Professional Documents
Culture Documents
153.00009710 I 2005-11
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents
Table of Contents
2.8 Warranty 10
Page 2
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents
7 Repair 51
7.1 Components Overview 52
Voith Turbo I 153.00009710 I arrtd I 2005-11
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents
8 Appendix 91
8.1 Tightening Torques 92
Voith Turbo I 153.00009710 I arrtd I 2005-11
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document
Page 5
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document Purpose of this Document
Gearbox-specific documents on the retarder Information on safe, professional installation and removal of the retarder On request
Page 6
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document Symbols and Identifications
Measures for the prevention of danger and its Imminently hazardous situation which, if not Item numbers with a slash
consequences. avoided, will result in death or serious injury.
1.6 Legal/Contact Information
Levels of danger Notes
For questions and work procedures not described in
The warnings are categorized into four levels of
danger: NOTE these documents, contact the respective organisation
for your area.
Information on easier and safer work with the
CAUTION retarder. Voith Turbo
Produktgruppe Retarder
Measures for easier and safer work with the
Potentially hazardous situation which, if not avoided, retarder.
may result in property damage. Postfach 1555
74555 Crailsheim
Distinctions
Deutschland
CAUTION One-step action instruction.
Voith Turbo I 153.00009710 I arrtd I 2005-11
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information
Page 8
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information Product Safety
2.1 Product Safety 2.4 Environmental Protection Damage to property via soiled parts!
Considerable damage or malfunctions may occur due
The retarder is constructed according to state of the Drained fuels and fluids, consumables and old parts
to soiling.
art technology and acknowledged safety regulations. must be disposed of properly.
Ensure cleanliness.
Nevertheless, hazardous situations and property
2.5 Troubleshooting
damage may occur as a result of improper usage, Damage to property via improper cleaning!
maintenance and repair. Voith provides a warranty/goodwill service for
Do not aim the jet of a high-pressure cleaner
Observe safety and warning information. defective parts only.
(steam-jet device) at valves, pressure sensors or
Do not replace parts on mere speculation. ventilators of the retarder.
2.2 Staff Qualification
2.6 Maintenance and Repair 2.7 Driving Mode
Allow only qualified professionals to carry out repair
and maintenance work. Ensure that the retarder is fully functional for all
Danger of burning and scalding via squirting oil!
The oil in the retarder may be hot. vehicle maneuvers, i.e.:
2.3 Safety-Conscious Working - Retarder properly filled with oil
Work carefully.
Voith does not assume any liability for personal injury - Retarder electronics connected and functional
and/or property damage caused by improper and Danger of burning and scalding via hot coolant! - Pneumatic control connected and functional
unprofessional work.
The coolant may be hot.
Observe the following regulations:
Work carefully.
Voith Turbo I 153.00009710 I arrtd I 2005-11
- Accident-prevention regulations
- Other generally acknowledged safety Danger of burns via hot parts!
regulations and occupational health Parts of the retarder may be hot.
- Motor vehicle regulations
Work carefully.
- Safety regulations for handling chemical
substances such as oils and greases Wear protective gloves or use cloths if necessary.
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information Warranty
Page 10
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Page 11
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Overview of the Modules
1900
Voith Turbo I 153.00009710 I arrtd I 2005-11
1600 100
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Overview of the Modules
3500 20000
103
5200/2
20000
Voith Turbo I 153.00009710 I arrtd I 2005-11
107
4200
2005
28004
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Retarder Identification
NOTE
Specify the following data in case you have
questions or are ordering spare parts:
- Serial number (Serien-Nr.)
- Voith item number (Voith-Sach-Nr.)
Voith-Sach-Nr.
Nr.
Ty
pV
R11
=
5E
2.03
; S
er
KW
ien-
/Jah
r
Kd.-Sach-Nr.
et
iR Nr.
h-
ac r.
-S N
ith h-
Vo ac
-S
Kd.
Voith Turbo I 153.00009710 I arrtd I 2005-11
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Controller Identification (VERATM)
Example:
NOTE
Specify the following data in case you have 084
022
e1
questions or are ordering spare parts:
0
.2
6
u .2 T
/ .1 -M TM
6
o 6 -T
s 8
- Serial number (Serial-No.)
