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Aftersales Service Manual Voith Retarder 115 E

15300009710 / cbtsd 02-11


Aftersales Service Manual
Voith Retarder 115 E
Table of Content
Table of Content
Page 2
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
1. Preface.................................................................................. 4
2. General ................................................................................. 9
2.1 Assembly Overview ....................................................................................10
2.2 Retarder Data Plate ....................................................................................12
2.3 Data Plate of Retarder-Control Unit ............................................................13
2.4 Function- and Operation Scheme...............................................................15
3. Maintenance ....................................................................... 19
3.1 Maintenance Work / Oil Change Intervals ..................................................20
3.2 Inspection of Oil Level.................................................................................23
3.3 Oil Change..................................................................................................26
4. Diagnosis / Troubleshooting ............................................... 32
4.1 Electrical Connections Diagram..................................................................33
4.2 Overview of Control Parts...........................................................................37
4.3 Troubleshooting Diagram............................................................................38
4.4 Troubleshooting and Remedies..................................................................41
4.5 Checking Supply-Air Pressure (p
v
) .............................................................77
4.6 Checking Constant-Air Pressure (p
y
) and Pump Pressure (p
dyn
) ...............78
4.7 Checking Control Current of Proportional Valve.........................................86
4.8 Checking Pressure Sensor .........................................................................88
4.9 Checking Temperature Adaption ................................................................90
4.10 Table of Measurements ..............................................................................93
Table of Content
Table of Content
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
5. Removing, Installing Retarder............................................. 99
6. Repair Retarder ................................................................ 110
6.1 Overall Illustration of Main Components ...................................................111
6.2 Removing, Checking and Installing Casing Ventlation .............................112
6.3 Removing, Cleaning and Installing Silencer .............................................122
6.4 Removing and Installing Water Neck........................................................123
6.5 Removing, Checking, Installing Heat Exchanger......................................124
6.6 Removing, Installing Oil Tank Cover.........................................................133
6.7 Removing, Installing Non-Return Valve Outlet .........................................136
7. Control Parts..................................................................... 139
7.1 Removing, Installing Proportional Valve and Damping Plate....................140
7.2 Removing, Installing Temperature Sensor Cooling Water........................141
7.3 Removing, Installing Temperature Sensor Oil ..........................................142
7.4 Removing, Installing Pressure Sensor......................................................143
8. Appendix........................................................................... 144
8.1 Retarder Data Sheet .................................................................................145
8.2 Tightening Torques...................................................................................146
Preface
Preface
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 03-01
1. Preface
This Aftersales Service Manual provides information and instructions on maintenance and repair
of the Voith Retarder 115 E. These instructions present the basis for performing appropriate and
expert maintenance and repair.
It is indispensable that you observe the safety instructions and warning notes in this manual.
Nevertheless, the user is obliged to exercise pertinent and professional care when handling
machines, aggregates and hot media such as for example oil or water.

Attention!
... points out safety instructions and warning notes where persons are endangered, quality of work-
manship is reduced or property damage may occur.
Notice
... points out information on improved handling of work at the retarder.
Preface
Preface
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 03-01
Attention!
Maintenance and repair work may only be carried out by accordingly qualified personnel.
Make sure that the retarder is fully functional during all vehicle manoeuvres!
Non-observance may inflict damages to the retarder!
When towing the vehicle, the following restrictions apply for the retarder:
- tow distance: up to 100 km
- towing speed: max 40 km/h.
The activated retarded may not be used as parking brake!
During failure of the retarder, or while temperature adaptation is active, use the service brake to
slow down the vehicle and switch into the lowest possible gear (target: high engine speed). This
vehicle state must be maintained until the retarder resumes full operation.
Unauthorized changes to the retarder, the use of spare parts, accessories, attachments and spe-
cial features not tested and released by Voith may negatively affect the security of the entire ve-
hicle. Voith does not assume any liability for damages arising as a result.
Preface
Preface
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 03-01
Attention!
The retarder is constructed according to the state of the art in technology and acknowledged
safety regulations. Nevertheless, hazardous situations and property damages may occur during
improper use, maintenance and repair.
Therefore, Voith is not capable of warning the user in this Aftersales Service Manual about any
situation conceivable in which he may suffer injuries and/or cause damage to the retarder. As a
consequence, it is indispensable that any person engaged in operation, servicing, maintenance
and repair of the retarder does not endanger his or her personal safety with the work and that
the retarder is not affected adversely, particularly with regard to the safety regulations.
Voith assumes no liability for personal and/or property damage caused by improper and
unprofessional work.
Absolute cleanliness is essential during all stages of the work process. The presence of dirt due
to improper handling may cause considerable material damages or malfunctions.
Be careful when handling hot media! Risk of burning and scalding!
Preface
Preface
Seite 7
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 03-01
Notice
The item numbers used in this documentation are the same as the item numbers in the spare
parts lists.
Exception:
Items and components with one- or two-digit item numbers are no spare parts and therefore are
not included in the spare parts lists.
Also items and components with dash numbers are no spare parts and therefore not included in
the spare parts lists.
The relevant regulations for prevention of accidents, other generally acknowledged safety
regulations and occupational health rules as well as the Motor Vehicle Regulations must be
observed. Voith assumes no liability for damages resulting from non-observance of these
regulations.
When handling oil, grease and other chemical substances, the pertinent safety regulations for
these products must be heeded!
For the sake of environmental protection, drained fuels and fluids must be disposed of according
to the relevant statutory regulations.
Information on the safe, technically correct and economical operation of the Voith Retarder 115
E are given in the operating instructions.
The valves and the pressure sensor of the retarder must be protected from the direct jet of a high-
pressure cleaner (steam-jet device).
When troubleshooting, do not replace parts on mere speculation. Warranty or goodwill service
will only be rendered if there is proof that the parts in question are really defective.
Preface
Preface
Seite 8
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 03-01
If you have any questions or if you are uncertain about work steps, which are not described in this
documentation, please ask your contact person responsible for your country or contact:

Voith Turbo GmbH & Co. KG
Department Retarder
PO box 1555
D-74555 Crailsheim

Phone: ++49 +7951 / 32-0
Fax: ++49 +7951 / 32-756
E-mail: service-retarder@voith.com

Direct dials:
Customer service line and spare parts:
32-401
32-422
32-1860
General
General
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
2. General
2.1 Assembly Overview ....................................................................................10
2.2 Retarder Data Plate ....................................................................................12
2.3 Data Plate of Retarder-Control Unit ............................................................13
2.4 Function- and Operation Scheme...............................................................15
General Assembly Overview
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
General Assembly Overview

Illustration: Voith Retarder R115 E
2.1 Assembly Overview
Basic Group with Heat Exchanger
4100
100
6400
3700
11001
100 Retarder housing
3700 Proportional valve
4100 Oil filler plug
M 30 x 1,5
6400 Heat exchanger
General Assembly Overview
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
General Assembly Overview
Basic Group with Heat Exchanger

Illustration: Voith Retarder 115 E

11002
103
107
4200
3700
6400
3500
5500/1
103 Screw plug
M 12 x 1,5
107 Oil drain plug
M 24 x 1,5
3500 Screw plug with sieve
M 30 x 1,5
3700 Proportional valve
4200 Oil drain plug
M 24 x 1,5
5500/1 Ventilation
6400 Heat exchanger
General Retarder Data Plate
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
General Retarder Data Plate

Illustration: Retarder Data Plate
2.2 Retarder Data Plate
The data plate is mounted on the left below of
the retarder housing in right direction of tra-
velling.
The following details are on the data plate:

a
d
e f
b
Voith-item-No
c
Type R 115 E
11003e
Serial No
Year of Man.
Cust. item No
Kd.-Sach-Nr.
Voith-Sach-Nr.
a) Type of Retarder
b) Serial number
6-digit number
c) Year of manufacturing
d) Retarder ratio (i
Ret
)
e) Customer-item number
f) Voith-item number
8-digit number
Notice
Please, always quote the retarder data when
submitting queries or ordering spare parts.
In this case a quick and working is possible.
General Data Plate of Retarder-Control
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
General Data Plate of Retarder-Control


Illustration: Data Plate of Retarder Control Unit Digiprop
2.3 Data Plate of Retarder-Control
Unit Digiprop
The data plate of the Digiprop-control unit
is mounted on the control unit and
contains following information:
B
a
s
is
-N
r.:
5
3
.x
x
x
x
.1
2
C
o
d
e
-N
r.:
x
x
x
S
e
rie
n
-N
r.:
x
x
x
x
/
V
O
IT
H
Basic-No.:
Code-No.:
Serial-No.:
VOITH
11004e
1. Basic-number
8-digit number
The last t wo digits show the
soft ware version.
Example: .12 = version 1.2
2. Code-number
3-digit number
(Adjusting of control unit)
3. Serial-number
5-digit number
with date of coding
4. Voith precast unit number as
well as customer number, if ne-
cessary
Notice
Please, always quote the retarder data and
retarder control unit data when submitting
queries or ordering spare parts.
In this case a quick and working is possible.
General Data Plate of Retarder-Control
General Data Plate of Retarder-Control
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11


Illustration: Data Plate of Retarder Control Unit VERA
Data Plate of Retarder-Control
Unit VERA
The data plate of the VERA-control unit is moun-
ted on the control unit and contains following
information:
Retarder Control Unit VE RA.STD
Serial-No. XXXX / 2002-08-01
Part-No. 67.2763.20
OEM-No.
V
O
I
T
H

T
U
R
B
O
X1 X2 X3
e
1
*
7
2
/
2
4
5
*
9
5
/
5
4
*
2
0
8
4
*
0
0
R
e
ta
r
d
e
r

C
o
n
tr
o
l
U
n
it V
E
R
A
.S
T
D
S
e
r
ia
l-N
o
. X
X
X
X
/
2
0
0
2
-0
8
-0
1
P
a
r
t-N
o
.
6
7
.2
7
6
3
.2
0
O
E
M
-N
o
.
V
O
I T
H
T
U
R
B
O
X
1
X
2
X
3
e
1
* 7
2
/ 2
4
5
* 9
5
/ 5
4
* 2
0
8
4
* 0
0
11005
1. Serial-number
4-digit number / date
2. Spare-part-number
8-digit number
3. OEM-number
Notice
Please, always quote the retarder data and
retarder control unit data when submitting
queries or ordering spare parts.
In this case a quick and working is possible.
General Function- and Operation Scheme
General - Function- and Operation Scheme
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Aftersales Service Manual Voith Retarder 115 E
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2.4 Function- and Operation Scheme
Illustration: Functional Drawing Retarder 115 E Digiprop

