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Voith Turbo

Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx


153.00009711 I 2007-09

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Table of Contents

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Table of Contents
1

About this Document

1.1
1.2
1.3
1.4
1.5
1.6

Purpose of this Document


Target Groups
Other Applicable Documents
Symbols and Identifications
Item Numbers
Imprint

6
6
6
7
7
7

Basic Safety Information

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9

Product Safety
Staff Qualification
Safety-Conscious Working
Environmental Protection
Special Tools
Diagnosis and Troubleshooting
Maintenance and Repair
Driving Mode
Warranty

9
9
9
9
9
9
9
10
10

Design and Function

11

3.1
3.2
3.3

Overview of the Modules


Retarder Identification
VERA Controller Identification

12
14
15

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Table of Contents

3.4
3.5
3.6

Digiprop Controller Identification


Function and Control Scheme
Function Description

16
17
19

Maintenance and Service

21

4.1
4.2
4.3
4.4

Maintenance Intervals
Oil Change
Checking the Oil Level
Draining the Coolant

22
23
26
29

Diagnosis and Troubleshooting

31

5.1
5.2
5.3
5.4

Overview
Checking
Checking
Checking

32
42
47
52

Removing and Installing the Retarder

54

Repair

62

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8

Components Overview
Top Oil Tank Cover
Bottom Oil Tank Cover
Cover for Casing Ventilation
Casing Ventilation
Retarder Ventilation
Basic Retarder
Inside Part (800)

63
70
72
74
77
81
82
83

of the Possible Complaints


the Constant-Air Pressure Control Loop
the Pump Pressure pdyn
the Proportional Valve Current

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Table of Contents

Pipe (5900)
Water Neck
Heat Exchanger
Pressure Control Valve
Non-Return Valve (inlet)
Non-Return Valve (outlet)
Oil Temperature Sensor
Coolant Temperature Sensor
Pressure Sensor
Proportional Valve and Damping Plate

85
86
88
93
96
98
101
103
105
106

Overview of the Tools

108

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7.9
7.10
7.11
7.12
7.13
7.14
7.15
7.16
7.17
7.18

Page 4

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I About this Document

About this Document

1.1

Purpose of this Document

1.2

Target Groups

1.3

Other Applicable Documents

1.4

Symbols and Identifications

1.5

Item Numbers

1.6

Imprint

Voith Turbo I 153.00009711 I arrtd I 2007-09


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1.

Page 5

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I About this Document

1.1

Purpose of this Document

This Aftersales Service Manual provides information


and instructions on the maintenance and repair of the
Voith Retarder VR 115 E 153.000188xx.

1.3

1.2

Purpose of this Document

Target Groups

This Aftersales Service Manual is intended for service


personnel for maintenance and diagnostics and may
not be reproduced or given to third parties.

Other Applicable Documents

Documents

Information

Voith item no.

Voith Retarder Oil change intervals/Oil selection list

Oil change intervals and approved oil types

153.000900xx

Cooling water quality list

Approved coolants

H67.2224xx

ECU specifications

Instructions on diagnosis for the VERA controller

on request

Operating instructions for retarder tester

Measured values for constant-air pressure and pump pressure

153.001508xx
Included in scope of delivery of
the retarder tester
(153.001085xx)

Voith Turbo I 153.00009711 I arrtd I 2007-09


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Operating instructions for "DIANA Lite" test software

Information on the testing of:

Constant-air pressure control loop

Pump pressure pdyn

Included in the scope of delivery


of the "DIANA Lite"
(153.000776xx)

Operating instructions for the "WinDia" diagnostic


software

Instructions on PC diagnosis for the Digiprop and VERA controllers

3623-020900

Conversion instructions for the basic retarder


VR 115 E

Instructions for removing and installing the basic retarder and returning
the basic retarder

153.002778xx

VR 115 E 153.001532xx ventilation conversion instructions

Instructions for converting the retarder ventilation

153.002005xx

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I About this Document

1.4

Symbols and Identifications

Structure of warnings

LEVEL OF DANGER

WARNING
Possible imminent danger that could lead to death
or serious injury if not prevented.

DANGER

Possible consequences if not heeded.


consequences.

1.5

The item numbers used are usually found in the spare


part lists.

Immediate danger that leads to death or serious in-

one- or two-digit item numbers

item numbers with a slash

jury if not prevented.

1.6
Levels of danger

Notes

The warnings are categorized into four levels of


danger:

CAUTION
Possible imminent danger that could lead to damage to property if not prevented.

NOTE
Information on easier and safer work with the retarder.
Measures for easier and safer work with the retarder.
Distinctions

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Item Numbers

Exceptions:

Type and source of danger!


Measures for the prevention of danger and its

Symbols and Identifications

CAUTION
Possible imminent danger that could lead to slight
injury if not prevented.

One-step action instruction.


1. First step of an action instruction. Other steps follow and are numbered in sequence.

Imprint

For questions and work procedures not described in


these documents, contact the respective organization
for your area.
Voith Turbo
Produktgruppe Retarder
Postfach 1555
74555 Crailsheim
Deutschland
Phone: 00 49 79 51 / 32-401, 32-422, 32-1860
Fax:
00 49 79 51 / 32-756
service-retarder@voith.com
www.voith.com

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Basic Safety Information

Basic Safety Information

2.1

Product Safety

2.2

Staff Qualification

2.3

Safety-Conscious Working

2.4

Environmental Protection

2.6

Diagnosis and Troubleshooting

2.7

Maintenance and Repair

2.8

Driving Mode

10

2.9

Warranty

10

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2.

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Basic Safety Information

2.1

Product Safety

The retarder is constructed according to the state of


the art in technology and acknowledged safety regulations.
Nevertheless, hazardous situations and property
damage may occur as a result of improper usage,
maintenance and repair.
Observe safety and warning information.

2.2

Staff Qualification

Allow only qualified professionals to carry out repair


and maintenance work.

2.3

Safety-Conscious Working

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Voith does not assume any liability for personal injury


and/or property damage caused by improper and unprofessional work.

2.4

Environmental Protection

Drained fuels and fluids, consumables and old parts


must be disposed of properly.

2.5

Special Tools

Product Safety

Danger of accidents if the retarder tester is used


improperly!
Diagnosis while the vehicle is traveling results in an
uncontrollable operating state of the vehicle.
Carry out diagnosis only while the vehicle is standing still.

Damage to property if false special tools are used!


The special tools required are described in the respective action instructions.
The chapter "Overview of the Tools" contains an overview of the special tools.

2.7

Maintenance and Repair

In the case of special tools that may only be used


from a specific version on, the version number is
contained in the last two digits of the Voith item no.
Example: H53.942811.

Work carefully.

Only use special tools from the specified ver-

Work carefully.

Danger of burning and scalding via squirting oil!


The oil in the retarder may be hot.

Danger of burning and scalding via hot coolant!


The coolant may be hot.

sion on.
Take the last two digits of the Voith item no. into

Danger of burns via hot parts!

account in the diagram of the special tools.

Parts of the retarder may be hot.

Observe the following regulations:


-

Accident-prevention regulations

2.6

Diagnosis and Troubleshooting

Other generally acknowledged safety regulations and occupational health

Voith provides a warranty/goodwill service for defective parts only.

Motor Vehicle Regulations

Safety regulations for handling chemical substances such as oils and greases

Work carefully.
Wear protective gloves or use cloths, if necessary.

Do not replace parts on mere speculation.

Page 9

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Basic Safety Information

Damage to property via soiled parts!

Driving after oil change/checking the oil level

Failure or performance reduction while driving

Considerable damage or malfunctions may occur due


to soiling.

Air is mixed in the oil!

During failure of the retarder, or while temperature adaptation is active:

Ensure cleanliness.
Damage to property via improper cleaning!
Do not aim the jet of a high-pressure cleaner
(steam-jet device) at valves, sensors or the exhaust
of the retarder.

2.8

Driving Mode

Ensure that the retarder is fully functional for all vehicle maneuvers, i.e.:

Voith Turbo I 153.00009711 I arrtd I 2007-09


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Driving Mode

Retarder is properly filled with oil

Retarder electronic equipment is connected


and is functional

Pneumatic control is connected and is


functional

Oil loss through retarder ventilation.


Ventilating the retarder:
-

If it exists and if possible: Switch off the retarder


foot operation.

Move the vehicle with 50 km/h

Activate the retarder in the first braking stage 5


times for approx. 5 s each.

Adjust the speed of the vehicle with the engine/service brake.


Engage the lowest possible gear to achieve a high
engine speed.
During a temperature adaptation continue driving in
this way until the retarder is available at full capacity
again.

Towing
Tow vehicle with retarder max. 100 km at max.
40 km/h.
Parking
Do not use retarder as a parking brake, as it does
not act as a brake when the vehicle is standing still.

2.9

Warranty

Voith accepts no liability for damage caused by


changes to the retarder or the use of spare parts, accessories, attachments and special features not tested and approved by Voith.
Use only parts approved by Voith to ensure the
safety of the vehicle and functioning of the
retarder.

Page 10

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

Design and Function

3.1

Overview of the Modules

12

3.2

Retarder Identification

14

3.3

VERA Controller Identification

15

3.4

Digiprop Controller Identification

16

3.5

Function and Control Scheme

17

3.6

Function Description

19

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3.

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

3.1

Overview of the Modules

Overview of the Modules


2810

Item No.
100

Name

3700

Retarder housing

1600

Valve cover for non-return valve (outlet)

1900

Non-return valve (inlet)

2810

Air and vent filter

3700

Proportional valve

4100

Screw plug/oil filler plug

4100

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1900

1600

100

28003

Page 12

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

Item No.

Name

103

Screw plug

107

Screw plug/oil drain plug

3500

Screw plug of the pressure control valve

4200

Screw plug/oil drain plug

5200b

5500

Coolant temperature sensor

5500

Retarder ventilation "R"

6400

Heat exchanger

20000

Overview of the Modules

6400

Water neck

3500

20000

103
5200b

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20000

107
4200

28004

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

3.2

Retarder Identification

Retarder Identification

NOTE
Specify the following data in case you have
questions or are ordering spare parts:
-

Serien-Nr. (Serial number)

Voith-Sach-Nr. (Voith item number)

Typ VR115E; Serien-Nr.


i Ret. = 2.03

KW/Jahr

Voith-Sach-Nr.
Nr.

er
; S

ien-

Voith Turbo I 153.00009711 I arrtd I 2007-09


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5E
/Jah
R11
KW
pV
Ty
2.03
=
et
iR
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N
ith
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ac
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Kd.

Kd.-Sach-Nr.

28001

Page 14

VERA Controller Identification

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

3.3

VERA Controller Identification

NOTE
Specify the following data in case you have
questions or are ordering spare parts:

Retarder Control Unit VERATM


Serial-No. XXXXXX / JJJJ-MM-TT
Part-No. VERA.D.H-E02.10-H67.2866.20
OEM-No. 0004463315 / EvoBus

X1

X2

e1 022084

Voith-Sach-Nr. (Voith item number)

Voith Turbo

VOITH

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Serien-Nr. (Serial number)

Voit
h Tu
rbo

VOI
TH

Specify the following data of the retarder (see


page 14):

R
S et
P er ar
O ar ia de
E t- l-N r
M N
C
-N o. o. o
n
o V XX t
r
. E
0 R X ol
0 A X U
0
X
.D X n
4
1
4 .H X it
6
/
3 -E J V
3
J E
1 0 J R
5 2 J A
/ .1 -M TM
E 0 M
v -H
o 6 -T
X
B 7
2
u .2 T
s 8
6
6

.2

Part-No. (Voith item number)

084

022

Serial-No. (Serial number)

e1

X3
28138

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

3.4

Digiprop Controller Identification

Digiprop Controller Identification

NOTE
Specify the following data in case you have
questions or are ordering spare parts:
-

Basis-Nr. (Serial number)

Serien-Nr. (Voith item number)

Voith Turbo I 153.00009711 I arrtd I 2007-09


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Specify the following data of the retarder (see


page 14):
-

Serien-Nr. (Serial number)

Voith-Sach-Nr. (Voith item number)

Ba
s
Co is-N
Se de-N r.:
r
VO ien- r.:
IT Nr.
H :

53
.
xx xxxx
x
.12
xx
xx
/

Basis-Nr.:
Code-Nr.:
Serien-Nr.:
VOITH
28002

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

3.5

Function and Control Scheme

Item No.