5 2 J A
E 0 M
B 7
1 0 J R
J E
v -H
3 -E J V
3
4 .H X it
X
.D X n
0 A X U
/
0 R X ol
- Part number (Part No.)
r
o V XX t
3
n
-N o. o. o
2
6
C
X
4
E t- l-N r
. E
O ar ia de
0
P er ar
Specify the following data of the retarder (see
S et
M N
R
rbo
1
h Tu
X
Voit
page 14): VOI
TH
Voith Turbo
e1 022084
Part-No. VERA.D.H-E02.10-H67.2866.20
OEM-No. 0004463315 / EvoBus
VOITH
X1 X2 X3
2005
28138
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Controller Identification (Digiprop)
Example:
NOTE
Specify the following data in case you have
questions or are ordering spare parts:
- Basic number (Basis-Nr.:)
- Serial number (Serien-Nr.:)
Specify the following data of the retarder (see
page 14): Ba
s
Co is-N
Se de-N r.:
r
- Serial number (Serien-Nr.) VO ien- r.: 53
IT Nr. .
H : xx xxxx
x .12
xx
- Voith item number (Voith-Sach-Nr.) xx
/
Voith Turbo I 153.00009710 I arrtd I 2005-11
Basis-Nr.:
Code-Nr.:
Serien-Nr.:
VOITH
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Function and Control Scheme
2100
1900 Non-return valve (inlet)
2100 Non-return valve (outlet) 4200 K
107
2200 Pressure control valve
Oil sump Coolant
Constant-air pressure py
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Function and Control Scheme
5200/2
300
5500
200
2200
Voith Turbo I 153.00009710 I arrtd I 2005-11
2100
107 4200 K
Constant-air pressure py
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Page 18
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Function Description
3.6 Function Description Proportional valve (3700) If the critical temperature threshold has been
Depending on the intensity of the electric input signal, exceeded, the braking torque is no longer active.
Non-return valve (inlet) (1900) the proportional valve (3700) issues a pneumatic
The controller also adjusts the braking torque if the
When the retarder is switched on, the oil sump is constant-air pressure which acts on the oil tank of the
temperature of the oil increases rapidly, regardless of
pressurized. This opens the non-return valve (inlet) retarder.
the actual temperature of the oil.
(1900) and allows oil into the working space.
Oil temperature sensor (5200/1) and During temperature adaptation or failure of the
Non-return valve (outlet) (2100) coolant (5200/2) retarder, you must use the service brake to slow down
In braking mode, the oil reaches the heat exchanger The temperature sensors are screwed into the cooling the vehicle.
from the working space via the non-return valve system of the vehicle (return pipe from retarder to heat
(outlet) (2100), is cooled down and is fed back into the exchanger) and in the oil duct of the retarder. The Pressure sensor (9000)
system circuit. temperature sensors pass on information on the The pressure sensor (9000) measures the pneumatic
temperature of the coolant and oil to the controller. constant-air pressure. A deviation from the allowed
Pressure control valve (2200) pressure tolerance is recognized as a fault and
Maximum values for the temperature of coolant and
In no-load operation of the retarder, the pressure displayed by the controller.
oil are set in the controller for protection of the cooling
control valve (2200) regulates the lubrication. system and the retarder. To prevent the values being
exceeded, the controller adapts the braking torque of
Casing ventilation (2300) the retarder accordingly via the constant-air
At the beginning of the braking process, the oil expels pressure py.
the air located in the system circuit from the retarder
via the casing ventilation (2300) and a de-aeration The braking torque and the heat produced regulate
Voith Turbo I 153.00009710 I arrtd I 2005-11
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service
Page 20
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Maintenance Intervals
Page 21
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Oil Change
4100
Item No. Designation
107 Screw plug M24x1.5, 4150
hexagon socket head, w.a.f. 12,
with copper sealing ring: 80 Nm
with integrated sealing ring: 47 Nm
108 Sealing ring A24x29, replace
3500 Screw plug M30x1.5,
hexagon socket head, w.a.f. 17,
with copper sealing ring: 130 Nm
with integrated sealing ring: 100 Nm
3550 Sealing ring A30x36, replace
4100 Screw plug M30x1.5,
hexagon socket head, w.a.f. 17,
with copper sealing ring: 130 Nm
with integrated sealing ring: 100 Nm
4150 Sealing ring A30x36, replace
4200 Screw plug M24x1,5, ac
h-
Nr
.
