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2
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5 R
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20t/24t
M
BR
n
State: October 1999
67.2964.10
VOITH TURBO
A N T R I E B S T E C H N I K
Operating Instructions
Gearbox Retarder System / GO170 - GO210 with R115E
DaimlerChrysler AG
Powertrain Business Unit
Transmissions
2 Betriebsanleitung Getriebe-Retarder-System
Operating Instructions Gearbox Retarder System 5
Preface 1
A future-oriented concept -
for your benefit
Everyone travelling with the bus expects safety and
comfortable driving. And the person who is driving a bus
expects optimal driving performance and optimal and
comfortable shifting. And who operates a bus expect a
long lifetime and maximum economic efficiency.
Our gearbox retarder system contributes a substantial
part to the realization of these requirements in the daily
bus traffic. Gearbox and retarder form a precise
matching system. Safety and comfort are combined with
the economical benefit.
We always wish you GOOD TRIP!
October 1999
Printed in Germany
DaimlerChrysler AG
Drive Train Division
Gearbox Product Group
Sales
Hauptstrae 107
D-76568 Gaggenau
Telephone 07225 / 61-65 56
Fax 07225 / 61-65 51
e-mail:
sales.transmissions@daimlerchrysler.com
Voith Turbo GmbH & Co. KG
Retarder Product Group
Voithstrae 1
P. O. Box 15 55
D-74555 Crailsheim
Telephone 07951 / 32-401, -422, -694
Fax 07951 / 32-756
e-mail:
retarder@voith.com
6 Operating Instructions Gearbox Retarder System
1 Preface
The Operating Instructions submitted contains important
information for a safe, proper and economical operation
of the gearbox retarder system.
The use of the gearbox retarder system as six-speed
synchronizer gearbox with integrated hydrodynamic
continuous service brake (retarder) is considered as pro-
per use for buses.
The directives for proper use of the gearbox retarder sy-
stem are to be observed strictly by the persons in char-
ge, in particular, by the staff in charge of operation and
repair.
The user is liable for any hazardous situation and dama-
ges resulting from improper use.
Observe the information in particular, the safety infor-
mation, for operation and perform the specified service
work in regular intervals and in time using the specified
fuels.
Only qualified staff is allowed to do the repair and
maintenance work. Enter the work performed in the ser-
vice table provided for this purpose enabling you to claim
full warranty.
Use only original spare parts in the event of a repair, cau-
se only this guarantees that your gearbox retarder sy-
stem meets the traffic safety and the design standard on
shipment.
For the purpose of technical development of our pro-
ducts and to maintain the progress, we reserve the right
for modification of the system illustrated in this instruc-
tion manual and for the applicable technical information
and form.
October 1999 - VOITH TURBO / DaimlerChrysler
Table of Contents
Operating Instructions Gearbox Retarder System 3
1. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. System Identification
3.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Retarder control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Illustrations Gearbox Retarder System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Operation
6.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Retarder
6.2.1 Temperature limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.2 Functions and indications of retarder stage switch, retarder pilot light . . . . . . . . . . . . 22
6.2.3 "Constant speed" function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.4 Pedal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table of Contents
4 Operating Instructions Gearbox Retarder System
7. Maintenance
7.1 Maintenance works / Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2 Gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3 Retarder oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.4 Gearbox oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.5 Retarder oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. Fuel Specification
8.1 Gearbox oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.2 Retarder oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.3 Retarder cooling water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9. Service Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10. Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operating Instructions Gearbox Retarder System 7
Safety Information 2
To guarantee sound operation of the gearbox retard-
er system and to exclude any risks due to improper
handling, please read and follow the safety informa-
tion mentioned on this and the next page as well as
in each chapter!
The safety symbols are explained below:
Warning!
Precautions and safety rules protecting persons from in-
juries or danger to their life.
Caution!
Special information and precautions preventing damage
to the gearbox retarder system or vehicle.
Non-observance leads to exclusion of warranty.
Note
Special information for better handling when operating
the gearbox retarder system and for maintenance work.
8 Operating Instructions Gearbox Retarder System
2 Safety Information
Warning!
Unauthorized modifications on the gearbox retarder
system and the use of spare parts, accessories, attach-
ments and special equipment not tested and released by
us, may have a negative effect on the safety of the com-
plete vehicle, for which liability is excluded for any result-
ing damages.