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Function and Control Scheme

Four-circuit protection valve

Air tank (auxiliary equipment)

Supply-air pressure pv "P"

Ventilation line "R"

Air and vent line "A"


constant-air pressure py

Oil tank

Rising duct

107

Oil drain plug

200

Stator

300

Rotor

1900

Non-return valve (inlet)

2100

Non-return valve (outlet)

2200

Pressure control valve

Name

2810

C
9000

2300

3700

P
A R

E
5200a
1900

6400

Vehicleelectronics

5200b
300
200
2200
5500 2100
107

4200

Oil sump

Coolant

Supply-air pressure pv

Pump pressure pdyn

Constant-air pressure py
28005

Page 17

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

Item No.

Function and Control Scheme

Name

2300

Casing ventilation

2810

Air and vent filter

3700

Proportional valve

4200

Oil drain plug

5200a

Oil temperature sensor

5200b

Coolant temperature sensor

5500

Retarder ventilation "R"

6400

Heat exchanger

9000

Pressure sensor

2810

C
9000

2300

3700

P
A R

E
5200a
1900

6400

Vehicleelectronics

5200b

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300
200
2200
5500 2100
107

4200

Oil sump

Coolant

Supply-air pressure pv

Pump pressure pdyn

Constant-air pressure py
28005

Page 18

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

3.6

Function Description

Ventilation line "R" (D)


Ventilation line for constant-air pressure py between
the proportional valve (3700) and the retarder ventilation "R" (5500).

Non-return valve (inlet) (1900)

Air and vent filter (2810)

When the retarder is switched on, the oil sump is pressurized with compressed air. This opens the non-return valve (input) (1900) and lets oil into the working
chamber via the rising duct (G).

Connects the retarder circuit with the atmosphere.


Aerates and ventilates the retarder circuit via the casing ventilation (2300).

Non-return valve (outlet) (2100)


Air and vent line "A" constant-air pressure py (E)
Air and vent line for constant-air pressure py between
the proportional valve (3700) and oil tank (F).
Rising duct (G)
Connection between oil tank, retarder circuit and heat
exchanger (6400). During braking oil flows from the oil
tank (F) via the rising duct (G) to the non-return valve
(inlet) (1900) in the retarder circuit. When switched
off, the oil coming from the heat exchanger (6400)
flows via the rising duct back into the oil tank (F).

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Stator (200)
In the stator (200) the oil is re-directed and is returned
to the rotor (300) at the internal diameter of the working chamber.
Rotor (300)
The rotor (300) must include the oil in its rotation and
accelerate it.

Function Description

In braking mode, the oil reaches the heat exchanger


(6400) from the working chamber via the non-return
valve (outlet) (2100), is cooled down and is fed back
into the system circuit or the oil tank.
A torque limiting valve is integrated in the non-return
valve (outlet) (2100). The torque limiting valve is a
safety valve and limits the braking torque of the retarder.

Proportional valve (3700)


The proportional valve (3700) is connected to the
compressed-air system of the vehicle (auxiliary equipment circuit). As soon as the proportional valve (3700)
receives an electrical input signal from the retarder
controller, it issues a pneumatic constant-air pressure
py which depends on the intensity of the electrical input signal and which acts on the oil tank (F) of the retarder.

Pressure control valve (2200)

Temperature sensors for oil (5200a) and coolant


(5200b)

The pressure control valve (2200) regulates the lubrication in no-load operation (non-braking mode) of the
retarder.

The temperature sensors pass on information on the


temperature of the oil and coolant to the retarder controller in the vehicle.

Casing ventilation (2300)


At the beginning of the braking process, the oil expels
the air located in the system circuit from the retarder
via the casing ventilation (2300) and the air and vent
filter (2810).
Once the system circuit is free of air, the casing ventilation (2300) closes.

Limiting points and maximum values for the coolant


and oil temperature are set in the controller to protect
the cooling system and the retarder.
If one of the temperature limiting points is exceeded
during braking, the braking torque is adjusted via the
constant-air pressure py until an equilibrium is
achieved between the produced braking energy and
the heat dissipated via the vehicle cooling system.
Page 19

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function

If one of the maximum values is exceeded, the braking torque is no longer actuated (corresponds to a reduction to 0).
In addition, the braking torque is adjusted if the oil
temperature rises rapidly (gradient), regardless of the
actual oil temperature.
The vehicle speed has to be adjusted with the service
brake while the adjustment is active.
Retarder ventilation "R" (5500)
When the retarder is switched off, the compressed air
in the oil tank (F) is emitted to the atmosphere via the
retarder ventilation "R" (5500).

Function Description

The three sections of the heat exchanger (6400) are


not interconnected.
The heat exchanger (6400) dissipates the generated
heat to the vehicle cooling system.
Pressure sensor (9000)
The pressure sensor (9000) measures the pneumatic
constant-air pressure py. A deviation from the permissible pressure tolerance (nominal/actual value comparison is carried out) is recognized as a fault and
displayed by the controller.

Heat exchanger (6400)

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Stainless steel heat exchanger 3 in 1 (three heat exchangers in one)

Large retarder oil circuit (active in braking mode)

Small retarder oil circuit (active in braking and noload operation)

Transmission oil cooling (always active)

Page 20

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

Maintenance and Service

4.1

Maintenance Intervals

22

4.2

Oil Change

23

4.3

Checking the Oil Level

26

4.4

Draining the Coolant

29

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4.

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

4.1

Maintenance Intervals

Maintenance Intervals

The maintenance intervals depend on the stress put


on the retarder and the oil sorts used.

CAUTION
Exceeding of the maintenance intervals/incorrect oil sort!
Damage to/failure of the retarder.
Observe the maintenance intervals.
Use only approved oils.

Activity

Interval

See

Change oil

Observe the specifications of the vehicle manufacturer.

Page 23

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If no specifications available: Observe Voith Retarder Oil change intervals/Oil selection list.
Checking the oil level

Page 26

Draining the coolant

Observe the specifications of the vehicle manufacturer.

Page 29

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

4.2

Oil Change

Item No.

Voith Turbo I 153.00009711 I arrtd I 2007-09


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Oil Change

4100

Name

107

Screw plug M 24 x 1.5;


hexagon socket head, w.a.f. 12;
with copper sealing ring (108): 80 Nm
with integrated sealing ring: 47 Nm

108

Sealing ring A 24 x 29; replace

3500

Screw plug M 30 x 1.5;


hexagon socket head, w.a.f. 17;
with copper sealing ring (3550): 130 Nm
with integrated sealing ring: 100 Nm

3550

Sealing ring A 30 x 36; replace

4100

Screw plug M 30 x 1.5;


hexagon socket head, w.a.f. 17;
with copper sealing ring (4150): 130 Nm
with integrated sealing ring: 100 Nm

4150

Sealing ring A 30 x 36; replace

4200

Screw plug M 24 x 1.5;


hexagon socket head, w.a.f. 12;
with copper sealing ring (4250): 80 Nm
with integrated sealing ring: 47 Nm

4250

Sealing ring A 24 x 29; replace

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

4150

.
Nr
h.
ac
Nr
.-S
hKd
ac
-S
ith

Vo

3550
3500

108
107
4250
4200

4250
4200

28009

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

Draining the oil

Oil filling level


Service filling (checking of the oil level, oil
change)

7.0 l

After replacement of the heat exchanger

7.5 l

Refilling after complete disassembly,


cleaning and emptied heat exchanger

7.8 l

1. Place oil collecting pan below the retarder.

manufacturer).
Tighten the hex.-head screws (6600) at the heat

Voith Turbo I 153.00009711 I arrtd I 2007-09


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exchanger (see page 88).

Lubricate the new sealing ring (108) with silicone-free and non-corrosive grease.

Screw in the screw plug (107) with sealing ring


(108) and tighten it to 80 Nm.

Face and hands could be burned.


switched off.

ter the oil change.

tighten, if necessary (see specifications of vehicle

Hot exiting oil!

Visual inspection of retarder for leaks before and af-

Check prop shaft screws for proper seating and

5. For screw plug (107) with copper sealing ring


(108):

WARNING

Ensure that the retarder and ignition are


Maintenance work during each oil change

Oil Change

CAUTION

For screw plug (107) with integrated sealing


ring:
-

Check the sealing ring for damage. If necessary, replace the screw plug (107).

Screw in the screw plug (107) and tighten it to


47 Nm.

Hot screw plugs!


Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if neces-

6. For screw plugs (4200) with copper sealing ring


(4250):
-

Lubricate the new sealing rings (4250) with silicone-free and non-corrosive grease.

Screw in the screw plugs (4200) with sealing


rings (4250) and tighten them to 80 Nm.

sary.

Requirements

2. Unscrew the screw plug (4100).

Vehicle is horizontal

3. Unscrew the screw plugs (107 and 4200).

Oil is at operating temperature (> 60 C)

4. Drain oil into an oil collecting pan.

Retarder is switched off

Ignition is switched off

NOTE
If the oil contains water: Check the heat exchanger (see page 88).

For screw plugs (4200) with integrated sealing


ring:
-

Check the sealing rings for damage. If necessary, replace the screw plugs (4200).

Screw in the screw plugs (4200) and tighten


them to 47 Nm.

Page 24

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

Servicing pressure control valve

Filling in the oil

NOTE

Ventilating the retarder

CAUTION

CAUTION

2 variants of the pressure control valve are possible:

Wrong oil type!

Air is mixed in the oil!

Pressure control valve with integrated sieve

Damage to/failure of the retarder.

Oil loss through retarder ventilation.

Pressure control valve without sieve. Sieve is located at the screw plug (3500)

Fill in only approved oil (see Voith Retarder Oil

Ventilate the retarder.

change intervals/Oil selection list).

Do not combine individual parts.


1. Unscrew the screw plug (3500).

1. Fill in the oil slowly via the bore of the screw plug
(4100).

2. For pressure control valve (2200) with integrated sieve: Drain any oil that has accumulated.

2. For screw plug (4100) with copper sealing ring


(4150):

For pressure control valve (2200) without sieve:


Clean the sieve at the screw plug (3500).
3. For screw plug (3500) with copper sealing ring
(3550):

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Oil Change

Lubricate the new sealing ring (3550) with silicone-free and non-corrosive grease.

Screw in the screw plug (3500) with sealing


ring (3550) and tighten it to 130 Nm.

For screw plug (3500) with integrated sealing


ring:
-

Check the sealing ring for damage. If necessary, replace the screw plug (3500).

Screw in the screw plug (3500) and tighten it


to 100 Nm.

Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease.

Screw in the screw plug (4100) with sealing


ring (4150) and tighten to 130 Nm.

1. If it exists and if possible: Switch off the retarder


foot operation.
2. Move the vehicle with 50 km/h.
3. Activate the retarder in the first braking stage 5
times for approx. 5 s each.

For screw plug (4100) with integrated sealing


ring:
-

Check the sealing ring for damage. If necessary, replace the screw plug (4100).

Screw in the screw plug (4100) and tighten it


to 100 Nm.

Page 25

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

4.3

Checking the Oil Level

Item No.