Notice
Example of application hand control Digiprop. Further OEM-specific versions are possible.
The given position numbers aren't identical with the position numbers of the spare part lists.
1 Heat exchanger complete 41 Filling duct
1/1 Retarder-oil cooling circuit 42 Oil tank
1/2 Gearbox-oil cooling circuit 43 Oil sump
19 Temperature sensor cooling water 44 Stator
20 Temperature sensor oil 46 Rotor
21 Proportional valve 55 Oil drain plugs
22 Ventilation 62 Pressure regulating valve
23 Casing ventilation 63 Non-return valve (inlet)
25 Air-pressure line A constant-air pressure (p
y
) 64 Non-return valve (outlet)
26 Air-pressure line supply-air pressure (p
v
) 72 Pressure sensor (OEM-specific)
36 Exhaust line R
25
26
23
36
1
19
63
20
43
46
22
44
62
55
64
A R
21
42
Oil sump
Supply-air pressure p
Constant-air pressure p
y
Coolant (water)
11006e
Pump pressure p
P
41
1/1 1/2
72
Vehicle
electronic
v
General Function- and Operation Scheme
General Function- and Operation Scheme
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Aftersales Service Manual Voith Retarder 115 E
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Functional Description
The Voith Retarder 115 E is a powerful, hydrodynamic continous brake of compact design.
The retarder is driven and braking torque is transmitted by pinions in the gearbox. The transmission ratio
enables the retarder to achieve high braking torques right down to low r.p.m. ranges with the compactest
configuration (small rotor/stator).
Retarder braking torque is sustained even when gear changes are made.
Do not use the switched-on retarder as handbrake while vehicle is in still-stand!
During a failure of the retarder, or while the temperature-adaptation is effective, the vehicle-speed must
be settled by using the service-brake and the lowest possible gear.
General Function- and Operation Scheme
General Function- and Operation Scheme
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Temperature Sensor Cooling Water (19), Oil (20)
The temperature sensors 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 adapted to protect the vehicle cooling system and
the retarder.
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 adaption range, the consequence is an adap-
tion of the retarder braking torque to protect the vehicle cooling system. If the temperature rises above
the temperature adaption range, there is no more braking torque output.
While the temperature adaption is effective or if there is a retarder failure, the service brake must be used
to control the vehicle.
Additionally the control unit cuts back braking torque if oil temperature rises too rapidly - irrespective of
actual oil temperature.
Pressure regulating valve (62)
The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder.
General Function- and Operation Scheme
General Function- and Operation Scheme
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Aftersales Service Manual Voith Retarder 115 E
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Pressure sensor (72)
The pressure sensor (72) observes the pneumatic constant-air pressure. At deviation of the permissible
pressure tolerance an error is stored from the control unit displayed in the vehicle display in dependence
of the OEM equipment.
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.
Non-return valve (63) inlet
When the retarder is switched on, the oil sump is pressurized, causing the check valve (63) to open and
the oil to enter the working space.
Non-return valve (64) outlet
The oil pressure in the working space opens the check valve (64), causing the oil to enter the heat
exchanger (1), to be cooled and to be returned to the working circuit.
Proportional valve (21)
Depending on the size of the electrical input signal a pneumatic constant-air pressure gets controlled from
the proportional valve to the oil tank of the retarder.
Maintenance
Maintenance
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Aftersales Service Manual Voith Retarder 115 E
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3. Maintenance
3.1 Maintenance Work / Oil Change Intervals ..................................................20
3.2 Inspection of Oil Level.................................................................................23
3.3 Oil Change..................................................................................................26
Maintenance Maintenance Work / Oil Change Intervals
Maintenance Maintenance Work / Oil Change Intervals
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Aftersales Service Manual Voith Retarder 115 E
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3.1 Maintenance Work / Oil Change Intervals
Maintenance work
At each oil change:
- Clean sieve of pressure regulating valve
- Check fastening screws of the retarder heat exchanger
- Check all screw plugs on leak and correct fitment
- Carry out visual inspection on possible leak and existing damages
Please note the following data into the service overview of the Operation Manual
Gearbox-Retarder-System / GO170 - GO210 with R 115 E :
- maintenance work been carried out
- the oil grade used for the oil change
Maintenance Maintenance Work / Oil Change Intervals
Maintenance Maintenance Work / Oil Change Intervals
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Aftersales Service Manual Voith Retarder 115 E
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Oil change intervals, operating specification
1) according operating specification
2) carry out change oil at the latest after 1 year, if fewer kilometres are travelled
3) carry out change oil at the latest after 2 year, if fewer kilometres are travelled
Please take into account the oil recommendation list (Voith code number 67.2246.11).
Single grade-mineral oil
1)
Synth. / part synth. oil
1)
Synthetic oil
1)
Normal duty 135.000 km
2)
180.000 km
3)
300.000 km
3)
Heavy duty 60.000 km
2)
90.000 km
3)
300.000 km
3)
Classification let-
ter
to DIN 51502
HD HC HC
Class of viscosity
to DIN 51511
SAE 10W
SAE 20W20
SAE 30
SAE 0W40
SAE 5W30
SAE 5W40
SAE 5W50
SAE 10W30
SAE 10W40
SAE 75W80
Performance
category
API - CC/SF
and higher
API - CC/SF
and higher
Emgard
MTF,Henkel
Maintenance Maintenance Work / Oil Change Intervals
Maintenance Maintenance Work / Oil Change Intervals
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Aftersales Service Manual Voith Retarder 115 E
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1. Normal duty
Example:
Long distance traffic
2. Heavy duty
Subject to more than normal stress.
Examples:
Use in regions with high ambient temperature (e.g. Saudi-Arabia)
High max. permissible weight with low rated engine power (< 6 kW / metric ton)
Streches with lots of hills and valleys
Extreme short-distance traffic with lots of gradients
The given maximum specified figures can be lowered, if overall maintenance cycles for the vehicle are
improved.
With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as other
factors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervals
between oil changes in individual cases.
For use in extremely cold zones, oils in an appropriately lower viscosity class must be used.
In doubts please contact our customer service.
Maintenance Inspection of Oil Level
Maintenance Inspection of Oil Level
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Aftersales Service Manual Voith Retarder 115 E
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3.2 Inspection of Oil Level
Notice
For satisfactory retarder operation it is important to adhere to the specified service filling of 7,0 litres and
to use only oils specified in the operating specifications for operating the retarder in the relevant applica-
tion.
The oil level check must be carried out with the vehicle in a horizontal position.
For the inspection of oil level, temperature of retarder oil must have reached the operating temperature.
Caution!
Two version of the screw plugs (107, 4100, 4200) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to
print.
The integrated sealing rings must be checked for possible damages during the inspection of oil level;
replace completely if necessary.
B) Version with loose inserted copper-sealing ring.
In this Aftersales Workshop Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in
brackets are valid.
The copper-sealing rings have to be renewed in general.
Maintenance Inspection of Oil Level
Maintenance Inspection of Oil Level
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11

Work scope
1. Push a clean vessel under retarder.

2. Screw out oil drain plugs and drain oil in clean vessel.
3. Check sealing rings of oil drain plugs for damages, renew oil drain plugs if necessary.
4. Screw in oil drain plugs and screw them tight.
Tightening torque oil drain plugs (107, 4200): 47 Nm (80 Nm)
5. Measure drained oil.
6. Top up any lacking oil according to the operating specifications, page 29.
4200
107
11007
107 Oil drain plug M 24 x 1,5
Inhex-head w.a.f. 12,
47 Nm (80 Nm)
4200 Oil drain plug M 24 x 1,5
Inhex.head w.a.f. 12,
47 Nm (80 Nm)
Caution! Risk of injury!
The oil drain plugs (107, 4200) and oil filler plug (4100) are hot (oil temperature)!
The retarder must be switched-off during the inspection of oil level!
If the retarder is switched-on during working step 2 and screwed out oil drain plugs and/or oil filler plug,
high risk of injury exist by hot leaving oil (increased pressure)!
Maintenance Inspection of Oil Level
Maintenance Inspection of Oil Level
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Aftersales Service Manual Voith Retarder 115 E
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7. Fill in slowly over a time period longer than 3 minutes the quantity of oil specified, in the bore of the
oil filler plug (4100).

8. Check sealing ring of oil filler plug for possible damages, renew oil filler plug if necessary.
9. Screw in oil filler plug and screw it tight.
Tightening torque oil filler plug (4100): 100 Nm (100 Nm)

10. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 times
for respectively approx. 5 seconds in position 2 at the retarder stage switch or brake stage 1.
Take the OEM specific using variants into account to this.
The vehicle must not go slower than 20 km/h at this.
Caution!
The retarder must only be filled with oil via the bore of the oil filler plug (4100)!
Notice
With determined lacking oil quantity check retarder for possible outer leak.
Hinweis
The following work step is required to the correct ventilation of the retarder system.
Nonobservance can cause oil leak via the ventilation.
If available, the foot control of the retarder must be switched off and switched on first after the described
work process again.
Maintenance Oil Change
Maintenance Oil Change
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Aftersales Service Manual Voith Retarder 115 E
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3.3 Oil Change
Notice
The gearbox- and retarder oil tanks are seperated from each other at the gearbox-retarder-system. Both
oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder
- without limited compromizes.
For satisfacory retarder operation, it is important to adhere to the specified service filling (see table
page 29) and to use only oils specified in the operating specifications page 21 for operating the retarder
in the relevant application.
For draining the oil the temperature of the retarder oil must have reached the operating temperature.
Ensure that during the entire oil change no constant-air pressure acts on the retarder, that means the
retarder must be switched off!
Maintenance Oil Change
Maintenance Oil Change
Page 27
Aftersales Service Manual Voith Retarder 115 E
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Attention!
Two versions of screw plugs (107, 3500, 4100, 4200) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to
print.
The integrated sealing rings must be checked for possible damages during the inspection of oil level;
replace completely if necessary.
B) Version with loose inserted copper-sealing ring.
In this Aftersales Workshop Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in
brackets are valid.
The copper-sealing rings have to be renewed in general.
Maintenance Oil Change
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Aftersales Service Manual Voith Retarder 115 E
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Maintenance Oil Change

Illustration: Oil change Retarder R 115 E

Lubricants and cleaning agents
3500
4100
4200 4200
107
11008
Kd.-Sach-Nr.
Voith-Sach-Nr.
107 Oil drain plug
M 24 x 1,5
Inhex-head w.a.f. 12
47 Nm (80 Nm)
3500 Screw plug with sieve
M 30 x 1,5
Inhex-head w.a.f. 17
100 Nm (100 Nm)
Clean sieve with appropriate
cleaning agent and blow out with
compressed-air
4100 Oil filler plug
M 30 x 1,5
Inhex-head w.a.f. 17
100 Nm (100 Nm)
4200 Oil drain plug oil tank
M24x1,5
Inhex-head w.a.f. 12
47 Nm (80 Nm)
Sieve in screw plug Benzine
Maintenance Oil Change
Maintenance Oil Change
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Aftersales Service Manual Voith Retarder 115 E
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Work scope
1. Push an oil collecting pan under the retarder.

2. Screw out the oil drain plugs (107 and 4200) and drain the oil.
3. Check integrated sealing rings of oil drain plugs on possible damages,
renew oil drain plugs if necessary.
4. Screw in the oil drain plugs tight.
Tightening torque oil drain plugs (107, 4200): 47 Nm (80 Nm)
Oil filling with heat exchanger
Service filling (oil change, inspection of oil level) 7,0 l
After exchange of heat exchanger 7,5 l
Attention! Risk of injury!
The oil drain plugs (107, 4200) are hot! Oil temperature!
4200
107
4200
11009
Maintenance Oil Change
Maintenance Oil Change
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Aftersales Service Manual Voith Retarder 115 E
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5. Screw screw plug with sieve (3500) out of the retarder.
6. Clean sieve in screw plug with appropriate cleaning agent (Benzine) and blow it out with
compressed-air.
7. Check integrated sealing ring of screw plug with sieve on possible damages,
renew screw plug if necessary.
8. Screw in screw plug with sieve hand-tight then tighten it.
Tightening torque screw plug (3500): 100 Nm (100 Nm)
9. Screw out oil filler plug (4100).

10. Fill in slowly over a time period longer than 3 minutes the quantity of oil, via the bore of the oil filler
plug, specified in accordance to the service filling (see table page 29).
This work step is required to the correct ventilation of the retarder system.
3500
11010
Kd.-Sach-Nr.
Voith-Sach-Nr.
4100
11011
Attention!
The retarder must only be filled with oil via the bore of the oil filler plug (4100)!
Maintenance Oil Change
Maintenance Oil Change
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Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
11. Check integrated sealing ring of oil filler plug on possible damages, renew oil filler plug if necessary.
12. Fit oil filler plug and screw it tight.
Tightening torque oil filler plug (4100): 100 Nm (100 Nm)
13. Operate the retarder after the oil change only during the drive at a speed of at least 50 km/h 5 times
for respectively approx. 5 seconds in position 2 at the retarder stage switch or brake stage 1.
Take the OEM specific using variants into account to this.
The vehicle must not go slower than 20 km/h at this.
Achtung!
The following work step is required to the correct ventilation of the retarder system.
Nonobservance can cause oil leak via the ventilation.
If available, the foot control of the retarder must be switched off and switched on first after the described
work process again.
Diagnosis / Troubleshooting
Diagnosis / Troubleshooting
Page 32
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
4. Diagnosis / Troubleshooting
4.1 Electrical Connections Diagram..................................................................33
4.2 Overview of Control Parts...........................................................................37
4.3 Troubleshooting Diagram............................................................................38
4.4 Troubleshooting and Remedies..................................................................41
4.5 Checking Supply-Air Pressure (p
v
) .............................................................77
4.6 Checking Constant-Air Pressure (p
y
) and Pump Pressure (p
dyn
) ...............78
4.7 Checking Control Current of Proportional Valve.........................................86
4.8 Checking Pressure Sensor .........................................................................88
4.9 Checking Temperature Adaption ................................................................90
4.10 Table of Measurements ..............................................................................93
Diagnosis / Troubleshooting Elektrical Connections Diagram
Page 33
Aftersales Service Manual Voith Retarder 115 E
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Diagnosis / Troubleshooting Elektrical Connections Diagram
4.1 Elektrical Connections
Diagram
(Voith-Wiringharness Digiprop without
CAN)
18
70 47 15 21
-
- +
+
+ -
19 20
17
4
16
69
4
2
X1
X2 X3
8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8
14
8
7
8
7
a
3
0
13 11 12 10 1 9 5 8 4 3 2 7 6
18 17 16 6 5 4 8 9 10 11 12 13 14 15 7
4
3 2 1 4
8 3 2 5 6 7
3 1 2
7
11012
1 2 4
.
.
.
.
P
U 72
2 Control unit
4 Connection terminal 15
15 ABS-signal
16 Retarder stage switch
17 Retarder pilot light
18 Brake light relay
19 Temperature sensor
cooling water
20 Temperature sensor oil
21 Proportional valve
47 Speedometer signal
69 Plug ISO-interface
70 Plug optional function
72 Pressure sensor
(OEM-specific)
Diagnosis / Troubleshooting Elektrical Connections Diagram
Page 34
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Diagnosis / Troubleshooting Elektrical Connections Diagram
Digiprop with CAN
21
- - + + + -
19 20
17
4
16
4
2
X1
X2 X3
8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8
18 17 16 6 5 4 8 9 10 11 12 13 14 15 7 3 1 2
7
1 2 4
.
P
U 72
CAN
11013
2 Control unit
4 Connection terminal 15
16 Retarder stage switch
17 Retarder pilot light
19 Temperature sensor
cooling water
20 Temperature sensor oil
21 Proportional valve
72 Pressure sensor
(OEM-specific)
Diagnosis / Troubleshooting Elektrical Connections Diagram
Page 35
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Diagnosis / Troubleshooting Elektrical Connections Diagram
VERA general
11014
47
4
2
X1
X2 X3
8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8
18
8
7
8
7
a
3
0
21
18 17 16 6 5 4 8 9 10 11 12 13 14 15 7 3 1 2
7
- +
19
+ -
20
1 2 4
P
U 72
17
4
.
CAN
80
- + - +
16 15
83
82 81
2 Control unit
4 Connection terminal 15
15 ABS-signal
16 Retarder stage switch
17 Retarder pilot light
18 Brake light relais
19 Temperature sensor
cooling water
20 Temperature sensor oil
21 Proportional valve
47 Speedometer signal
72 Pressure sensor
(OEM-specific)
80 On/off valve
81 Input (3 times)
82 Output (3 times)
83 ISO-diagnosis
Diagnosis / Troubleshooting Elektrical Connections Diagram
Page 36
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Diagnosis / Troubleshooting Elektrical Connections Diagram
VERA DAFBUS
11015
4
2
X1
X2 X3
8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8
18
8
7
8
7
a
3
0
21
18 17 16 6 5 4 8 9 10 11 12 13 14 15 7 3 1 2
7
- +
19
+ -
20
1 2 4
P
U
72
93
CAN
- +
90
94
16
92
91
4
.
96
95
2 Control unit
4 Connection terminal 15
16 Retarder stage switch
18 Brake light relais
19 Temperature sensor
cooling water
20 Temperature sensor oil
21 Proportional valve
72 Pressure sensor
(OEM-specific)
90 Fan relais
91 Brake valve
92 Diagnosis K-Lead
93 Fault light
94 Operating light
95 Foot Off/On
96 Indication light
Diagnosis / Troubleshooting Overview of Control Parts
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Aftersales Service Manual Voith Retarder 115 E
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Diagnosis / Troubleshooting Overview of Control Parts
4.2 Overview of Control Parts
71
32
33
31
34 35
40
61
11016
39
19
1
20
2
21
26
72
P
36
11
25 A
R
Notice
The given position-numbers are not identical
with position-numbers of spare parts lists.
1 Heat exchanger
2 Control unit (e.g. Digiprop/
VERA)
11 Connection control current of
proportional valve
19 Temperature sensor
cooling water
20 Temperature sensor oil
21 Proportional valve
25 Compressed-air pressure line
constant-air pressure (p
y
)
26 Compressed-air pressure line
suppla-air pressure (p
v
)
31 Compressed-air pressure line
(pressure regulator - four-
circuit protection valve)
32 Compressed-air pressure line
(four-circuit protection valve -
air tank for auxiliary equip-
ment) with with test connec-
tion
33 Compressed-air pressure line
(brake circuit 1)
34 Compressed-air pressure line
(brake circuit 2)
35 Compressed-air pressure line
(parking brake)
36 Ventilation line
connection R
39 Electrical lead (temperature
sensor cooling water) to
control unit, 2 wires)
40 Electrical lead (temperature
sensor oil) to control unit,
2 wires)
61 Four-circuit protection valve
71 Air tank for auxiliary
equipment
72 Pressure sensor
(OEM-specific)
Diagnosis / Troubleshooting Troubleshooting Diagram
Diagnosis / Troubleshooting Troubleshooting Diagram
Seite 38
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
4.3 Troubleshooting Diagram
Complaint
Retarder
R 115 E
A
Retarder
Pilot Light
(Standard
version)
B
Oil leak via
ventilation
and / or non
or too low
braking
efficiency
*
* Notice:
OEM-specific is an on-board-diagnosis
possible (display).
Notice the information from the vehicle
manufacturer to it.
11017e
Diagnosis / Troubleshooting Troubleshooting Diagram
Diagnosis / Troubleshooting Troubleshooting Diagram
Page 39
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11