When in contact with oils, greases and other chemical
substances, e.g. retarder oil, observe the safety regula-
tions applicable to these products.
Be cautious when you are in contact with hot operat-
ing fluids! Danger of burning or scald!
In case of unsafe road conditions (slick ice, snow,
gravel etc.) or risk of aquaplaning operate the retarder
carefully and gradually only. In an extreme case, leave
the retarder switched off!
Observe these precautions, in particular, for vehicles
without ABS system!
Switch off the retarder main switch (if available - see ve-
hicle manual) for vehicles without ABS system.
For empty running vehicles or vehicles without body
(e.g. transfer) operate the retarder carefully!
The switched-on retarder will not lock or secure the
parked vehicle!
In the event of retarder failure or when the tempera-
ture control is effective (see page 20), use the service
brake to adapt the vehicle speed.
Operating Instructions Gearbox Retarder System 9
Safety Information 2
The gearbox retarder system is manufactured to the
latest design standards and approved safety regulations.
Nevertheless, hazards and damage to property may oc-
cur in case of improper use.
The user/owner has the obligation to always operate
the system in sound condition.
In case of malfunctions, observe the relevant informa-
tion.
We will not assume liability for injuries and/or damage
to property, resulting from non-observance of the safety
information, instruction manual or violation of the duty of
care in handling, operation, maintenance and repair of
the retarder.
We are not in the position to give explicit warnings ev-
erywhere in this instruction manual, in case of any think-
able situation, which may lead to a risk of injury for the
operator and/or damage to the system described. It is
therefore absolutely necessary that everyone in charge
of operation and maintenance of the gearbox retarder
system does not put its own safety at risk by the selected
mode of operation and that it has no negative effect on
the gearbox retarder system, in particular, with regard to
the safety.
We are not liable for personal injury and/or damage to
property caused by improper and unprofessional opera-
tion.
Together with the vehicle instruction manual, the in-
struction manual must always be available at the site
where the vehicle is in service. An incomplete or illegible
instruction manual should to be replaced immediately.
The relevant regulations for the prevention of acci-
dents, the other safety engineering and industrial medi-
cine rules generally approved as well as the Road Traffic
Act are to be observed. We are not liable for damages
originating from disregarding these regulations.
10 Operating Instructions Gearbox Retarder System
2 Safety Information
Do not start the vehicle without oil in gearbox and/or
retarder.
In the event of a gearbox failure it is necessary to re-
move the cardan shaft or the two axle stub shafts prior
to towing the vehicle. The openings then need to be cov-
ered according to the vehicle manufacturers specifica-
tions.
Operating Instructions Gearbox Retarder System 11
System identification: gearbox 3.1
The gearbox identification (nameplate) is located on the
side of gearbox retarder system, i.e. on the right-hand
side in driving direction, with the following data (exam-
ple):
Please enter the gearbox data, indicated on your gear-
box retarder system, on the left-hand side nameplate.
Please let us know these data in the event of any queries
or spare parts orders.
Bez.
Code
Fortl. Nr.
M-Code
Variante Nr.
M+P-07A-1705
DAIMLERCHRYSLER
Bez. GO 170-6/8,2
Code G 714.100 L
Fortl. Nr.
M-Code
Variante Nr.
DAIMLERCHRYSLER
unit
series
design
LHD vehicle
gear ratio 1st gear
number of gears
input torque (x 10)
gearbox bus
71 4. 692 L GO 170 - 6 / 8,2
gearbox number
gearbox part number
M+P-07A-1704a
12 Operating Instructions Gearbox Retarder System
3.2 System identification: retarder
The retarder identification (nameplate) is located on the
gearbox retarder system, on the bottom right-hand side
(front) in driving direction, with the following data:
Please enter the retarder data, indicated on your gear-
box retarder system, on the left-hand side nameplate.
Please let us know these data in the event of any queries
or spare parts orders.
CW/Year
Serial-No
M+P-07A-1707
000000
45/1999 KW/Jahr
Voith part number
8-digit number
Year of manufacture
Series number (brake number)
6-digit number
DaimlerChrysler part number
Retarder transmission(i
Ret
)
M+P-07A-1706a
Operating Instructions Gearbox Retarder System 13
System identification: retarder control unit 3.3
The Digiprop control unit identification (nameplate) is lo-
cated on the control unit, with the following data:
1. Voith number
8-digit number
It is possible to derive the software version from the
last two digits.