4100

Name

107

Screw plug M 24 x 1.5;


hexagon socket head, w.a.f. 12;
with copper sealing ring (108): 80 Nm
with integrated sealing ring: 47 Nm

108

Sealing ring A 24 x 29; replace

4100

Screw plug M 30 x 1.5;


hexagon socket head, w.a.f. 17;
with copper sealing ring (4150): 130 Nm
with integrated sealing ring: 100 Nm

4150

Sealing ring A 30 x 36; replace

4200

Screw plug M 24 x 1.5;


hexagon socket head, w.a.f. 12;
with copper sealing ring (4250): 80 Nm
with integrated sealing ring: 47 Nm

4250

Sealing ring A 24 x 29; replace

NOTE
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Checking the Oil Level

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

4150

.
Nr
h.
ac
Nr
.-S
hKd
ac
-S
ith

Vo

108
107
4250
4200

4250
4200

28154

Page 26

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

CAUTION

Oil filling level


Service filling (checking of the oil level, oil
change)

7.0 l
Hot screw plugs!

Checking the Oil Level

For screw plug (107) with integrated sealing


ring:
-

Check the sealing ring for damage. If necessary, replace the screw plug (107).

Screw in the screw plug (107) and tighten it to


47 Nm.

Hands could be burned.


Work carefully.

Requirements

Vehicle is horizontal

Oil is at operating temperature (> 60 C)

Retarder is switched off

Ignition is switched off

Wear protective gloves or use cloths, if necessary.


2. Unscrew the screw plug (4100).

6. For screw plugs (4200) with copper sealing ring


(4250):
-

Lubricate the new sealing rings (4250) with silicone-free and non-corrosive grease.

Screw in the screw plugs (4200) with sealing


rings (4250) and tighten them to 80 Nm.

3. Unscrew the screw plugs (107 and 4200).


4. Drain oil into an oil collecting pan.

Draining the oil


1. Place oil collecting pan below the retarder.

WARNING
Hot exiting oil!
Face and hands could be burned.

5. For screw plug (107) with copper sealing ring


(108):

For screw plugs (4200) with integrated sealing


ring:

Lubricate the new sealing ring (108) with silicone-free and non-corrosive grease.

Check the sealing rings for damage. If necessary, replace the screw plugs (4200).

Screw in the screw plug (107) with sealing ring


(108) and tighten it to 80 Nm.

Screw in the screw plugs (4200) and tighten


them to 47 Nm.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Ensure that the retarder and ignition are


switched off.

Page 27

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

Measuring the volume

Filling in oil

1. Measure the volume of the drained oil.

1. Fill in the oil slowly via the bore of the screw plug
(4100).

NOTE
If oil is missing: Check the retarder valve for
leaks.

CAUTION

2. For screw plug (4100) with copper sealing ring


(4150):
-

Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease.

Screw in the screw plug (4100) with sealing


ring (4150) and tighten to 130 Nm.

Wrong oil type!


Damage to/failure of the retarder.
Fill in only approved oil (see Voith Retarder Oil
change intervals/Oil selection list).

Checking the Oil Level

Ventilating the retarder

CAUTION
Air is mixed in the oil!
Oil loss through retarder ventilation.
Ventilate the retarder.
1. If it exists and if possible: Switch off the retarder
foot operation.
2. Move the vehicle with 50 km/h.

For screw plug (4100) with integrated sealing


ring:
-

Check the sealing ring for damage. If necessary, replace the screw plug (4100).

Screw in the screw plug (4100) and tighten it


to 100 Nm.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

2. If necessary correct the oil volume.

3. Activate the retarder in the first braking stage 5


times for approx. 5 s each.

Page 28

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

4.4

Draining the Coolant

Draining the Coolant

NOTE
Depending on the vehicle manufacturer, the design
of the water neck can differ.
If the screw plug (20300) does not exist: Drain
the coolant at the vehicle (see specifications of
vehicle manufacturer).

Item No.

Name

20000

Water neck

20300

Screw plug M 14 x 1.5;


hexagon insert bit, w.a.f. 13;
32 Nm

20400

Sealing ring A 14 x 20; replace

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
Requirements

Retarder is switched off

Ignition is switched off

.
Nr
h.
ac
Nr
.-S
hKd
ac
-S
ith
Vo

20000
20400
20300

28155

Page 29

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service

1. Place a clean coolant collecting pan under the


retarder.

Draining the Coolant

5. Fill the vehicle and retarder cooling circuit (see


specifications of vehicle manufacturer).

CAUTION
Hot parts and coolant!
Burns and scalding could occur.
Work carefully.
Wear protective gloves or use cloths if necessary.
2. Unscrew the screw plug (20300) and drain the
coolant.
3. Lubricate the new sealing ring (20400) with silicone-free, non-corrosive grease.
4. Screw in the screw plug (20300) with sealing ring
(20400) and tighten it to 32 Nm.

CAUTION
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Wrong coolant type!


Damage to the vehicle and retarder cooling circuit.
Observe the specifications of the vehicle manufacturer or those of Voith Turbo cooling water
quality list.

Page 30

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

5.

Diagnosis and Troubleshooting

5.1

Overview of the Possible Complaints

32

5.2

Checking the Constant-Air Pressure Control Loop

42

5.3

Checking the Pump Pressure pdyn


Checking the Proportional Valve Current

47
52

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

5.4

Page 31

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

5.1

Overview of the Possible Complaints

Overview of the Possible Complaints

No.

Complaint

See

Retarder pilot light flashes (standard type)

Page 33

On-board diagnosis is possible at some vehicle manufacturers


(display).
Observe the specifications of the vehicle manufacturer.
B

Oil loss via retarder ventilation (5500) or air and vent


filter (2810)

Page 34

No or insufficient brake efficiency

Page 36

Other external leak

Page 38

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Ensure that there are no leaks at the screw plugs or sealing


rings.

Page 32

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Overview of the Possible Complaints

Retarder pilot light flashes (standard type)

NOTE
On-board diagnosis is possible at some vehicle
manufacturers (display).
Observe the specifications of the vehicle manufacturer.

No.

Activity

1.

Check the operation (for retarder braking, nominal


speed of the engine, if possible).

2.

Instruct the driver. In doing so, observe the operating


conditions.

3.

Check oil temperature sensor (see page 101).

Result

Continue with No.

NOK

2.

OK

3.

NOK

4.

OK

5.

Check coolant temperature sensor (see page 103).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

4.

Replace oil temperature sensor (see page 101).


and/or
Replace coolant temperature sensor (see page 103).

5.

Check cooling system of the vehicle (see specifications of vehicle manufacturer).

NOK = does not work correctly


OK = works correctly

Page 33

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Oil loss via retarder ventilation (5500) or air and vent filter (2810)

No.

Activity

1.

Check whether the retarder leaks oil via the retarder


ventilation (5500).

Yes

2.

No

8.

Check whether water is contained in the oil (emulsion).

Yes

3.

No

5.

Check the heat exchanger (see page 88).

NOK

4.

OK

7.

NOK

6.

Check the gearbox oil level and correct it (see specifications of vehicle manufacturer).

OK

8.

If the gearbox oil level is too low and the retarder oil level is too high:

Yes

8.

2.

3.

4.

Replace the heat exchanger (see page 88).

5.

Check the retarder oil level and correct it (see


page 26).

6.

Overview of the Possible Complaints

Result

Continue with No.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Check gearbox ventilation and repair/clean, if necessary (see specifications of vehicle manufacturer).
Problem occurs again?
NOK = does not work correctly
OK = works correctly

Page 34

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

No.

Activity

7.

Possible entry of water from outside into the retarder


system:

Result

Overview of the Possible Complaints

Continue with No.

NOK

9.

OK

10.

Via retarder ventilation (5500) or air and vent filter


(2810), e.g. through steam-jet device or splash water.

Convert the retarder ventilation, if necessary (see


VR 115 E 153.001532xx ventilation conversion instructions).
or

8.

Check casing ventilation (see page 77).

9.

Replace casing ventilation (see page 77).

10.

Remove valve cover (1600).

Yes

11.

Check whether non-return valve (outlet) has a Voith


item no. H67.255022 or H67.387310 and higher (see
page 98).

No

12.

NOK

12.

OK

13.

11.
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Through leaks in retarder housing.

Check non-return valve (outlet) (see page 98).

12.

Replace non-return valve (outlet) (see page 98).

13.

Install basic retarder (see page 82).

NOK = does not work correctly


OK = works correctly

Page 35

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

No or insufficient brake efficiency

No.

Activity

1.

Check whether an external leak is visible at retarder


(except retarder ventilation).

2.

Repair retarder.

3.

Check retarder oil level (see page 26).


Check gearbox oil level (see specifications of vehicle
manufacturer).

Continue with No.

Yes

2.

No

3.

NOK

B, No. 6., Page 34


4.

Check constant-air pressure control loop (see


page 42).

NOK

5.

OK

6.

5.

Repair constant-air pressure control loop (see


page 42).

6.

Check proportional valve current as well as leads and


plug connections (see page 52).

NOK

7.

OK

10.

Check oil temperature sensor and supply line (see


page 101).

NOK

8.

Check coolant temperature sensor and supply line


(see page 103).

OK

9.

7.
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Result

OK

4.

Overview of the Possible Complaints

NOK = does not work correctly


OK = works correctly

Page 36

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

No.

Activity

8.

Replace oil temperature sensor or supply line (see


page 101).

Result

Overview of the Possible Complaints

Continue with No.

and/or
Replace coolant temperature sensor or supply line
(see page 103).
9.

Carry out diagnosis with "WinDia" (see "WinDia"


operating instructions). Use Voith ECU specification
for this.
or
Carry out off-board diagnosis (see specifications of
vehicle manufacturer).

10.

Check pump pressure pdyn (see page 47).


Check constant-air pressure py (see page 42).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

11.

Check casing ventilation (see page 77).

NOK

11.

OK

14.

NOK

12.

OK

13.

12.

Replace casing ventilation (see page 77).

13.

Contact Voith.

14.

Complaint mentioned above is not possible.

Clarify the complaint again with the customer or perform the tests once again.
NOK = does not work correctly
OK = works correctly

Page 37

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Overview of the Possible Complaints

Other external leak

NOTE
Ensure that there are no leaks at the screw
plugs or sealing rings.

No.

Activity

1.

Check whether the retarder leaks oil near the heat


exchanger.

Yes

2.

No

3.

2.

Check retarder housing near the heat exchanger for


leaking. If necessary, contact Voith.

3.

Check whether the retarder leaks water near the


heat exchanger.

Yes

4.

No

13.

NOK

5.

OK

6.

NOK

7.

OK

8.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

4.

Check heat exchanger (see page 88).

5.

Replace heat exchanger (see page 88).

6.

Check hose connection between water neck at heat


exchanger and water pipe in the vehicle (see specifications of vehicle manufacturer).

Result

Continue with No.

NOK = does not work correctly


OK = works correctly

Page 38

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

No.

Activity

7.

Replace hose connection (see specifications of vehicle manufacturer).

8.

Check gaskets (21000) at water necks (see page 86).

NOK

9.

OK

10.

9.

Replace gaskets (20100) (see page 86).

10.

Check sealing ring (5360) at the coolant temperature


sensor (see page 103).

Result

Continue with No.

NOK

11.

OK

12.

11.

Replace sealing ring (5360) (see page 103).

12.

Contact Voith.

13.

Check whether the retarder leaks near the casing


ventilation cover (see page 74).

14.

Check sealing, replace, if necessary (see page 74).

15.

Check whether the retarder leaks near the


Oil tank cover top (see page 70)
or
Oil tank cover bottom (see page 72).

Yes

14.

No

15.

Overview of the Possible Complaints

Yes

16.

No

17.

NOK = does not work correctly


OK = works correctly

Page 39

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

No.

Activity

16.

Top:

Result

Overview of the Possible Complaints

Continue with No.

Check intermediate washer (8000), replace, if necessary.


Insert combined hex.-head screws (3100 and 3300)
with thread seal (see page 70).
Bottom:
Check gasket (2600), replace, if necessary (see
page 72).
17.

18.

Check whether the retarder leaks near the non-return


valve (inlet).
Version with integrated sealing ring:

Yes

18.

No

19.

Check the sealing ring.


