Aftersales Service Manual Voith Retarder VR 115 HV FL

Voith Turbo
Aftersales Service Manual Voith Retarder VR 115 HV FL
153.00571510 I 2014-12
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Contents
Contents
1 About this document 5

1.1 Purpose of this document 6
1.2 Target groups 6
1.3 Other applicable documents 6
1.4 Symbols and identifications 7
1.5 Item numbers 7
1.6 Imprint 7
2 Basic Safety Information 8

2.1 Product safety 9
2.2 Staff qualification 9
2.3 Safety-conscious working 9
2.4 Environmental protection 9
2.5 Special tools 9
2.6 Diagnosis and troubleshooting 9
2.7 Maintenance and repair 9
Voith Turbo I 153.00571510 I arsad I 2014-12
2.8 Basic driving modes 10

2.9 Storage 10
2.10 Warranty 10
3 Design and Function 11

3.1 Overview of the assemblies 12
3.2 Retarder identification 14
© 2014
3.3 Identification of VERA™ controller 15
Page 2
3.4 Functional and control diagram 16

3.5 Functional Description 17
4 Maintenance and Service 19

4.1 Maintenance intervals 20
4.2 Oil change 21
4.3 Coolant 25
5 Diagnosis and troubleshooting 27

5.1 Overview of possible complaints 28
5.2 Checking the oil level 35
5.3 Check the constant-air pressure control loop 39
5.4 Checking thepump pressure pdyn 43
5.5 Testing the proportional valve current 47
6 How to remove and re-install the retarder 49
7 Repair 52
7.1 Overview of components 53
7.2 Retarder ventilation 57

7.3 Oil separator assembly 59
7.4 Casing ventilation 60
7.5 Check valve (inlet) 67
7.6 Check valve (outlet) 69
7.7 2/2-way valve 71
7.8 Diaphragm housing cover 73
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7.9 Diaphragms 75
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7.10 Heat exchanger 82

7.11 Water connector 86
7.12 Circuit components 87
7.13 Outlet throttle 92
7.14 Valve block 93
7.15 Oil temperature sensor 95
7.16 Coolant temperature sensor 97
8 Overview of tools 99
8.1 Diagnosis 100
8.2 Repair 102
© 2014
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I About this document
1. About this document
1.1 Purpose of this document 6

1.2 Target groups 6
1.3 Other applicable documents 6
1.4 Symbols and identifications 7
1.5 Item numbers 7
1.6 Imprint 7
© 2014
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I About this document Purpose of this document
1.1 Purpose of this document 1.2 Target groups
This Aftersales Service Manual provides information This Aftersales Service Manual is intended for service
and instructions on maintenance and repair of the personnel for maintenance and diagnosis and may
Voith Retarder VR 115 HV FL. neither be reproduced nor passed on to third parties.
1.3 Other applicable documents
Document Information Voith Article No.

Voith Retarder oil change intervals/oil selection list Oil change intervals and approved oil types 153.004557xx
Coolant quality list Approved coolants H67.2224xx
ECU specifications Instructions for diagnosis of the VERA™ controller On request
Operating manual for retarder tester Measured values for constant-air pressure py and pump pressure pdyn 153.001355xx, included in scope
of supply of the retarder tester
(153.001085xx)
Operating manual for 'DIANA Lite' test software Information on the testing of: Included in the scope of delivery
• Constant-air pressure control loop of the "Diana Lite" test software
(153.000776xx)
• Pump pressure pdyn
Conversion instructions for basic retarder VR 115 HV Instructions for removing and installing the circuit parts and returning the On request
FL defective circuit parts
© 2014
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I About this document Symbols and identifications
1.4 Symbols and identifications 1.5 Item numbers

WARNING
Structure of warnings The item numbers used are usually included in the
Potentially hazardous situation that, if not avoided,
spare part lists.
could result in death or serious injury.
LEVEL OF DANGER Exceptions:
Type and source of danger!
• Single- or two-digit item numbers
Possible consequences in case of non-observance. DANGER
 Measures for the prevention of danger and its Imminently hazardous situation that, if not avoided,
• Item numbers with a slash
consequences. will result in death or serious injury.
1.6 Imprint
Levels of danger Notes
For questions and work procedures not described in
The warnings are categorized into four levels of dan-
these documents, contact the respective organisation
ger: NOTICE for your area.
Information on easier and safer working on the re-
Voith Turbo
ATTENTION tarder.
Commercial Vehicles
Potentially hazardous situation which, if not avoid-  Measures to make working on the retarder eas-
ier and safer. P.O. Box 1555
ed, may result in damage to property.
74555 Crailsheim
Distinctions Germany
ATTENTION
 One-step action instruction. Phone: +49 79 51 / 32-1555

Potentially hazardous situation that, if not avoided, Fax: +49 79 51 / 32-1506
1. First step of an action instruction. Other steps fol- support-retarder@voith.com
could result in minor or moderate injury. low and are numbered consecutively. www.voith.com
© 2014
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Basic Safety Information Imprint
2. Basic Safety Information
2.1 Product safety 9

2.2 Staff qualification 9
2.3 Safety-conscious working 9
2.4 Environmental protection 9
2.5 Special tools 9
2.6 Diagnosis and troubleshooting 9
2.7 Maintenance and repair 9
2.8 Basic driving modes 10
2.9 Storage 10
2.10 Warranty 10
© 2014
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Basic Safety Information Product safety
2.1 Product safety 2.4 Environmental protection Danger of accidents if the retarder tester is used
improperly!
The retarder has been designed and manufactured  Dispose of drained fuels and fluids, consumables
Diagnosis while the vehicle is traveling results in an
according to the state of the art in technology and ap- and old parts properly. uncontrollable operating state of the vehicle.
proved safety regulations.
2.5 Special tools  Only perform diagnosis when the vehicle is parked.
Nevertheless, hazardous situations and property
damage may occur as a result of improper usage,
maintenance and repair.
Damage to property if wrong special tools are 2.7 Maintenance and repair
used!
 Observe safety and warning information. The special tools required are described in the re- Danger of burns and scalding by splashing oil!
spective action instructions. The oil in the retarder may be hot.
2.2 Staff qualification The chapter “Overview of tools” contains an overview
 Work carefully.
of the special tools.
 Allow only qualified staff to carry out repair and
maintenance work. For special tools that may only be used starting Danger of burning and scalding by hot coolant!
from a specific version, the version number is indi- The coolant may be hot.
cated in the last two digits of the Voith article number.
2.3 Safety-conscious working  Work carefully.
Example: H53.942811.
Voith does not assume any liability for personal injury  Only use special tools starting from the speci- Danger of burns by hot parts!
and/or damage to property caused by improper and
fied version.
unprofessional work. Components of the retarder may be hot.
 Observe the last two digits of the Voith article num-
 Observe the following regulations:  Work carefully.

ber in the illustrations of the special tools.
- Regulations for the prevention of accidents  Wear safety gloves or use cloth.
- Other generally approved safety 2.6 Diagnosis and troubleshooting
regulations and occupational health Damage to property due to soiled parts!
- Motor vehicle regulations Voith assumes warranty or provides a goodwill settle- Considerable damage or malfunctions may occur due
ment for defective parts only. to soiling.
- Safety regulations for handling chemical sub-
© 2014
stances such as oils and greases  Do not replace parts on mere speculation.  Always pay attention to cleanliness.
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Basic Safety Information Basic driving modes
Damage to property due to improper cleaning! Parking lubricants, spare parts, accessories, attachments and
special equipment not tested and approved by Voith.
 Do not aim the jet of a high-pressure cleaner  Do not use the retarder as a parking brake, as it
(steam-jet cleaner) at valves, sensors or the ventila- does not have any braking effect when the vehicle  Use only parts approved by Voith to ensure the
tion of the retarder. stands still. safety of the vehicle and func-tioning of the retard-
er.
2.8 Basic driving modes Failure or performance reduction while driving
 Use only oils and lubricants approved by Voith to
In case the retarder fails, or while temperature adap-
 Check the following to ensure that the retarder is ful- ensure the safety of the vehicle and func-tioning of
tation is active:
ly functional for all vehicle maneuvers, i.e.: the retarder.
 Adjust the speed of the vehicle with the engine/ser-
- Retarder is properly filled with oil
vice brake.
- Retarder electronics is connected and function-
al  Engage the lowest possible gear in order to achieve
- Pneumatic control is connected and functional a high engine speed.
- Retarder is connected to the vehicle's cooling
 During a temperature adaptation continue driving
system
until the retarder is again available with full power.
Driving after oil change/checking the oil level

2.9 Storage
 When starting to drive: Activate the retarder briefly
in braking stage 2 or 3.  Store and transport the retarder in an upright posi-
tion, otherwise oil may escape.