Nr
.
.-S h-
108
with copper sealing ring: 80 Nm
107
Voith Turbo I 153.00009710 I arrtd I 2005-11
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Oil Change
Visual inspection of retarder for leaks before and Ensure that the retarder and ignition are switched
after the oil change. off.
Check prop shaft screws for proper seating and
tighten if necessary (See specifications of vehicle
manufacturer).
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Oil Change
Pressure control valve 2. Lubricate the new sealing ring (4150) with
silicone-free, non-corrosive grease.
NOTE 3. Screw in the screw plug (4100) with sealing ring
There are two variants of the pressure control (4150) and tighten to 130 Nm.
valve.
- Pressure control valve variant 1 without sieve. De-aerating the retarder
Sieve is at the screw plug (3500)
- Variant 2; sieve is located directly in the CAUTION
pressure control valve
Oil ejection!
1. Unscrew the screw plug (3500). De-aeration not performed.
De-aerate retarder.
2. Drain any oil that has accumulated in the oil
collecting pan. 1. Switch off the retarder foot control if present and
possible.
3. Lubricate the new sealing ring (3550) with
silicone-free, non-corrosive grease. 2. Move vehicle at 50 km/h.
4. Screw in the screw plug (3500) with sealing ring 3. Activate retarder at brake stage one five times for
(3550) and tighten to 130 Nm. approx. 5 sec. each time.
CAUTION
Wrong oil type!
Damage to/failure of the retarder.
Use only approved oil (see oil specification list).
Page 24
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Checking the Oil Level
4100
Item No. Designation
107 Screw plug M24x1.5, 4150
hexagon socket head, w.a.f. 12,
with copper sealing ring: 80 Nm
with integrated sealing ring: 47 Nm
108 Sealing ring A24x29, replace
4100 Screw plug M30x1.5,
hexagon socket head, w.a.f. 17,
with copper sealing ring: 130 Nm
with integrated sealing ring: 100 Nm
4150 Sealing ring A30x36, replace
4200 Screw plug M24x1.5,
hexagon socket head, w.a.f. 12,
with copper sealing ring: 80 Nm
with integrated sealing ring: 47 Nm
4250 Sealing ring A24x29, replace
.
Nr
h-
ac .
.-S Nr
Kd h-
ac
-S
NOTE
ith
Vo
108
107
Voith Turbo I 153.00009710 I arrtd I 2005-11
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Checking the Oil Level
Ignition switched off 7. Screw in the screw plugs (4200) with sealing ring
(4250) and tighten to 80 Nm.
Draining the oil
Measuring the volume
1. Place oil collecting pan below the retarder.
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 26
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Checking the Oil Level
CAUTION
Oil ejection!
De-aeration not performed.
De-aerate retarder.
Page 27
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Draining the Coolant
NOTE
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive
grease before installation.
Requirements
CAUTION
Nr
h-
ac .
.-S Nr
Kd h-
ac
-S
ith
20000
Vo
Voith Turbo I 153.00009710 I arrtd I 2005-11
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Draining the Coolant
CAUTION
Incorrect coolant!
Damage to vehicle and retarder cooling circuits.
Observe the specifications of the vehicle
manufacturer or those of Voith Turbo cooling
water quality list.
Page 29
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting
Page 30
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart
A
Retarder
pilot light
(standard
type)*
No or
* insufficient
On-board diagnosis is possible if the
OEM equipment allows it (display). brake efficiency
Observe the specifications of the
vehicle manufacturer.