Replace non-return valve (inlet), if necessary (see
page 96).
Version with copper sealing ring (1950):
Replace sealing ring (1950).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Insert non-return valve (inlet) with thread seal (see


page 96).
19.

20.

Check whether the retarder leaks near the interstice


retarder/gearbox.
Check sealing surface between gearbox and
retarder.

Yes

20.

No

21.

NOK = does not work correctly


OK = works correctly

Page 40

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

No.

Activity

21.

Check whether the retarder leaks at the gearbox


flange near the radial shaft sealing ring.

Result

Overview of the Possible Complaints

Continue with No.

Yes

22.

No

23.

22.

Replace the radial shaft sealing ring (see specifications of vehicle manufacturer).

23.

Contact Voith.

NOK = does not work correctly

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

OK = works correctly

Page 41

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

5.2

Checking the Constant-Air Pressure Control Loop

Checking the Constant-Air Pressure Control Loop

NOTE

4100
4150

The constant-air pressure control loop check provides information about

internal and external leaks of the retarder

proper functioning of the retarder

proper control of the retarder

Item No.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

99/7

Name
Pressure gauge 06 bar

50/56a

Retarder tester

50/56b

Cable 1: to the proportional valve

50/56c

Cable 2: to the pressure sensor (9000)

50/56d

Cable 3: to the temperature sensors

50/56e

Cable 4: to the vehicle voltage supply/


PC interface

3700

99/7

50/56c

50/56a
50/56e
50/56d

50/56b

9000

3700

Proportional valve

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
28173

Page 42

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Item No.
4100

Checking the Constant-Air Pressure Control Loop

Name
Screw plug M 30 x 1.5;
hexagon socket head, w.a.f. 17;
with copper sealing ring (4150): 130 Nm
with integrated sealing ring: 100 Nm

4100

4150

Sealing ring A 30 x 36; replace

4150

9000

Pressure sensor

50/56c

99/7

9000

NOTE

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

50/56a
50/56e
50/56d

50/56b

3700

28173

Page 43

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Checking the Constant-Air Pressure Control Loop

Requirements

Special tools

CAUTION

Ignition is switched off

Retarder is switched off

Hands could be burned.

Battery voltage: 1832 V

Work carefully.

Supply-air pressure pv in auxiliary circuit 611 bar

Oil level is checked and in order (see page 26)

Electrical system of vehicle is checked and in order


(see specifications of vehicle manufacturer)

Electrical connections of the retarder are completely disconnected from the vehicle

Hot parts!

153.001085xx

153.000776xx

Retarder tester,
complete in a
case

Test software
"DIANA Lite"

50/56

50/56i

H53.1403xx
Pressure gauge
06 bar
99/7

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

NOTE
With the test software "DIANA Lite" (50/56i), measured values can be read out and stored via the PC
in addition to the tests with the retarder tester.
The stored measured values can be transmitted to
the Voith customer service for evaluation (see operating instructions on CD-ROM).

Commercially available tools

Wear protective gloves or use cloths, if necessary.


Connecting the pressure gauge

4100

99/7

4150

DANGER
Danger of accidents if the retarder tester is
used improperly!
Uncontrollable operating state of the vehicle.
Carry out diagnosis only while the vehicle is
standing still.

28081

1. Unscrew the screw plug (4100) with the sealing


ring (4150).
2. Connect the pressure gauge (99/7) to the bore of
the screw plug (4100).

Multimeter

Page 44

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Connecting the retarder tester

Checking the supply voltage of the pressure sensor

VR 115 E
50/56b

83310

153.000

50/56a

50/56c

2
3
4

153.00
15

9000

08341

50

3.0

6. Switch on the vehicle ignition.

3700

83

51

50/56e

5200a
5200b

15.Start the "DIANA-Lite" test software.

7. Set the "RETARDER TYP" (Retarder type) switch


at the retarder tester (50/56a) to "5".

16.Load the template for the retarder tester (see


operating instructions of "DIANA-Lite" test software).

8. Switch the toggle switch to the position "EIN mit


Regelkreis" (ON with control loop).

17.Set the "STELLDRUCK" (constant-air pressure)


switch at the retarder tester to "25%".

NOTE

9. Connect the multimeter to the "U_Versorgung"


(U_Supply) socket (measuring type: V).

153.00083610

28082

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


(3700).
2. Connect cable 2 (50/56c) to the pressure sensor
(9000).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Checking the proportional valve

/56

00

Checking the Constant-Air Pressure Control Loop

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


sensor (5200a) and to the coolant temperature
sensor (5200b).
4. Connect cable 4 (50/56e) to the vehicle voltage
supply/PC interface.
5. Connect all the cables to the retarder tester (50/
56a) (see also the operating instructions of the
retarder tester).

10.Read the measured value: Setpoint 4.755.25 V.


11.If the value deviates: Replace the pressure sensor
(9000) (see page 105).
Checking the signal value of the pressure sensor
12.Connect the multimeter to the "U_py IST"
(U_py actual) socket (measuring type: V).
13.Read the measured value: Setpoint 0.2750.725 V.
14.If the value deviates: Replace the pressure sensor
(9000) (see page 105).

To assess the operation of the proportional valve


(3700), the results of the following test are only valid during a testing period of 60 seconds maximum.
18.In "DIANA-Lite" read the "Stelldruck IST" (Constant-air pressure INST) measured value and the
measured value at the pressure gauge (99/7):
Setpoint after approx. 20 seconds:
Position of "STELLDRUCK" (constant-air
pressure) switch

Setpoint Constant-air
pressure py

0%

0 bar

25%

0.551.05 bar

50%

1.241.74 bar

75%

1.802.30 bar

100%

2.603.10 bar

Page 45

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

19.Repeat the test in the switch positions "50%",


"75%" and "100%".
20.If one of the values deviates: Check the proportional valve (3700) and damping plate (3800) and
replace, if necessary (see page 106).
Disconnecting the retarder tester

Checking the Constant-Air Pressure Control Loop

For screw plug (4100) with integrated sealing


ring:
-

Check the sealing ring for damage. If necessary, replace the screw plug (4100).

Screw in the screw plug (4100) and tighten it


to 100 Nm.

27.Complete the retarder and vehicle.

21.Set the "STELLDRUCK" (constant-air pressure)


switch at the retarder tester to "0%".
22.Switch the toggle switch to the "AUS" (off) position.
23.Switch off the vehicle ignition.
24.Disconnect the retarder tester (50/56a) and all
cables.
25.Disconnect the pressure gauge (99/7).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

26.For screw plug (4100) with copper sealing ring


(4150):
-

Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease.

Screw in the screw plug (4100) with sealing


ring (4150) and tighten it to 130 Nm.

Page 46

Checking the Pump Pressure pdyn

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

5.3

Checking the Pump Pressure pdyn

NOTE
50/56c

Checking the pump pressure pdyn provides information about

the mechanical status of the rotor parts

internal leaks of the retarder

proper functioning of the retarder

50/56b

50/56a
50/56e

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Item No.

Name

50/56a

Retarder tester

50/56b

Cable 1: to the proportional valve

50/56c

Cable 2: to the pressure sensor (9000)


and to the pressure sensor (50/56g)

50/56d

Cable 3: to the temperature sensors

50/56e

Cable 4: to the vehicle voltage supply/


PC interface

50/56g

Pressure sensor pdyn 030 bar

9000

3700

50/56d

.
Nr
hac
.
Nr
.-S
hKd
ac
-S
ith
Vo

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

50/56g

104
103
28025

Page 47

Checking the Pump Pressure pdyn

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Item No.
103

104

Name
Screw plug M 12 x 1.5;
hexagon socket head, w.a.f. 6;
with copper sealing ring (104): 20 Nm
with integrated sealing ring: 13 Nm

50/56c

9000

Sealing ring A12 x 15.5; replace

3700

Proportional valve

9000

Pressure sensor

50/56b

50/56a

NOTE

50/56e

3700

50/56d

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

.
Nr
hac
.
Nr
.-S
hKd
ac
-S
ith
Vo

50/56g

104
103
28025

Page 48

Checking the Pump Pressure pdyn

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Requirements

Special tools

153.001085xx

153.000776xx

Retarder tester,
complete in a
case

Test software
"DIANA Lite"

50/56

50/56i

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Ignition is switched off

Retarder is switched off

If the prop shaft screws are screwed in from the


transmission side:

Supply-air pressure pv in auxiliary circuit 611 bar

Ensure that the prop shaft screws are screwed


out at the drive-side flange.

Oil level is checked and in order (see page 26)

or

Electrical system of vehicle is checked and in order


(see specifications of vehicle manufacturer)

Electrical connections of the retarder are completely disconnected from the vehicle

NOTE
With the test software "DIANA Lite" (50/56i), measured values can be read out and stored via the PC
in addition to the tests with the retarder tester.
The stored measured values can be transmitted to
the Voith customer service for evaluation (see operating instructions on CD-ROM).

NOTE

Constant-air pressure control loop is checked and


in order (see page 42)

No external leaks are detected at retarder

Vehicle is secured

Prop shaft is removed from flanges and is secured


(see specifications of vehicle manufacturer)

Secure the prop shaft screws.

CAUTION
Hot parts and oil!
Hands can be burned and scalded.
Work carefully.
Wear protective gloves or use cloths, if necessary.

DANGER
Danger of accidents if the retarder tester is
used improperly!
Uncontrollable operating state of the vehicle.
Carry out diagnosis only while the vehicle is
standing still.

Page 49

Checking the Pump Pressure pdyn

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Connecting the pressure sensor

Connecting the retarder tester

50/56g 104

NOTE

VR 115 E

Due to construction, a small amount of oil may leak


out; this does, however, not affect retarder operation.

50/56a

83310

104

50/56c

2
3
4

103

50/56b

153.000

153.00
15

08341

50

3.0

/56

00

2. Connect the pressure sensor (50/56g) with sealing ring (104).

9000
50/56g

83

51

50/56e

28027

3700

5200a
5200b

153.00083610

28083

3. Connect cable 1 (50/56b) to the proportional valve


(3700).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

28026

1. Unscrew screw plug (103) and remove sealing


ring (104).

4. Connect cable 2 (50/56c) to the pressure sensor


(9000) and to the pressure sensor (50/56g) .
5. Connect cable 3 (50/56d) to the oil temperature
sensor (5200a) and to the coolant temperature sensor (5200b).
6. Connect cable 4 (50/56e) to the vehicle voltage
supply/PC interface.
7. Connect all the cables to the retarder tester (50/
56a) (see also the operating instructions of the
retarder tester).

Page 50

Checking the Pump Pressure pdyn

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

Checking the pump pressure pdyn


8. Switch on the vehicle ignition.
9. Set the "RETARDER TYP" (Retarder Type) switch
at the retarder tester to "5".

NOTE

10.Switch the toggle switch to the position "EIN mit


Regelkreis" (ON with control loop).

If the setpoint of the constant-air pressure py is


reached, but the pump pressure pdyn is undershot,
the retarder has an internal defect.

11.Start the "DIANA-Lite" test software

Install the basic retarder (see page 82).

12.Load the template for the retarder tester (see


operating instructions of "DIANA-Lite" test software).
13.Start the engine and warm it up to operating temperature.

NOTE
Shift in direct gear (ratio 1:1).
The engine speed 1000 min-1 then corresponds to
the prop shaft speed of 1000 min-1.
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

18.When the engine speed is 1000 min-1 , read the


"Gehusedruck Ist" (Housing pressure actual)
measured value in "DIANA Lite": Setpoint > 9 bar.

14.Adjust the engine speed to 1000 min-1.


15.Set the "STELLDRUCK" (constant-air pressure)
switch at the retarder tester to "25%".

NOTE
Test when the "STELLDRUCK" (constant-air pressure) switch is set to "100%":
"Gehusedruck Ist" (Housing pressure actual)
setpoint > 12 bar.
Is normally not possible with the retarder tester
when the vehicle is standing still.