Towing
2.10 Warranty
 Tow the vehicle with the retarder rotating for max.
100 km at max. 40 km/h. Voith does not assume any liability for damages
caused by changes to the retarder, or the use of oils,
 Recommended by Voith: Remove the prop shaft.
© 2014
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Design and Function Warranty
3. Design and Function
3.1 Overview of the assemblies 12

3.2 Retarder identification 14
3.3 Identification of VERA™ controller 15
3.4 Functional and control diagram 16
3.5 Functional Description 17
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Design and Function Overview of the assemblies
3.1 Overview of the assemblies

3100
Item No. Designation 1200
2700
801a Screw plug/oil drain plug
3200a
801b Screw plug/coolant drain plug
900 Diaphragm housing cover
1200 Valve block VERA™
2700 Retarder ventilation; 900
from retarder Serial No. 3968217, in addi-
tion, the illustrated protective plate is 3800a
mounted
3100 Assembly - oil separator
3200a Oil temperature sensor 3200b
3200b Coolant temperature sensor
3800a Non-return valve (outlet)
801b
© 2014
801a 36501
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Design and Function Overview of the assemblies
Item No. Designation

100 Retarder housing 3500
3500 2/2-way valve
3600 Service measuring point
3700 Screw plug/oil filler plug
3800b Non-return valve (inlet)
3700
3600
3800b
100
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Design and Function Retarder identification
3.2 Retarder identification
NOTICE
 Specify the following data if you have questions
or are ordering spare parts:
1
- Serial No. (1) 0003394116
2
- Voith Article No. (2)
153.00177420
- OEM Article No. (3; example) 3
00123456789
16
41 .10
39 61 95
03 8 02
00 67.3430
H 30
A9
© 2014
36504
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Design and Function Identification of VERA™ controller
3.3 Identification of VERA™ controller
Location of the retarder controller in the vehicle is de-

scribed in the vehicle manufacturer's documentation.
NOTICE
84
20
02
x
e1
7x
06
 Specify the following data if you have questions T
-T 53
TM
.0
00
A M x-1 xx
or are ordering spare parts: i
ER J-M .x Sx
t V JJ Dxx/ ZG X3
n /J -
l U x .D.x xxx
tro xxx A xx
- Serien-Nr. (Serial No.) C on x ERxxx
V
xx X2
er .
rd No
ta al- o. .
Re eri rt N No
- Voith Sach-Nr. (Part No.) S a M
o
rb
P E
X1
u
T
h
it
O
o
V
 Specify the following retarder data (see
H
IT
VO
Page 14):
- Serial No.
- Voith Article No.
Retarder Control Unit VERATM

Vo i t h Tu r b o
Serial-No. xxxxx / JJJJ-MM-TT

Part No. VERA.D.x-Dxx.xx-153.000067xx
e1 022084
OEM No. xxxxxxxxxx / ZGSxxx
VOITH
X1 X2 X3
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Design and Function Functional and control diagram
3.4 Functional and control diagram

E
A Rotor
NSG9 R 12
B Stator
D 2700
C Oil reservoir
3500 A1
D Oil equalizing tank A2NG4 1200
2 NG3
E Ventilation duct “R”
G 5 1p 3 P
F Aeration and ventilation duct "A1" 3100 C
G Aeration and ventilation duct "A2"
800 Heat exchanger 3200a p
2300
1000 Diaphragm 1000 1000 F
3800b
1200 Valve block
2300 Casing ventilation
A B
2700 Retarder ventilation "R"
3100 Assembly - oil separator 3800a
800
3200a Oil temperature sensor
3200b Coolant temperature sensor

3200b
3500 2/2-way valve
3800a Non-return valve (outlet)
3800b Non-return valve (inlet)
Oil sump
Constant-air pressure py
© 2014
Coolant
36507
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Design and Function Functional Description
3.5 Functional Description Diaphragm (1000) Casing ventilation (2300)

The retarder's oil tank (C) is located between the dia- At the beginning of the braking process, the oil dis-
Rotor (A) phragms (1000). Purpose of the diaphragms (1000) is places the air that is in the system circuit. The air is
The rotor (A) must include the oil in its rotation and ac- to separate the retarder oil and the constant-air forced out via the casing ventilation (2300) and the oil
celerate it. pressure py. separator (3100).
Stator (B) When the retarder is switched off, the constant-air Once the system circuit is free of air, the casing venti-
pressure py present at the diaphragms (1000) is rout- lation (2300) closes.
In stator (B), the oil is re-routed and returned to the ro-
ed through the valve block (1200) and escapes at the
tor (A) at the internal diameter of the working cham-
retarder ventilation (2700). The constant-air Retarder ventilation "R" (2700)
ber.
pressure py and the retarder ventilation (2700) are not When the retarder is switched off, the constant-air
connected to the retarder oil. pressure py present at the diaphragms (1000) is rout-
Oil compensation tank (D)
ed through the valve block (1200) and escapes into
When the retarder is switched off, the oil compensa- Valve block (1200) the atmosphere at the retarder ventilation (2700).
tion tank (D) takes up some of the oil flowing back
The valve block (1200) is connected to the com-
from the system circuit. The oil returns into the oil tank
pressed air system of the vehicle (auxiliary equipment Oil separator (3100)
(C) via the open 2/2-way valve (3500). The air sepa-
circuit). The proportional valve integrated in the valve The oil separator (3100) separates out the oil from the
rated from the oil is fed into the atmosphere via the oil
block (1200) receives an electrical input signal from exhaust air. The exhaust air containing a minimum of
compensation tank (D) and the oil separator (3100).
the retarder controller. A pneumatic constant-air oil comes out of the system circuit via the casing ven-
pressure py is then applied to the diaphragms (1000). tilation (2300) and from the oil compensation tank (D).
Heat exchanger (800)
This is dependent on the intensity of the electrical in-
The heat exchanger (800) dissipates the generated put signal. As a result, pressure is applied to the oil in Temperature sensors for oil (3200a) and coolant
heat to the vehicle cooling system. the oil tank (C). (3200b)
A pressure sensor integrated in the valve block (1200) The temperature sensors pass on information on the
measures and regulates the pneumatic constant-air temperature of oil and coolant to the retarder control-
pressure py. ler in the vehicle.
To protect both the cooling system and the retarder,

limits and maximum values for the coolant and oil tem-
© 2014
perature are set in the controller.
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Design and Function Functional Description
If one of the temperature limits is exceeded during There is a connection to the atmosphere via the oil
braking, the braking torque is adjusted by means of separator (3100).
the constant-air pressure py. The braking torque is ad-
The 2/2-way valve (3500) prevents too much of the oil
justed until an equilibrium is achieved between the
returning into the oil tank (C) from entering the oil
produced braking energy and the heat that is dissipat-
compensation tank (D).
ed via the vehicle cooling system.
The oil that has accumulated in the oil compensation
If one of the maximum values is exceeded, the brak-
tank (D) flows back into the oil tank (C) via the open 2/
ing torque is no longer active (corresponds to a reduc-
2-way valve (3500).
tion to 0).
In addition, irrespective of the actual temperature of Check valve (outlet) (3800a)

the oil, the braking torque is adjusted if the gradient of In braking mode, the oil reaches the heat exchanger
the oil temperature rises steeply. (800) from the working space via the check valve (out-
let) (3800a), is cooled down and is fed back into the
The vehicle speed has to be adjusted with the service
system circuit or the oil reservoir (C).
brake while the adjustment is active.
Check valve (inlet) (3800b)

2/2-way valve (3500)
When the retarder is switched on, pressure is applied
The 2/2-way valve (3500) closes when the retarder is
to the oil via the diaphragms (1000). This opens the
switched on. This separates the connection between
check valve (inlet) (3800b) and allows the oil into the
the oil tank (C) and the oil compensation tank (D) and
working chamber.
the oil separator (3100).
When the retarder is switched off, the 2/2-way valve

(3500) is opened again with a time delay.
The air in the oil tank (C) and in the oil flowing back
out of the system circuit can escape into the oil com-
pensation tank (D) via the open 2/2-way valve (3500).
© 2014
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Maintenance and Service Functional Description
4. Maintenance and Service
4.1 Maintenance intervals 20

4.2 Oil change 21
4.3 Coolant 25
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Maintenance and Service Maintenance intervals
4.1 Maintenance intervals

ATTENTION
The maintenance intervals depend on the stress put
Exceeding the maintenance intervals/wrong
on the retarder.
type of oil!
Damage to/failure of the retarder.
 Observe the maintenance intervals.
 Use only approved oils.
Activity Interval See

Changing the oil See the specifications of the vehicle manufacturer and/or the Page 21
Voith Retarder oil change intervals/oil selection list.
Draining the coolant Observe the vehicle manufacturer's instructions. Page 25
© 2014
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Maintenance and Service Oil change
4.2 Oil change

801 Screw plug M 14 x 1,5;
30 Nm
802 Sealing ring A 14 x 20; to be replaced
30 Nm
100 Nm
3700
5000
5100
3600
802
801
© 2014
36505
Page 21
Auxiliaries
NOTICE
Manual tire filler
 Apply silicone-free and non-corrosive grease to
the sealing rings, O-rings, and shaft sealing
rings before installation. Special tools
Oil filling quantity

Variant Variant
1* 2*
Service filling 5.6 l 5.6 l
(oil change, check of oil lev-
el) “A” 36609 153.000885xx
After replacement of the 7.0 l 6.7 l
heat exchanger
Maintenance work to be performed whenever the Throttle piece
After replacement of circuit 7.0 l 6.7 l oil is changed
parts and drained heat ex- 50/31
changer  Visual inspection of retarder for leaks before and af-
*Oil filling quantity is dependent on the heat exter the oil change.
changer variant (dimension "A", see the following
table and illustration).  Tighten the hexagon head screws (5400) on the
heat exchanger (see Page 82).
Heat exchanger Dimension "A"

Variant 1 approx. 100 mm Additional maintenance work to be performed
every other time the oil is changed
Variant 2 approx. 83 mm
 Replace the oil separator on the oil separator as-
sembly (see Page 59).
© 2014
Page 22
Preconditions
3600
• Vehicle in horizontal position
• Oil at operating temperature (>60°C) 50/31

• Retarder is switched off
• Ignition is switched off

50/39
Draining the oil
1. Put an oil pan under the retarder.
WARNING 801 36508 36503
Hot oil coming out! 2. Unscrew the screw plug (801) and drain the oil.
Face and hands could be burned. 4. Screw in the throttle piece (50/31) with existing
 Ensure that the retarder and ignition are WARNING sealing ring (5000).
switched off. 5. Tighten the throttle piece to 10 Nm.
Hot oil comes out at increased pressure!
Face and hands could be burned.
6. Connect the manual tire filler (50/39) to the throttle
 Unscrew the plug screw (3600) slowly.
ATTENTION piece (50/31).
Hot screw plugs! 3. Unscrew the screw plug (3600) slowly. NOTICE
Hands could be burned.
 Work carefully. To completely empty the retarder circuit, pulsed air
is applied to the bore of the screw plug (3600).
 Wear safety gloves or use cloth.
 Do not apply permanent air pressure.
© 2014
Page 23
7. Apply short pulses of air onto the bore of the 13.Screw in the screw plug (3600) with sealing ring
retarder's screw plug (3600). (5000) and tighten to 30 Nm.
8. Repeat the procedure until only oil mist comes out Filling with oil
at the bore of the screw plug (801).
14.Unscrew the screw plug (3700).
NOTICE
 If the oil contains water (emulsion):
ATTENTION
check the heat exchanger (see page 82 ff). Wrong oil type!
 If there are particles (shavings) in the oil: Damage to/failure of the retarder.
- Dismantle the complete retarder (except for  Fill in only approved oil (see Voith Retarder oil
circuit parts) and clean all components (they change intervals/oil selection list).
must be free of dirt, metallic residues and wa-
ter) 15.Fill in oil slowly through the borehole in the screw
- Replace circuit components (see page 87 ff) plug (3700).
For oil filling quantity, see Page 22.
- Replace heat exchanger
(see page 82 ff) 16.Apply silicone-free and non-corrosive grease to
- Replace diaphragms (see page 75 ff) the new sealing ring (5100).
17.Screw in the screw plug (3700) with sealing ring

