Professional Documents
Culture Documents
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Table of Contents
Table of Contents
1
1.1
1.2
1.3
1.4
1.5
1.6
6
6
6
7
7
7
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
11
3.1
3.2
3.3
12
14
15
Page 2
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Table of Contents
3.4
3.5
3.6
16
17
19
21
4.1
4.2
4.3
4.4
Maintenance Intervals
Oil Change
Checking the Oil Level
Draining the Coolant
22
23
26
29
31
5.1
5.2
5.3
5.4
Overview
Checking
Checking
Checking
32
42
47
52
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
Page 3
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
108
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
1.1
1.2
Target Groups
1.3
1.4
1.5
Item Numbers
1.6
Imprint
1.
Page 5
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I About this Document
1.1
1.3
1.2
Target Groups
Documents
Information
153.000900xx
Approved coolants
H67.2224xx
ECU specifications
on request
153.001508xx
Included in scope of delivery of
the retarder tester
(153.001085xx)
3623-020900
Instructions for removing and installing the basic retarder and returning
the basic retarder
153.002778xx
153.002005xx
Page 6
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I About this Document
1.4
Structure of warnings
LEVEL OF DANGER
WARNING
Possible imminent danger that could lead to death
or serious injury if not prevented.
DANGER
1.5
1.6
Levels of danger
Notes
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
Item Numbers
Exceptions:
CAUTION
Possible imminent danger that could lead to slight
injury if not prevented.
Imprint
Page 7
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Basic Safety Information
2.1
Product Safety
2.2
Staff Qualification
2.3
Safety-Conscious Working
2.4
Environmental Protection
2.6
2.7
2.8
Driving Mode
10
2.9
Warranty
10
2.
Page 8
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Basic Safety Information
2.1
Product Safety
2.2
Staff Qualification
2.3
Safety-Conscious Working
2.4
Environmental Protection
2.5
Special Tools
Product Safety
2.7
Work carefully.
Work carefully.
sion on.
Take the last two digits of the Voith item no. into
Accident-prevention regulations
2.6
Safety regulations for handling chemical substances such as oils and greases
Work carefully.
Wear protective gloves or use cloths, if necessary.
Page 9
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Basic Safety Information
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.:
Driving Mode
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
Page 10
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function
3.1
12
3.2
Retarder Identification
14
3.3
15
3.4
16
3.5
17
3.6
Function Description
19
3.
Page 11
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function
3.1
Item No.
100
Name
3700
Retarder housing
1600
1900
2810
3700
Proportional valve
4100
4100
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
3500
4200
5200b
5500
5500
6400
Heat exchanger
20000
6400
Water neck
3500
20000
103
5200b
20000
107
4200
28004
Page 13
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:
-
KW/Jahr
Voith-Sach-Nr.
Nr.
er
; S
ien-
5E
/Jah
R11
KW
pV
Ty
2.03
=
et
iR
Nr.
hac r.
-S
N
ith
hVo
ac
-S
Kd.
Kd.-Sach-Nr.
28001
Page 14
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function
3.3
NOTE
Specify the following data in case you have
questions or are ordering spare parts:
X1
X2
e1 022084
Voith Turbo
VOITH
Voit
h Tu
rbo
VOI
TH
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
084
022
e1
X3
28138
Page 15
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function
3.4
NOTE
Specify the following data in case you have
questions or are ordering spare parts:
-
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
Page 16
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Design and Function
3.5
Item No.
Oil tank
Rising duct
107
200
Stator
300
Rotor
1900
2100
2200
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
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.
Name
2300
Casing ventilation
2810
3700
Proportional valve
4200
5200a
5200b
5500
6400
Heat exchanger
9000
Pressure sensor
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
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
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).
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
The pressure control valve (2200) regulates the lubrication in no-load operation (non-braking mode) of the
retarder.
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
Page 20
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
4.1
Maintenance Intervals
22
4.2
Oil Change
23
4.3
26
4.4
29
4.
Page 21
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
4.1
Maintenance Intervals
Maintenance Intervals
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
Page 23
If no specifications available: Observe Voith Retarder Oil change intervals/Oil selection list.
Checking the oil level
Page 26
Page 29
Page 22
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
4.2
Oil Change
Item No.
Oil Change
4100
Name
107
108
3500
3550
4100
4150
4200
4250
NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
4150
.
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Vo
3550
3500
108
107
4250
4200
4250
4200
28009
Page 23
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
7.0 l
7.5 l
7.8 l
manufacturer).