22.For screw plug (103) with copper sealing ring


(108):
-

Lubricate the new sealing ring (104) with silicone-free and non-corrosive grease.

Screw in the screw plug (103) with sealing ring


(108) and tighten it to 20 Nm.

For screw plug (103) with integrated sealing


ring:
-

Check the sealing ring for damage. If necessary, replace the screw plug (103).

Screw in the screw plug (103) and tighten it to


13 Nm.

23.Complete the retarder and vehicle.

Disconnecting the pressure sensor and retarder


tester
19.Set the "STELLDRUCK" (constant-air pressure)
switch at the retarder tester to "0%".
20.Disconnect the retarder tester (50/56a) and all
cables.

16.Adjust the engine speed back to 1000 min-1 .


21.Disconnect the pressure sensor (50/56g).
17.Set the"STELLDRUCK" (constant-air pressure)
switch at the retarder tester to "50%".
Page 51

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

5.4

Checking the Proportional Valve


Current

Special tools

Checking the Proportional Valve Current

Requirements

Ignition is switched off

Retarder is switched off

Battery voltage: 2428 V

Electrical system of vehicle is checked and in order


(see specifications of vehicle manufacturer)

Fuse for retarder controller is checked and in order

Male and female plug connectors at proportional


valve are checked for damage or wear (notch
scratches).

3700
98/8

99/3
H53.8198xx
Measuring
adapter

99/3

1. Disconnect the plug from the proportional valve


(3700) and connect it to the measuring adapter
(99/3).
2. Connect the plug of the measuring adapter to the
proportional valve (3700).

NOTE
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Electrical lead and plug connections are checked


(visual inspection) and in order

28019

When performing measurements using a commercially available multimeter (without real r.m.s. value
measurement), exact readout of these measured
values is not possible (display jumps).

3. Connect the multimeter (98/8) (measuring type:


mA).
4. Turn the "Prop valve" switch at the measuring
adapter to Position "I".
5. Switch on the vehicle ignition.

Commercially available tools

6. Shift the retarder to the highest gear.

Multimeter (98/8) with real r.m.s. value measurement, e.g. Fluke 179

Page 52

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting

NOTE

Controller

Voith item no.


(Code-No.)

Setpoint

Digiprop

138, 152, 155

396596 mA

150

365565 mA

151

379579 mA

7. Read the measured value at the multimeter (98/8)


and compare it to the specified setpoint:

153

423623 mA

157, 158

409609 mA

Controller

Voith item no.


(Part-No.)

Setpoint

159

534546 mA

H67.2763xx

440640 mA

179, 180,
502, 504, 508, 512,
514

440640 mA

VERA

510

430630 mA

Due to continuous readjustment in the control loop,


the measured values may not be constant, but are
within the specified range.

H67.2866xx
H67.3449xx
H67.3457xx
H67.3658xx
153.000586xx

Checking the Proportional Valve Current

8. If the value deviates: Check the leads, connectors


and retarder controller and replace them, if necessary.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

9. Disconnect the multimeter (98/8).


10.Pull the plug from the measuring adapter (99/3)
and connect it to the proportional valve (3700).

Page 53

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder

6.

Removing and Installing the Retarder

DANGER
Retarder can fall!
Your body can be crushed severely.
Secure retarder and gearbox against falling.
Use a suitable lifting device.

CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths if

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

necessary.

Page 54

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder

Item No.

Name

800

Inside part

850

Outer race;
replace, when the inside part (800) is replaced

25300
25000

25300

850

25000

Shim

25100

O-ring 14 x 4; replace

25200

Hex.-head screw M 10 x 70;


hexagon insert bit, w.a.f. 16;
58 Nm

25300

Hex.-head screw M 10 x 60;


hexagon insert bit, w.a.f. 16;
58 Nm

25200

NOTE

25100

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

25200

800
28046

Page 55

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder

Aids

Special tools

Thread seal
Loctite 5203

for sealing surface gearbox


housing/retarder housing

Requirements

Retarder with gearbox is removed from vehicle


(see specifications of vehicle manufacturer)

Removing the retarder

25200

25300

0
80
62 265
FJ 6
48

H67.3320xx
Puller
98/3

H67.3224xx

H67.3319xx

Measuring
device

Marking punch

98/1

98/4

Retarder is switched off

Ignition is switched off

Supply-air pressure pv is drained

Electrical connecting leads are disconnected

Supply-air pressure line py is removed

Retarder oil is drained (see page 23)

Oil is drained from the gearbox (see specifications


of vehicle manufacturer)

Coolant is drained (see page 29)

Prop shaft at the gearbox flange is removed from


the flanges (see specifications of vehicle manufacturer)

25200
28029

M 10

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Tools for self-fabrication

15

80
28028

Output flange is removed (see specifications of vehicle manufacturer)

Tacho-sensor and output speed sensor are removed (see specifications of vehicle manufacturer)

2 x Threaded bolt
Material: St 37-2, DIN 17100 (1.80)

1. Unscrew the hex.-head screws (25200) and


(25300).

CAUTION
Unprotected inside part (800)!
Damage to the inside part (800).
Ensure that the inside part (800) is not damaged
when it is put down.
2. Use a suitable lifting device to remove the retarder
from the gearbox.

Page 56

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder

CAUTION

Determining the shim

NOTE

Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.

25100
28036

3. Remove the O-rings (25100) from the gearbox.

The thickness D of the shim is calculated in accordance with the following equation:
Thickness D = Dimension B Dimension A 0.02
mm

The distance of the gearbox housing sealing


surface to the outer race contact surface (850) in
the gearbox housing is measured for dimension
B.

Dimension A is the distance between the retarder housing sealing surface and the outer race
ring and is calculated in accordance with the following equation:
Dimension A = H Dimension C

NOTE
In order to facilitate the removal, heat the gearbox housing to approx. 80 C in the area of the
outer race (850).

Removing the outer race (850) and shim (25000)


1. Pull off the outer race (850) using the puller (98/3).

2. Remove the shim (25000).

H is noted in the factory by Voith on the measuring device.

The distance from the top edge of the measuring device to the measuring panel in the measuring device is measured for dimension C.
A digital depth gauge is included in the
measuring device (98/1) scope of delivery.

98/3

00
628
265
FJ
486

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

25000
850

28181

Page 57

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder

4. Tighten the hex.-head screws with 10 Nm.

NOTE
Carry out measurements at the gearbox and the
retarder at room temperature in a vertical position.
Ensure that the gearbox and retarder have
cooled down.

5. Turn the pinion manually 15 times clockwise and


then 15 times counter-clockwise.

850
800
98/1
28032

2. Place the outer ring (850) onto the inside part


(800).

6. Measure dimension C with the digital depth


gauge: From the top edge of the measuring device
to the measuring panel in the measuring device
(98/1).

98/1
28031

7. Note dimension C.

1. Measure dimension B and note the value.


Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

28086

28084

3. Place the measuring device (98/1) on the retarder


housing and fasten with 4 hex.-head screws
M 10 x 40.
Page 58

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder

H = xxx,xx

98/1

28085

8. Read dimension H from the measuring device (98/1)


(see arrow/diagram).
9. Calculate dimension A:
Dimension A = H Dimension C.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

10.Calculate thickness D of the shim:


Thickness D = Dimension B Dimension A
0.02 mm
11.Remove the measuring device (98/1).
12.Remove the outer ring (850).
Shims with the following thicknesses D can be ordered from Voith Turbo GmbH & Co. KG:
Thickness D [mm]

Voith item no.

0.52

67.3426xx

0.55

67.3427xx

Thickness D [mm]

Voith item no.

0.58

67.3428xx

0.61

67.3429xx

0.64

67.3430xx

0.67

67.3431xx

0.70

67.3432xx

0.73

67.3433xx

0.76

67.3434xx

0.79

67.3435xx

0.82

67.3436xx

0.85

67.3437xx

0.88

67.3438xx

0.91

67.3439xx

0.94

67.3440xx

0.97

67.3441xx

1.00

67.3442xx

NOTE
If necessary, use two shims in order to realize
the compensation dimension.

Installing the outer race (850) and shim (25000)

850

25000

98/4

28135

NOTE
If two shims are used: Insert the thicker shim
first into the gearbox housing.
1. Insert the shim (25000) into the gearbox housing.

NOTE
If the inside part (800) was replaced:
Replace the outer ring (850).

If the calculated compensation dimension cannot be achieved exactly with the shims: Use the
next smaller compensation dimension.

Page 59

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder

CAUTION
Hot parts!

Installing the retarder

25100

Hands could be burned.


Work carefully.
Wear protective gloves or use cloths, if necessary.

NOTE
In order to facilitate installation heat the gearbox
housing to approx. 80 C in the area of the outer
race (850).
2. Insert the outer ring (850) into the gearbox housing.

28037

1. Clean the sealing surface of the retarder housing


(1).
2. Place the gearbox so that the sealing surface
faces upwards.

3. Clean the sealing surface of the gearbox housing


and apply Loctite 5203.
4. Lubricate the new O-rings (25100) with siliconefree and non-corrosive grease and insert them
into the gearbox housing.
5. Screw the two threaded bolts into the gearing
housing (see arrows/diagram).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

3. Knock in the outer race (850) until it stops using


the marking punch (98/4).

28038

Page 60

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder

25200

25200
25200

25300
28039

6. Place the retarder on the gearing housing.


7. Screw in the three hex.-head screws (25200).
8. Unscrew the threaded bolts.
9. Screw in the two hex.-head screws (25200).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

10.Tighten the hex.-head screws (25200) with


58 Nm.
11.Screw in the hex.-head screws (25300) and
tighten it with 58 Nm.

Page 61

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.

Repair

7.1

Components Overview

63

7.2

Top Oil Tank Cover

70

7.3

Bottom Oil Tank Cover

72

7.4

Cover for Casing Ventilation

74

7.5

Casing Ventilation

77

7.6

Retarder Ventilation

81

7.7

Basic Retarder

82

7.8

Inside Part (800)

83

7.9

Pipe (5900)

85

7.10

Water Neck

86

7.11

Heat Exchanger

88

7.12

Pressure Control Valve

93

7.13

Non-Return Valve (inlet)

96

7.14

Non-Return Valve (outlet)

98

7.15

Oil Temperature Sensor

101

7.16

Coolant Temperature Sensor

103

7.17

Pressure Sensor

105

7.18

Proportional Valve and Damping Plate

106

Page 62

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.1

Components Overview

Item No.

Retarder housing

107

Screw plug M 24 x 1.5;


hexagon socket head, w.a.f. 12;
with copper sealing ring (108): 80 Nm
with integrated sealing ring: 47 Nm

Valve cover

1700

O-ring 60 x 3

1900

Non-return valve (inlet) M 48 x 1.5;


hexagon insert bit, w.a.f. 55;
with copper sealing ring (1950): 280 Nm
with integrated sealing ring: 280 Nm
Sealing ring A 48 x 55

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

4100
4150

3300

3100

9000

5901

6100
6101

2810
2800

2801

6101

2301

3300

Sealing ring A 24 x 29

1600

1950

5901

5900

Name

100

108

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Components Overview

2000
8000
6600

100

2300

6700

5300
3850 5200a
3800
3850
3900

6600
6700
7600
7500
7300
7300
7300 7500
6400
6700
6600
2600
20100
1950
20000

2900
5600
2206
5500
4000
108
5400 3700
3500
107
3550
2200

2500

3100
Replace component
Check component
according to specifications
and replace, if necessary
Perform visual inspection
and replace, if necessary

2105
2100
2106

1700 1600

4250

1900
4250

4200 4200
3100

6700
6600
20100

20200
5200b
5300
20200

20000
20400 20300
28047

Page 63

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Item No.