9. Apply silicone-free and non-corrosive grease to
(5100) and tighten to 100 Nm.
the new sealing ring (802).
10.Screw in the screw plug (801) with new sealing NOTICE

ring (802) and tighten to 30 Nm.
 When starting to drive: Activate the retarder
briefly in braking stage 2 or 3.
11.Remove the manual tire filler (50/39) and unscrew
the throttle piece (50/31).
12.Apply silicone-free and non-corrosive grease to

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Maintenance and Service Coolant
4.3 Coolant

800 Heat exchanger
801b Screw plug M 14 x 1,5;
Innensechskant, SW 6
30 Nm
Preconditions
801b
802
801b
800
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Maintenance and Service Coolant
1. Put a clean coolant catch pan under the retarder.
ATTENTION
Hot parts and hot coolant!
Risk of burns and scalding injuries.
 Work carefully.
2. Unscrew the screw plug (801b) and drain the cool-

ant.
ATTENTION
Wrong coolant type!
Damage to the vehicle and retarder cooling circuit.
 Observe the vehicle manufacturer's instructions
or those of the Voith Turbo coolant quality list.
3. Fill the vehicle and retarder cooling circuit (see the

vehicle manufacturer's instructions).
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Diagnosis and troubleshooting Coolant
5. Diagnosis and troubleshooting
5.1 Overview of possible complaints 28

5.2 Checking the oil level 35
5.3 Check the constant-air pressure control loop 39
5.4 Checking thepump pressure pdyn 43
5.5 Testing the proportional valve current 47
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Diagnosis and troubleshooting Overview of possible complaints
5.1 Overview of possible complaints
No. Complaint See

A Retarder pilot light flashes (standard design): Page 29
On-board diagnosis is enabled by some vehicle manu-
facturers (display).
 Observe the vehicle manufacturer's instructions.
B Oil leaking out on retarder ventilation (2700) or oil sep- Page 30
arator (3101)
C No or insufficient brake efficiency Page 31
D Other external leaks: Page 33
 Ensure that there are no leaks on the screw plugs
or sealing rings.
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Page 28
A Retarder pilot light flashes (standard design)
NOTICE NOTICE
On-board diagnosis is enabled by some vehicle Carry out test steps in the specified sequence.
manufacturers (display). When the cause of error was found, all other test
 Observe the vehicle manufacturer's instruc- steps can be omitted.
tions.
No. Activity
1.  Check the actuation (retarder braking preferably at NOK  Instruct the driver. In doing so, observe the operating conditions.
nominal engine speed).
OK  Check the oil temperature sensor (3200), replace if necessary (see Page 104).
 Check the coolant temperature sensor (3200), replace if necessary (see Page 97).
 Check the cooling system of the vehicle (see the vehicle manufacturer's instructions).
NOK = does not work correctly

OK = works correctly
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Page 29
B Oil leaking out on retarder ventilation (2700) or oil separator (3101)
NOTICE
Carry out test steps in the specified sequence.
When the cause of error was found, all other test
steps can be omitted.
No. Activity
Precondition:
• Supply air OK
• Retarder oil level OK (see Page 35)
• Gearbox oil level OK
1.  Check whether oil leaks out on the retarder venti- Yes  Check diaphragms (1000) for damage and correct installation position, replace if nec-
lation (2700). essary (see Page 75).
No  Continue with Step No. 2.
2.  Check whether the retarder leaks out on the oil –  If the leaking oil contains water (emulsion):
separator (3101). - Check the heat exchanger (800), replace if necessary (see Page 82).
- Check whether it is possible for water to enter the retarder system from outside:
Through the oil separator (3101), e.g. through a steam-jet cleaner or splash water.
 Check the casing ventilation (2300), replace if necessary (see Page 60).
 Check the 2/2-way valve (3500), replace if necessary (see Page 71).
 Please contact Voith.

© 2014
Page 30
C No or insufficient brake efficiency
NOTICE
Carry out test steps in the specified sequence.
When the cause of error was found, all other test
No. Activity
Precondition:
• Supply air OK
• Retarder oil level OK (see Page 35)
• Gearbox oil level OK
1.  Check whether an external leak is visible on the re- Yes  Repair retarder.
tarder (except retarder ventilation). No  Continue with Step No. 2

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Page 31
No. Activity
2.  Check the constant-air pressure control loop (see NOK  Replace valve block
Page 39). OK  Check the proportional valve current as well as supply lines and plug connections (see
Page 47).
 Check oil temperature sensor (3200) and supply line, replace if necessary (see
Page 104).
 Check coolant temperature sensor (3200) and supply line, replace if necessary (see
Page 97).
 Perform diagnosis with WinDia®. Use the Voith ECU specification for this.
–or–
 Perform an off-board diagnosis (see the vehicle manufacturer's instructions).
 Continue with Step No. 3
3.  Check the dynamic pressure pdyn (see Page 43). NOK  Check the casing ventilation (2300) (see Page 60).
 Replace circuit components (33) (see Page 87).
OK Complaint mentioned above is not possible.
 Clarify the complaint again with the customer or perform the tests once again.

© 2014
Page 32
D Other external leaks
NOTICE NOTICE
Carry out test steps in the specified sequence. Ensure that there are no leaks on the screw plugs
When the cause of error was found, all other test or sealing rings.
No. Activity
1.  Check whether the retarder leaks oil or water near Yes  Check heat exchanger (800) and O-rings (3300), replace if necessary (see Page 82).
the heat exchanger (800).  Check the hose connection between the water connector on the heat exchanger (800)
and the water pipe in the vehicle (see the vehicle manufacturer's instructions).
No  Continue with Step No. 2
2.  Check whether the retarder leaks near the check Yes  Check the check valve (inlet or outlet) (3800) (see page 67 ff).
valve (inlet or outlet) (3800).
3.  Check whether the retarder leaks near the housing Yes  Check diaphragms for damage and correct installation position, replace if necessary
cover of the diaphragms. (see page 75 ff).
 Replace O-ring (3900).

4.  Check whether the retarder leaks near the circuit Yes  Remove, reseal and refit the circuit components (33) (see Page 87).
parts (33). No  Continue with Step No. 5

© 2014
Page 33
No. Activity
5.  Check if the retarder is leaky around the water con- Yes  Check water connector (5700) and moulded seal (5600), replace if necessary (see
nector (5700). Page 86).
No  Please contact Voith.

© 2014
Page 34
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Diagnosis and troubleshooting Checking the oil level
5.2 Checking the oil level

30 Nm
30 Nm
100 Nm
3700
5000
5100
NOTICE
3600
rings before installation.
Oil filling quantity

Service filling (oil change, check of oil 5.6 l

level)
802
801
© 2014
36505
Page 35
Draining the oil

Auxiliaries
Manual tire filler 3600
1. Put an oil pan under the retarder.
Special tools WARNING

Hot oil coming out!
 Ensure that the retarder and ignition are
switched off.
ATTENTION
153.000885xx 801 36508
Hot screw plugs!
Hands could be burned. 2. Unscrew the screw plug (801) and drain the oil.
Throttle piece
 Work carefully.
50/31  Wear safety gloves or use cloth. WARNING
Hot oil comes out at increased pressure!
Preconditions
 Unscrew the plug screw (3600) slowly.
• Vehicle in horizontal position
3. Unscrew the screw plug (3600) slowly.

• Oil at operating temperature (>60°C)

© 2014
Page 36
8. Repeat the procedure until only oil mist comes out

at the bore of the screw plug (801). NOTICE
9. Apply silicone-free and non-corrosive grease to  If the oil contains water (emulsion):
50/31 the new sealing ring (802). check the heat exchanger (see page 82 ff).
 If there are particles (shavings) in the oil:
10.Screw in the screw plug (801) with new sealing
- Dismantle the complete retarder (except for
ring (802) and tighten to 30 Nm.
50/39 circuit parts) and clean all components (they
11.Remove the manual tire filler (50/39) and unscrew must be free of dirt, metallic residues and wa-
the throttle piece (50/31). ter)
- Replace circuit components (see page 87 ff)
12.Apply silicone-free and non-corrosive grease to
- Replace heat exchanger
36503 (see page 82 ff)
13.Screw in the screw plug (3600) with sealing ring - Replace diaphragms (see page 75 ff)
4. Screw in the throttle piece (50/31) with existing (5000) and tighten to 30 Nm.
sealing ring (5000).
Measuring the volume NOTICE
5. Tighten the throttle piece to 10 Nm.
 If the retarder oil level is too low:
6. Connect the manual tire filler (50/39) to the throttle NOTICE Check the retarder for leaks.
piece (50/31). For technical reasons, it is possible for the drained-  If the retarder oil level is too low and the gearbox
off oil quantity to be up to 0.2 l less than the service oil level is too high:
NOTICE filling of 5.6 l. Check gearbox ventilation and repair if neces-

sary (see the vehicle manufacturer's instruc-
To completely empty the retarder circuit, pulsed air tions).
is applied to the bore of the screw plug (3600).
 Do not apply permanent air pressure. 1. Measure the volume of the drained oil.
7. Apply short pulses of air onto the bore of the 2. If necessary, correct the oil volume.
retarder's screw plug (3600).
© 2014
Page 37
Filling with oil
3. Unscrew the screw plug (3700).
ATTENTION
Wrong oil type!
Damage to/failure of the retarder.
 Fill in only approved oil (see Voith Retarder oil
change intervals/oil selection list).
4. Fill in oil slowly through the borehole in the screw

plug (3700).
For oil filling quantity, see Page 22.