**
Before troubleshooting, ensure that there
are no leaks at the screw plugs or sealing rings! C
2005
28013_en
Page 31
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart
Check the
Retarder operation (for NIO Replace
* pilot light
A (standard
type)*
FLASHING?
Temperature
adaptation
retarder braking,
nominal speed
of the engine, IO Check
NIO
temperature
sensor
if possible) temperature
sensors
(oil/coolant)
(see page 84 onw.) IO Check vehicle
cooling system
in accordance
with the
information from
the vehicle
Voith Turbo I 153.00009710 I arrtd I 2005-11
manufacturer
IO = in order
2005
Page 32
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart
Replace casing
Oil loss via Replace casing NIO ventilation
ventilation (5500) 2810 ventilation
Check
outlet valve
(see page 81 onw.)
Contact Replace
Voith IO NIO outlet valve
IO = in order
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart
C insufficient
brake efficiency
(except for
retarder ventilation) No
NIO IO
Check
P (dynamic) and
py (static)
If the static and dynamic
pressure are in order,
(see page 39 onw.) the complaint mentioned
Check oil level
of retarder and above cannot be made.
Check NIO IO Clarify the complaint
gearbox temperature
(see page 25) again with the customer
sensors and or perform the tests
B NIO IO
leads
(see page 84 onw.) Contact Voith
once again.
NIO IO
Check constant-
air pressure
control loop
(see page 36) Replace Contact Voith
temperature
Voith Turbo I 153.00009710 I arrtd I 2005-11
sensors or leads
NIO IO
Check damping
plate
(see page 89)
Replace damping Replace pressure sensor or
plate NIO IO proportional valve
IO = in order
2005
Page 34
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart
or:
Leaky near Leaky near Leaky near
the heat the casing bottom oil tank non-return
exchanger ventilation cover (2500)? valve inlet (1900)
(800)? cover (2800)?
(see page 71 onw.) (see page 63 onw.) (see page 61 onw.) (see page 79 onw.)
Other external
D leak**
Yes No Yes No Yes No Yes No Contact Voith
connections
at the retarder (see page 86 onw.)
IO = in order
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Constant-Air Pressure Control Loop
NOTE
The measurement of the constant-air pressure
control loop provides information on
- internal and external leaks
- proper functioning
Voith Turbo I 153.00009710 I arrtd I 2005-11
Vo
.-S
ith
ac
-S
h-
ac
Nr
h-
Nr
.
.
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Constant-Air Pressure Control Loop
tester (99/30).
With the test software "Diana-Lite" (99/40),
measured values can be read out and stored via the 3. Vehicle ignition: ON
PC in addition to the tests with the retarder tester.
The stored measured values can be transmitted to 4. Toggle switch at the retarder tester in position "EIN
the Voith customer service for evaluation (see mit Regelkreis.
operating instructions on CD-ROM).
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Constant-Air Pressure Control Loop
5. With the multimeter (measuring type: volts), 8. After approx. 20 seconds, the value "Act.setting
measure the voltage at the retarder tester socket pressure" displayed in Diana-Lite and the value
"U_Versorgung". displayed on the air pressure gauge (99/7) have to
The value must lie between 4.75 and 5.25 V. lie between 2.6 and 3.1 bar.
If this value is not reached: Replace proportional If these values are not reached: Replace
valve (3700). proportional valve (3700).
6. With the multimeter (measuring type: volts), 9. Retarder tester switch "Stelldruck in position
measure the voltage at the retarder tester socket "0%".
"U_py IST".
10.Toggle switch at the retarder tester in position
The value must lie between 0.3 and 0.7 V.
"AUS".
NOTE
To assess the operation of the proportional valve
(3700), the results of the following test are only
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 38
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Pump Pressure (pdyn)
NOTE
Checking the pump pressure pdyn provides
information on
- the mechanical status of the rotor parts
Voith Turbo I 153.00009710 I arrtd I 2005-11
- internal leaks Kd
Vo
.-S
ith
ac
-S
h-
ac
Nr
h-
Nr
.
.