Illustration: Complaint main group A
Activate
flash code
and read out
fault code *
* Retarder
Pilot L ight
(Standard
version)
A
Permanent light in
position 0 after
lamp test?
Clear fault
and
erase
fault memory *
no function?
Check pilot light
and renew,
if necessary
flashes?
Temperature
adaption
OK NOK
Check operation
(during Retarder
braking
most possible
engine
nominal speed)
Instruct driver!
OK NOK
Check
temp.-sensors
(oil / water)
(page 90 ff)
Replace
temp.-sensos
(page 141, 142)
Check vehicle
cooling system:
- coolant level
- Thermostat
- Coolant pump
- Radiator fan
- Radiator on
pollution
11018e
Check
fuse
ABS or
idle switch
active?
* OE M-specific is an on-board-diagnosis
possible (display).
Notice the information from the vehicle
manufacturer to it.
* Notice the information of the
vehicle manufacturer
Diagnosis / Troubleshooting Troubleshooting Diagram
Diagnosis / Troubleshooting Troubleshooting Diagram
Seite 40
Aftersales Service Manual Voith Retarder 115 E
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Prior work
Check retarder system on outer leaks (apart from ventilation)
Check whether running in instruction was carried out after oil change, carry out if necessary

Illustration: Complaint main group B
11019e
Check retarder
oil level
(page 23 ff)
OK NOK
Yes No
Water in oil
(emulsion)
(page 124 ff)
Check
heat exchanger
Correct
retarder oil level
OK NOK
NOK OK
Check p (dynam.)
and py (statisch)
(page 78 ff)
For examination the retarder
oil level must be correct!
NOK OK
Check temperature
adaption or
temp.-sensors (oil/water)
and pressure sensor or
leads
(page 88 ff)
OK NOK
Check
gearbox oil level
check p (static)
(page 78 ff)
y
Replace
temperature sensors
or leads
(page 141, 142)
Consultation
Voith
B
Check
retarder oil level
too
low
too
high
NOK OK
Check
gear box oil level
Check
gear box oil level
too
high
too
low
Correct
retarder- and
gearbox oil level
Check
gearbox oil level
too
high
too
low
Correct
retarder- and
gearbox oil level
Yes No
Outer Leak
(apart ventilation)
Repair
Retarder
Correct
retarder- and
gearbox oil level
If problem occours again:
Consultation Voith
OK NOK
Check
gearbox ventilation
Correct retarder-
and gearbox
oil level
If problem occours again:
Consultation Voith
For examination the retarder
oil level must be correct!
At complaint "non or
too low braking
efficiency":
Consultation Voith
At complaint
"Oil leak via
ventilation":
continue with
checking casing
ventilation
NOK OK
Check vehicle
compressed-air
system
NOK OK
Check supply-
air pressure
(page 77)
Proportional valve or
damping plate
mechanically defect
NOK OK
Check
casing ventilation
(page 112 ff)
OK NOK
Replace
casing ventilation
(page 112 ff)
p (dynamic)
NOK
p (static)
NOK
y
Check
proportional valve
(page 86 ff)
NOK OK
Replace
proportinal valve
(page 140)
If problem occours again:
Consultation Voith
No Yes
Outlet valve
.11 and higher?
Replace
outlet valve
(page 136 ff)
If problem occours again:
Replace
proportional valve.
Contact
vehicle
manufacturer
Compressed-air pressure
line to prop. valve
interrupted or
leaking
Oil leak via ventilation
and / or non or
too low
brake efficiency
Check control
current of prop.
valve as well as
leads und
plug connections
(page 86 ff)
Repair gearbox
ventilation;
correct retarder- and
gearbox oil level
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 41
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
4.4 Troubleshooting and remedies
Requirements for check
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
Version Digiprop with and without CAN:
for check with multimeter must be at the control unit
pin 15 (plug X1) Ground (terminal 31),
at pin 7 and pin 13 (plug X1) must be connected terminal 15
Version VERA:
for check with multimeter must be at the control unit
pin 14 (plug X1) Ground (terminal 31),
at pin 7 (plug X1) must be connected terminal 15
Note
Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary
(see page 29).
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 42
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11

Note
The retarder pilot light additionally has the function of a fault code. An on-board-diagnosis (display) is
OEM-specific possible. Heed herefore the statements of the vehicle manufacturer:
slight fault
Permanent light in position 0 - 5 of retarder stage switch, braking is still possible to limited
extent.
serious fault
Permanent light in position 0 - 5 of retarder stage switch,, braking is no longer possible -
the retarder is switched off.
Note
If 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.
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 43
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Connector arrangement and pin assignment

Plug X1 control unit (Digiprop)
Note
All plugs illustrated from plug-in side (i.e. leads at back).
11020
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
1 Not in use or CAN-LOW
2 Not in use or CAN-GROUND
3 Not in use or CAN-HIGH
4 Retarder stage switch, Position 3
5 Retarder stage switch, Position 2
6 Retarder stage switch, Position 1
7 Terminal 15
8 Retarder stage switch, Position 5
9 Retarder stage switch, Position 4
10 Retarder stage switch +
11 ISO-interface, L-lead
12 ISO-interface, K-lead
13 Connected with terminal 15
14 Not in use
15 Terminal 31
16 Output / high side 2 HS2
17 Not in use
18 Output / high side 1 HS1
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 44
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Plug X2 control unit (Digiprop)
Plug X3 control unit (Digiprop)
11021
1 4 7
2 5 8
3 6 9
1 Not operational
2 Proportional valve -
3 Proportional valve +
4 Cooling-water temperature-sensor -
5 Cooling-water temperature-sensor +
6 Not operational
7 Not in use
8 Oil-temperature sensor -
9 Oil-temperature sensor +
11022
1 4 7 10
2 5 8 11
3 6 9 12
1 Input / pull up DIU 1
2 Speedometer signal
3 ABS-signal
4 Input / pull down DID 2
5 Input / pull down DID 1
6 Pressure-sensor ground
7 Pressure-sensor signal voltage
8 Retarder pilot light
9 Input / pull down DID 3
10 Pressure-sensor supply voltage
11 Stop light relais
12 Input / pull down / PWM-in DID4
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 45
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Plug optional functions (cable Digiprop)
Plug ISO-interface (cable Digiprop)
2
1
4
3
6
5
8
7
10
9
12
11
14
13
11023
1 Retarder stage switch +
2 Input / pull down DID 1
3 Input / pull down DID 2
4 Input / pull down DID 3
5 Input / pull down / PWM -in DID 4
6 Input / pull up DIU 1
7 Pressure-sensor Ground
8 Pressure-sensor signal voltage
9 Pressure-sensor supply voltage
10 Output / high side HS1
11 Output / high side 2 HS2
12 Not operational
13 Terminal 15
14 Terminal 31
2 1
4 3
11024
1 K-lead
2 L-lead
3 Terminal 15
4 Terminal 31
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 46
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Connector arrangement and pin assignment

Plug X1 control unit (VERA)
Note
All plugs illustrated from plug-in side (i.e. leads at back).
11025
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
1 CAN-LOW
2 CAN-GROUND
3 CAN-HIGH
4 Retarder stage switch, Position 0
5 Retarder stage switch, Position 1
6 Retarder stage switch, Position 2
7 Terminal 15 = battery voltage
8 Retarder stage switch, Position 3
9 Retarder stage switch, Position 4
10 Retarder stage switch +
11 Speedometer signal
12 ISO-interface, K-lead
13 ABS-signal
14 Terminal 31 = Ground
15 Retarder pilot light
16 Brake light relais
17 Engine speed
18 Retarder stage switch, Position 5
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 47
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Plug X2 control unit (VERA)
Plug X3 control unit (VERA)
11026
1 4 7
2 5 8
3 6 9
1 Output / highside OUT 1
2 Output / highside OUT 2
3 Output / highside OUT 3
4 Input / analog IN 3
5 Input / analog IN 1
6 Not in use (boot 1)
7 Not in use (boot 2)
8 Not in use (boot 3)
9 Input / digital IN 2
11027
1 4 7 10
2 5 8 11
3 6 9 12
1 Cooling-water temperature-sensor -
2 Cooling-water temperature-sensor +
3 Proportional valve +
4 Proportional valve -
5 Oil-temperature sensor +
6 Oil-temperature sensor -
7 Pressure-sensor signal voltage
8 Pressure-sensor Ground
9 Pressure-sensor supply voltage
10 Not in use (switch valve +)
11 Not in use (switch valve -)
12 Not in use
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 48
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Plug cooling-water temperature pick-up
Plug oil temperature pick-up
Plug proportional valve
11028
1
2
3
4
11029
1 Proportional valve +
2 Proportional valve
3 Not in use
4 Not in use
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 49
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Plug retarder stage switch
11030
1 2 3 4
5 6 7 8
1 Not in use
2 Position 5
3 Position 4
4 Retarder stage switch +
5 Position 3
6 Position 2
7 Position 1
8 Bridge to pin 4
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 50
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
A. With fault code, e.g. retarder control unit reports fault
Special tool
Service cable (only Digiprop)
Commercially available tool
Multimeter recommended: Fluke 87
Note
The fault memory can be read-out from blinking code of retarder pilot light via service-cable (53.8224.10
only Digiprop), if this function is realised.
An on-board-diagnosis (display) is OEM-specific possible. Heed herefore the statements of the vehicle
manufacturer.
53.8224.10
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 51
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault memory readout via retarder pilot light blinking code
Fault memory readout with service cable (only Digiprop)
Requirements
Retarder stage switch in position O.
Vehicle at standstill, ignition ON
1. L-lead of service interface connected to ground 2s. For this pupose, press L - pushbutton on
service cable
2. First fault as blinking code output.
3. Item 2 and 3 repeated for more blinking code outputs.
Meaning
Long blinking signals (2 sec.) tens unit.
Short blinking signals (0,5 sec.) single unit.
Note
If sveral faults have been stored in the memory, they are output in the sequence of their occurence,
but always only one fault per triggering.
Exception:
The fault Coding Fault is not held in the memory but is output via the blinking code.
The blinking code can be read-out of control unit by using the service cable (only Digiprop) or
retarder stage switch.
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 52
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault memory read out with retarder stage switch
The blinking code can be triggered with the retarder stage switch during the service function
(vehicle ignition system ON and v = 0):
1. Retarder stage switch in position 0
2. Retarder stage switch in position 1
3. Retarder stage switch in position 0
4. First fault as blinking code
5. Items from ...3 for more blinking code outputs
There is a break of 3 seconds before and after each blinking code output, during this time the retarder
pilot light is switched off.