6. Screw in the screw plug (3700) with sealing ring

(5100) and tighten to 100 Nm.
NOTICE
 When starting to drive: Activate the retarder
briefly in braking stage 2 or 3.

© 2014
Page 38
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Diagnosis and troubleshooting Check the constant-air pressure control loop
5.3 Check the constant-air pressure

control loop
NOTICE
The constant-air pressure control loop check pro-
vides information on:
• internal and external leaks of the retarder
99/7
• proper functioning of the retarder
• proper control of the retarder
50/56b
99/7 Manometer 0–6 bar
50/56a Retarder-Prüfgerät
50/56b Kabel 1 to the valve block
50/56d Kabel 3: to the temperature sensors 50/56a
50/56e Kabel 4: to the vehicle power supply / PC 50/56e
interface 50/56d
© 2014
36575
Page 39
pletely disconnected from the vehicle

Special tools
NOTICE
With the test software "DIANA Lite" (50/56i), mea-
ATTENTION
sured values can be read out and stored via the PC Hot parts!
in addition to the tests with the retarder tester. Hands could be burned.
The stored measured values can be transmitted to
 Work carefully.
the Voith customer service for evaluation (see op-
erating instructions on CD-ROM).
153.001085xx 153.000776xx H53.1403xx

Commercially available tools NOTICE
Retarder-Prüf- Prüfsoftware Manometer 0– Multimeter On account of the design, a small amount of oil may
gerät, im Koffer "DIANA Lite" 6 bar leak out, but this does not affect retarder operation.
komplett Preconditions
50/56 50/56i 99/7
DANGER
• Retarder is switched off Diagnosis with the retarder tester while the ve-
NOTICE • Battery voltage 18–32 V hicle is in motion!
An uncontrollable operating state of the vehicle
The test software "DIANALite" (50/56i) is included • Supply-air pressure pv at 6–11 bar in auxiliary cir- could result.
in the retarder tester scope of delivery (50/56) cuit Danger of accident.
• Oil level was checked and found to be OK (see  Only perform a diagnosis while the vehicle is
Page 35) stationary.
• Vehicle's electrical system was checked and found

to be OK (see the vehicle manufacturer's instruc-
tions)
• Electrical connections of the retarder are com-

© 2014
Page 40
Connecting the pressure gauge 2. Connect the pressure gauge (99/7) to the bore of retarder tester).
the screw plug (3700).
Connecting the retarder tester
VR 115 HV FL
3700
50/56b 1200
5100 153.0008
3310
1
2
50/56a
3
50
4
15 /5
3.0
00 6d
83
51
0
3200a
36601 3200b
50/56e
153.00083610
1. Unscrew the screw plug (3700).

36599
1. Connect cable 1 (50/56b) to the valve block

(1200).
2. Connect cable 3 (50/56d) to the oil temperature

sensor
99/7 (3200a) and to the coolant temperature sensor

(3200b).
3. Connect cable 4 (50/56e) to the vehicle power

supply / PC interface.
36576
4. Connect all cables to the retarder tester (50/56a)
(see also the operating instructions for the
© 2014
Page 41
Checking the supply voltage of the pressure sen- Checking the valve block 18.Repeat the test in the switch positions 50%, 75%,
sor and 100%.
14.Start the "DIANA Lite" test software.
5. Switch on the vehicle ignition. 19.If one of the values deviates: check valve block
15.Load the template for the retarder tester (see
(1200) and replace it, if necessary(see Page 93).
6. Set the "RETARDERTYP" (Retarder type) switch Operating Instructions of "DIANA Lite" test soft-
on the retarder tester (50/56a) to "8". ware). 20.Set the “CONSTANT-AIR PRESSURE” switch on
the retarder tester to 0%.
7. Switch the toggle switch to the “ON with control 16.Set the “CONSTANT-AIR PRESSURE” switch on
loop” position. the retarder tester to 25%. 21.Switch the toggle switch to the “OFF” position.
8. Connect the multimeter to the “U_Supply” socket NOTICE 22.Switch off the vehicle ignition.
(measured in V).
To assess the operation of the proportional valve 23.Disconnect the retarder tester (50/56a) and pres-
9. Read the measured value: Nominal value 4.75– block (1200), the results of the following test are sure gauge (99/7).
5.25 V. only valid during a test period of maximum 60 sec-
onds. 24.Apply silicone-free and non-corrosive grease to
10.If the value deviates: replace valve block (1200) the new O-ring (5100).
(see Page 93).
17.In "DIANA-Lite", read the "constant-air pressure - 25.Screw in the screw plug (3700) with O-ring (5100)
actual" measured value and the measured value and tighten to 100 Nm.
Checking the signal value of the pressure sensor
on the pressure gauge (99/7): Setpoint after
11.Connect the multimeter to the "U_py ACTUAL" approx. 20 seconds: 26.Complete the retarder and vehicle.
socket (measured in V). "Constant-air Constant-air pressure py [bar]

pressure" Permissible range

12.Read the measured value: Setpoint 0.3–0.7 V.
switch
13.If the value deviates: replace valve block (1200) 0% 0
(see Page 93). 25% 0.55–1.05
50% 1.25–1.75
75% 1.95–2.45
© 2014
100% 2.60–3.10
Page 42
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Diagnosis and troubleshooting Checking thepump pressure pdyn
5.4 Checking thepump pressure pdyn
NOTICE
Checking the pump pressure pdyn provides infor-
mation about
• the mechanical status of the rotor parts
• internal leaks in the retarder
• proper functioning of the retarder
50/56b
Innensechskant, SW 6
30 Nm
50/56a Retarder-Prüfgerät 50/56c
50/56b Kabel 1 to the valve block 50/56a
50/56c Kabel 2: to the pressure sensor (50/56g) 50/56e
50/56d Kabel 3: to the temperature sensors 50/56d

50/56e Kabel 4: to the vehicle power supply / PC

50/56g
interface
50/56g Drucksensor pdyn 0–30 bar 5000
3600
© 2014
36572
Page 43
Preconditions
Special tools
NOTICE
If the prop shaft screws are screwed in from the
• Retarder is switched off transmission side:
 Ensure that the prop shaft screws are removed
• Battery voltage 18–32 V
on the output side flange of the transmission.
• Supply-air pressure pv at 6–11 bar in auxiliary cir- –or–
cuit  Secure the prop shaft screws.
153.001085xx 153.000776xx
• Oil level was checked and found to be OK (see
Page 35)
Retarder-Prüf- Prüfsoftware
ATTENTION
gerät, im Koffer "DIANA Lite" • Vehicle's electrical system was checked and found
Hot parts and hot oil!
komplett to be OK (see the vehicle manufacturer's instruc-
Hands can be burned and scalded.
tions)
50/56 50/56i  Work carefully.
• Electrical connections of the retarder are com-  Wear safety gloves or use cloth.
pletely disconnected from the vehicle
NOTICE
• There are no external leaks on the retarder
With the test software "DIANA Lite" (50/56i), mea- NOTICE
sured values can be read out and stored via the PC • Vehicle is secured On account of the design, a small amount of oil may
in addition to the tests with the retarder tester.
leak out, but this does not affect retarder operation.
The stored measured values can be transmitted to • Prop shaft is removed from flanges and secured
the Voith customer service for evaluation (see op- (see the vehicle manufacturer's instructions)
erating instructions on CD-ROM).
© 2014
Page 44
3. Connect cable 1 (50/56b) to the valve block

DANGER (1200).
Diagnosis with the retarder tester while the ve- 4. Connect cable 2 (50/56c) to the pressure sensor
hicle is in motion! (50/56g).
An uncontrollable operating state of the vehicle
5. Connect cable 3 (50/56d) to the oil temperature
could result.
sensor
Danger of accident.
(3200a) and to the coolant temperature sensor
 Only perform a diagnosis while the vehicle is
(3200b).
stationary.
6. Connect cable 4 (50/56e) to the vehicle power
Connecting the pressure sensor 50/56g supply / PC interface.
36574
7. Connect all cables to the retarder tester (50/56a)
2. Connect the pressure sensor (50/56g). (see also the operating instructions for the
retarder tester).
Connecting the retarder tester
Checking the pump pressure pdyn
VR 115 HV FL 8. Switch on the vehicle ignition.
3600
50/56b0 1200
8331
153.000
1
9. Set the "RETARDERTYP" (Retarder type) switch

50/56c
2
50/56a 153.00 on the retarder tester to "8".

08341 50/56g
0
3
50
5000 15 /56
4
3.0 10.Switch the toggle switch to the “ON with control

00 d
83
51 3200a loop” position.
36573 0
3200b
50/56e 11.Start the "DIANA-Lite" test software.
1. Unscrew the screw plug (3600) with the sealing 153.00083610
ring (5000). 12.Load the template for the retarder tester (see the
36598
operating instructions of the "DIANA-Lite" test
© 2014
software).
Page 45
13.Start the engine and warm it up to operating tem-

perature. NOTICE
If the sepoint of the constant-air pressure py is
NOTICE achieved, but not the pump pressure pdyn, the re-
 Shift into direct gear (ratio 1:1). tarder has an internal defect.
The engine speed then corresponds to the propel-  Replace circuit components (see Page 87).
ler shaft speed.
14.Set the “CONSTANT-AIR PRESSURE” switch on NOTICE

the retarder tester to 25%. Test when the "CONSTANT-AIR PRESSURE"
switch is set to "100%":
15.Adjust engine speed:
"Housing pressure - Actual" setpoint > 12 bar.
- for iRet = 2.133 to 1000 rpm This is normally not possible with the retarder tester
- for iRet = 1.97 to 1100 rpm when the vehicle is at standstill.
- for iRet = 1.828 to 1150 rpm
19.Set the “CONSTANT-AIR PRESSURE” switch on
16.Set the “CONSTANT-AIR PRESSURE” switch on
20.Disconnect the retarder tester (50/56a) and all
cables.
17.Readjust engine speed:
21.Disconnect the pressure sensor (50/56g).