28025
Page 39
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Pump Pressure (pdyn)
Page 40
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Pump Pressure (pdyn)
Page 41
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Proportional Valve Current
Multimeter (98/8) with real r.m.s. value 6. Shift the retarder to the highest gear.
measurement, e.g. Fluke 179
2005
Page 42
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Proportional Valve Current
510 430630 mA
2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder
Page 44
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder
DANGER
Retarder can fall!
Your body can be crushed severely.
Secure retarder against falling.
Use a suitabe device for hanging it up.
CAUTION
Improper removal/installation!
Damage to/failure of the retarder.
Warranty is voided.
Request and use gearbox-specific documents
and special tools from VOITH.
CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 45
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder
NOTE
Lubricate sealing rings, O-rings and shaft
Voith Turbo I 153.00009710 I arrtd I 2005-11
800
2005
28046
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder
Removal
Special tools NOTE
25200
The shim must always be redetermined if 25300
- the inside part (800) is replaced
- the retarder is attached to the gearbox
- the retarder has been repaired
- the gearbox has been repaired
FJ 6280 0
486 265
15
M10
2 x Threaded bolt
2005
Page 47
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder
NOTE
Carry out measurements at the retarder and 850
25000 gearbox in the vertical position at room
850 temperature.
800
The retarder and gearbox must have cooled
98/4
down.
265
00
628
486
FJ
25100
28036 28032
3. Remove O-rings (25100) from the gearbox. 2. Place the bearing outer ring (850) onto the inside
part (800).
NOTE
B
For easier removal, heat the housing near the Pos.1 Pos. 2
bearing outer ring to approx. 80 C.
4. Remove outer ring (850) with the puller for the 98/1
bearing outer ring (98/4) and remove the 28031
shim (25000).
Voith Turbo I 153.00009710 I arrtd I 2005-11
10 Nm.
Page 48
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder
28035
6. Place the depth caliper gauge on the retarder Dimension A outside tolerance range!
housing interface and zero it. Damage to/failure of the retarder.
Contact Voith. 28135
8. Measure dimension A from the measuring surface 1. Fit the shim (25000) into the gearbox housing.
Voith Turbo I 153.00009710 I arrtd I 2005-11
0.02 mm.
Page 49
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder
28038 28039
5. Clean sealing surface of the gearbox housing and 8. Place retarder on the gearbox housing.
apply surface seal A002989712010 (Voith item
9. Screw in hex head screws (25200).
No. H53.3305xx).
10.Screw out threaded bolts M10x80.
6. Lubricate the new O-rings (25100) with silicone-
free, non-corrosive grease and insert them into 11.Tighten hex head screws (25200) to 58 Nm.
gearbox housing.
28037 12.Screw in hex head screws (25300) and tighten to
NOTE 58 Nm.
3. Clean sealing surface of the retarder housing (1).
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 50
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair
7. Repair
Page 51
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview
2500
3100 1900
NOTE 2105
4250 20200
4250 5200/2
4200 4200
Observe the reduced tightening torque with the 2100 6700 5300
integrated sealing ring. 2106 6600 20200
3100
The copper sealing ring variant is described in the 1700 1600 20000
instructions. 20100 20400 20300
2005
28047
Page 52
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview
2500
3100 1900
NOTE 2105
4250 20200
5200/2
4250 4200 4200
Observe the reduced tightening torque with the 2100 6700 5300
integrated sealing ring. 2106 6600 20200
3100
The copper sealing ring variant is described in the 1700 1600 20000
instructions. 20100 20400 20300
2005
28047
Page 53
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview
2500
3100 1900
NOTE 2105
4250 20200
5200/2
4250 4200 4200
Observe the reduced tightening torque with the 2100 6700 5300
integrated sealing ring. 2106 6600 20200
3100
The copper sealing ring variant is described in the 1700 1600 20000
instructions. 20100 20400 20300
2005
28047
Page 54
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview
2500
3100 1900
4250 20200
NOTE 2105 4250 4200 4200
5200/2
2100 6700 5300
Observe the reduced tightening torque with the
2106 6600 20200
integrated sealing ring. 3100
The copper sealing ring variant is described in the 1700 1600 20000
20100 20400 20300
instructions.