Name

2000

Top oil tank cover

2100

Non-return valve (outlet)

2105

O-ring 34 x 3

2106

O-ring 54 x 3

2200

Pressure control valve, complete;


with integrated sieve
without sieve. Sieve at the screw plug
(3500)

2206

O-ring 21.5 x 2.5

2300

Casing ventilation

2301

O-ring 55 x 3

2500

Bottom oil tank cover

2600

Gasket

5901

5900

4100
4150

3300

3100

9000

5901

6100
6101

2810

2301

3300
2800

2801

6101

2000
8000
6600

100

2300

6700

5300
3850 5200a
3800
3850
3900

6600
6700
7600
7500
7300
7300
7300 7500
6400
6700
6600
2600
20100
1950
20000

2900

NOTE
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Components Overview

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

5600
2206
5500
4000
108
5400 3700
3500
107
3550
2200

2500

3100
Replace component
Check component
according to specifications
and replace, if necessary
Perform visual inspection
and replace, if necessary

2105
2100
2106

1700 1600

4250

1900
4250

4200 4200
3100

6700
6600
20100

20200
5200b
5300
20200

20000
20400 20300
28047

Page 64

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Item No.

Cover for casing ventilation

2801

Cover

2810

Air and vent filter M 12 x 1.5;


hexagon insert bit, w.a.f. 17;
10 Nm

3100

3300

3500

3550

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Name

2800

2900

Components Overview

5900

Screw plug M 30 x 1.5;


hexagon socket head, w.a.f. 17;
with copper sealing ring (3550): 130 Nm
with integrated sealing ring: 100 Nm
Sealing ring A 30 x 36

2810

3100

2800

2801

6101

2301

2000
8000
6600

100

2300

6700

5300
3850 5200a
3800
3850
3900

6600
6700
7600
7500
7300
7300
7300 7500
6400
6700
6600
2600
20100
1950
20000

2900
5600
2206
5500
4000
108
5400 3700
3500
107
3550

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

3300

6100
6101

3300

Combined hex.-head screw M 8 x 30;


hexagon insert bit, w.a.f. 13;
30 Nm
Combined hex.-head screw M 8 x 80;
hexagon insert bit, w.a.f. 13;
30 Nm

4100
4150

9000

5901

Gasket

5901

2200

2500

3100
Replace component
Check component
according to specifications
and replace, if necessary
Perform visual inspection
and replace, if necessary

2105
2100
2106

1700 1600

4250

1900
4250

4200 4200
3100

6700
6600
20100

20200
5200b
5300
20200

20000
20400 20300
28047

Page 65

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Item No.

Name

3700

Proportional valve

3800

Damping plate

3850

O-ring 16 x 3

3900

Combined hex.-head screw M 8 x 20;


hexagon insert bit, w.a.f. 13;
30 Nm

4000

4100

4150

Screw plug M 30 x 1.5;


hexagon socket head, w.a.f. 17;
with copper sealing ring (4150): 130 Nm
with integrated sealing ring: 100 Nm
Sealing ring A 30 x 36

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

5901

5900

4100
4150

3300

3100

9000

5901

6100
6101

2810
2800

2801

6101

2301

3300

Hex.-head nut M 8;
hexagon insert bit, w.a.f. 13;
18 Nm

NOTE
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Components Overview

2000
8000
6600

100

2300

6700

5300
3850 5200a
3800
3850
3900

6600
6700
7600
7500
7300
7300
7300 7500
6400
6700
6600
2600
20100
1950
20000

2900
5600
2206
5500
4000
108
5400 3700
3500
107
3550
2200

2500

3100
Replace component
Check component
according to specifications
and replace, if necessary
Perform visual inspection
and replace, if necessary

2105
2100
2106

1700 1600

4250

1900
4250

4200 4200
3100

6700
6600
20100

20200
5200b
5300
20200

20000
20400 20300
28047

Page 66

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Item No.
4200

4250
5200a

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

5200b

Components Overview

Name
Screw plug M 24 x 1.5;
hexagon socket head, w.a.f. 12;
with copper sealing ring (4250): 80 Nm
with integrated sealing ring: 47 Nm

5901

5900

5901

Sealing ring A 14 x 20

5400

Wave spring

5500

Washer silencer

5600

Circlip JL 30 x 1.2

5900

Pipe; with union nuts;


60 Nm

5901

O-ring 15.3 x 2.4

6100
6101

2810

3100

2800

2801

6101

2301

3300

Coolant temperature sensor M 14 x 1.5;


hexagon insert bit, w.a.f. 27;
30 Nm

5300

3300
9000

Sealing ring A 24 x 29
Oil temperature sensor M 14 x 1.5;
hexagon insert bit, w.a.f. 27;
30 Nm

4100
4150

2000
8000
6600

100

2300

6700

5300
3850 5200a
3800
3850
3900

6600
6700
7600
7500
7300
7300
7300 7500
6400
6700
6600
2600
20100
1950
20000

2900
5600
2206
5500
4000
108
5400 3700
3500
107
3550
2200

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

2500

3100
Replace component
Check component
according to specifications
and replace, if necessary
Perform visual inspection
and replace, if necessary

2105
2100
2106

1700 1600

4250

1900
4250

4200 4200
3100

6700
6600
20100

20200
5200b
5300
20200

20000
20400 20300
28047

Page 67

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Item No.

Components Overview

Name

6100

Pipe

6101

O-ring 15.3 x 2.4

6400

Heat exchanger

6600

Hex.-head screw M 14 x 45;


hexagon insert bit, w.a.f. 22;
in case of mounting with angle measuring tool:
Initial torque: 50 Nm
Final torque: 30
in case of mounting with torque wrench:
Initial torque: 50 Nm
Final torque: 130 Nm

5901

5900

6700

Washer A 14

7300

O-ring 15 x 4

7500

O-ring 45 x 5

7600

O-ring 25 x 4

8000

Intermediate washer 196 x 144 x 2

3300

3100

9000

5901

6100
6101

2810
3300
2800

2801

6101

2301

2000
8000
6600

100

2300

6700

5300
3850 5200a
3800
3850
3900

6600
6700
7600
7500
7300
7300
7300 7500
6400
6700
6600
2600
20100
1950
20000

2900
5600
2206
5500
4000
108
5400 3700
3500
107
3550
2200

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

4100
4150

2500

3100
Replace component
Check component
according to specifications
and replace, if necessary
Perform visual inspection
and replace, if necessary

2105
2100
2106

1700 1600

4250

1900
4250

4200 4200
3100

6700
6600
20100

20200
5200b
5300
20200

20000
20400 20300
28047

Page 68

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Item No.
9000

Name
Pressure sensor M 16 x 1.5;
hexagon insert bit, w.a.f. 27;
30 Nm

20000

Water neck

20100

Gasket

20200

Combined hex.-head screw M 8 x 80;


hexagon insert bit, w.a.f. 13;
30 Nm

20300

20400

Sealing ring A 14 x 20

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

5901

5900

4100
4150

3300

3100

9000

5901

6100
6101

2810
2800

2801

6101

2301

3300

Screw plug M 14 x 1.5;


hexagon insert bit, w.a.f. 13;
32 Nm

NOTE

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Components Overview

2000
8000
6600

100

2300

6700

5300
3850 5200a
3800
3850
3900

6600
6700
7600
7500
7300
7300
7300 7500
6400
6700
6600
2600
20100
1950
20000

2900
5600
2206
5500
4000
108
5400 3700
3500
107
3550
2200

2500

3100
Replace component
Check component
according to specifications
and replace, if necessary
Perform visual inspection
and replace, if necessary

2105
2100
2106

1700 1600

4250

1900
4250

4200 4200
3100

6700
6600
20100

20200
5200b
5300
20200

20000
20400 20300
28047

Page 69

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.2

Top Oil Tank Cover

Item No.

6101

Name

3300

6100

100

Retarder housing

2000

Top oil tank cover

2800

Cover for casing ventilation

3100

Combined hex.-head screw M 8 x 30;


hexagon insert bit, w.a.f. 13;
30 Nm

3100

Combined hex.-head screw M 8 x 80;


hexagon insert bit, w.a.f. 13;
30 Nm

2000

3300

6100

Pipe; take installation position into account

6101

O-ring 15.3 x 2.4; replace

8000

Intermediate washer 196 x 144 x 2; replace

NOTE
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Top Oil Tank Cover

6101

2800

8000

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
In case of retarders from Voith item no. H67.150030
upwards:

100

Aids
Thread seal Loctite 572

for bores of the combined


hex.-head screws
28072

Page 70

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Requirements

Installing

Retarder is switched off

Ignition is switched off

1. Clean the sealing surfaces at the retarder housing


and at the oil tank cover (2000).

CAUTION
Hot parts!
Hands could be burned.

Top Oil Tank Cover

2. In case of retarders from Voith item no.


H67.150030 upwards: Apply thread seal Loctite
572 to the bores of the combined hex.-head
screws (3100 and 3300).
3. Insert a new intermediate washer (8000).

Work carefully.
Wear protective gloves or use cloths, if necessary.
Removing
1. Unscrew the combined hex.-head screws (3100
and 3300).
2. Remove the oil tank cover (2000).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

3. Remove the intermediate washer (8000).


4. Remove the pipe (6100) with the O-rings (6101).

4. Lubricate the new O-rings (6101) with siliconefree and non-corrosive grease and pull them onto
the pipe (6100).
5. Lubricate bore for the pipe (6100) into the casing
ventilation cover (2800) with silicone-free and noncorrosive grease.
6. Insert the pipe (6100) in the oil tank cover (2000)
and casing ventilation cover (2800). In doing so,
observe the installation position.
7. Screw on the oil tank cover (2000) with the combined hex.-head screws (3100 and 3300).
8. Tighten the combined hex.-head screws (3100
and 3300) crosswise with 30 Nm.

Page 71

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.3

Bottom Oil Tank Cover

Bottom Oil Tank Cover

Item No.

Name

2500

Bottom oil tank cover

2600

Gasket, replace

3100

Combined hex.-head screw M 8 x 30;


hexagon insert bit, w.a.f. 13;
30 Nm

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

2600

2500

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

3100

28073

Page 72

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Requirements

Bottom Oil Tank Cover

CAUTION

Retarder is switched off

Ignition is switched off

bined hex.-head screws!

Retarder oil is drained (see page 23)

Cover can buckle.

Incorrect sequence when tightening the com-

Screw the combined hex.-head screws tight in


the prescribed sequence.

CAUTION
Hot parts!
Hands could be burned.
Work carefully.

Wear protective gloves or use cloths, if neces-

5
3

sary.

7
2

17
Removing
1. Unscrew the combined hex.-head screws (3100).
2. Remove the oil tank cover (2500).
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

3. Remove the gasket (2600).


Installing

8
9

16

10
15

11
14

12
13

28074

4. Screw the combined hex.-head screws (3100)


tight in the prescribed sequence with 30 Nm.

1. Clean the sealing surfaces at the retarder housing


and at the oil tank cover (2500).
2. Insert new gasket (2600).
3. Screw on the oil tank cover (2500) with the combined hex.-head screws (3100).
Page 73

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.4

Cover for Casing Ventilation

Cover for Casing Ventilation


3300

Item No.

Name

2800

Cover for casing ventilation

2801

Cover

2900

Gasket, replace

3300

Combined hex.-head screw M 8 x 80;


hexagon insert bit, w.a.f. 13;
30 Nm

6100

Pipe; take installation position into account

6101

O-ring 15.3 x 2.4; replace

NOTE

2800

6101
6100
2801

6101

2900

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

NOTE
If the casing ventilation cover (2800) is replaced:
Order the sealing cover (2801) as well.

28180

Page 74

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Cover for Casing Ventilation

Removing

Requirements

Retarder is switched off

Ignition is switched off

6101
6100
6101

3300

Proportional valve and damping plate are removed


(see page 106)

CAUTION
Hot parts!

28052

Hands could be burned.

28050

Work carefully.
Wear protective gloves or use cloths, if neces-

4. Remove the pipe (6100).


1. Unscrew the combined hex.-head screws (3300).

sary.