- for iRet = 1.97 to 1100 rpm 22.Apply silicone-free and non-corrosive grease to
- for iRet = 1.68 to 1200 rpm 23.Screw in the screw plug (3600) with sealing ring
(5000) and tighte to 30 Nm.
18.In "DIANA Lite", read off the measured value
"Housing pressure - Actual": Setpoint > 8 bar. 24.Complete the retarder and vehicle.
© 2014
Page 46
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Diagnosis and troubleshooting Testing the proportional valve current
5.5 Testing the proportional valve cur- Preconditions Scope of work for testing
rent
Sepcial tool • Retarder is switched off

98/8
• Battery voltage 18–32 V
• Vehicle's electrical system was checked and found

to be OK (see the vehicle manufacturer's instruc-
VOITH Messadapter 153.00013210
tions)

Drucksensor Steuerdruck
Schaltventil
Propventil
Schaltventil
Propventil
• The fuse for the retarder controller was checked
and found to be OK 99/10
153.000132xx
• Male and female plug connectors at valve block 36577
Messadapter checked for damage or wear (notch scratches) and

in order 1. Disconnect the plug from the valve block (1200)
99/10 and connect it to the measuring adapter (99/10).
• Electrical lead-in cable and connector were
checked (visual inspection) and found to be OK 2. Connect the plug of the measuring adapter (99/
NOTICE 10) to the valve block (1200).
When measurements are made with a commercial- 3. Connect the multimeter (98/8) (measuring type:
ly available multimeter (without real r.m.s. value
mA).
measurement), exact readout of these measured

values is not possible (display jumps). 4. Turn the "Prop flow" switch at the measuring
adapter to Position "I".
Commercially available tools 5. Switch on the vehicle ignition.

Multimeter (98/8) with r.m.s. measurement, e.g.
METRIX MTX 3281
© 2014
Page 47
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Diagnosis and troubleshooting Testing the proportional valve current
6. Switch the retarder to the highest stage.
NOTICE
The measured values correspond to the state of the
art at the time of going to print. The manufacturer
reserves the right to make modifications.
7. Read off the measured value on the multimeter

(98/8): Setpoint 471–771 mA.
8. If the value differs: Check lines, connectors and

the retarder controller, and replace if necessary.
© 2014
Page 48
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I How to remove and re-install the retarder
6. How to remove and re-install the retarder
DANGER ATTENTION ATTENTION

Retarder may fall down! Hot parts! Improper removal/installation!
Body can be crushed severely. Hands could be burned. Retarder will be damaged.
 Secure the retarder against falling down.  Work carefully. When using a hydraulic piston for lifting:
 Use a suitable lifting device.  Wear safety gloves or use cloth.  Do not press directly onto the heat exchanger
with the hydraulic jack.
 Use a wooden board or similar as protection.
© 2014
Page 49

11 Electrical connection for valve block
26 Supply-air pressure line pv,
valve block connection
3200/10
95/1 Collar nut M 14 x 1.5;
170 Nm
95/2 Hexagon screw M 14 x 1,5 x 120; 26
170 Nm 100
96 Hose clamp
97 Hose nipple
100 Retarder
50300 O-ring 198 x 3, to be replaced
3200/10 Oil temperature sensor connection
3200/20 Coolant temperature sensor connection
95/3
50300
NOTICE
 Apply silicone-free and non-corrosive grease to 11
the sealing rings, O-rings, and shaft sealing 96
rings before installation. 97

3200/20
96 97
95/2
95/1
© 2014
95/2 95/1 36578
Page 50
Preconditions
• Supply-air pressure pv discharged
• Retarder oil was drained (see Page 21)
• Coolant was drained (see Page 25)
• Oil was drained from the transmission (see the vehicle manufacturer's instruc-
tions)
© 2014
Page 51
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair
7. Repair
7.1 Overview of components 53

7.2 Retarder ventilation 57
7.3 Oil separator assembly 59
7.4 Casing ventilation 60
7.5 Check valve (inlet) 67
7.6 Check valve (outlet) 69
7.7 2/2-way valve 71
7.8 Diaphragm housing cover 73
7.9 Diaphragms 75
7.10 Heat exchanger 82
7.11 Water connector 86
7.12 Circuit components 87
7.13 Outlet throttle 92
7.14 Valve block 93
7.15 Oil temperature sensor 95

7.16 Coolant temperature sensor 97
© 2014
Page 52
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Overview of components
7.1 Overview of components

Replace component
3200a
Item No. Designation Check component according to specifications and
5000 replace, if necessary
300 Sealing plate
5500
800 Heat exchanger Perform a visual inspection and replace compo-
3000
1000 Diaphragm 4800 3101
4500
1200 Valve block 3500
2200 4200
2200 O-ring 125 x 2,5 3501 2300
2301 4400
2301 O-ring 55 x 3 4700
2700 Disk silencer 42 x 2 5800
2800 O-ring 38 x 3 5700

300
2900 Circlip 42 x 1,75 3800 3900
5600 1000
3000 O-ring 6 x 3 1201 1200
3101 Oil separator 3800 4100
3400
3300 3300
3200b 1000 5900

5000 2900 6000
4000
2700
800 2800
900 4300
© 2014
5400 36542
Page 53
Item No. Designation Replace component

3200a
3200a Oil temperature sensor M 14 x 1,5; Check component according to specifications and
Außensechskant, SW 27; 28 Nm 5000 replace, if necessary
3200b Coolant temperature sensor M 14 x 1,5; 5500
Außensechskant, SW 27; 28 Nm Perform a visual inspection and replace compo-
3300 O-ring 37,46 x 5,33 3000

3400 O-ring 60 x 5 4800 3101
4500
3500 2/2-way valve M 36 x 1,5; 3500
Innensechskant, SW 19; 130 Nm 2200 4200
3501 2300
3501 Sealing ring A 36 x 42
2301 4400
Innensechskant, SW 17; 100 Nm 4700
5800
3800 Check valve M 48 x 1,5;
5700
Außensechskant, SW 55; 180 Nm
300
3900 O-ring 253,6 x 3,53 3800 3900
5600 1000
4000 Intermediate ring 270/220 x 52,5 1201 1200
3800 4100
3400
3300 3300
3200b 1000 5900

5000 2900 6000
4000
2700
800 2800
900 4300
© 2014
5400 36542
Page 54

3200a
4100 Hexagon screw M 8 x 20; Check component according to specifications and
Außensechskant, SW 13; 22 Nm 5000 replace, if necessary
4200 Hexagon screw M 8 x 70; 5500
Innensechsrund; 15 Nm Perform a visual inspection and replace compo-

Außensechskant, SW 16; 50 Nm 4800 3101
4500
4400 Socket head screw M 8 x 20 3500
Innensechskant, SW 5; 17 Nm 2200 4200
3501 2300
4500 O-ring 198 x 3
4800 Cover A 20 2301 4400
5000 Sealing ring A 14 x 20 4700
5800
5100 Sealing ring A 30 x 36
5700
5600 1000
5500 Hexagon screw M 10 x 40; 1201 1200
3400
3300 3300
3200b 1000 5900

5000 2900 6000
4000
2700
800 2800
900 4300
© 2014
5400 36542
Page 55

3200a
5600 Mould sealing Check component according to specifications and
5700 Water connector 5000 replace, if necessary
5500
5800 Hexagon screw M 10 x 40; Perform a visual inspection and replace compo-
5900 Protection plate; 3000
from retarder Serial No. 3968217 4800 3101
4500
(see Page 14) 3500
6000 Socket head screw M 8 x 12 2200 4200
3501 2300
Innensechskant, SW 5; 20 Nm
2301 4400
4700
5800
5700
300
3800 3900
5600 1000
1201 1200
3800 4100
3400
3300 3300
3200b 1000 5900

5000 2900 6000
4000
2700
800 2800
900 4300
© 2014
5400 36542
Page 56
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Retarder ventilation
7.2 Retarder ventilation

2700 Disk - silencer 42 x 2;
check, clean and blow out with com-
pressed air
2800 O-ring 38 x 3; to be replaced
2800
2900 Circlip 42 x 1,75 2700
5900 Protection plate; 2900
from retarder Serial No. 3968217
(see Page 14)
6000 Socket head screw M 8 x 12
Auxiliaries
5900 6000
Gasoline for cleaning pur- For disk - silencer
poses
DANGER
Retarder ventilation heavily soiled or covered
with paint!
Retarder reduces braking power only delayed.
 Replace the retarder ventilation.
© 2014
36543
Page 57
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Retarder ventilation
ATTENTION
Retarder ventilation mechanically damaged!
Malfunction of the retarder.
 Replace the retarder ventilation.
Preconditions

© 2014
Page 58
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Oil separator assembly
7.3 Oil separator assembly

5500
3100 Oil separator assembly
3101 Oil separator
3100
Außensechskant, SW 16;
30 Nm
ATTENTION
Hot parts!
 Work carefully.
Preconditions

© 2014
36544
Page 59
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Casing ventilation
7.4 Casing ventilation
Item No. Designation 2300/1

2301
2300/1 Valve insert 2300
2300/2
2300/2 Float, normal weight max. 12 g
2300/3 Float cage 2300/3
NOTICE
sealing rings and O-rings before installation.
NOTICE
 Observe the installation position of float:
The side marked "O" to face upwards.
© 2014
36545
Page 60
Auxiliaries Item No. Designation