2005
28047
Page 55
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview
2500
3100 1900
4250 20200
NOTE 2105 4250 4200 4200
5200/2
2100 6700 5300
Observe the reduced tightening torque with the
2106 6600 20200
integrated sealing ring. 3100
The copper sealing ring variant is described in the 1700 1600 20000
20100 20400 20300
instructions.
2005
28047
Page 56
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview
2500
3100 1900
4250 20200
NOTE 2105
2100
4250 4200 4200
5200/2
6700 5300
Observe the reduced tightening torque with the 2106 6600 20200
integrated sealing ring. 3100
1700 1600 20000
The copper sealing ring variant is described in the 20100 20400 20300
2005
instructions.
28047
Page 57
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview
2500
integrated sealing ring. 3100 1900
The copper sealing ring variant is described in the 4250 20200
instructions. 2105 4250 5200/2
4200 4200
2100 6700 5300
2106 6600 20200
3100
1700 1600 20000
20100 20400 20300
2005
28047
Page 58
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Top Oil Tank Cover
NOTE
Lubricate sealing rings, O-rings and shaft 8000
sealing rings with silicone-free, non-corrosive
grease before installation.
Voith Turbo I 153.00009710 I arrtd I 2005-11
Sealing agent
Requirements
Page 59
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Top Oil Tank Cover
3. Remove the intermediate washer (8000). 7. Tighten combined hex head screws (3100 and
3300) crosswise to 30 Nm.
4. Remove the pipe (6100).
Installation
NOTE
Use sealing agent Loctite 572 with retarders
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 60
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Bottom Oil Tank Cover
NOTE
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive
grease before installation. 2500
3100
NOTE
Voith Turbo I 153.00009710 I arrtd I 2005-11
28073
Page 61
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Bottom Oil Tank Cover
Requirements
CAUTION
Retarder switched off
Incorrect sequence when tightening the
Ignition switched off combined hex head screws!
Retarder oil discharged (see page 22) Cover can buckle.
Screw tight combined hex head screws in the
CAUTION prescribed sequence.
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary. 6
5 7
Removal 4 3 8
17 2 1 9
1. Unscrew the combined hex head screws (3100).
16 10
2. Remove bottom oil tank cover (2500). 15 11
14 12
3. Remove cover gasket bottom (2600).
13 28074
Installation
4. Screw tight combined hex head screws in the
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 62
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation
NOTE 2300/3
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive
grease before installation.
Cleaning agent
2005
Float Spirit
28048
Page 63
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation
7 mm
60 mm
Material: St 37 Removal
Special tools
Weight: 0.085 kg 28049_en
Test ring
99/4 3300
H53.7712xx H53.9428xx
Requirements
Page 64
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation
2800 99/5
100
2300/1
2900 98/9
2301
2. Remove cover of casing ventilation (2800). 5. Knock valve insert (2300/1) with the impact puller 7. Take O-ring (2301) out of the groove in the valve
(99/5) and the adapter (98/9) upward from the insert (2300/1).
3. Remove casing ventilation cover gasket (2900).
retarder housing (100).
6101
2300/2
6100 100
6101
2300/3
Voith Turbo I 153.00009710 I arrtd I 2005-11
28052
28054
Page 65
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation
Checking Installation
28057
2300/1
5. Check the sealing edge of the radial shaft sealing
ring (arrow) in the valve insert (2300/1):
28056
- For this purpose, place the float (2300/2) on a
suitable object (e.g. hex head nut).
2. Check the float (2300/2) for damaged surfaces
2301
and sealing areas (arrow). - Place the valve insert (2300/1) on the float
(2300/2) and weigh it down using the test ring
28058
3. Weight float (2300/2): Specified weight: max. 12 g. (99/4).
4. For exceeded specified weight: replace the entire - Fill empty space between float (2300/2) and 1. Apply silicone-free and non-corrosive grease to a
casing ventilation (2300). upper edge of valve insert with spirit. new O-ring (2301) and pull it onto the valve insert
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 66
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation
NOTE
2300/2 98/9 Ensure proper installation position of the pipe
(6100) in the top oil tank cover (2000).