Tighten the hex.-head screws (6600) at the heat
Lubricate the new sealing ring (108) with silicone-free and non-corrosive grease.
WARNING
Oil Change
CAUTION
Check the sealing ring for damage. If necessary, replace the screw plug (107).
Lubricate the new sealing rings (4250) with silicone-free and non-corrosive grease.
sary.
Requirements
Vehicle is horizontal
NOTE
If the oil contains water: Check the heat exchanger (see page 88).
Check the sealing rings for damage. If necessary, replace the screw plugs (4200).
Page 24
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
NOTE
CAUTION
CAUTION
Pressure control valve without sieve. Sieve is located at 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.
Oil Change
Lubricate the new sealing ring (3550) with silicone-free and non-corrosive grease.
Check the sealing ring for damage. If necessary, replace the screw plug (3500).
Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease.
Check the sealing ring for damage. If necessary, replace the screw plug (4100).
Page 25
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
4.3
Item No.
4100
Name
107
108
4100
4150
4200
4250
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.
4150
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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
7.0 l
Hot screw plugs!
Check the sealing ring for damage. If necessary, replace the screw plug (107).
Requirements
Vehicle is horizontal
Lubricate the new sealing rings (4250) with silicone-free and non-corrosive grease.
WARNING
Hot exiting oil!
Face and hands could be burned.
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).
Page 27
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
Filling in 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
Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease.
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.
Check the sealing ring for damage. If necessary, replace the screw plug (4100).
Page 28
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
4.4
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
20400
NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
Requirements
.
Nr
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ac
Nr
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hKd
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Vo
20000
20400
20300
28155
Page 29
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Maintenance and Service
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
Page 30
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
5.
5.1
32
5.2
42
5.3
47
52
5.4
Page 31
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
5.1
No.
Complaint
See
Page 33
Page 34
Page 36
Page 38
Page 32
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
NOTE
On-board diagnosis is possible at some vehicle
manufacturers (display).
Observe the specifications of the vehicle manufacturer.
No.
Activity
1.
2.
3.
Result
NOK
2.
OK
3.
NOK
4.
OK
5.
4.
5.
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.
Yes
2.
No
8.
Yes
3.
No
5.
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.
5.
6.
Result
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.
Result
NOK
9.
OK
10.
8.
9.
10.
Yes
11.
No
12.
NOK
12.
OK
13.
11.
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007
12.
13.
Page 35
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
No.
Activity
1.
2.
Repair retarder.
3.
Yes
2.
No
3.
NOK
NOK
5.
OK
6.
5.
6.
NOK
7.
OK
10.
NOK
8.
OK
9.
7.
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007
Result
OK
4.
Page 36
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
No.
Activity
8.
Result
and/or
Replace coolant temperature sensor or supply line
(see page 103).
9.
10.
11.
NOK
11.
OK
14.
NOK
12.
OK
13.
12.
13.
Contact Voith.
14.
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
NOTE
Ensure that there are no leaks at the screw
plugs or sealing rings.
No.
Activity
1.
Yes
2.
No
3.
2.
3.
Yes
4.
No
13.
NOK
5.
OK
6.
NOK
7.
OK
8.
4.
5.
6.
Result
Page 38
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
No.
Activity
7.
8.
NOK
9.
OK
10.
9.
10.
Result
NOK
11.
OK
12.
11.
12.
Contact Voith.
13.
14.
15.
Yes
14.
No
15.
Yes
16.
No
17.
Page 39
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
No.
Activity
16.
Top:
Result
18.
Yes
18.
No
19.
20.
Yes
20.
No
21.
Page 40
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
No.
Activity
21.
Result
Yes
22.
No
23.
22.
Replace the radial shaft sealing ring (see specifications of vehicle manufacturer).
23.
Contact Voith.
OK = works correctly
Page 41
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
5.2
NOTE
4100
4150
Item No.
99/7
Name
Pressure gauge 06 bar
50/56a
Retarder tester
50/56b
50/56c
50/56d
50/56e
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
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
4150
9000
Pressure sensor
50/56c
99/7
9000
NOTE
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
Requirements
Special tools
CAUTION
Work carefully.
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
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).
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
Multimeter
Page 44
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
VR 115 E
50/56b
83310
153.000
50/56a
50/56c
2
3
4
153.00
15
9000
08341
50
3.0
3700
83
51
50/56e
5200a
5200b
NOTE
153.00083610
28082
/56
00
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
Check the sealing ring for damage. If necessary, replace the screw plug (4100).