Display example for fault code 23 (Digiprop)
E Retarder pilot light ON
A Retarder pilot light OFF
t Time
Display example for fault code 23 (Digiprop):
The number of tens units first indicated as long ON time: each 2 seconds
The number of single unit then is indicated as short ON time: each 0,5 seconds
Breaks between each ON time: each 1 second
If an actual fault occours (before triggering blinking code of retarder pilot light is switched ON) the retarder
pilot light switches to permanent light again after the blinking code.
Is there only one stored fault, the retarder pilot light is OFF after the output (only for Digiprop).
2

s
e
c
1

s
e
c
0
,
5


s
e
c
1

s
e
c
1

s
e
c
1

s
e
c
0
,
5


s
e
c
0
,
5


s
e
c
2

s
e
c
11031
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 53
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11

Display example for fault code 23 (VERA)
E Retarder pilot light ON
A Retarder pilot light OFF
t Time
Display example for fault code 20 (only for VERA):
The number of tens units first indicated as long ON time: each 2 seconds
Then blinking code goes off, no single unit in this method
Breaks between each ON time: each 1 second
2

s
e
c
1

s
e
c
2

s
e
c
11032
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 54
Aftersales Service Manual Voith Retarder 115 E
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Delete fault memory (only for Digiprop)
No marginal notes in accordance with fault memory read out.
1. Vehicle ignition system: OFF
2. Servcie interface L-lead connected to ground. For this purpose, press L-pushbutton of
service cable.
3. Vehicle ignition system: ON
4. Release L-lead from ground after 2 sec.
Delete fault memory (only for VERA)
It is only possible to delete fault memory via WinDia.
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 55
Aftersales Service Manual Voith Retarder 115 E
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Version Digiprop
1)
X 1/15 = ground control unit
2)
Only, if no fault is recognizable after a complete check of the periphery: change control unit.
Note
Meaning of entries in Measurement/test connection column: X 1/15 X3/11
Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test
connection
1)
Result/
Set point
Cause/
Remedy
2)
Code Test step
01 Stop light relay/
Short circuit to
ground
slight 1 s - Ignition: OFF
- Pull plug X3 out of
control unit
X 3/11 X 1/15 Relay is
installed:
250-350
Check lead, plugs
and relay or
consumers
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 56
Aftersales Service Manual Voith Retarder 115 E
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Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
03 HS 1 output
Short circuit
slight 1 s - Ignition: OFF
- Pull plug X1 out of
control unit
X 1/18 X 1/15 Relay is
installed:
250-350
Check lead, plugs
and relay
or consumers
04 HS 2 output
Short circuit
slight 1 s - Ignition: OFF
- Pull plug X1 out of
control unit
X 1/16 X 1/15 Relay is
installed:
250-350
Check lead, plugs
and relay
or consumers
05 Terminal 15
Undervoltage
serious 60 s - Ignition: OFF
- Pull plug X1 out of
control unit
- Ignition: ON
X 1/7 V X 1/15 17,5 V Check lead, plugs
and fuses
06 Terminal 15
Overvoltage
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)
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 57
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
* Fault is in serious class, if temperature sensor for oil and water are defect at the same time.
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
08
09
Cooling-water
temperature
sensor
Discontinuity /
Short circuit to
battery


serious/
slight *
1 s - Ignition: OFF
- Pull plug X2 out of
control unit
X 2/5 X 2/4 20C 10C =
1039 - 1117

60C 10C =
1194 - 1271

80C 10C =
1271 - 1347

Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.
Check lead and
sensor
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 58
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
11
12
Oil temperature
sensor
Discontinuity /
Short circuit to
battery

serious/
slight *
1 s - Ignition: OFF
- Pull plug X2 out of
control unit
X 2/9 X 2/8 20C 10C =
1039 - 1117

60C 10C =
1194 - 1271

80C 10C =
1271 - 1347

Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.
Check lead and
sensor
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 59
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
13 1 Retarder stage
switch
Undefined
switch state
serious 1s - Ignition: ON
- Retarder stage
switch:
Position 0
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V

0 V
0 V
0 V
0 V
0 V
Check lead, plug and
retarder stage switch
13 2 - Ignition: ON
- Retarder stage
switch:
Position 1
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V

0 V
0 V
0 V
0 V
Check lead, plug and
retarder stage switch
13 3 - Ignition: ON
- Retarder stage
switch:
Position 2
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V
17,5 V

0 V
0 V
0 V
Check lead, plug and
retarder stage switch
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 60
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
13 4 - Ignition: ON
- Retarder stage
switch:
Position 3
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V
17,5 V
17,5 V

0 V
0 V
Check lead, plug and
retarder stage switch
13 5 - Ignition: ON
- Retarder stage
switch:
Position 4
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V

0 V
Check lead, plug and
retarder stage switch
13 6 - Ignition: ON
- Retarder stage
switch:
Position 5
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
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 Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 61
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement / Operati-
on
Measurement/
Test connec-
tion
Result/
Set point
Cause/
Remedy
Code Test step
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 0 V Check lead and
plug
15 Retarder stage
switch
Short circuit to
battery
serious 1 s - Ignition: OFF
- Pull plug X1 out of
control unit
- Retarder stage switch:
Position 5
X 1/10 X 1/15 Resistor
endless
Single check of
stages for
short circuit
16 Speedometer
signal
Discontinuity
serious 2 s - Ignition: ON X 3/2 V X 1/15 1 V Check lead and
speedometer
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 62
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
18 Speedometer signal
Short circuit to battery
undefined signal
serious 2 s - Ignition: OFF
- Pull plug X3 out of
control unit
- Ignition: ON
X 3/2 V X 1/15 9 V Check lead and
speedometer
19 ABS
Short circuit to ground
serious 60 s - Ignition: ON X 3/3 V X 1/15 3,5 V Check lead,
relay and
ABS-control unit
21 ABS-Signal undefined serious 1 s - Ignition: ON X 3/3 V X 1/15 16,5 V Check lead,
relay and
ABS-control unit
22 Internal fault
ABS-current path
serious 1 s - - - Replace control
unit
23 Proportional valve
Fault No. 1:
Short circuit to battery
serious 1 s - Ignition: OFF
- Pull plug X2 out of
control unit
- Ignition: ON
X 2/3 V X 1/15 10 V Check lead
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 63
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
24 1 Proportional valve
Fault No. 2:
- Short circuit proportional
valve magnetic
- Short circuit connection
lead proportional valve
- Discontinuity proportio-
nal valve magnetic
Valve magnetic
- Discontinuity connec-
tion lead proportional
valve
- Short circuit to ground at
proportional valve
- Prop.- and shift valve
interchanged
serious 1 s - Ignition: ON
- Pull plug X2 out
of control unit
X 2/2 X 2/3 18-25 Check lead and
proportional
valve
(valve block)
2 - Ignition: OFF
- Pull plug X2 out
of control unit
X 2/3 X 1/15 Resistor
endless
Check lead and
proportional
valve
(valve block)
3 - Ignition: OFF
- Pull plug X2 out
of control unit
X 2/2 X 1/15 Resistor
endless
Check lead and
valve block
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 64
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
25 Valve block
Fault No. 3:
defective control unit
serious 10 s Replace
control unit
27 Valve block
Fault No. 5:
defective control unit
serious 2 s Replace
control unit
28 Terminal 30
Undervoltage
serious 60 s - Ignition: OFF
- Pull plug X1 out of
control unit
- Ignition: ON
X 1/13 V X 1/15 17,5 V Check lead,
plug and fuse
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 3 s - 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
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 65
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
33 Retarder pilot light:
Short circuit to battery
serious 3 s - Ignition: ON
- Retarder stage
switch:
Position 1
X 3/8 V X 1/15 2 V Check lead and
retarder pilot
light
35 Fault control unit serious 500 ms / 123 s Replace
control unit
37 Fault foot operation slight 100 ms / 1 s Check installation in
accordance with
OEM - as well as
Voith requirements
38 1 Fault constant-air
pressure
slight 1 s to 10 s Ignition: ON
Position 0
X 3/7 V X 1/15
and
X 3/10 V X 1/15
0,3-0,7 V
4,75-5,25
V
Pressure sensor
wiring harness
If deviation: step 2
2 Troubleshooting in
wiring harness,
pressure sensor,
proportional valve,
supply-air pressure,
ECU
(Contact Voith)
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 66
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Version VERA
Note
- X1 / 14 = Ground control unit
- replace control unit first, if complete check of periphery did not yield any faults
- Project specifically is normally only a part of the listed pins used (e.g.: ABS not via pin X1/13, but via CAN)
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
1 1 Data set
fault
heavy immediately af-
ter ignition ON
Parameter setting fault,
new parameter setting
2 1 EEprom
fault
heavy immediately af-
ter ignition ON
Replace control unit
3 1 ROM
fault
heavy approx. 10s after
ignition ON
Replace control unit
4 1 SIBA
fault
heavy 60 ms Replace control unit
5 1 Proportional-
valve chasssis
ground end,
interruption,
short circuit,
connecting lead
heavy 1s - Ignition: OFF
- disconnect
plug X3
X 3/3 X 3/4 18 ... 25 Check electrical lead
and proportional valve
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 67
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
5 2 X 3/3 X 1/14 Resistor endless Check electrical lead
and proportional val-
ve
5 3 X 3/3 X 1/14 Resistor endless Check electrical lead
and proportional val-
ve
6 1 Proportional-
valve
battery short cir-
cuit
heavy 1s - Ignition: OFF
- Pull off plug X1,
X3
- Ignition: ON
X 3/3 V X 1/14 10 V Check electrical lead
and plug
8 1 Proportional-
valve-control,
int. fault at con-
trol unit
heavy 3s Replace control unit
9 1 Terminal 15
undervoltage
heavy 60s - Ignition: OFF
- Pull off plug X1
- Ignition: ON
X 1/7 V X 1/14 17,5 V Check electrical lead,
fuse and plug
10 1 Terminal 15
overvoltage
heavy 10s - Ignition: OFF
- Pull off plug X1,
X3
- Ignition: ON
X 1/7 V X 1/14 32,5 V Check electrical unit
of vehicle (see manu-
facturers instruc-
tions)
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 68
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
11 1 Retarder stage
switch
undefined con-
dition
heavy 2s - Ignition: ON
- Retarder stage
switch: position 0
X 1/10 V X 1/14
X 1/5 V X 1/14
X 1/6 V X 1/14
X 1/8 V X 1/14
X 1/9 V X 1/14
X 1/18 V X 1/14
17,5 V
0 V
0 V
0 V
0 V
0 V
Check electrical lead,
plug and retarder sta-
ge switch
2 - Ignition: ON
- Retarder stage
switch: position 1
X 1/10 V X 1/14
X 1/5 V X 1/14
X 1/6 V X 1/14
X 1/8 V X 1/14
X 1/9 V X 1/14
X 1/18 V X 1/14
17,5 V
17,5 V
0 V
0 V
0 V
0 V
Check electrical lead,
plug and retarder sta-
ge switch
3 - Ignition: ON
- Retarder stage
switch: position 2
X 1/10 V X 1/14
X 1/5 V X 1/14
X 1/6 V X 1/14
X 1/8 V X 1/14
X 1/9 V X 1/14
X 1/18 V X 1/14
17,5 V
17,5 V
17,5 V
0 V
0 V
0 V
Check electrical lead,
plug and retarder sta-
ge switch
4 - Ignition: ON
- Retarder stage
switch: position 3
X 1/10 V X 1/14
X 1/5 V X 1/14
X 1/6 V X 1/14
X 1/8 V X 1/14
X 1/9 V X 1/14
X 1/18 V X 1/14
17,5 V
17,5 V
17,5 V
17,5 V
0 V
0 V
Check electrical lead,
plug and retarder sta-
ge switch
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 69
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
11 5 - Ignition: ON
- Retarder stage
switch: position 4
X 1/10 V X 1/14
X 1/5 V X 1/14
X 1/6 V X 1/14
X 1/8 V X 1/14
X 1/9 V X 1/14
X 1/18 V X 1/14
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V
0 V
Check electrical lead,
plug and retarder sta-
ge switch
6 - Ignition: ON
- Retarder stage
switch: position 5
X 1/10 V X 1/14
X 1/5 V X 1/14
X 1/6 V X 1/14
X 1/8 V X 1/14
X 1/9 V X 1/14
X 1/18 V X 1/14
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V
Check electrical lead,
plug and retarder sta-
ge switch
12 1 Retarder stage
switch
chasssis ground
end
heavy 1s - Ignition: OFF
- Pull off plug X1
- Retarder stage
switch: position 5
X 1/10 X 1/14 Resistor endless Check each stage on
chsssis ground end
13 1 Retarder stage
switch
battery shortcir-
cuit
heavy 10s - Ignition: OFF
- Pull off plug X1
- Retarder stage
switch: position 0
X 1/10 V X 1/14 0 V Check electrical lead
and plug
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 70
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
16 1 Temperature-
sensors
(both sensors
defect)
heavy 1s See blinking code 17
to 20
17 1 Cooling-water
temperature
sensor
interruption
light 1s - Ignition: OFF
- Pull off plug X3
X 3/1 X 3/2 20C 10 C =
1039 - 1117
60C 10 C =
1194 - 1271

80C 10 C =
1271 - 1347

Note:
The measuring in
one temperature
range normally is
sufficient.
Check electrical lead,
sensor and plug
18 1 Cooling-water
temperature
sensor
chasssis ground
end
light 1s - Ignition: OFF
- Pull off plug X1,
X3
X 3/2 X 1/14 Resistor endless Check electrical lead
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 71
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
19 1 Oil-temperature
sensor
interruption
light 1s - Ignition: OFF
- Pull off plug X3
X 3/5 X 3/6 20C 10 C =
1039 - 1117
60C 10 C =
1194 - 1271