2300/3 9. Insert pipe (6100) into top oil tank cover (2000).
28059 28053
2. Clean float with spirit. 7. Press valve insert (2300/1) carefully into the
retarder housing with the impact puller (99/5) and 2900
3. Insert float (2300/2) into the float cage (2300/3).
the adapter (98/9).
4. Place valve insert (2300/1) on float cage (2300/3). 2000
5. Clean sealing surface on retarder housing (100) 6100
and cover of casing ventilation (2800). 6101
6. Coat hole of casing ventilation in the retarder 28136
housing with silicone-free and non-corrosive
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 67
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation
6100
3300
2800
28061
Page 68
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Retarder Ventilation
5600 Circlip
CAUTION
5400 Retarder ventilation mechanically defective!
5500
Retarder fault.
Replace retarder ventilation.
5600 Requirements
28062
Voith Turbo I 153.00009710 I arrtd I 2005-11
Cleaning agent
Retarder ventilation Benzine
2005
Page 69
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Water Neck
NOTE 20100
Lubricate sealing rings, O-rings and shaft 20000
sealing rings with silicone-free, non-corrosive 20200
grease before installation.
Requirements
20000
Voith Turbo I 153.00009710 I arrtd I 2005-11
CAUTION
20200
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
2005
28063
Page 70
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger
6700
6600
NOTE
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive
6700
grease before installation.
6600
2005
28064
Page 71
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger
Requirements Removal
NOTE
Retarder switched off
Observe the reduced tightening torque with the 6400
integrated sealing ring. Ignition switched off
The copper sealing ring variant is described in the
Supply-air pressure discharged
instructions.
Retarder oil discharged (see page 23) 6600
Pressure test
equipment DANGER 7600
50/22 Heat exchanger can fall! 7500
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 72
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger
C
A B
28068
CAUTION
Heat exchanger leaky!
Retarder fault.
If air bubbles appear in the water or an external
leak is detected, replace the heat exchanger.
Page 73
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger
7300 6700
CAUTION 7500 28070
6700
Possible water residue in retarder! 6600
1. Lubricate the new O-rings (7300, 7500 and 7600) 6700
Oil ejection via ventilation. with silicone-free, non-corrosive grease and insert 6600 28066
Retarder fault.
into retarder housing (100).
Fill retarder with 7.0 litres of engine oil or flush 3. Place the heat exchanger (6400) onto the retarder
oil. Apply brakes lightly several times to flush the
100 housing (100).
retarder system. Discharge flush oil. Repeat 2 to
3 times.
4. Screw in hex head screws (6600) with washers
De-oil the cooling circuit and heating system (6700).
according to the vehicle manufacturers
instructions. 5. Tighten hex head screws (6600) crosswise to
Voith Turbo I 153.00009710 I arrtd I 2005-11
150 Nm.
28174
2005
Page 74
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger
100
6400
28175
Page 75
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Control Valve
NOTE Kd
.-S
ac
h-N
ac
r.
h-N
r.
-S
ith
Vo
NOTE 2206
Observe the reduced tightening torque with the 3550
integrated sealing ring.
Voith Turbo I 153.00009710 I arrtd I 2005-11
3500
The copper sealing ring variant is described in the 2200
instructions.
2005
28075
Page 76
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Control Valve
Requirements
Special tool
Retarder switched off
Vo
.-S
ith
ac
-S
h-
ac
Nr.
h-
Nr.
CAUTION
Hot parts! 99/5
H53.7712xx
Hands could be burned.
Work carefully. 28077
Impact puller Wear protective gloves or use cloths if necessary.
99/5
Removal NOTE
Tools for self-fabrication There are two variants of the pressure control
valve.
- Pressure control valve variant 1 without sieve.
M8 Sieve is at the screw plug (3500)
- Variant 2; sieve is located directly in the
Kd.
Voi
-S
ac
th-S
h-
ac
h-
Nr.