5. Pull off the O-rings (6101).

2800

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

2900

28051

2. Remove the casing ventilation cover (2800).


3. Remove the gasket (2900).
Page 75

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Cover for Casing Ventilation

5. Put the casing ventilation cover (2800) onto the


pipe (6100).

Installing

2000
6100

6. Screw on the casing ventilation cover (2800) with


the combined hex.-head screws (3300).

2900

6101

7. Tighten the combined hex.-head screws (3300)


crosswise to 30 Nm.

28136
28060

3. Insert new gasket (2900).


1. Lubricate the new O-rings (6101) with siliconefree and non-corrosive grease and pull them onto
the pipe (6100).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

2. Insert the pipe (6100) into the oil tank cover top
(2000). In doing so, observe the installation position.

6100
3300
2800

28061

4. Lubricate bore for the pipe (6100) into the casing


ventilation cover (2800) with silicone-free and noncorrosive grease.

Page 76

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.5

Casing Ventilation

Casing Ventilation

Item No.
2300

Name
Casing ventilation

2300/1

Valve insert

2300/2

Float; specified weight max. 12 g;


for casing ventilation from Voith item no.
H53.133214 upwards take installation position into account:
the side marked "O" faces upwards

2300/3

Float cage

2301

2300/1

O-ring 55 x 3; replace

2300

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

2301
2300/2
2300/3

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Aids
Ethyl alcohol

for float

28048

Page 77

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

CAUTION

Casing Ventilation

CAUTION

Tools for self-fabrication


Hot parts!

Damage to components.

Hands could be burned.

Only use special tools in the specified version.

Work carefully.

Take the last two digits of the Voith item no. into

40.5 mm
60 mm

account in the diagram of the special tools.

7 mm

False special tools!

H67.2757xx

Wear protective gloves or use cloths, if necessary.


Removing

Special tools
Test ring
99/4

99/5

Material: St 37
Weight: 0.085 kg

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

98/9
H53.7712xx

H53.942811

Impact puller

Adapter

99/5

98/9

The test ring (99/4) can be ordered from Voith Turbo


GmbH & Co. KG: Voith item no. H67.2757xx.
Requirements
28053

Retarder is switched off

Ignition is switched off

1. Screw the impact puller (99/5) to the adapter (98/9).

Proportional valve and damping plate are removed


(see page 106)

2. Use the impact puller (99/5) including the adapter


(98/9) to pull the valve insert (2300/1) upwards
and out.

Casing ventilation cover is removed (see page 74)

Page 78

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Casing Ventilation

Checking

2300/2

1. Check the casing ventilation (2300) for soiling and


sludge and clean it.

99/4
2300/2

2300/3
2300/1

2300/2

28054

28057

3. If necessary, remove the float (2300/2) and the


float cage (2300/3).
28056

2300/1

2. Check the float (2300/2) for damaged surfaces


and sealing areas (see arrow/diagram).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

3. Weigh the float (2300/2): Specified weight:


max. 12 g.
4. For exceeded specified weight: Replace the entire
casing ventilation (2300).

2301

5. Check the sealing edge of the radial shaft sealing


ring in the valve insert (2300/1) (see arrow/diagram):
-

Place the float (2300/2) on a suitable object,


e.g. hex.-head nut.

Place the valve insert (2300/1) on the float and


weigh it down using the test ring (99/4).

Fill the empty space between the float (2300/2)


and upper edge of the valve insert with ethyl alcohol.

NOTE
28055

4. Remove O-ring (2301) of the groove in the valve


insert (2300/1).

The sealing edge is damaged, if the fluid level


drops within 1 minute.
6. If the sealing edge is damaged: Replace the casing
ventilation (2300).
Page 79

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Casing Ventilation

Installing

CAUTION

99/5

2300/1

Grease at the radial shaft sealing ring!


Malfunction of the retarder.

98/9

2300/2

Do not lubricate the radial shaft sealing ring.

2300/3
28059

2300/1
2. Clean the float with ethyl alcohol.

NOTE
For casing ventilation from Voith item no.
H53.133214 upwards:

2301

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

28058

1. Lubricate the new O-ring (2301) with silicone-free


and non-corrosive grease and pull it on the valve
insert (2300/1).

28053

7. Use the impact puller (99/5) including the adapter


(98/9) to press the casing ventilation (2300) carefully in.
8. Complete the retarder.

Observe the installation position of the float: The


side marked "O" upwards.
3. Insert the float (2300/2) into the float cage (2300/3).
4. Place valve insert (2300/1) on float cage (2300/3).
5. Clean the sealing surfaces at the retarder housing
and at the casing ventilation cover (2800).
6. Lubricate the bore of the casing ventilation (2300)
in the retarder housing with silicone-free and noncorrosive grease.
Page 80

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.6

Retarder Ventilation

Item No.

Retarder Ventilation

Requirements

Retarder is switched off

Ignition is switched off

Name

5400

Corrugated spring; replace

5500

Disc silencer; check, clean and blow out


with compressed air

5600

Circlip

DANGER
Heavily soiled or painted-over retarder ventilation!
Retarder reduces braking power after a delay.

5400
5500

Replace retarder ventilation.

CAUTION

5600

Mechanically damaged retarder ventilation!


Malfunction of the retarder.
Replace retarder ventilation.

r.
ch-N
-Sa
-Nr.
Kd.
ach
h-S
Voit

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

28062

Aids
Benzine

for disc silencer

Page 81

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.7

Basic Retarder

Item No.
33

Name
Basic retarder

850

Outer race; replace

3700

Proportional valve

3800

Damping plate

5200a

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Basic Retarder

Oil temperature sensor

6400

Heat exchanger

9000

Pressure sensor

25000

Shim

25100

O-ring 14 x 4; replace

25200

Hex.-head screw M 10 x 70;


hexagon insert bit, w.a.f. 16;
58 Nm

25300

Hex.-head screw M 10 x 60;


hexagon insert bit, w.a.f. 16;
58 Nm

NOTE
Instructions are enclosed with the basic retarder
(spare part). These describe the removal/installation and return of the defective basic retarder (see
conversion instructions for basic retarder VR 115 E).

25000

25300

850

5200a
25200

3700
9000

3800

25100

25200

6400

33

28182

Page 82

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.8

Inside Part (800)

Inside Part (800)

Item No.
800

Name
Inside part

800

Commercially available tools


Hot plate
Requirements

Retarder is removed (see page 54)

Removing
Use a suitable puller to pull the inside part (800)

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

from the retarder shaft.

28184

Page 83

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Inside Part (800)

Installing

CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.
1. Use a hot plate to heat the inside part (800) to
approx. 100 C.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

2. Press the inside part (800) onto the retarder shaft


until it stops.

Page 84

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.9

Pipe (5900)

Pipe (5900)

Item No.

Name

5900

Pipe; with union nuts;


60 Nm

5901

O-ring 15.3 x 2.4; replace

5900

Requirements

5901

Retarder is removed (see page 54)

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

5901

28183

Page 85

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.10

Water Neck

Water Neck

NOTE
Depending on the vehicle manufacturer, the design
of the water neck can differ (see specifications of
vehicle manufacturer).

Item No.

Name

20000

Water neck

20100

Gasket, replace

20200

Combined hex.-head screw M 8 x 80;


hexagon insert bit, w.a.f. 13;
30 Nm

20100
20000
20200

NOTE

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

.
Nr
h.
ac
Nr
.-S
hKd
ac
-S
ith
Vo

20100
20000
20200

28063

Page 86

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Water Neck

Requirements

Retarder is switched off

Ignition is switched off

Coolant is drained (see page 29)

CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if neces-

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

sary.

Page 87

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.11

Heat Exchanger

Item No.

Name

6400

Heat exchanger

6600

Hex.-head screw M 14 x 45;


hexagon insert bit, w.a.f. 22;
in case of mounting with angle measuring tool:
Initial torque: 50 Nm
Final torque: 30
in case of mounting with torque wrench:
Initial torque: 50 Nm
Final torque: 130 Nm

6700

Washer A 14

7300

O-ring 15 x 4; replace

7500

O-ring 45 x 5; replace

7600

O-ring 25 x 4; replace

NOTE
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

Heat Exchanger

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

NOTE
Please procure any connecting pieces that are
not listed here by yourself.

6700

6600

7600
7500
7300
7300
6400

7300
7500

6700
6600

6700
6600
28064

Page 88

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Heat Exchanger

Removing

Requirements

Special tools

Retarder is switched off

Ignition is switched off

Supply-air pressure pv is drained

Retarder oil is drained (see page 24)

Coolant is drained (see page 29)

Water neck is removed (see page 86)

6400

H67.1948xx
Pressure test
equipment

DANGER

50/22

Heat exchanger can fall!


Commercially available tools
Rotation angle measuring tool 3/4"

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Color black

Temperature-resistant
50 C ... + 250 C

Voith item no.


190.001697xx

For sealing surface heat


exchanger/
retarder housing

6700

6700
6600

6700
6600
28066

1. Unscrew the hex.-head screws (6600) with washers (6700).

Your body can be crushed severely.


Secure the heat exchanger against falling.

2. Remove the heat exchanger (6400).

Use a suitable lifting device.

Aids
Elring sealing compound
Dirko-S Profi press HT:

6600

CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.

Page 89

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Heat Exchanger

2. Connect the compressed-air line with pressure


reducer to connection (A).

CAUTION

7600
Hot water!

7500
7300
7300

Hands could be burned.


Work carefully.

Installing

NOTE
The water and oil section of new heat exchangers
are coated with anti-corrosion oil.
Before installation drain any anti-corrosion oil
and rinse the water section with hot water.

Wear protective gloves or use cloths, if necessary.

7300

7500

28067

3. Remove the O-rings (7300, 7500 and 7600).

100

3. Fill the water section of the heat exchanger (6400)


with hot water (approx. 70 C).
4. Slowly pressurize the heat exchanger (6400) with
a max. of 10 bars overpressure.

Checking

50/22

7600
7500
7300
7300

CAUTION

6400

Heat exchanger leaks!


Malfunction of the retarder.

7300

7500

28070

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

If air bubbles occur in the water or if an external


leak is found: Replace the heat exchanger.

5. Repeat the test at the connections (B and C).

1. Lubricate the new O-rings (7300, 7500 and 7600)


with silicone-free and non-corrosive grease and
insert into the retarder housing.

A B
28068

1. Install the pressure-test equipment (50/22) using


O-rings to the heat exchanger (6400).
Page 90

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Heat Exchanger

4. Screw on the hex.-head screws (6600) with washers (6700).

28174

2. Apply sealing compound to the two sealing surfaces (see dashed lines/figure).

6400

CAUTION

5. Tighten the hex.-head screws (6600) crosswise


with 50 Nm.

In case of water in the retarder!

6. In case of mounting with angle measuring tool:


Tighten the hex.-head screws (6600) crosswise
with 30.

Fill the retarder with 7.0 liters engine oil or flush


oil.

In case of mounting with torque wrench: Tighten


the hex.-head screws (6600) crosswise with
130 Nm.
7. Complete the retarder.

Oil emission through retarder ventilation.


Malfunction of the retarder.

Flush the retarder system by braking several


times lightly.
Drain the oil.
Repeat the process 2 or 3 times.
De-oil the cooling and heating system (see
specifications of vehicle manufacturer).

CAUTION
Wrong coolant type!
Damage to the vehicle and retarder cooling circuit.
Observe the specifications of the vehicle manufacturer or those of Voith Turbo cooling water
quality list.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

6600
6700
6700
6600

6700
6600

8. Fill the vehicle and retarder cooling circuit (see


specifications of vehicle manufacturer).

28066

3. Place the heat exchanger (6400) on the retarder


housing.

Page 91

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Heat Exchanger

6400

28175

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

9. Seal the gap between the heat exchanger and the


retarder housing (see dashed line/figure).

Page 92

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.12

Pressure Control Valve

Pressure Control Valve

Item No.