NOTICE
Spitir for float 10 Plate 140x30x8; S 235JR
If the impact puller (Voith Article No. H53.7712xx)
11 2 x web 30x8x8, S 235JR; weld onto
cannot be used to remove the casing ventilation for
ATTENTION plate
reasons of space, a Auszieher (98/7) is available
for in-house production as an alternative. 12 Hex. screw M8x90; DIN 931
Wrong adapter!
13a Hex. nut M8; ISO 4032
Damage to casing ventilation.
 Only use adapters (98/9) from Voith Article No. Tools for self-fabrication 13b Hex. nut M8; ISO4032; attach to screw
(12)
H53.942811 onward.
12
10 13a Tools for self-fabrication
Special tools
11 13b 11
8
16 Ø10
8 8
Ø 40,5 mm
7 mm
12
Ø 60 mm
37,5 37,5 27079

H53.7712xx H53.9428xx
Prüfring
Schlag- Adapter
99/4
30
auszieher
99/5 98/9 Material: St 37

140
36605 Weight: 0.085 kg
Auszieher The test ring (99/4) can be ordered from Voith Turbo
98/7 GmbH & Co. KG: Voith Article No. H67.2757xx.
© 2014
Page 61
2. Use the impact puller (99/5) including the adapter

ATTENTION (98/9) to pull the valve insert (2300/1) upwards
and out of the retarder housing.
Hot parts!
Hands could be burned. 2300/1
2300/2
0
 Work carefully.
 Wear safety gloves or use cloth. 2300/3
Preconditions
• Retarder is switched off 2301
• Ignition is switched off 36568
• Oil separator module (3100) removed (see

Page 59) 4. Take the O-ring (2301) out of the groove of the
36567 valve insert (2300/1).
Remove with Schlagauszieher (99/5)
3. If necessary, remove the float (2300/2) and the
99/5
float cage (2300/3) from the retarder housing.
98/9
36566
© 2014
1. Bolt the impact puller (99/5) to the adapter (98/9).
Page 62
Remove with Auszieher (98/7) (98/9) to pull the valve insert (2300/1) upwards
98/7 and out of the retarder housing; tighten the hex.
nut (13a) to do so.
98/9
2300/1
2300/2
0
2300/3
2301
36568
36606
1. Screw in Auszieher (98/7) using the adapter (98/ 4. Take the O-ring (2301) out of the groove of the
36567 valve insert (2300/1).
9).
)
3. If necessary, remove the float (2300/2) and the

float cage (2300/3) from the retarder housing.
13a
98/7
36607
© 2014
2. Use the extractor (98/7) along with the adapter
Page 63
Checking Install with Schlagauszieher (99/5)
1. Check the casing ventilation (2300) for dirt or oil

residues and clean it. 99/4
2300/2
0 2300/1
0
2300/1
2300/2
2301
36570
36568
5. Check the sealing edge of the radial shaft sealing
ring in the valve insert (2300/1) (see arrow/illustra- 1. Apply silicone-free and non-corrosive grease to
36569
tion): the new O-ring (2301) and pull it on the valve
- Place the float (2300/2) on a suitable object, insert (2300/1).
2. Check the float (2300/2) for damaged surfaces
e.g. hex.-head nut.
and sealing areas (see arrow/illustration).
- Place the valve insert (2300/1) on the float and
3. Weigh the float (2300/2): Normal weight max. 12 weigh it down using the test ring (99/4). 2300/1
g.
- Fill the empty space between the float (2300/2)
4. If the weight is higher: Replace the entire casing and upper edge of the valve insert with ethyl al-
0
ventil-ation (2300). cohol. 2300/2
NOTICE
The sealing edge is damaged if the fluid level drops 2300/3
within 1 minute.
© 2014
36571
Page 64
2. Clean the float with ethyl alcohol. 7. Use the impact extractor (99/5) along with the
adapter (98/9) to press the casing ventilation
NOTICE (2300) carefully into the retarder housing.
2300/1
 Observe the installation position of float: 8. Complete the retarder.
The side marked "O" to face upwards.
0
Install with Auszieher (98/7) 2300/2
3. Insert the float (2300/2) into the float cage (2300/
3).
4. Place valve insert (2300/1) on the float cage 2300/3

(2300/3).
2300/1
36571
the bore of the casing ventilation (2300) in the
retarder housing. 2. Clean the float with ethyl alcohol.
6. Insert the casing ventilation (2300) into the NOTICE

retarder housing. 2301
 Observe the installation position of float:
99/5 The side marked "O" to face upwards.
36568
98/9 3. Insert the float (2300/2) into the float cage (2300/
3).
the new O-ring (2301) and pull it on the valve
insert (2300/1). 4. Place valve insert (2300/1) on the float cage

(2300/3).

the bore of the casing ventilation (2300) in the
retarder housing.
© 2014
36566 6. Insert the casing ventilation (2300) into the
Page 65
retarder housing.
13a
98/7
36607
7. Use the extractor (98/7) along with the adapter

(98/9) to press the casing ventilation (2300) care-
fully into the retarder housing.
8. Complete the retarder.

© 2014
Page 66
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Check valve (inlet)
7.5 Check valve (inlet)

3800 Check valve (inlet), complete
3800/1 Guide M 48 x 1,5;
3800/2 Spring
3800/3 Piston
NOTICE
3800
3800/3
3800/2
3800/1
© 2014
36547
Page 67
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Check valve (inlet)
Checking Installation
Auxiliaries
Thread sealant Loctite 243 for threads of the guide 3800/1 1. Apply Loctite 243 to the thread
of the guide (3800/1).
ATTENTION 2. Screw in the check valve (inlet) (3800) and tighten

to 180 Nm.
Hot parts!
 Work carefully. 3800/3
Preconditions
3800/2
• Ignition is switched off 1. Check the rubber coating of the piston (3800/3) for
• Retarder oil was drained (see Page 21) damage.
Replace the complete check valve (inlet) (3800), if
necessary.
Removal
2. Check the guide (3800/1) and spring (3800/2) for
1. Unscrew the guide (3800/1). wear.
Replace the complete check valve (inlet) (3800), if
2. Remove the spring (3800/2) and piston 83800/3) necessary.

from the retarder housing.
© 2014
Page 68
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Check valve (outlet)
7.6 Check valve (outlet)

3800 Check valve (outlet), complete
3800/1 Guide M 48 x 1,5;
3800/2 Spring
3800/3 Piston
NOTICE
3800
3800/3
3800/2
3800/1
© 2014
36548
Page 69
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Check valve (outlet)
Checking Installation
Auxiliaries
Thread sealant Loctite 243 for threads of the guide 3800/1 1. Apply Loctite 243 to the thread of the
guide (3800/1).
ATTENTION 2. Screw in the check valve (inlet) (3800) and tighten

it to 180 Nm.
Hot parts!
 Work carefully. 3800/3
Preconditions
3800/2
• Ignition is switched off 1. Check the rubber coating of the piston (3800/3) for
• Retarder oil was drained (see Page 21) damage.
If necessary, replace the complete check valve
(outlet) (3800).
Removal
2. Check the guide (3800/1) and spring (3800/2) for
1. Unscrew the guide (3800/1). wear.
If necessary, replace the complete check valve
2. Remove the spring (3800/2) and piston 83800/3) (outlet) (3800).

from the retarder housing.
© 2014
Page 70
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair 2/2-way valve
7.7 2/2-way valve

4800
3500 2/2-way valve, M 36 x 1,5; 3500
3501
3501 Sealing ring A 36 x 42; to be replaced 3502
3502 O-ring 28 x 2; to be replaced 3503

4800 Cover A 20
NOTICE
ATTENTION
Hot parts!
 Work carefully.
Preconditions

© 2014
36549
Page 71
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair 2/2-way valve
Removal Checking 4. If there are signs for corrosion:

- Check and repair the compressed air system
ATTENTION (see vehicle manufacturer's instructions).
Improper removal! - Replace the 2/2-way valve (3500).

Damage to the 2/2-way valve (3500).
 Do not remove/install the 2/2-way valve (3500)
with impact screwdriver.
NOTICE
If the screw plug looses from the valve body during
removal:
 Take out the sealing ring (3501). 36602
 Screw in the screw plug manually without a seal-
ing ring (3501) until the screw plug touches the 1. Check whether the brass piston is in the correct
retarder housing and the valve body engages. position (see A/illustration).
 Manually loosen and unscrew the screw plug
with the engaged valve body. 2. If the piston is stuck (see B/illustration), replace
the complete 2/2-way valve (3500).
–or–
 Pull the valve body out of the retarder housing
NOTICE
using a bearing outer race puller.

Bearing outer race puller: e.g. Kukko, tool No. 21-5, If there are signes for corrosion on the 2/2-way
Ø 28–40 mm and bead breaker No. 22-1 valve, there is water in the vehicle's compressed air
system.
3. Check the 2/2-way valve for signs for corrosion.

© 2014
Page 72
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Diaphragm housing cover
7.8 Diaphragm housing cover

4300

300 Sealing plate; to be replaced
4300 Hexagon screw M 10 x 40;
Außensechskant, SW 16; 900
50 Nm
Auxiliaries
300
2 stud bolts M 10
ATTENTION
Hot parts!
 Work carefully.
© 2014
36550
Page 73
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Diaphragm housing cover
1. Screw two M 10 stud bolts into the retarder hous- 4. Screw in the hex. screw (1) hand-tight.
ATTENTION ing (see arrows/illustration).
5. Tighten the hex. screw (2) to 17 Nm.
Improper removal! 2. Position the new sealing plate (300) onto the
Malfunction/damage to the retarder. 6. Tighten the hex. screw (1) to 17 Nm.
retarder housing.
 To remove/install the diaphragm housing cover: 7. Tighten hex. screw (3) to 50 Nm.
3. Put the new diaphragm housing cover (900) onto
Lay the retarder on one side.
the retarder housing. 8. Unscrew the stud bolts M10.
Preconditions
ATTENTION 9. Tighten the hex. screws in the specified sequence
• Ignition is switched off (4-8) to 50 Nm.
Wrong sequence when tightening the hex.
• Retarder was removed (see Page 49) screws! 10.Tighten hex. screw (9) to 50 Nm.
Damage to the diaphragms.
• Valve block was removed (see Page 93) 11.Tighten hex. screw (2) to 50 Nm.
 Tighten the hex. screws in the specified se-
quence. 12.Tighten the hex. screws in the specified sequence
Removal
(10-13) to 50 Nm.
1. Unscrew the hex. screws (4300).
13.Tighten hex. screw (1) to 50 Nm.
2. Remove the diaphragm housing cover (900). 4 5 6
3. Remove the sealing plate (300).