Nr.
pressure control valve
With variant 1, the pressure control valve (2200)
Voith Turbo I 153.00009710 I arrtd I 2005-11
Page 77
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Control Valve
Installation
r.
h-N .
ac r
.-S h-N
Kd ac
-S
th
Voi
2206
2200 28078
Page 78
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Inlet
NOTE
1950
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive 1900/3
grease before installation. 1900/2
1900/1
Sealing agent
Nr.
h-
ac
-S Nr.
Kd. ac
h-
th-S
Voi
1900
Requirements
28079
Page 79
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Inlet
Installation
CAUTION
Hot parts! NOTE
Hands could be burned. Use sealing agent Loctite 572 with retarders
Work carefully. starting with Voith item No. H67.1500.30.
Wear protective gloves or use cloths if necessary. Only in conjunction with copper sealing ring.
1. Check rubber coating of the piston (1900/3) for 4. Tighten non-return valve inlet (1900) with 280 Nm.
damage.
Replace the complete non-return valve inlet (1900)
if necessary.
if necessary.
2005
Page 80
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Outlet
NOTE
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive
grease before installation. Kd
.-S
ith
ac
-S
h-
ac
Nr
h-
.
Nr
.
Vo
2105
2106
Voith Turbo I 153.00009710 I arrtd I 2005-11
1700
1600
2100 3100
2005
28080
Page 81
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Outlet
Removal Checking
Special tool
1. Unscrew the combined hex head screws (3100). 2100
2105
2. Remove the valve cover (1600). 1
153.000052xx
Puller
for non-return 28158
valve outlet
Page 82
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Outlet
Installation
100
2100
28178
Page 83
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Oil Temperature Sensor
NOTE
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive
grease before installation.
Requirements
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
2005
28115
Page 84
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Oil Temperature Sensor
NOTE
Measuring in one temperature range is usually
sufficient.
Polarity is irrelevant.
Temperature Resistance
20 C 10 C 10391117
60 C 10 C 11941271
80 C 10 C 12711347
Voith Turbo I 153.00009710 I arrtd I 2005-11
2005
Page 85
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Coolant Temperature Sensor
NOTE 5200/2
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive
grease before installation. 5300
Requirements
CAUTION
Voith Turbo I 153.00009710 I arrtd I 2005-11
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if necessary.
2005
28114
Page 86
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Coolant Temperature Sensor
NOTE
Measuring in one temperature range is usually
sufficient.
Polarity is irrelevant.
Temperature Resistance
20 C 10 C 10391117
60 C 10 C 11941271
80 C 10 C 12711347
Voith Turbo I 153.00009710 I arrtd I 2005-11
2005
Page 87
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Sensor
NOTE 9000
Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free, non-corrosive
grease before installation.
Requirements
CAUTION
Hot parts!
Hands could be burned.
Voith Turbo I 153.00009710 I arrtd I 2005-11
Work carefully.
Wear protective gloves or use cloths if necessary.
2005
28116
Page 88
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Proportional Valve and Damping Plate
3900
NOTE 3700
28113
Page 89
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Proportional Valve and Damping Plate
Requirements
NOTE
Check damping plate (3800) for mechanical and
aging damage and replace if necessary.
Voith Turbo I 153.00009710 I arrtd I 2005-11
2005
Page 90
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix
8. Appendix
Page 91
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix Tightening Torques
Initial torque: 50 Nm
Final torque: 30 Angle
3500 Screw plug M30x1.5, hexagon socket head, w.a.f. 17 With copper sealing ring: 130 Nm
With integrated sealing ring: 100 Nm
3900 Combined hex head screw M8x20, hexagon insert bit, w.a.f. 13 30 Nm
4000 Hex head nut M8, hexagon insert bit, w.a.f. 13 18 Nm
2005
Page 92
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix Tightening Torques
Page 93
Voith Turbo
Produktgruppe Retarder
Postfach 1555
74555 Crailsheim
Deutschland
Phone: 00 49 79 51 / 32-0
Fax: 00 49 79 51 / 32-756
service-retarder@voith.com
www.voith.com
Engineered reliability.