notice

Heed the statements of the vehicle-manufacturer respecting the cooling water-quality,


as well as the VOITH cooling water-list in the appendix.

cbtd 98-01
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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 8.2/4

Repair

8.2

Heat Exchanger
6.

Removing, Checking and Installing


Aluminium Heat Exchanger (Continue)

If the heat exchanger (1000) had been leaking in the oil section, splush the retarder:
While flushing, brake lightly several times to avoid the retarder oil overheating.
Caution! Risk of injury!

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


Fill retarder with 5,5 litres engine oil or flushing oil. Flush the retarder system by braking several
times and drain the oil through the oil drain plugs (1700, 1000/3). Repeat the procedure two or
three times until no more oil is visible in the water.
Screw oil drain plug (1700, 1000/3) tight with new sealing rings.
Oil drain plug retarder (1700)
66 Nm
Oil drain plug heat exchanger (1000/3)
25 Nm
7.

Screw out oil drain plug leakage oil (1000/1) and drain any leaking oil and water which has
collected.

8.

Fill in retarder oil in accordance with the operating specifications (see Section 3.2 Oil change
and annex).

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Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 8.2/5

Control Parts

9.1

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53.2659.10

Control Parts

Proportional valve.................................................................. in preparation


Cooling Water Temperature Pick-up ..................................................................9.1/1
Oil Temperature Pick-up ..................................................................................9.1/2

Aftersales Service Manual VOITH Retarder 120 Digiprop


Page 9/1

Control Parts

9.1

Control Parts

Removing and installing cooling water


temperature pick-up

Caution! Risk of injury!


The temperature pick-up is heated up
(cooling water temperature)!
Job scope
1.

2.

3.

Disconnect cooloing water temperature


pick-up (19). Tightening torque 28 Nm
The electrical lead of the temperature
pick-up is pured alternatively.
Screw out temperature pick-up (19) and
lock the opening immediately with one
stuffing.

38
19

Mount the temperature pick-up (19) in


reverse sequence.

16074

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Page 9.1/1

Control Parts

9.1

Control Parts
(Continue)

Removing and installing oil temperature pick-up

Caution! Risk of injury!


The oil control plug is heated up (oil temperature)!
Job scope
1.

Disconnect oil temperature pick-up (20). Tightening torque 28 Nm


The electrical lead of the temperature pick-up is pured alternatively.

2.

Screw out temperature pick-up (20) and lock the opening immediately with one stuffing.

3.

Mount the temperature pick-up (20) in reverse sequence.

cbtd 98-01
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Page 9.1/2

Annex

10

Annex

Data Sheet
Miscellaneous Conversions
Operating Specifications
Spare Parts Lists
Other Information

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Aftersales Service Manual VOITH Retarder R 120 Digiprop


Page 10/1

Data Sheet VOITH Retarder 120 Digiprop


Max. braking torque at prop shaft M (Br) ma x

2000 Nm *

Max. retarder speed (= max. prop shaft speed v(m ax. )

4870 r.p.m. at vps = 2400 r.p.m.

with stainless-steel heat exchanger

v(m ax. ) = 3000 r.p.m.

with aluminium heat exchanger

v(m ax. ) = 2800 r.p.m.

Working medium

Oil grade given in Operating Specification

Service filling:

With AKG heat exchanger

service filling (Oil change, checking oil level)

5,5 Litre

4,5 Litre

after complete taking apart and cleaning

5,8 Litre **

new filling

6,0 Litre

6,5 Litre

Overall weight (with flange and heat exchanger, without oil filling)

Overall weight will depend on the retarder version.

**

Emptied heat exchanger

cbtd 98-01
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With heat exchanger L+R

approx. 70 kg *

Service-Handbuch VOITH Retarder R 120 Digiprop


Seite 10/2

Miscellaneous Conversions Retarder 120 with Digiprop Control

cbtd 98-01
53.2659.10

GB

USA

GB

USA

10 oC

50 oF

50 o F

110 Nm

81 lbf-ft

81 lbf-ft

20 o C

68 oF

68 o F

150 Nm

111 lbf-ft

111 lbf-ft

60 o C

140 o F

140 oF

375 Nm

277 lbf-ft

277 lbf-ft

70 o C

158 o F

158 oF

1000 Nm

740 lbf-ft

740 lbf-ft

80 o C

176 o F

176 o F

1250 Nm

925 lbf-ft

925 lbf-ft

95 o C

203 oF

203 oF

1500 Nm

1110 lbf-ft

1110 lbf-ft

105 oC

221 o F

221 oF

1750 Nm

1295 lbf-ft

1295 lbf-ft

125 oC

257 oF

257 oF

2000 Nm

1480 lbf-ft

1480 lbf-ft

185 oC

365 oF

365 oF

1,15 - 1,45 bar

16,7 - 21,0 psi

16,7 - 21,0 psi

225 oC

437 oF

437 oF

1,45 - 1,75 bar

21,0 - 25,4 psi

21,0 - 25,4 psi

10 Nm

7 lbf-ft

7 lbf-ft

1,75 - 2,05 bar

25,4 - 29,7 psi

25,4 - 29,7 psi

13 Nm

10 lbf-ft

10 lbf-ft

2,05 - 2,35 bar

29,7 - 34,1 psi

29,7 - 34,1 psi

23 Nm

17 lbf-ft

17 lbf-ft

2,35 - 2,65 bar

34,1 - 38,4 psi

34,1 - 38,4 psi

25 Nm

18 lbf-ft

18 lbf-ft

7 bar

101,5 psi

101,5 psi

32 Nm

24 lbf-ft

24 lbf-ft

9 bar

130,5 psi

130,5 psi

50 Nm

37 lbf-ft

37 lbf-ft

12 bar

174 psi

174 psi

66 Nm

49 lbf-ft

49 lbf-ft

14 bar

203 psi

203 psi

100 Nm

74 lbf-ft

74 lbf-ft

16 bar

232 psi

232 psi

Service-Handbuch VOITH Retarder R 120 Digiprop


Seite 10/3

Miscellaneous Conversions Retarder 120 with Digiprop Control (Continue)

cbtd 98-01
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GB

USA

0 - 25 bar

0 - 362,5 psi

0 - 362,5 psi

0 - 10 bar

145 psi

145 psi

0,2 l

0,044 UK gal

0,053 US gal

0,5 l

0,110 UK gal

0,132 US gal

4,5 l

0,99 UK gal

1,188 US gal

5,5 l

1,210 UK gal

1,452 US gal

5,8 l

1,276 UK gal

1,531 US gal

6,0 l

1,320 UK gal

1,584 US gal

6,5 l

1,430 UK gal

1,716 US gal

1000 km

621,4 miles

621,4 miles

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Seite 10/4