Lubricate the new sealing ring (4150) with silicone-free and non-corrosive grease.
Page 46
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
5.3
NOTE
50/56c
50/56b
50/56a
50/56e
Item No.
Name
50/56a
Retarder tester
50/56b
50/56c
50/56d
50/56e
50/56g
9000
3700
50/56d
.
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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
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
3700
Proportional valve
9000
Pressure sensor
50/56b
50/56a
NOTE
50/56e
3700
50/56d
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
.
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50/56g
104
103
28025
Page 48
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
or
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
Vehicle is secured
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
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
50/56g 104
NOTE
VR 115 E
50/56a
83310
104
50/56c
2
3
4
103
50/56b
153.000
153.00
15
08341
50
3.0
/56
00
9000
50/56g
83
51
50/56e
28027
3700
5200a
5200b
153.00083610
28083
28026
Page 50
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
NOTE
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
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.
Lubricate the new sealing ring (104) with silicone-free and non-corrosive grease.
Check the sealing ring for damage. If necessary, replace the screw plug (103).
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Diagnosis and Troubleshooting
5.4
Special tools
Requirements
3700
98/8
99/3
H53.8198xx
Measuring
adapter
99/3
NOTE
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007
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).
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
Setpoint
Digiprop
396596 mA
150
365565 mA
151
379579 mA
153
423623 mA
157, 158
409609 mA
Controller
Setpoint
159
534546 mA
H67.2763xx
440640 mA
179, 180,
502, 504, 508, 512,
514
440640 mA
VERA
510
430630 mA
H67.2866xx
H67.3449xx
H67.3457xx
H67.3658xx
153.000586xx
Page 53
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder
6.
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
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
25300
25200
NOTE
25100
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
Requirements
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
25200
28029
M 10
15
80
28028
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)
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
NOTE
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.
25100
28036
The thickness D of the shim is calculated in accordance with the following equation:
Thickness D = Dimension B Dimension A 0.02
mm
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).
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
25000
850
28181
Page 57
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Removing and Installing the Retarder
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.
850
800
98/1
28032
98/1
28031
7. Note dimension C.
28086
28084
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
0.52
67.3426xx
0.55
67.3427xx
Thickness D [mm]
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.
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!
25100
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
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
Page 61
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
7.
Repair
7.1
Components Overview
63
7.2
70
7.3
72
7.4
74
7.5
Casing Ventilation
77
7.6
Retarder Ventilation
81
7.7
Basic Retarder
82
7.8
83
7.9
Pipe (5900)
85
7.10
Water Neck
86
7.11
Heat Exchanger
88
7.12
93
7.13
96
7.14
98
7.15
101
7.16
103
7.17
Pressure Sensor
105
7.18
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
Valve cover
1700
O-ring 60 x 3
1900
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
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
2100
2105
O-ring 34 x 3
2106
O-ring 54 x 3
2200
2206
2300
Casing ventilation
2301
O-ring 55 x 3
2500
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.
2801
Cover
2810
3100
3300
3500
3550
Name
2800
2900
Components Overview
5900
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
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
4000
4100
4150
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
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
5901
6100
6101
2810
3100
2800
2801
6101
2301
3300
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
Item No.
Components Overview
Name
6100
Pipe
6101
6400
Heat exchanger
6600
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
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
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
NOTE
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
Item No.
6101
Name
3300
6100
100
Retarder housing
2000
2800
3100
3100
2000
3300
6100
6101
8000
NOTE
Voith Turbo I 153.00009711 I arrtd I 2007-09
2007
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
Page 70
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
Requirements
Installing
CAUTION
Hot parts!
Hands could be burned.
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).
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
Item No.
Name
2500
2600
Gasket, replace
3100
NOTE
Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and non-corrosive
grease before installation.
2600
2500
3100
28073
Page 72
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
Requirements
CAUTION
CAUTION
Hot parts!
Hands could be burned.
Work carefully.
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
8
9
16
10
15
11
14
12
13
28074
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
7.4
Item No.
Name
2800
2801
Cover
2900
Gasket, replace
3300
6100
6101
NOTE
2800
6101
6100
2801
6101
2900
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
Removing
Requirements
6101
6100
6101
3300
CAUTION
Hot parts!
28052
28050
Work carefully.
Wear protective gloves or use cloths, if neces-
sary.
2800
2900
28051
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
Installing
2000
6100
2900
6101
28136
28060
2. Insert the pipe (6100) into the oil tank cover top
(2000). In doing so, observe the installation position.