80C 10 C =
1271 - 1347

Note:
The measuring in
one temperature
range normally is
sufficient.
Check electrical lead
and plug
20 1 Oil-temperature
sensor
chasssis ground
end
light 1s - Ignition: OFF
- Pull off plug X1,
X3
X 3/5 X 1/14 Resistor endless Check electrical lead
and plug
21 1 Speedometer
signal
interruption
heavy 2s - Ignition: ON X 1/11 V X 1/14 1 V Check electrical lead
and speedometer
22 1 Speedometer
signal
battery shortcir-
cuit
heavy 2s - Ignition: OFF
- Pull off plug X1
- Ignition: ON
X 1/11 V X 1/14 9 V Check electrical lead
and speedometer
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 72
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
23 1 Retarder pilot
light
interruption,
chasssis ground
end
heavy 1s - Ignition: OFF
- Pull off plug X1
- Ignition: ON
X 1/15 V X 1/14 17,5 V Check electrical lead
and fuse
24 1 Retarder pilot
light
interruption,
battery shortcir-
cuit
heavy 3s - Ignition: ON
- Retarder stage
switch: position 1
X 1/15 V X 1/14 2 V Check electrical lead
and retarder pilot
light
25 1 Pressure sensor
fault (supply)
light 0,5s - Ignition: ON X 3/8 V X 3/9 4,75 ... 5,25 V Check electrical lead
26 1 Pressure sensor
interruption,
chasssis ground
end
light 1s - Ignition: OFF
- Pull off plug X1,
X3
X 3/7 X 1/14 Resistor endless Check electrical lead
and pressure-sensor
27 1 Pressure sensor
battery shortcir-
cuit
light 1s - Ignition: ON X 3/9 V X 3/8 4,75 ... 5,25 V Check electrical lead
and pressure-sensor
28 1 Pressure sensor
unplausible
signal
light 10s - Ignition: ON
- Retarder stage
switch: position 0
X 3/7 V X 3/8 0,3 ... 0,7 V Check electrical lead
and pressure-sensor
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 73
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
29 1 ABS
chasssis ground
end
heavy 60s - Ignition: ON X 1/13 V X 1/14 3,5 V Check electrical lead,
relay and ABS-con-
trol unit
30 1 ABS
undefined con-
dition
heavy 5s - Ignition: ON X 1/13 V X 1/14 16,5 V Check electrical lead,
relay and ABS-con-
trol unit
31 1 ABS
int. fault at con-
trol unit
heavy 1s Replace control unit
33 1 Brake light relay
chasssis ground
end
light 1s - Ignition: OFF
- Pull off plug X1
X 1/16 X 1/14 At installed relay
250-350
Check electrical lead
plug and relay or con-
sumer
34 1 Brake light relay
interruption,
battery shortcir-
cuit
light 1s - Ignition: OFF
- Pull off plug X1
X 1/16 X 1/14 < 1,5k Check electrical lead
plug and relay or con-
sumer
2 - Ignition: OFF
- Pull off plug X1
- Ignition: ON
X 1/16 V X 1/14 0 V Check electrical lead
plug and relay or con-
sumer
35 1 Output 1
(OUT-1)
chasssis ground
end
light 1s - Ignition: OFF
- Pull off plug X2
X 2/1 X 1/14 At installed con-
sumer
> 150
Check electrical lead
plug and relay or con-
sumer
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 74
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
36 1 Output 1
(OUT-1)
interruption,
battery short cir-
cuit
light 1s - Ignition: OFF
- Pull off plug X2
X 2/1 X 1/14 < 3k Check electrical lead
plug and relay or con-
sumer
2 - Ignition: OFF
- Pull off plug X2
- Ignition: ON
X 2/1 V X 1/14 0 V Check electrical lead
plug and relay or con-
sumer
37 1 Output 2
(OUT-2)
chasssis ground
end
light 1s - Ignition: OFF
- Pull off plug X2
X 2/2 X 1/14 At installed con-
sumer
> 150
Check electrical lead
plug and relay or con-
sumer
38 1 Output 2
(OUT-2)
interruption,
battery shortcir-
cuit
light 1s - Ignition: OFF
- Pull off plug X2
X 2/2 X 1/14 < 3k Check electrical lead
plug and relay or con-
sumer
2 - Ignition: OFF
- Pull off plug X2
- Ignition: ON
X 2/2 V X 1/14 0 V Check electrical lead
plug and relay or con-
sumer
39 1 Output 3
(OUT-3)
chasssis ground
end
light 1s - Ignition: OFF
- Pull off plug X2
X 2/3 X 1/14 At installed con-
sumer
> 150
Check electrical lead
plug and relay or con-
sumer
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 75
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Blink-
Code
Test step
40 1 Output 3
(OUT-3)
interruption,
battery shortcir-
cuit
light 1s - Ignition: OFF
- Pull off plug X2
X 2/3 X 1/14 < 3k Check electrical lead
plug and relay or con-
sumer
2 - Ignition: OFF
- Pull off plug X2
- Ignition: ON
X 2/3 V X 1/14 0 V Check electrical lead
plug and relay or con-
sumer
41 1 CAN-fault mes-
sages failing to
appear, inter-
ruption
heavy 1s Check electrical con-
nections and leads of
vehicle CAN-Bus
42 1 CAN
BusOff
heavy 200ms Check electrical con-
nections and leads of
vehicle CAN-Bus
46 1 Retarder foot-
switch
chasssis ground
end (IN-3)
light 500ms - Ignition: ON X 2/4 V X 1/14 > 0,4 V Check analoge foot-
pedal, electrical lead
and plug
Diagnosis / Troubleshooting Troubleshooting and remedies
Diagnosis / Troubleshooting Troubleshooting and remedies
Page 76
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
B. Without fault code
Hinweis
Retarder faults without fault code are not recognized electronically.
Diagnosis / Troubleshooting Checking Supply-Air Pressure (pv)
Diagnosis / Troubleshooting Checking Supply-Air Pressure (pv)
Page 77
Aftersales Service Manual Voith Retarder 115 E
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4.5 Checking Supply-Air Pressure (p
v
)
Work scope test
1. Connect appropriate test pressure gauge to test connection of compressed-air line (32) at
four-circuit protection valve - air tank for auxiliary equipment and check supply-air pressure (p
v
).
Minimum pressure: 6 bar
Maximum pressure: 11 bar

11033
32
Notice
If pressure is not within the specified range, the compressed-air system must be checked according to
the manufacturers data.
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Page 78
Aftersales Service Manual Voith Retarder 115 E
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Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
4.6 Checking Constant-Air
Pressure (p
y
) and
Pump Pressure (p
dyn
)
Requirements for check
Retarder stage switch in position 0
Vehicle ignition OFF

11034
103
4100
Kd.-Sach-Nr.
Voith-Sach-Nr.
103 Screw plug
(test connection pump pressure)
M12x1,5
Inhex-head w.a.f. 6
13 Nm (20 Nm)
4100 Oil filler plug
M30x1,5
Inhex-head, w.a.f. 17
100 Nm (100 Nm)
Notice
The pump pressure check provides e.g.
information on internal leaks and on the
correct operation of the retarder.
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Page 79
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Requirements for check
Retarder stage switch in position 0
Vehicle ignition OFF
Vehicle electrical system (e.g. battery voltage, fuse etc.) checked in accordance with the Owners
Manual for the vehicle and found satisfactory
Compressed-air pressure 6 - 11 bar
Special tools:
Compressed-air Oil-pressure gauge
pressure gauge
0 - 6 bar 0 - 25 bar
99/7 99/1
H53.478810
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Page 80
Aftersales Service Manual Voith Retarder 115 E
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Attention!
Two version of the screw plugs (107, 3500, 4100, 4200) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to
print.
The integrated sealing rings must be checked for possible damages during the inspection of oil level;
replace completely if necessary.
B) Version with loose inserted copper-sealing ring.
In this Aftersales Workshop Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in
brackets are valid.
The copper-sealing rings have to be renewed in general.
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Page 81
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Work scope check
1. Screw out oil filler plug (4100).

99/7 Air-pressure gauge 53.1403.10
2. Connect air-pressure gauge (99/7) to bore of oil filler plug (4100).
4100
11035
Attention! Risk of injury!
The oil filler plug (4100) and the retarder are hot! oil temperature!
99/7
11036
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Page 82
Aftersales Service Manual Voith Retarder 115 E
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3. Screw out screw plug (103).

99/1 Oil-pressure gauge 53.4788.10

4. Connect oil-pressure gauge (99/1) to bore of screw plug (103).
Attention! Risk of injury!
The screw plug (103) and the oil are hot! Oil temperature!
103
11037
11038
99/1
Attention!
Easy oil-exit is caused constructively, but has no effect on function of retarder, however.
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Page 83
Aftersales Service Manual Voith Retarder 115 E
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5. Drive the vehicle with a prop shaft speed of v
ps
= 1000 r.p.m.
6. Shift the retarder stage switch to position 5 while on move at prop shaft speed v
ps
= 1000 r.p.m. and
read-off pump pressure (p
dyn
) of oil-pressure gauge (99/1).
7. Compare read-off pump pressure with the minimum value of dynamic pump pressure (p
dyn
)
according to the table see pages 93 ff.
8. Compare read-off constant-air pressure (p
y
) with determined value of constant-air pressure (p
y
)
according tables on pages 93 ff.

Notice
Shift into direct gear (ratio 1:1).
The engine speed 1000 r.p.m.

corresponds to prop shaft speed of 1000 r.p.m..
Attention!
If the nominal value of the constant-air pressure (p
y
) is obtained, however the pump pressure is below,
the retarder is inside defect.
If the respectively required set point is fallen at the measuring of the constant-air pressure (p
y
), either a
leak of the retarder or a defect is due to the control (see troubleshooting diagram).
The constant-air pressure (p
y
) must not change during the drive.
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Page 84
Aftersales Service Manual Voith Retarder 115 E
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99/1 Oil-pressure gauge 53.4788.10
9. Disconnect oil-pressure gauge (99/1).
10. Screw tight screw plug (103).
Tightening torque screw plug (103): 13 Nm (20 Nm)
Attention! Risk of injury!
Screwing of oil-pressure gauge and retarder are hot!
When screwing out oil-pressure gauge (99/1) hot oil can flow out!
11039
99/1
103
11040
Notice
Check sealing ring of screw plug (103) for a possible damage, replace screw plug (103) if necessary.
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Diagnosis / Troubleshooting Checking Constant-Air Pressure (py) and Pump Pressure (pdyn)
Page 85
Aftersales Service Manual Voith Retarder 115 E
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99/7 Air-pressure gauge 53.1403.10
11. Disconnect air-pressure gauge (99/7).
12. Screw tight oil filler plug (4100).
Tightening torque oil filler plug (4100): 100 Nm (100 Nm)
Attention! Risk of injury!
The screwing of the air-pressure gauge and the retarder are hot!
99/7
11041
4100
11042
Notice
Check sealing ring of oil filler plug (4100) for a possible damage, replace oil filler plug (4100), if necessary.
Diagnosis / Troubleshooting Checking Control Current of Proportional Valve
Diagnosis / Troubleshooting Checking Control Current of Proportional Valve
Page 86
Aftersales Service Manual Voith Retarder 115 E
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4.7 Checking Control Current of Proportional Valve
Requirements for check
Battery voltag 24 - 28 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
Plug at proportional valve and socket checked for damage as well as wear (notch scratches)
Electrical lead and plug-in connection checked (visual examination) and found satisfactory
Special tool:
Measuring adapter
99/3
Commercially available tool
Multimeter Fluke 87 or 79 (otherwise possible differing in measurements!)
Diagnosis / Troubleshooting Checking Control Current of Proportional Valve
Diagnosis / Troubleshooting Checking Control Current of Proportional Valve
Page 87
Aftersales Service Manual Voith Retarder 115 E
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Work scop check

98/8 Multimeter
99/3 Measuring adapter 53.8198.10
1. Disconnect plug at proportional valve (21) and connect with measuring adapter (99/3).
2. Connect plug of measuring adapter (99/3) with the proportional valve (21).
3. Connect the Multimeter (98/8). Switch position: mA.
4. Turn switch Propvalve at measuring adapter (99/3) in position I .
5. Shift the retarder stage switch in position 5 and compare the read-off value with the given values of
the control current of the proportional valve in accordance with the tables see page 93 ff.
6. Disconnect plug of measuring adapter (99/3) and connect to the proportional valve (21) again.
11043
98/8
99/3
21
Diagnosis / Troubleshooting Checking Pressure Sensor
Diagnosis / Troubleshooting Checking Pressure Sensor
Page 88
Aftersales Service Manual Voith Retarder 115 E
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4.8 Checking Pressure Sensor
Requirements for check
Vehicle ignition OFF
Connected pressure gauge constant-air pressure
Retarder stage switch in position 0
Electrical lead and plug-in connection checked (visual examination) and found satisfactory
Special tool:
Measuring adapter
99/3
Commercially available tool
Multimeter recommended: Fluke 87
Diagnosis / Troubleshooting Checking Pressure Sensor
Diagnosis / Troubleshooting Checking Pressure Sensor
Page 89
Aftersales Service Manual Voith Retarder 115 E
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Work scope check

98/8 Multimeter
99/3 Measuring adapter 53.8198.10
1. Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3).
2. Connect plug of measuring adapter (99/3) to pressure sensor (38).
3. Connect electrical lead ground of multimeter (98/8) to measuring socket 4 (ground) of adapter.
4. Turn switch Propvalve at measuring adapter (99/3) in position Propventil .
5. Now, switch on vehicle ignition!
6. Connect electrical lead positive of Multimeter (98/8) to measuring socket 1 (positive).
7. The measured voltage must be between 4,75 and 5,25 V.

8. Connect electrical lead positive of Multimeter (98/8) to measuring socket 2 (output).
9. Compare measured voltage in conjunction of constant-air pressure with values on page 93 ff. For the
purpose of comparison a manometer "p
y
" must be parallelly installed (unless for pressure = 0 / Re-
tarder OFF) see page 78 ff.
10. Switch-off vehicle ignition after measurements!
11. Reconnect after removing measuring adapter (99/3) the electrical lead to the pressure sensor.
11044
98/8
99/3
38
Notice
If there is an error (wire or sensor), the supply voltage is switched off by the control unit. Check the wire
or the sensor and replace the defect part, if necessary.
Diagnosis / Troubleshooting Checking Temperature Adaption
Diagnosis / Troubleshooting Checking Temperature Adaption
Page 90
Aftersales Service Manual Voith Retarder 115 E
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4.9 Checking Temperature Adaption
Requirements for check
Battery voltage 24 - 28 V
Vehicle ignition OFF
Pressure gauge constant-air pressure connected
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
Electrical lead and plug-in connection checked (visual examination) and found satisfactory
Special tool:
Temperature simulator
99/2
Diagnosis / Troubleshooting Checking Temperature Adaption
Diagnosis / Troubleshooting Checking Temperature Adaption
Page 91
Aftersales Service Manual Voith Retarder 115 E
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99/2 Temperature simulator 53.8207.10
Work scope check
1. Disconnect electrical lead cooling water (39) and electrical lead oil (40) to cooling-water tempera-
ture-sensors (19) and oil (20) and connect these to the temperature simulator (99/2).