12 13 1 7
Installation
11
8
NOTICE
 Ensure that the diaphragm housing cover (900)
is dry and free of dirt. 10
3
2 9
© 2014
36583
Page 74
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Diaphragms
7.9 Diaphragms
1000b
1000a Diaphragm
1000b Diaphragm 3900
3900 O-ring 253,6 x 3,53; to be replaced
4000 Intermediate ring
4000
NOTICE
the sealing rings, O-rings, and shaft sealing 1000a
NOTICE
 The diaphragms can be replaced when the re-
tarder is in horiozontal and/or vertical position
(see Page 77ff).
When the diaphragms are mounted horizontally
it is necessary to remove the retarder from the
vehicle.
When the diaphragms are mounted vertilally, it
is not mandatory to remove the retarder from the
vehicle.
An oil leak will result in case of a minimal devia-
tion when positioning the diaphragms!
Voith therefore recommends the replacement in
hori-zontal position (with retarder removed).
© 2014
36551
Page 75
Removal
ATTENTION
Hot parts! ATTENTION
Hands could be burned. Incorrect sequence during removal!
 Work carefully. Damage to the 2/2-way valve (3500)
 Wear safety gloves or use cloth.  Ensure that the 2/2-way valve (3500) has been
removed.
Preconditions
1. Remove the first diaphragm (1000b).
2. Pull the intermediate ring (4000) manually care-
• When the diaphragms are mounted horizontally:
fully and smoothly from the retarder
Retarder was removed (see Page 49)
housing (100).
• 2/2-way valve was removed (see Page 71)
3. Remove the O-ring (3900).
• Diaphragm housing cover was removed (see
4. Remove the second diaphragm (1000a).
Page 73)
© 2014
Page 76
Installation in horizontal position

(retarder removed from the vehicle)
1000b
100
NOTICE 4000
 Ensure that the following parts are dry and free

of dirt:
- Diaphragms (1000a and 1000b)
- Retarder housing (100) 3900
100
- Diaphragm housing cover (900)
1000a
36603 36593
2. Insert the first diaphragm (1000a) centered. In 3. Apply silicone-free and non-corrosive grease all
doing so, observe the installation position of the around the sealing bead of the diapragm (1000a)
diaphragm bead. (see gray area/illustration).
36592

the retarder housing (100) in the contact area of
the bead of the diaphragm (1000a) (see gray
© 2014
area/illustration).
Page 77
8. Apply silicone-free and non-corrosive grease all

around the sealing bead of the diaphragm
1000b
(1000b).
4000
9. Install the sealing plate (300) and diaphragm
housing cover (900) (see Page 73).
10.Complete the retarder.
3900
100
1000a
36603

the new O-ring (3900) and pull it onto the interme-
diate ring (4000).
5. Carefully insert the intermediate ring (4000) into

the retarder housing (100) and press it in uni-
formly by hand.

the intermediate ring (4000) in the contact area of
the diaphragm (1000b).
7. Place the second diaphragm (1000b) centered on

the intermediate ring. In doing so, observe the
installation position of the diaphragm bead.
© 2014
Page 78
Installation in vertical position

(retarder not removed from the vehicle)
4000 4000
NOTICE
 Ensure that the following parts are dry and free
of dirt:
- Diaphragms (1000a and 1000b)
- Retarder housing (100)
- Diaphragm housing cover (900)
1000a
Auxiliaries
36610 36611
Loctite 435 Fixing the diaphragms
Use Loctite 435 only! Oth-
er products may destroy 1. On the intermediate ring (4000), apply evenly dis- 2. Position the new diaphragm (1000a) centered on
the diaphragms. tributed 6 points of Loctite 435 (see the red points the intermediate ring (4000) and slightly press
in the illustration) to the sealing surface of the evenly down the sealing bead by hand (see the
housing-side diaphragm (1000a). arrow in the illustration).
NOTICE 3. Lubricate the sealing bead of the diaphragm

(1000a) all around with silicone-free and non-cor-
 Work step 2 that is described in the following rosive grease.
has to be completed after max. 20 seconds.

Bonding is hand-tight between 10 and 20 sec-
onds. Corrections are then no longer permitted!
NOTICE
If this is the case:  To facilitate the fitting of the diaphragm (1000b),
Remove again the diaphragm and dispose of it position the intermediate ring (4000) with the al-
properly. Then fully remove any residues and ready mounted diaphragm (1000a) pointing
adhesive residues from the intermediate ring us- downwards into the diaphragm housing cover
ing a suitable cleaning agent, and repeat the (900).
mounting process with a new diaphragm.
© 2014
Page 79
4. On the intermediate ring (4000), apply evenly dis- 5. Position the new diaphragm (1000b) centered on
tributed 6 points of Loctite 435 (see the red points the intermediate ring (4000) and slightly press
4000
in the illustration) to the circular groove of the evenly down the sealing bead by hand (see the
housing-side diaphragm (1000b). arrow in the illustration).
NOTICE 6. Apply silicone-free and non-corrosive grease all

around the sealing bead of the diaphragm
 Work step 5 that is described in the following (1000b).
has to be completed after max. 20 seconds.
Bonding is hand-tight between 10 and 20 sec-
3900
onds. Corrections are then no longer permitted! 1000a
If this is the case: 1000b
Remove again the diaphragm and dispose of it
36612 properly. Then fully remove any residues and
adhesive residues from the intermediate ring us-
ing a suitable cleaning agent, and repeat the
mounting process with a new diaphragm.
4000
1000b 4000
36614

the new O-ring (3900) and pull it on the intermedi-
ate ring (4000).
8. Insert uniformly by hand the completed unit

(1000a, 1000b, 3900 and 4000) into the retarder
housing.
36613
© 2014
Observe the mounting position!
Page 80
9. Install the sealing plate (300) and diaphragm

housing cover (900) (see Page 73).
10.Complete the retarder.

© 2014
Page 81
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Heat exchanger
7.10 Heat exchanger

800 Heat exchanger
3200 Coolant temperature sensor M 14 x 1,5;
28 Nm
3300 O-ring 37,46 x 5,33; to be replaced
50 Nm
NOTICE
 Apply silicone-free and non-corrosive grease to 3300 5000
the sealing rings, O-rings, and shaft sealing 3200
3400
3300
800
© 2014
5400 36552
Page 82
Removal
NOTICE DANGER
 Please procure any connecting pieces that are Heat exchanger can fall down! NOTICE
not listed here. Body can be crushed severely. If the heat exchanger is replaced:
 Secure the heat exchanger against falling down.  Unscrew the coolant temperature sensor (3200)
 Use a suitable lifting device. with sealing ring (5000).
Special tools
1. Unscrew the hexagon head screws (5400) and

Auxiliaries
remove the heat exchanger (800).
Elring sealing compound For sealing surface heat
Dirko-S Profi press HT: exchanger/ 2. Remove the O-rings (3300 and 3400).
retarder housing
• Color: black
• Temperature-resistant
–50 °C ... + 250 °C
153.001375xx • Voith Article No.
190.001697xx
Abpressplatte
Preconditions
50/58
ATTENTION • Ignition is switched off

Hot parts! • Retarder oil was drained (see Page 21)

 Work carefully.
 Wear safety gloves or use cloth. • Electrical connecting cable was disconnected on
the coolant temperature sensor
• Coolant connecting hose was removed from the

© 2014
heat exchanger
Page 83
Checking
ATTENTION
the O-rings (3300 and 3400) and insert them into Heat exchanger leaks!
the grooves of the pressure-test plate (50/58). Malfunction of the retarder.
 If air bubbles appear in the water or if an exter-
nal leak is detected: Replace the heat exchang-
800/1 er.
A 7. If air bubbles appear in the water at the water con-

nector (800/1): Replace the heat exchanger.
50/58
8. Drain the overpressure.
C B
800
36600
2. Attach the pressure-test plate (50/58) with hex.

screws to the heat exchanger (800).
3. Close connections "B" and "C".