6100
3300
2800
28061
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
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
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
Damage to components.
Work carefully.
Take the last two digits of the Voith item no. into
40.5 mm
60 mm
7 mm
H67.2757xx
Special tools
Test ring
99/4
99/5
Material: St 37
Weight: 0.085 kg
98/9
H53.7712xx
H53.942811
Impact puller
Adapter
99/5
98/9
Page 78
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
Casing Ventilation
Checking
2300/2
99/4
2300/2
2300/3
2300/1
2300/2
28054
28057
2300/1
2301
NOTE
28055
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
Casing Ventilation
Installing
CAUTION
99/5
2300/1
98/9
2300/2
2300/3
28059
2300/1
2. Clean the float with ethyl alcohol.
NOTE
For casing ventilation from Voith item no.
H53.133214 upwards:
2301
28058
28053
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
7.6
Retarder Ventilation
Item No.
Retarder Ventilation
Requirements
Name
5400
5500
5600
Circlip
DANGER
Heavily soiled or painted-over retarder ventilation!
Retarder reduces braking power after a delay.
5400
5500
CAUTION
5600
r.
ch-N
-Sa
-Nr.
Kd.
ach
h-S
Voit
28062
Aids
Benzine
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
3700
Proportional valve
3800
Damping plate
5200a
Basic Retarder
6400
Heat exchanger
9000
Pressure sensor
25000
Shim
25100
O-ring 14 x 4; replace
25200
25300
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
Item No.
800
Name
Inside part
800
Removing
Use a suitable puller to pull the inside part (800)
28184
Page 83
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
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.
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
5901
5900
Requirements
5901
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
20100
20000
20200
NOTE
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
CAUTION
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if neces-
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
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
6400
H67.1948xx
Pressure test
equipment
DANGER
50/22
Color black
Temperature-resistant
50 C ... + 250 C
6700
6700
6600
6700
6600
28066
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
CAUTION
7600
Hot water!
7500
7300
7300
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.
7300
7500
28067
100
Checking
50/22
7600
7500
7300
7300
CAUTION
6400
7300
7500
28070
A B
28068
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
Heat Exchanger
28174
2. Apply sealing compound to the two sealing surfaces (see dashed lines/figure).
6400
CAUTION
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.
6600
6700
6700
6600
6700
6600
28066
Page 91
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
Heat Exchanger
6400
28175
Page 92
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
7.12
Item No.
Name
2200
2206
3500
3550
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
Requirements
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.
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.
M8
Nr.
hac
Nr.
-S
hKd.
ac
th-S
Voi
M 20 x 1.5
Adapter
50/43
3500
3550
28076
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
Installing
NOTE
2 variants of the pressure control valve are possible:
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.
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).
2206
2200
28078
Page 95
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
7.13
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
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
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
Requirements
Checking
Installing
CAUTION
Lubricate the new sealing ring (1950) with silicone-free and non-corrosive grease.
1900/1
Hot parts!
Hands could be burned.
Work carefully.
Wear protective gloves or use cloths, if necessary.
1900/3
Removing
1. Unscrew the guide (1900/1).
1900/2
28179
Page 97
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
7.14
Item No.
Name
1600
Valve cover;
take installation position into account
1700
O-ring 60 x 3; replace
2100
2105
O-ring 34 x 3; replace
2106
O-ring 54 x 3; replace
3100
NOTE
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
Checking
Removing
Special tools
2100
1
2
153.000052xx
Puller
28158
50/1
Requirements
50/1
CAUTION
Hot parts!
28153
Page 99
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
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 Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
7.15
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.
Requirements
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
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
Temperature
Page 102
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
7.16
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
Requirements
28114
Page 103
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Repair
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
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.
Requirements
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
Item No.
3850
Name
3700
Proportional valve
3800
3850
O-ring 16 x 3; replace
3900
4000
Hex.-head nut M 8;
hexagon insert bit, w.a.f. 13;
18 Nm; replace
3800
3850
3900
4000
3700
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
Requirements
NOTE
Page 107
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Overview of the Tools
8.
8.1
Diagnosis
109
8.2
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
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
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
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
H53.8198xx
Measuring
adapter
99/3
Page 110
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E 153.000188xx I Overview of the Tools
8.2
Activity
Special tools
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)
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
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
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
M8
H53.7712xx
M 20 x 1.5
Impact puller
Adapter
99/5
50/43
Non-return valve
(outlet)
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.