2. Set rotary switch of temperature simulator (99/2) to 95C cooling water temperature and 165C oil
temperature.
3. Switch-on vehicle ignition!
4. Operate retarder at highest braking stage.
Constant-air pressure (p
y
) control current must reach values given on table on pages 93 ff.
5. Set the rotary switch of the temperature simulator (99/2) to 105
o
C cooling water temperature. The
constant-air pressure p
y
must drop below the set maximum pressure. Set rotary switch of
temperature simulator (99/2) to 125
o
C cooling water temperature.
There must be no more output of constant-air pressure p
y
.
6. Set rotary switch of temperature simulator (99/2) again to 95
o
C cooling water temperature.
Wasser l
99/2
39
40
11045
Notice
Pay attention to the correct connection of the plugs for water and oil.
If the two sensors are too far away from each other, then these have to be checked separated.
Diagnosis / Troubleshooting Checking Temperature Adaption
Diagnosis / Troubleshooting Checking Temperature Adaption
Page 92
Aftersales Service Manual Voith Retarder 115 E
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7. Set rotary switch of temperature simulator (99/2) to 185
o
C oil temperature.
The constant-air pressure must drop below the set maximum pressure.
8. Set rotary switch of temperature simulator (99/2) to 225
o
C oil temperature.
There must be no more output of constant-air pressure p
y
.
9. Take measurement for resistance on both temperature sensors according table on page 93 ff.
10. Switch-off vehicle ignition!
11. Reconnect electrical connection lead cooling water (39) and electrical connection lead oil (40) to
temperature sensors cooling water (19) and oil (20).
Diagnosis / Troubleshooting Table of Measurements
Diagnosis / Troubleshooting Table of Measurements
Page 93
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
4.10 Table of Measurements
Digiprop without CAN
With pressure sensor
1) Retarder stage switch in highest shift position!
2) The code-number is on the control unit.
3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!)
4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
5) The values are not steadily because of continuous control in the closed loop (however within the stated range).
.
Code-Number
2)
OLD NEW
Amperage
control current mA
1) 3) 5)
Constant-air pressure (p
y
)
(static)
4) 1)
nominal value [bar]
Pump pressure
(dynamic)
1)
v
ps
= 1000 r.p.m.

(minimum value) [bar]
038 138 396 - 596 2,05 - 2,35 18
050 150 365 - 565 1,60 - 1,90 13,5
051 151 379 - 579 1,80 - 2,10 15
052 152 396 - 596 2,05 - 2,35 17
053 153 423 - 623 2,45 - 2,75 20
055 155 396 - 596 2,05 - 2,35 17
057 157 409 - 609 2,25 - 2,55 18,5
058 158 409 - 609 2,25 - 2,55 18,5
079 179 440 - 640 2,70 - 3,00 22
080 180 440 - 640 2,70 - 3,00 22
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Diagnosis / Troubleshooting Table of Measurements
Diagnosis / Troubleshooting Table of Measurements
Page 94
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Digiprop with CAN
With pressure sensor
1) Retarder stage switch in highest shift position!
2) The code-number is on the control unit.
3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!)
4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
5) The values are not steadily because of continuous control in the closed loop (however within the stated range).

.
Code-Number
2)
Amperage
control current mA
1) 3) 5)
Constant-air pressure (p
y
)
(static)
4) 1)
nominal value [bar]
Pump pressure
(dynamic)
1)
v
ps
= 1000 r.p.m.

(minimum value) [bar]
502 440 - 640 2,70 - 3,00 22
504 440 - 640 2,70 - 3,00 22
508 440 - 640 2,70 - 3,00 22
510 430 - 630 2,55 - 2,85 21
512 440 - 640 2,70 - 3,00 22
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Diagnosis / Troubleshooting Table of Measurements
Diagnosis / Troubleshooting Table of Measurements
Page 95
Aftersales Service Manual Voith Retarder 115 E
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Without pressure sensor / without CAN
1) Retarder stage switch in highest shift position!
2) The code-number is on the control unit.
3) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!)
4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
5) The values are not steadily because of continuous control in the closed loop (however within the stated range).

Code-Number
2)
OLD NEW
Amperage
control current mA
1) 3) 5)
Constant-air pressure (p
y
)
(static)
4) 1)
nominal value [bar]
Pump pressure
(dynamic)
1)
v
ps
= 1000 r.p.m.
(minimum value) [bar]
059 159 534 - 546 2,60 - 3,10 22
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Diagnosis / Troubleshooting Table of Measurements
Diagnosis / Troubleshooting Table of Measurements
Page 96
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
VERA DAFBUS
1) Retarder stage switch in highest shift position!
2) If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!)
3) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
4) The values are not steadily because of continuous control in the closed loop (however within the stated range).

Serial-Number Amperage
control current mA
1) 2) 4)
Constant-air pressure (p
y
)
(static)
3) 1)
nominal value [bar]
Pump pressure
(dynamic)
1)
v
ps
= 1000 r.p.m.
(minimum value) [bar]
H67.276320 440 - 640 2,70 - 3,00 22
Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.
Diagnosis / Troubleshooting Table of Measurements
Diagnosis / Troubleshooting Table of Measurements
Page 97
Aftersales Service Manual Voith Retarder 115 E
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Voltage measurement at the pressure sensor


Notice
These values represent the state of the art at the time going to print. The manufacturer reserves the right
to make further modifications.
0
1
2
3
4
5
0,5
1,5
2,5
3,5
4,5
0
0,5 1 1,5 2 2,5 3 3,5 4
[ BAR ]
[ V ]
11046
Diagnosis / Troubleshooting Table of Measurements
Diagnosis / Troubleshooting Table of Measurements
Page 98
Aftersales Service Manual Voith Retarder 115 E
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Resistance measuring at the temperature sensor

Temperature Resistor
20C 10 C 1039 - 1117
60C 10 C 1194 - 1271
80C 10 C 1271 - 1347
Notice
The measuring in one temperature area normally is sufficient.
These values represent the state of the art at the time going to print. The manufacturer reserves the right
to make further modifications.
Removing, Installing Retarder
Removing, Installing Retarder
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5. Removing, Installing Retarder
Removing, Installing Retarder
Page 100
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Removing, Installing Retarder

Illustration: Removing, installing retarder
Prior work
Cooling water drained *
Oil drained of retarder
(see page 26)
Propeller shaft at the gearing flange
removed *
Oil drained of gearbox *
Waterneck removed
(see page 123)
Speedometer sensor removed *
Output shaft-flange removed *
* Notice the information of the vehicle
manufacturer

25100
25000
850
25300
25300
4100
25200
25200
850/1
11047
Notice
The shim must always be determined newly,
if:
taper roller bearing (800) is renewed
Retarder is installed at gearbox
Retarder was repaired
Gearbox was repaired
850/1 Taper roller bearing
850 Outer race
Only removing, if the tapered
roller bearing is replaced or a
new shim enclosed
4100 Screw plug
M 30 x 1,5
Inhex-head w.a.f. 17
100 Nm (100 Nm)
25000 Shim
25100 O-Ring, renewed
coat with silicone-free and
non-corrosive grease for
installation
25200 Hex.-head screw
M 10 x 70
Hex head w.a.f. 16
58 Nm
25300 Hex.-head screw
M 10 x 60
Hex head w.a.f. 16
58 Nm
Removing, Installing Retarder
Removing, Installing Retarder
Page 101
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Special tools: Tool for local fabrication
Measuring device Drive in tool Puller Threaded bolt
Bearing outer ring Bearing outer ring
98/1 98/3 98/4

Sealants and lubricants
O-Ring Silicone-free and
non-corrosive grease
Retarder housing Omnifit FD 10-1042
67.3224.10 67.3319.10
FJ 6280 0
486 265
67.3320.10
15
80
M
1
0
28028e
Material: St37-2, DIN 17100 (1.80)
Removing, Installing Retarder
Removing, Installing Retarder
Page 102
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Removing
1. Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove with
appropiate lifting device retarder from gearbox.
Achtung!
Two version of the screw plugs (4100) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to
print.
The integrated sealing rings must be checked for possible damages during the inspection of oil level;
replace completely if necessary.
B) Version with loose inserted copper-sealing ring.
In this Aftersales Workshop Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in
brackets are valid.
The copper-sealing rings have to be renewed in general.
25300
11049
25200
25200
4100
Removing, Installing Retarder
Removing, Installing Retarder
Page 103
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98/4 Puller bearing outer ring 67.3320.10
2. Remove O-Ring (25100) from gearbox.

3. Pull off outer ring (850) with puller bearing outer ring (98/4) and remove shim (25000).
11050
850
25000
98/4
25100
F J 6 2 8 0 0
4 8 6 2 6 5
Notice
Carry out following working step, if:
- taper roller bearing (800) is renewed
- Retarder is installed at gearbox
- Retarder was repaired
- Gearbox was repaired
Removing, Installing Retarder
Removing, Installing Retarder
Page 104
Aftersales Service Manual Voith Retarder 115 E
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Assembling
1. Determine thickness of shim as follows:


1.1 Measure the distance "B" between bearing surface on retarder side of the gearbox and the bearing
surface of the shim and note value.
Notice
The shim must always be determined newly, if:
taper roller bearing (800) is renewed
Retarder is installed at gearbox
Retarder was repaired
Gearbox was repaired
11051
B
Attention!
The measurings described below may only carried out at ambient temperature and with the retarder in
vertical position (see illustration)!
Removing, Installing Retarder
Removing, Installing Retarder
Page 105
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1.2 Put the bearing outer ring (850) on the taper roller bearing (850/1).

98/1 Measuring device 67.3224.10
1.3 Put measuring device (98/1) on gearbox and tighten hex.-head screws handtight (3 Nm).
1.4 Put the lever from position 1 in position 2 to pressurize the drive shaft with a defined preload of
approx. 400 N.
1.5 Turn the pinion by hand 15 times clockwise and after that 15 times counterclockwise.
850
850/1
11052
98/1
Pos.1
Pos. 2
11053
Removing, Installing Retarder
Removing, Installing Retarder
Page 106
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1.6 Set the vernier depth gauge on gearbox seperation area and zero vernier depth gauge.
1.7 Put vernier depth gauge on the measuring area of the measuring plate.
1.8 Measure distance of measuring area of the measuring plate to seperation area of the retarder
housing and note value "A".
1.9 Determine thickness of shim as follows:
Thickness of shim = dimension B minus dimension A minus 0,02mm
11054
11055
Removing, Installing Retarder
Removing, Installing Retarder
Page 107
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98/3 Drive in tool 67.3319.10
2. Put shim (25000) into the gearbox housing (if removed).


3. Insert bearing outer ring (850 if removed) into the gearbox housing and knock this with the drive in
tool (98/3) in as far as possible.
Notice
The thicker shim must always be placed first in the gearbox housing.
11056
850
25000
98/3
Notice
If taper roller bearing was replaced, also replace the bearing outer ring (850).
Notice
If necessary warm housing for the simpler assembly in the area of the bearing outer ring to
approx. 80C.
Removing, Installing Retarder
Removing, Installing Retarder
Page 108
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4. Clean sealing surface of retarder housing (1).
5. Turn gearbox till the sealing surface points up (gearing stands vertically).
6. Clean sealing surface of gearbox housing and coat with sealant Loctite 5203.
7. Coat O-Ring (25100) with silicon free and non-corrosive grease and place in gearbox.
8. Turn two threaded bolts M 10 x 80 (see arrows) into the gerarbox housing .
The threaded bolts are needed so that the sealing surfaces (gearbox/retarder) can be assembled
congruently.
11057
1
11058
25100
Removing, Installing Retarder
Removing, Installing Retarder
Page 109
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
9. Place retarder at gearbox and fix this with 5 hex.-head screws (25200).
Tightening torque hex.-head screws (25200): 58 Nm
10. Screw out again the two threaded bolts M 10 x 80.
11. Insert the 17 hex.-head screws (25300) and tighten them.
Tightening torque hex.-head screws (25300): 58 Nm
25200
25200
25200
25300
11059
Repair Retarder
Repair Retarder
Page 110
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
6. Repair Retarder
6.1 Overall Illustration of Main Components ...................................................111
6.2 Removing, Checking and Installing Casing Ventilation.............................112
6.3 Removing, Checking and Installing Silencer.............................................122
6.4 Removing and Installing Water Neck........................................................123
6.5 Removing, Checking and Installing Heat Exchanger................................124
6.6 Removing and Installing Oil Tank Cover...................................................133
6.7 Removing, Installing Non-Return Valve Outlet .........................................136
Repair Retarder Overall Illustration of Main Components
Repair Retarder Overall Illustration of Main Components
Page 111
Aftersales Service Manual Voith Retarder 115 E
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6.1 Overall Illustration of Main Components
Illustration: Components Retarder 115 E
4200
3100
2500
2600
107
7500
6101
6100
6101
9000
4100
3900
2900
5500
3700
4000
103
6600
5200
5300
3300
3300
2800
5400
5600
5300
5200
109
7300
7300
7600
7500
3100
2000
8000
6400
20100
20000
20200
6600
6600
20000
20200
20100
4100
2300/1
2301
2300
2300/2
2300/3
3500
3800
3850
3850
6700
6700
2100
2105
2106
1700
1600
3100
2810
20300
20400
6700
11060
100
20300
20400
100 Retarder housing
103 Screw plug
M12 x 1,5,
inhex-head, w.a.f. 6
107 Oil drain plug Retarder
M 24 x 1,5,
inhex.-head, w.a.f. 12
109 Screw plug
M 24 x 1,5,
inhex.-head, w.a.f. 12
1600 Valve cover
1700 O-Ring 60 x 3
2000 Top cover
2100 Non-return valve outlet, complete
2105 O-Ring, 34 x 3
2106 O-Ring, 54 x 3
2300 Casing ventilation
2300/1 Valve insert
2300/2 Float
2300/3 Float cage
2301 O-Ring 55 x 3
2500 Bottom cover
2600 Bottom gasket
2800 Cover for casing ventilation
2810 Vent and air filter
M 12 x 1,5,
hex.-head, w.a.f. 17
2900 Gasket
3100 Combined hex.-head screw
M 8 x 30,
hex.-head, w.a.f. 13
3300 Combined hex.-head screw
M 8 x 80,
hex.-head, w.a.f. 13
3500 Screw plug with sieve,
M 30 x 1,5,
inhex.-head, w.a.f. 17
3700 Proportional valve
3800 Damping plate
3850 O-Ring 16 x 3
3900 Combined hex.-head screw
M 8 x 20,
hex.-head, w.a.f. 13
4000 Hex.-head nut M8,
hex.-head, w.a.f. 13
4100 Screw plug
M 30 x 1,5,
inhex.-head, w.a.f. 17
4200 Screw plug
M 24 x 1,5,
inhex.-head, w.a.f. 12
5200 Temperature sensor
5300 Sealing ring A 14 x 20
5400 Corrugated spring
5500 Disc (silencer) D 30 x 4
5600 Retaining ring JL 30 x 1,2
6100 Pipe
6101 O-Ring 15,3 x 2,4
6400 Heat exchanger
6600 Hex.-head screw
M 14 x 45,
hex.-head, w.a.f. 22
old:
hex.-head screw with flange
M 14 x 40,
hex.-head, w.a.f. 19
6700 Washer A15
7300 O-Ring 15 x 4
7500 O-Ring 45 x 5
7600 O-Ring 25 x 4
8000 Intermdiate plate 196 x 144 x 2
9000 Pressure sensor 0 to 4 bar
20000 Water neck
20100 Gasket, renew
20200 Combined hex.-head screw
M 8 x 80,
hex.-head, w.a.f. 13
20300 Screw plug
M 14 x 1,5,
hex.-head, w.a.f. 13
20400 Sealing ring A 14 x20
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
Page 112
Aftersales Service Manual Voith Retarder 115 E
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6.2 Removing, Checking and Installing Casing Ventilation