Name

2200

Pressure control valve, complete;


with integrated sieve
without sieve. Sieve at the screw plug
(3500)

2206

O-ring 21.5 x 2.5; replace

3500

Screw plug M 30 x 1.5;


hexagon socket head, w.a.f. 17;
with copper sealing ring (3550): 130 Nm
with integrated sealing ring: 100 Nm

3550

Sealing ring A 30 x 36; replace

r.
h-N
ac
r.
.-S
h-N
Kd
ac
-S
ith

Vo

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

2206
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007

3550
3500
2200

28075

Page 93

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Special tools

Pressure Control Valve

Requirements

Retarder is switched off

Ignition is switched off

Retarder oil is drained (see page 23)

Nr.
hac
Nr.
.-S
hKd
ac
-S
ith

Vo

CAUTION
H53.7712xx
Impact puller
99/5

99/5

Hot parts!
Hands could be burned.

28077

Work carefully.
Wear protective gloves or use cloths, if necessary.

For pressure control valve (2200) with integrated


sieve:

Removing

2. For pressure control valve (2200) with integrated sieve: Screw the impact puller (99/5) to the
screw plug (50/43).
3. Use the impact puller (99/5) to knock out the complete pressure control valve (2200) out of the
retarder housing.

Tools for self-fabrication

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

M8
Nr.
hac
Nr.
-S
hKd.
ac
th-S
Voi

M 20 x 1.5
Adapter
50/43

3500

3550

28076

1. Unscrew the screw plug (3500) with the sealing


ring (3550).
Page 94

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Installing

Pressure Control Valve

3. Use the impact puller (99/5) to press the complete


pressure control valve (2200) carefully in.

NOTE
2 variants of the pressure control valve are possible:

4. For screw plug (3500) with copper sealing ring


(3550):

Pressure control valve with integrated sieve

Pressure control valve without sieve. Sieve is located at the screw plug (3500)

Lubricate the new sealing ring (3550) with silicone-free and non-corrosive grease.

Screw in the screw plug (3500) with sealing


ring (3550) and tighten it to 130 Nm.

Do not combine individual parts.

For screw plug (3500) with integrated sealing


ring:

r.
h-N .
ac
r
.-S
h-N
Kd
ac
-S
th
Voi

Check the sealing ring for damage. If necessary, replace the screw plug (3500).

Screw in the screw plug (3500) and tighten it


to 100 Nm.

2206

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

2200

28078

1. Lubricate the new O-ring (2206) with silicone-free


and non-corrosive grease and pull it onto the pressure control valve (2200).
2. For pressure control valve (2200) with integrated sieve: If necessary, screw the impact puller
(99/5) to the screw plug (50/43).

Page 95

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.13

Non-Return Valve (inlet)

Non-Return Valve (inlet)

Item No.
1900

Name
Non-return valve (inlet), complete

1900/1

Guide M 48 x 1.5
hexagon insert bit, w.a.f. 55;
with copper sealing ring (1950): 280 Nm
with integrated sealing ring: 280 Nm

1900/2

Spring

1900/3

Piston

1950

Sealing ring A 48 x 55; replace

NOTE
1950

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

1900/3
1900/2
1900/1

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

In case of retarders from Voith item no. H67.150030


upwards and copper sealing ring (1950):
Aids
Thread seal Loctite 572

for the guide thread

Nr.
hac
Nr.
-S
hKd.
ac
th-S
Voi

1900

28079

Page 96

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Non-Return Valve (inlet)

Requirements

Checking

Installing

Retarder is switched off

In case of retarders from Voith item no.

Ignition is switched off

1. For guide (1900/1) with integrated sealing ring:


Check the sealing ring for damage. If necessary,
replace the complete non-return valve (inlet)
(1900).

CAUTION

H67.150030 upwards and copper sealing ring


(1950):
-

Apply Loctite 572 to the thread of the guide


(1900/1).

Lubricate the new sealing ring (1950) with silicone-free and non-corrosive grease.

Screw in the non-return valve (inlet) (1900) with


sealing ring (1950).

Tighten the non-return valve (inlet) (1900) with


280 Nm.

1900/1

Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.

1900/3

For guide (1900/1) with integrated sealing ring:


Screw in the non-return valve (inlet) (1900) and
tighten it with 280 Nm.

Removing
1. Unscrew the guide (1900/1).

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

2. Remove the spring (1900/2) and piston (1900/3)


from the retarder housing.

1900/2
28179

2. Check the rubber coating of the piston (1900/3) for


damage. If necessary, replace the complete nonreturn valve (inlet) (1900).
3. Check the guide (1900/1) and spring (1900/2) for
wear. If necessary, replace the complete nonreturn valve (inlet) (1900).

Page 97

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.14

Non-Return Valve (outlet)

Non-Return Valve (outlet)

Item No.

Name

1600

Valve cover;
take installation position into account

1700

O-ring 60 x 3; replace

2100

Non-return valve (outlet), complete;


take installation position into account

2105

O-ring 34 x 3; replace

2106

O-ring 54 x 3; replace

3100

Combined hex.-head screw M 8 x 30;


hexagon insert bit, w.a.f. 13;
30 Nm

NOTE

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

.
Nr
h.
ac
Nr
.-S
hKd
ac
-S
ith

Vo

2105
2106
1700
2100

1600
3100

28080

Page 98

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Non-Return Valve (outlet)

Checking

Removing

Special tools

1. Unscrew the combined hex.-head screws (3100).

2100
1

2. Remove the valve cover (1600).

2
153.000052xx
Puller
28158

50/1

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Requirements

50/1

Retarder is switched off

Ignition is switched off

Retarder oil is drained (see page 23)

CAUTION
Hot parts!

28153

3. Push the puller (50/1) onto the non-return valve


(outlet) (2100) until it latches in.
4. Pull the non-return valve (outlet) (2100) out of the
retarder housing.
5. Remove the O-rings (1700, 2105 and 2106).

1. Check the rubber coating of the valve disk (1) for


damage. If necessary, replace the complete nonreturn valve (outlet) (2100).
2. Check the bore or sleeve for wear and eccentricity
(see arrow/diagram). If necessary, replace the
complete non-return valve (outlet) (2100).
3. Press the valve disk (1) until it stops and check the
guide piston (2) for wear. If necessary, replace the
complete non-return valve (outlet) (2100).

Hands could be burned.


Work carefully.
Wear protective gloves or use cloths, if necessary.

Page 99

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Non-Return Valve (outlet)

Installing
1. Lubricate the new O-rings (2105 and 2106) with
silicone-free and non-corrosive grease and pull
them onto the non-return valve (outlet) (2100).

2100

28178

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

2. Use a suitable tool to press the non-return valve


(outlet) (2100) into the retarder housing. In doing
so, observe the installation position (see arrow/
diagram).
3. Lubricate the O-ring (1700) with silicone-free and
non-corrosive grease and pull it onto the valve
cover (1600).
4. Screw on the valve cover (1700) with the combined hex.-head screws (3100). In doing so,
observe the installation position.
5. Tighten the combined hex.-head screws (3100)
crosswise to 30 Nm.
Page 100

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.15

Oil Temperature Sensor

Oil Temperature Sensor

Item No.
5200a

5300

Name
Oil temperature sensor M 14 x 1.5;
hexagon insert bit, w.a.f. 27;
30 Nm
Sealing ring A 14 x 20; replace

NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Requirements

Retarder is switched off

Ignition is switched off

Electrical connecting leads are disconnected

5300
5200a

CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.
28115

Page 101

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Oil Temperature Sensor

Checking the internal resistance

NOTE
Measuring in one temperature range is usually sufficient.
Polarity irrelevant.

Resistance

20 C 10 C

10391117

60 C 10 C

11941271

80 C 10 C

12711347

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Temperature

Page 102

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.16

Coolant Temperature Sensor

Coolant Temperature Sensor

Item No.
5200b

5300

Name
Coolant temperature sensor M 14 x 1.5;
hexagon insert bit, w.a.f. 27;
30 Nm
Sealing ring A 14 x 20; replace

NOTE

5200b

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

5300

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Requirements

Retarder is switched off

Ignition is switched off

Coolant is drained (see page 29)

Electrical connecting leads are disconnected

28114

Page 103

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Coolant Temperature Sensor

CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.
Checking the internal resistance

NOTE
Measuring in one temperature range is usually sufficient.
Polarity irrelevant.

Resistance

20 C 10 C

10391117

60 C 10 C

1194271

80 C 10 C

1271347

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Temperature

Page 104

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.17

Pressure Sensor

Pressure Sensor

Item No.
9000

Name
Pressure sensor M 16 x 1.5;
hexagon insert bit, w.a.f. 27;
30 Nm

NOTE

9000

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Requirements

Retarder is switched off

Ignition is switched off

Electrical connecting leads are disconnected

CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.
28116

Page 105

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

7.18

Proportional Valve and Damping Plate

Proportional Valve and Damping


Plate

Item No.

3850

Name

Supply-air pressure pv "P"

Electrical connecting lead

3700

Proportional valve

3800

Damping plate; replace if damaged

3850

O-ring 16 x 3; replace

3900

Combined hex.-head screw M 8 x 20;


hexagon insert bit, w.a.f. 13;
30 Nm; replace

4000

Hex.-head nut M 8;
hexagon insert bit, w.a.f. 13;
18 Nm; replace

3800

3850

3900
4000

3700

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

NOTE

3900

4000

Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.

28113

Page 106

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair

Proportional Valve and Damping Plate

Requirements

Retarder is switched off

Ignition is switched off

Supply-air pressure pv is drained

Supply-air pressure line py (C) is removed

Electrical connecting lead is disconnected from


proportional valve. (H) Male and female connector
are checked for damage or wear (notch scratches)

NOTE

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Check damping plate (3800) for mechanical and


aging damage and replace, if necessary.

Page 107

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Overview of the Tools

8.

Overview of the Tools

8.1

Diagnosis

109

8.2

Removing and Installing the Retarder

111

8.3

Repair

112

CAUTION
False special tools!
Damage to components.
Only use special tools from the specified version on.
Take the last two digits of the Voith item no. into

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

account in the diagram of the special tools.

Page 108

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Overview of the Tools

8.1

Diagnosis

Activity

Special tools

Tools for self-fabrication

Checking the constantair pressure control


loop

153.001085xx

153.000776xx

H53.1403xx

Retarder tester,
complete in a
case

Test software
"DIANA Lite"

Pressure gauge
06 bar

50/56

50/56i

99/7

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Checking the pump


pressure pdyn

153.001085xx

153.000776xx

Retarder tester,
complete in a
case

Test software
"DIANA Lite"

50/56

50/56i

Page 109

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Overview of the Tools

Activity

Special tools

Checking the
proportional valve
current

Tools for self-fabrication

H53.8198xx
Measuring
adapter

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

99/3

Page 110

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Overview of the Tools

8.2

Removing and Installing the Retarder

Activity

Special tools

Tools for self-fabrication

0
80
62 265
FJ 6
48

M 10

Removing and
installing the retarder

H67.3224xx

H67.3319xx

Puller

Measuring
device

Marking punch

98/3

98/1

98/4

80
28028

2 x Threaded bolt
Material: St 37-2, DIN 17100 (1.80)

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

H67.3320xx

15

Page 111

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Overview of the Tools

8.3

Repair

Activity

Special tools

Tools for self-fabrication

40.5 mm
60 mm
H53.7712xx

H53.942811

H67.2757xx

Impact puller

Adapter

Test ring

99/5

98/9

99/4

7 mm

Casing ventilation

Material: St 37
Weight: 0.085 kg

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

Heat exchanger

H67.1948xx
Pressure test
equipment
50/22

Page 112

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Overview of the Tools

Activity

Special tools

Tools for self-fabrication

Pressure control valve

M8

H53.7712xx

M 20 x 1.5

Impact puller

Adapter

99/5

50/43

Non-return valve
(outlet)

Voith Turbo I 153.00009711 I arrtd I 2007-09


2007

153.000052xx
Puller
50/1

Page 113

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.

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