4. Fill the water section of the heat exchanger (800)

with hot water (approx. 70°C).
5. Connect the compressed-air line with pressure

reducer to connection "A".
6. Slowly pressurize the heat exchanger (800) with a

max. of 4 bar overpressure.
© 2014
Page 84
Installation 3. Insert heat exchanger (800) and fasten with hexa- 7. Refill with oil (see "Oil change" on Page21).
gon head screws (5400).
NOTICE 4. Tighten the hex.-head screws (5400) crosswise to
The water and oil sections of new heat exchangers 50 Nm.
are coated with anti-corrosion oil.
 Before installation, drain any anti-corrosion oil
and flush the water section with hot water.
ATTENTION
Wrong coolant type!
Damage to the vehicle and retarder cooling circuit.
 Observe the vehicle manufacturer's instructions
or those of the Voith Turbo coolant quality list.
6. Fill the vehicle and retarder cooling circuit (see the

100
3300 3300 vehicle manufacturer's instructions).
3400
ATTENTION
Beware of water residues in the retarder!
Oil loss via oil separator.
800 5400 36604
Malfunction of the retarder.
 Fill the retarder with 5.6 l engine oil or flush oil.

the new O-rings (3300 and 3400) and insert them  Flush the retarder system by braking lightly sev-
into the grooves of the retarder housing (100). eral times.
 Drain the oil.
2. Apply Dirko-S Profi press HT to the sealing sur-
 Repeat the process 2 or 3 times.
faces of the retarder housing (100) (see dashed
line/figure 36104).  De-oil the cooling and heating system (see the
vehicle manufacturer's instructions).
© 2014
Page 85
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Water connector
7.11 Water connector

5600 Mould sealing, to be replaced
5700 Water connector
50 Nm
NOTICE
 Install the mould sealing (5600) dry.
5600
5700
5800
© 2014
36608
Page 86
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Circuit components
7.12 Circuit components

33 Circuit components
2200 O-ring 125 x 2,5; to be replaced
4200 Hexagon head screw M 8 x 70;
Innensechsrund
15 Nm
3000
2200
NOTICE 33 4500

50300
4200
© 2014
36553
Page 87

50 Nm
50300 O-ring, 198 x 3; to be replaced
NOTICE
2200
33 4500
NOTICE
Instructions will be attached to the circuit parts 4200
(spare part) in which the installation/removal and
return of the defective circuit parts is described 50300
(conversion instructions for basic retarder
VR 115 HV FL).
4200
© 2014
36553
Page 88
If the stator gets stuck in the retarder housing: Removal

Auxiliaries
Elring sealing compound for sealing surface circuit 1. Unscrew the hex. screws (4200).
Dirko-S Profi press HT: parts/ Commercially available tools
retarder housing
• Color: black Two-arm universal puller
• Temperature-resistant
–50°C ... + 250 °C
50/59 33
• Voith Article No.
ATTENTION
190.001697xx Hot parts!
Special tools  Work carefully.
4200
NOTICE 4200 36596
If the retarder circuit components are mechanically

2. Remove the circuit parts (33) using the removal
defective:
device (50/59).
 Disassemble the complete retarder (except for
153.001547xx
the circuit parts) and clean all components (they
must be free of dirt, metallic residues and water)
Abziehvorrich-  Replace the heat exchanger (see Page 82).
tung
 Replace diaphragms (see Page 75)
50/59
Preconditions
• Retarder was removed (see Page 49)

© 2014
Page 89
Installation
1. Clean and dry the retarder housing in the mount-

ing area of the retarder circuit components (33).

the insertion chamfer of the O-ring (2200) in the
retarder housing.

the new O-ring (2200) and pull it on in the retarder
housing.
36097 4. Apply silicone-free and non-coorrisive grease to

the new O-rings (3000 and 4500) and insert them
3. If necessary, use the two-arm universal puller to in the retarder circuit components (33).
pull the stator out of the retarder housing.
4. Remove O-rings (2200, 3000 and 4500).

© 2014
Page 90
NOTICE
 Do not apply Dirko-S Profi press HT in the lower
section of the retarder circuit components (33)
(see dimensioning/illustration).
5. Apply sealing compound Dirko-S Profi press HT to

the retarder circuit components (33) on the seal-
ing surfaces of the retarder housing as a caterpil-
lar max. 0.5 mm high and max. 1.5 mm wide (see
dashed line/illustration).
6. Install retarder circuit components (33).
7. Screw in the hex. screws (4200) and tighten to

15 Nm.

26 ±3
30 ±3
© 2014
36554
Page 91
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Outlet throttle
7.13 Outlet throttle

4400 Socket head screw M 8 x 20
Innensechskant, SW 5;
17 Nm
4700 Outlet throttle
ATTENTION
Hot parts!
 Work carefully.
4700
Preconditions
4400
• Retarder was removed (see Page 49)
• Circuit components were removed (see Page 87)

© 2014
36584
Page 92
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Valve block
7.14 Valve block

4100

1200 Valve block
1201 Seal assembly valve block
1201/1 O-ring; to be replaced
1201/2 Mould sealing, to be replaced 1201
Außensechskant, SW 13; 1200
22 Nm 1201/1
1201/2
ATTENTION
Hot parts!
 Work carefully.
NOTICE
 Use only the VOSS 232 plug-in system on the

valve block (1200).
The VOSS 230 plug-in system must not be used.
© 2014
36556
Page 93
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Valve block
Preconditions
• Supply-air pressure was released
• Compressed air line was removed on the valve

block
• Electrical connection was disconnected on the

valve block. Connector and mating connector were
checked for damage or wear (notch scratches),
and replaced, if necessary.
© 2014
Page 94
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Oil temperature sensor
7.15 Oil temperature sensor

3200 Oil temperature sensor M 14 x 1,5;
28 Nm
5000 Sealing ring A 14 x 20; to be replaced 3200
5000
ATTENTION
Hot parts!
 Work carefully.
Preconditions
• Electrical connection was disconnected on the oil

temperature sensor. Male and female connectors

were checked for damage or wear (notch scratch-
es), and replaced, if necessary.
© 2014
36557
Page 95
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Oil temperature sensor
Checking the internal resistance
NOTICE
Measuring in one temperature range is usually suf-
ficient.
Polarity: any.
Temperature Resistance
20°C ± 10 °C 1039–1117 Ω
60 °C ± 10 °C 1194–1271 Ω
80°C ± 10 °C 1271–1347 Ω
© 2014
Page 96
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Coolant temperature sensor
7.16 Coolant temperature sensor

3200 Coolant temperature sensor M 14 x 1,5;
28 Nm
ATTENTION
Hot parts!
 Work carefully.
Preconditions

• Electrical connecting line at the coolant tempera-

ture sensor disconnected. Male and female con-
nector checked for damage or wear (notch
scratches) and replaced if necessary
5000
3200
© 2014
36558
Page 97
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Repair Coolant temperature sensor
Checking the internal resistance
NOTICE
Measuring in one temperature range is usually suf-
ficient.
Polarity: any.
Temperature Resistance
20°C ± 10 °C 1039–1117 Ω
60 °C ± 10 °C 1194–1271 Ω
80°C ± 10 °C 1271–1347 Ω
© 2014
Page 98
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Overview of tools
8. Overview of tools
8.1 Diagnosis 100

8.2 Repair 102
© 2014
Page 99
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Overview of tools Diagnosis
8.1 Diagnosis
Task Special tools Tools for self-fabrication

Checking the constant- –
air pressure control
loop
153.001085xx 153.000776xx H53.1403xx
Retarder-Prüf- Prüfsoftware Manometer 0–

gerät, im Koffer "DIANA Lite" 6 bar
komplett
50/56 50/56i 99/7
Check pump pressure –
pdyn
153.001085xx 153.000776xx
Retarder-Prüf- Prüfsoftware
gerät, im Koffer "DIANA Lite"
komplett
50/56 50/56i
© 2014
Page 100
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Overview of tools Diagnosis

Testing the proportion- –
al valve current

Schaltventil
Propventil
153.000132xx
Messadapter
99/10
© 2014
Page 101
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV FL I Overview of tools Repair
8.2 Repair

Casing ventilation
Ø 40,5 mm
7 mm
Ø 60 mm
H53.7712xx H53.9428xx
27079
Schlag- Adapter Prüfring

auszieher
99/5 98/9 99/4
© 2014
Page 102

Casing ventilation
12
10 13a
11 13b 11
8
16
Ø10
8 8
12
37,5 37,5
30
140
36105
Auszieher
98/7
© 2014
Page 103

Heat exchanger –
153.001375xx
Abpressplatte
50/58
Circuit components –
153.001547xx
Abziehvorrich-
tung
50/59
?
© 2014
Page 104
Voith Turbo
Commercial Vehicles
P.O. Box 15 55
74555 Crailsheim
Germany
Phone: +49 79 51 32 1555

Fax: +49 79 51 32 1506
support-retarder@voith.com
www.voith.com
Engineered reliability.

Aftersales Service Manual Voith Retarder VR 115 HV FL

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Aftersales Service Manual Voith Retarder VR 115 HV FL

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Voith Turbo

Aftersales Service Manual Voith Retarder VR 115 HV FL

1 About this document 5

2 Basic Safety Information 8

2.8 Basic driving modes 10

3 Design and Function 11

3.3 Identification of VERA™ controller 15

3.4 Functional and control diagram 16

4 Maintenance and Service 19

5 Diagnosis and troubleshooting 27

6 How to remove and re-install the retarder 49

7.2 Retarder ventilation 57

7.10 Heat exchanger 82

1. About this document

1.1 Purpose of this document 6

1.1 Purpose of this document 1.2 Target groups

1.3 Other applicable documents

Document Information Voith Article No.

1.4 Symbols and identifications 1.5 Item numbers

 One-step action instruction. Phone: +49 79 51 / 32-1555

2. Basic Safety Information

2.1 Product safety 9

 Observe the following regulations:  Work carefully.

Driving after oil change/checking the oil level

tion, otherwise oil may escape.

3. Design and Function

3.1 Overview of the assemblies 12

3.1 Overview of the assemblies

Item No. Designation

3.2 Retarder identification

3.3 Identification of VERA™ controller

Location of the retarder controller in the vehicle is de-

Retarder Control Unit VERATM

Serial-No. xxxxx / JJJJ-MM-TT

3.4 Functional and control diagram

3200b Coolant temperature sensor

3.5 Functional Description Diaphragm (1000) Casing ventilation (2300)

To protect both the cooling system and the retarder,

perature are set in the controller.

In addition, irrespective of the actual temperature of Check valve (outlet) (3800a)

Check valve (inlet) (3800b)

When the retarder is switched off, the 2/2-way valve

4. Maintenance and Service

4.1 Maintenance intervals 20

4.1 Maintenance intervals

Activity Interval See

4.2 Oil change

Item No. Designation

Oil filling quantity

Heat exchanger Dimension "A"

• Oil at operating temperature (>60°C) 50/31

• Ignition is switched off

Draining the oil

1. Put an oil pan under the retarder.

WARNING 801 36508 36503

17.Screw in the screw plug (3700) with sealing ring

10.Screw in the screw plug (801) with new sealing NOTICE

12.Apply silicone-free and non-corrosive grease to

the new sealing ring (5000).

Item No. Designation

1. Put a clean coolant catch pan under the retarder.

2. Unscrew the screw plug (801b) and drain the cool-

3. Fill the vehicle and retarder cooling circuit (see the