Prior jobs
Vehicle ignition switched off
Retarder switched off
Proportional valve and damping plate removed (see page 140)
Notice
This working step can be performed with retarder removed or installed.
Attention! Risk of injury!
Retarder housing is hot!
Repair Retarder Removing, Checking and Installing Casing Ventilation
Page 113
Aftersales Service Manual Voith Retarder 115 E
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Repair Retarder Removing, Checking and Installing Casing Ventilation

Illustration: Casing ventilation

11061
2300/1
2900
2800
3300
2301 2300
2300/2
2300/3
6101
6100
6101
2300 Casing ventilation
2300/1 Valve insert
2300/2 Float
desired weight 11g 1 g
2300/3 Float cage
2301 O-Ring 55 x 3, renew,
coat with silicon-free and non-
corrosive grease for installation
2800 Cover casing ventilation
2900 Gasket casing ventilation,
renew
3300 Combined hex.-head screw
M 8 x 80, renew
hex.-head, w.a.f. 13, 30 Nm
6100 Air-pipe
coat with silicon-free and non-
corrosive grease for installation
6101 O-Ring 15,2 x 2,4, erneuern
coat with silicon-free and non-
corrosive grease for installation
sealant and lubricant
O-Ring silicon-free and
non-corrosive grease
Float Methylated spirit
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
Page 114
Aftersales Service Manual Voith Retarder 115 E
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Special tools: Tool for local fabrication
Impact puller Adapter Test ring
99/5 98/7 99/7

Notice
The test ring also can be ordered with Voith item-number 67.2757.10 at Voith Turbo GmbH&Co. KG.
40,5 mm

7

m
m
60 mm
28049e
Material: St 37
Weight: 0,085 kg
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
Page 115
Aftersales Service Manual Voith Retarder 115 E
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Removing
1. Screw out combined hex.-head screws (3300).
2. Remove cover (2800) with gasket (2900) from retarder housing.
Clean sealing surface.
3300
11063
11064
2900
2800
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
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Aftersales Service Manual Voith Retarder 115 E
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3. Remove air-pipe (6100) and O-Rings (6101).

99/5 Impact puller 53.7712.10
98/7 Adapter 53.9428.10
4. Use impact puller (99/5) and adapter (98/7) to extract valve insert of retarder housing (100).
11065
6101
6100
6101
11066
99/5
100
98/7
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
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Aftersales Service Manual Voith Retarder 115 E
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5. Take float (2300/2) and float cage (2300/3) out of retarder housing (100).
6. Lever out O-Ring (2301) of groove of valve insert (2300/1) and remove this.
2300/2
2300/3
11067
100
11068
2300/1
2301
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
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Checking
1. Check float (2300/2) on damages of surfaces and sealing surfaces (arrow).
2. Weigh float (2300/2).
The desired weight is 11 g 1 g. If the weight is more than the desired weight renew complete casing
ventilation.


99/7 Test ring 67.2757.10
3. Check sealing edge of radial shaft sealing ring (arrow) in valve insert (2300/1). Put down valve insert
(2300/1) on float (2300/2) than weigh down valve insert with test ring (99/7).
Fill up the hollow space between float and upper edge of valve insert with methylated spirit. If the
sealing edge is not damaged, the fluid level must not alter in the course of 1 minute.
If necessary, renew complete casing ventilation.
2300/2
11069
Notice
Oil has penetrated into the float, the retarder is impaired in its operation.
2300/2
2300/1
99/7
11070
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
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Aftersales Service Manual Voith Retarder 115 E
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Installing
1. Coat new O-ring (2301) with silicon-free and non-corrosive grease and pull on valve insert (2300/1).
2. Insert float (2300/2) and float cage (2300/3) in valve insert (2300/1).
11071
2300/1
2301
2300/1
2300/2
2300/3
11072
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
Page 120
Aftersales Service Manual Voith Retarder 115 E
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99/5 Impact puller 53.7712.10
98/7 Adapter 53.9428.10
3. Coat bore of casingventilation in retarder housing (100) with silicon-free and non-corrosive grease.
4. Insert casing ventilation in retarder housing (100).
5. Use the impact puller (99/5) and adapter (98/9) to knock in the casing ventilation.
6. Coat new O-rings (6101) with silicon-free and non-corrosive grease and pull over air-pipe (6100).
7. Coat bore for air-pipe (6100) in cover (2000) with silicon-free and non-corrosive grease.
8. Slip air-pipe (6100) in to the cover (2000).
11073
99/5
100
98/7
6100
2000
11074
6101
Repair Retarder Removing, Checking and Installing Casing Ventilation
Repair Retarder Removing, Checking and Installing Casing Ventilation
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Aftersales Service Manual Voith Retarder 115 E
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9. Place new gasket (2900) on retarder housing.
10. Coat bore for air-pipe (6100) in cover (2800) with silicon-free and non-corrosive grease.
11. Slip cover (2800) in air-pipe (6100) and place this at retarder housing.
12. Screw in combined hex.-head screws (3300) and screw them tight.
Tightening torque combined hex.-head screw (3300): 30 Nm.
11075
2900
2800
3300
6100
11076
Repair Retarder Removing, Cleaning and Installing Silencer
Page 122
Aftersales Service Manual Voith Retarder 115 E
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Repair Retarder Removing, Cleaning and Installing Silencer

Illustration: Silencer
6.3 Removing, Cleaning and
Installing Silencer

Cleaning agent
Kd.-Sach-Nr.
Voith-Sach-Nr.
5500
5400
5600
11077
Notice
This work step can be performed with retarder
installed or removed.
5400 Corrugated spring
5500 Disc (silencer) D 30 x 4,
clean with appropriate cle-
aning agent (Benzine) and
blow out with compressed-air
5600 Circlip JL 30 x 1,2
dished side must face
silencer
Silencer Benzine
Repair Retarder Removing and Installing Water Neck
Page 123
Aftersales Service Manual Voith Retarder 115 E
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Repair Retarder Removing and Installing Water Neck

Illustration: Water neck
6.4 Removing and Installing
Water Neck
Prior jobs
Vehicle ignition OFF
Retarder switched off
Cooling water drained

11078
20100
20000
20000
20200
20200
20100
Kd.-Sach-Nr.
Voith-Sach-Nr.
20000 Water neck
20100 Gasket, renew
20200 Combined hex.-head screw
M 8 x 80
hex.-head, w.a.f. 13,
30 Nm
Repair Retarder Removing, Checking, Installing Heat Exchanger
Repair Retarder Removing, Checking, Installing Heat Exchanger
Page 124
Aftersales Service Manual Voith Retarder 115 E
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6.5 Removing, Checking, Installing Heat Exchanger
Prior jobs
Vehicle ignition OFF
Retarder removed (see page 99)
With installed retarder:
Oil drained from retarder (see page 26 ff)
Cooling water drained
Water neck removed (see page 123)
Notice
If necessary, the heat exchanger can be removed also with mounted retarder.
Attention!
The heat exchanger must be secured before removing with appropriate parts!
Notice
A throttle disk can be installed between heat exchanger and housing at retarder with ending number .10
in the type plate. This must be removed. In connection with this, the retarder control unit has to be
progammed on the latest for this retarder valid code and the non-return valve (outlet) must be installed
as of code number 67.2550.22.
Repair Retarder Removing, Checking, Installing Heat Exchanger
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Repair Retarder Removing, Checking, Installing Heat Exchanger

Illustration: Removing heat exchanger

Lubricant
4200
11079
107
4200
7300
7300
7600
7500
7500
6400
6600
6600
6700
6700
107 Oil drain plug retarder
M 24 x 1,5,
inhex.-head, w.a.f. 12,
47 Nm (80 Nm)
4200 Oil drain plug oil tank
M 24 x 1,5,
inhex.-head, w.a.f. 12,
47 Nm (80 Nm)
6400 Heat exchanger
6600 Hex.-head screw
M 14 x 45, renew
hex.-head, w.a.f. 22,
Pre-torque: 50 Nm
Final torque: 30turning angle
old version:
hex.-head screw
M14 x 40 with flange,
hex.-head, w.a.f. 19
6700 Washer A15
7300 O-ring 15 x 4, renew
coat with silicon-free and non-
corrosive grease for installation
7500 O-ring 45 x 5, renew
coat with silicon-free and non-
corrosive grease for installation
7600 O-ring 25 x 4, renew
coat with silicon-free and non-
corrosive grease for installation
O-rings silicon-free and
non-corrosive grease
Repair Retarder Removing, Checking, Installing Heat Exchanger
Repair Retarder Removing, Checking, Installing Heat Exchanger
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Aftersales Service Manual Voith Retarder 115 E
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Attention!
Two versions of screw plugs (107, 4200) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to
print.
The integrated sealing rings must be checked for possible damages during the installation of the heat
exchanger; replace complete screw plug if necessary.
B) Version with loose inserted copper-sealing ring.
In this Aftersales Service Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in
brackets are valid.
The copper-sealing rings are generally to be renew.
Repair Retarder Removing, Checking, Installing Heat Exchanger
Repair Retarder Removing, Checking, Installing Heat Exchanger
Page 127
Aftersales Service Manual Voith Retarder 115 E
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Special tool
Pressure test plate
99/6

Commercially available tool
Turning angle measuring tool 3/4 e.g. Messrs Richard Abr. Herder
Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
Ordering No. 8200-02
67.1948.10
Repair Retarder Removing, Checking, Installing Heat Exchanger
Repair Retarder Removing, Checking, Installing Heat Exchanger
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Aftersales Service Manual Voith Retarder 115 E
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4200
107
4200
11080
Notice
If this work sequence is performed with the retarder in situ, the following prior jobs must be performed:
1. Screw out oil-drain plugs (107 and 4200) as well as the oil filler plug (for quicker drain) and
drain oil.
2. Shut, if available, the stopcocks in the cooling-water circuit of the vehicle.
3. Remove the cooling water hoses of the heat exchanger.
Repair Retarder Removing, Checking, Installing Heat Exchanger
Repair Retarder Removing, Checking, Installing Heat Exchanger
Page 129
Aftersales Service Manual Voith Retarder 115 E
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Removing
1. Screw out hte four hex.-head screws (6600) and remove washers (6700).
2. Remove heat exchanger (6400).
3. Remove O-rings (7300, 7500 and 7600).
11081
6400
6600
6600
6600
6700
6700
6700
11082
7300
7500
7300
7600
7500
7300
Repair Retarder Removing, Checking, Installing Heat Exchanger
Repair Retarder Removing, Checking, Installing Heat Exchanger
Page 130
Aftersales Service Manual Voith Retarder 115 E
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Checking

99/6 Pressure test plate 67.1948.10
1. Install pressure test plate (99/6) with O-rings at heat exchanger (6400) and connect compressd-air
pressure lines to bottom connection (arrow).
2. Fill heat exchanger (6400) on water side with hot water (approx. 70
o
C).
3. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the
heat exchanger).

99/6 Pressure test plate 67.1948.10
4. Connect compressed-air line to top connection (arrow).
5. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the
heat exchanger).

99/6 6400
11083
Notice
If air bubbles form in the hot water the heat exchanger is leaking and must be exchanged.
99/6 6400
11084
Notice
If air bubbles form in the hot water the heat exchanger is leaking and must be exchanged.
New heat exchanger are wetted with corrosion-inhibiting oil in the water- and oil section of the heat
exchanger.
Prior to installing a new heat exchanger, drain any corrosion-inhibiting oil which may have collected and
flush it out with hot water in the water section of the heat exchanger.
Repair Retarder Removing, Checking, Installing Heat Exchanger
Repair Retarder Removing, Checking, Installing Heat Exchanger
Page 131
Aftersales Service Manual Voith Retarder 115 E
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Installing
1. Fit new O-rings (7300, 7500 and 7600) in the bores and coat them with silicon-free and
non-corrosive grease.
2. Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) with
washers (6700) tight.
Initial torque: 50 Nm
Final torque: 30turning angle
11085
7300
7300
7500
7500
7300
7600
11086
6400
6600
6600
6600
6700
6700
6700
Repair Retarder Removing, Checking, Installing Heat Exchanger
Repair Retarder Removing, Checking, Installing Heat Exchanger
Page 132
Aftersales Service Manual Voith Retarder 115 E
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3. Install retarder, if necessary (see page 99 ff).
4. Fill in cooling-water and bleed cooling-water circuit.
If available, open the check valves in the flow- and return pipe of the cooling-water section.

5. Flush the retarder, if the heat exchanger has leaked as follows:
To flush the retarder, fill it with 7,0 litres of engine- or flushing oil. Apply the brakes gently several
times to flush out the retarder system and drain the oil through the oil drain plugs (107 and 4200).
Repeat the procedure 2 or 3 times.
6. Check integrated sealing rings of oil-drain plugs for possible damages;
renew oil-drain plug if necessary.
7. Screw oil-drain plug (107, 4200) tight
Tightening torque oil-drain plug (107, 4200): 47 Nm (80 Nm)
8. Fill in retarder oil (see page 29).
9. If heat exchanger were leaking, deoil cooling- and heatingsystem of vehicle according manufacturer
instructions.
Attention!
If the heat exchanger leaks, there is water present in the retarder. If the retarder is filled up, a mixture of
oil and water is created, causing the oil in the retarder to foam and escape through the casing ventilation
system to the atmosphere. For this reason, it is indispensible to flush out the retarder after repair!
While flushing, apply the brake gently several times to prevent the retarder oil warming up excessively.
4200
107
4200
11087
Repair Retarder Removing, Installing Oil Tank Cover
Page 133
Aftersales Service Manual Voith Retarder 115 E
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Repair Retarder - Removing, Installing Oil Tank Cover

Illustration: Top Oil Tank Cover
6.6 Removing, Installing Oil Tank
Cover
A) Top Oil Tank Cover
Prior jobs
Vehicle ignition switched OFF
Retarder switched off
Lubricant
6101
6100
6101
8000
2000
9000
3300
3100
11088
Notice
This working step can be performed with
retarder removed or installed..
Attention! Risk of injury!
The retarder housing is hot!
2000 Top cover
3100 Combined hex.-head screw
M 8 x 30, renew
hex.-head, w.a.f. 13
30 Nm
3300 Combined hex.-head screw
M 8 x 80, renew
inhex.-head, w.a.f. 13
30 Nm
6100 Air-pipe
6101 O-Ring 15,3 x 2,4,
renew
coat with silicon-free and
non-corrosive grease for
installation
8000 Intermediate plate, renew
9000 Pressure sensor
O-ring Silicon-free and
non-corrosive grease
Repair Retarder Removing, Installing Oil Tank Cover
Page 134
Aftersales Service Manual Voith Retarder 115 E
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Repair Retarder Removing, Installing Oil Tank Cover

Illustration: Bottom Oil Tank Cover
B) Bottom Oil Tank Cover
Prior jobs
Vehicle ignition switched OFF
Retarder switched off
Retarder oil drained (see page 26 ff)

11089
4200
3100
2500
2600
2500 Bottom cover
2600 Bottom gasket, renew
3100 Combined hex.-head screw
M 8 x 30, renew,
hex.-head, w.a.f. 13,
Heed tightening sequence!
30 Nm
4200 Oil drain plug oil tank
M 24 x 1,5
inhex.-head, w.a.f. 12
47 Nm (80 Nm)
Repair Retarder Removing, Installing Oil Tank Cover
Repair Retarder Removing, Installing Oil Tank Cover
Seite 135
Aftersales Service Manual Voith Retarder 115 E
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Installation note
Pay attention to the mounting position of the gasket and the cover!
Tighten all combined-hex.-head screws in specified sequence 1 to 17 first with 14 to 19 Nm.
The combined-hex.-head screws are then tightened in the same sequence with 30 Nm.
Attention!
Two versions of screw plugs (4200) are possible:
A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to
print.
The integrated sealing rings must be checked for possible damages during the installation of the heat
exchanger; replace complete screw plug if necessary.
B) Version with loose inserted copper-sealing ring.
In this Aftersales Service Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in
brackets are valid.
The copper-sealing rings are generally to be renew.
12
13
14
15
16
7
4
3
2
1
5
6
7
8
9
10
11
11090
Repair Retarder Removing, Installing Non-Return Valve (Outlet)
Page 136
Aftersales Service Manual Voith Retarder 115 E
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Repair Retarder Removing, Installing Non-Return Valve (Outlet)

Illustration: Non-Return Valve (Outlet)
6.7 Removing, Installing
Non-Return Valve (Outlet)
Prior job
Retarder oil drained (see page 26 ff)
11091
2105
2106
1700
1600
3100
2100
Kd.-Sach-Nr.
Voith-Sach-Nr.
1600 Valve cover
Heed mounting position!
1700 O-ring 60 x 3, renew,
coat with silicon-free and
non-corrosive grease for
installation
2100 Non-return valve (outlet)
Heed mounting position!
coat bore with silicon-free and
non-corrosive grease for
installation
2105 O-ring 34 x 3, renew,
coat with silicon-free and
non-corrosive grease for
installation
2106 O-ring 54 x 3, renew,
coat with silicon-free and
non-corrosive grease for
installation
3100 Combined hex.-head screw
M 8 x 30
hex.-head, w.a.f. 13
30 Nm
Lubricant
O-ring Silicon-free and
non-corrosive grease
Repair Retarder Removing, Installing Non-Return Valve (Outlet)
Repair Retarder - Removing, Installing Non-Return Valve (Outlet)
Page 137
Aftersales Service Manual Voith Retarder 115 E
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Special tool
Puller
non-return valve (outlet)
71/1
153.00005210
Repair Retarder Removing, Installing Non-Return Valve (Outlet)
Repair Retarder Removing, Installing Non-Return Valve (Outlet)
Page 138
Aftersales Service Manual Voith Retarder 115 E
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Removing
1. Screw out combined hex.-head screws (3100) of valve cover (1600).
2. Remove valve cover (1600).

71/1 Puller
3. Position puller (71/1) up to engaging to torque limiter valve and pull out non-return valve of its seat.
4. Remove O-rings (1700, 2106 and 2105).
Installing
1. Install non-return valve in reverse sequence.
11092
71/1
Control Parts
Control Parts
Page 139
Aftersales Service Manual Voith Retarder 115 E
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7. Control Parts
7.1 Removing, Installing Proportional Valve and Damping Plate....................140
7.2 Removing, Installing Temperature Sensor Cooling Water........................141
7.3 Removing, Installing Temperature Sensor Oil ..........................................142
7.4 Removing, Installing Pressure Sensor......................................................143
Control Parts Removing, Installing Proportional Valve and Damping Plate
Page 140
Aftersales Service Manual Voith Retarder 115 E
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Control Parts Removing, Installing Proportional Valve and Damping Plate

Illustration: Proportional Valve and Damping Plate
7.1 Removing, Installing
Proportional Valve and
Damping Plate
Prior jobs
Vehicle ignition switched off
Retarder switched off
Supply-air pressure discharged
Plug at the proportional valve as well as
connector checked for damage or wear (notch-
es).
Lunbricant
11093
26
39
3900
4000
3800
3900
3700
4000
3850
3850
26 Compressed-air line p
v
39 Electrical connection lead
3700 Proportional valve
3800 Damping plate,
renew if necessary
3850 O-ring 16 x 3, renew
coat with silicon-free and
non-corrosive grease for
installation
3900 Hex.-head screw
M 8 x 20, renew,
hex.-head, w.a.f. 13,
30 Nm
4000 Hex.-had nut M8,
renew,
18 Nm
Achtung
If, during repair work the hex.-head nuts
(4000) or the hex.-head screws (3900) have to
be unscrewed the damping plate also has to
be checked on mechanical and aging dama-
ges and to be renewed, if necessary.
O-ring Silicon-free and
non-corrosive grease
Control Parts Removing, Installing Temperature Sensor Cooling Water
Page 141
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Control Parts Removing, Installing Temperature Sensor Cooling Water

Illustration: Temperature Sensor Cooling Water
7.2 Removing, Installing
Temperature Sensor Cooling
Water
Prior jobs
Vehicle ignition switched off
Retarder switched off
Cooling water drained

5300
5200
1109
5200 Temperature sensor cooling
water,
28 Nm
5300 Sealing ring A14 x 20,
renew
Attention! Risk of injury!
The cooling water is hot!
Notice
Please, bear in mind to the instructions
regarding the quality of coolant given from the
vehicle manufacturer or Voith Turbo cooling-
water quality list (Voith Item-No. 67.2224.10).
Control Parts Removing, Installing Temperature Sensor Oil
Page 142
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Control Parts Removing, Installing Temperature Sensor Oil

Illustration: Temperature Sensor Oil
7.3 Removing, Installing
Temperature Sensor Oil
Prior jobs
Vehicle ignition switched off
Retarder switched off

5300
5200
11095
5200 Temperature sensor Oil,
28 Nm
5300 Sealing ring A14 x 20,
renew
Control Parts Removing, Installing Pressure Sensor
Page 143
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
Control Parts Removing, Installing Pressure Sensor

Illustration: Pressure Sensor
7.4 Removing, Installing Pressure
Sensor
Prior jobs
Vehicle ignition switched off
Retarder switched off

9000
11096
9000 Pressure sensor,
30 Nm
Appendix
Appendix
Page 144
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
8. Appendix
8.1 Retarder Data Sheet .................................................................................145
8.2 Tightening Torques...................................................................................146
Appendix Retarder Data Sheet
Appendix Retarder Data Sheet
Page 145
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
8.1 Retarder Data Sheet
* dependent from the retarder and vehicle configuration
Data Sheet Voith Retarder 115 E
Max. possible braking torque at prop shaft M
(Br) max
at retarder ratio 1:2.03 * 3700 Nm
Maximum Retarder Speed n
max.
= 4800 min
-1
at v
ps
= 2365 min
-1
Working Medium Oil according Operating Specification
Control Medium Compressed-Air
Supply-Air Pressure 7 to 10 bar
Service filling:

- Service filling (Oil change, inspection of oil level)

- after exchange of heat exchanger


7,0 Litre

7,5 Litre
Weight of unit (with het exchanger unit and service filling) approx. 73 kg
Appendix Tightening Torques
Appendix Tightening Torques
Page 146
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11
8.2 Tightening Torques
Pos.-No.: Title Dimensions Tightening torque
103 Screw plug M 12 x 1,5, Inhex.-head, w.a.f. 6 With integrated sealing ring: 13 Nm
With a loose sealing ring: 20 Nm
105 Screw plug M 22 x 1,5, Inhex.-head, w.a.f. 10 With integrated sealing ring: 35 Nm
With a loose sealing ring: 70 Nm
107 Oil drain plug M 24 x 1,5, Inhex.-head, w.a.f. 12 With integrated sealing ring: 47 Nm
With a loose sealing ring: 80 Nm
1400 Dodecagonal nut M 38 x 1,5, w.a.f. 55 426 Nm
2810 Vent and air filter M 12 x 1,5, w.a.f. 17 10 Nm
3100 Combined hex.-head screw M 8 x 30, Hex.-head, w.a.f. 13 30 Nm
3300 Combined hex.-head screw M 8 x 80, Hex.-head, w.a.f. 13 30 Nm
3400 Dowel screw M 14 x 48, Hex.-head, w.a.f. 19 Initial torque: 50 Nm
Final torque: 30turning angle
3500 Screw plug with sieve M 30 x 1,5, Inhex.-head, w.a.f. 17 With integrated sealing ring: 100 Nm
With a loose sealing ring: 100 Nm
3900 Combined hex.-head screw M 8 x 20, Hex.-head, w.a.f. 13 30 Nm
4000 Hex.-head nut M 8, w.a.f. 13 18 Nm
4100 Oil filler plug / screw plug M 30 x 1,5, Inhex.-head, w.a.f. 17 With integrated sealing ring: 100 Nm
With a loose sealing ring: 100 Nm
4200 Oil drain plug M 24 x 1,5, Inhex.-head, w.a.f. 12 With integrated sealing ring: 47 Nm
With a loose sealing ring: 80 Nm
Appendix Tightening Torques
Appendix Tightening Torques
Page 147
Aftersales Service Manual Voith Retarder 115 E
15300009710 / cbtsd 02-11

Pos.-Nr.: Bezeichnung Abmessungen Anziehdrehmoment
5200 Temperature sensor oil / water M 14 x 1,5, Hex.-head, w.a.f. 21 28 Nm with copper sealing ring
6600 Combined hex.-head screw M 14 x 45, Hex.-head, w.a.f. 22 Initial Torque: 50 Nm
Final torque: 30turning angle
9000 Pressure sensor M 16 x 1,5, Hex.-head, w.a.f. 27 30 Nm
20200 Combined hex.-head screw M 8 x 80, Hex.-head, w.a.f. 13 30 Nm
20300 Screx plug M 14 x 1,5, Hex.-head, w.a.f. 13 32 Nm
25200 Hex.-head screw M 10 x 70, Hex.-head, w.a.f. 16 58 Nm
25300 Hex.-head screw M 10 x 60, Hex.-head, w.a.f. 16 58 Nm