Example: .12 = version 1.2
2. Code number
3-digit number
(adjustment of control unit)
3. Serial number
5-digit number
also indicating the coding date
4. Client number
(DaimlerChrysler part number)
Please enter the identification data, indicated on your
control unit, on the left-hand side nameplate. Please let
us know these data in the event of any queries or spare
parts orders.
V
o
ith
-N
r.:
5
3
.xxxx.1
2
C
o
d
e
-N
r.:
xxx
S
e
rie
n
-N
r.:
xxxx/ D
a
tu
m
K
u
n
d
e
n
-N
r.:
Voith-Nr.:
Code-Nr.:
Serien-Nr.: Datum:
Kunden-Nr.:
M+P-07A-1617
14 Operating Instructions Gearbox Retarder System
4 Illustrations Gearbox Retarder System
Side view
26/100/116 Screw plug oil screen
(demounting height 120 mm)
26/100/122 Oil filler plug gearbox
26/100/125 Oil drain plug gearbox (bottom side)
26/100/206 Tacho signal
26/250/047 Starter interlock switch *
26/250/068 Inductive pickup for overspeed protection *
26/400/083 Oil temperature sensor gearbox *
26/400/089 Backup lamp switch *
3500 Screw plug with screen
3700 Proportional valve retarder control
* = optional
3700 26/250/068 26/400/089
26/400/083
26/100/125 26/100/125 26/100/122
26/100/116
3500
26/100/206
26/250/047
M+P-07A-1708
Operating Instructions Gearbox Retarder System 15
Illustrations Gearbox Retarder System 4
Top view
25/250/068 Clutch booster
26/150/ Input shaft
26/250/ Clutch wear indicator *
26/250/047 Starter interlock switch *
26/250/068 Inductive pickup for overspeed protection *
26/350/ Gearshift shaft
26/400/089 Backup lamp switch *
3700 Proportional valve retarder control
4100 Oil filler plug retarder
6400 Heat exchanger retarder
* = optional
3700
6400 4100 26/350/
26/400/089
26/250/068
26/250/
25/250/068
26/250/047
26/150/
M+P-07A-1710
16 Operating Instructions Gearbox Retarder System
4 Illustrations Gearbox Retarder System
100/1 Nameplate
26/100/125 Oil drain plugs gearbox
107 Oil drain plug retarder (system)
3500 Screw plug with screen
4200 Oil drain plugs retarder
5500 Retarder ventilation
6400 Heat exchanger retarder
6400/1 Water return connection (example)
6400/2 Water supply connection (example)
107
4200
3500
5500
6400
100/1
6400/1
6400/2
26/100/125
26/100/125
M+P-07A-1709
Operating Instructions Gearbox Retarder System 17
General description 5
Warning!
The switched-on retarder will not secure the parked ve-
hicle!
Note
The retarder braking torque is sustained even when gear
changes are made!
The gearbox retarder system is a six-speed synchro-
mesh gearbox, with a hydrodynamic continuous service
brake (retarder), integrated in the gearbox housing, for
buses with a permissible total weight up to 24 tons.
The connection from gearshift lever to gearbox is made
through linkage or Bowden cables.
The retarder stage switch can be used for control of 5
brake stages - from position 2 to 5 with increasing brake
force.
The function of position 1 is constant speed (control to
constant speed).
As special version, the retarder stage switch may addi-
tionally combined in connection with ABS-system, with a
3- or 4-stage pedal-actuation via the brake valve or a
pressure switch unit of the vehicle service brake.
18 Operating Instructions Gearbox Retarder System
6.1 Operation: gearbox
Warning!
Prior to starting the vehicle engine, push the gearshift le-
ver into idle position (L)!
Caution!
For correct operation of the gearbox it is necessary to
push the clutch pedal all the way down. Hence there
must be no obstacles in the floor area below the foot con-
trols. Observe that any additional floor mats have a good
contact to the floor and are not getting in contact with the
pedals.
Shift without using any force.
Shift to reverse gear (R) only at engine idle speed and
parking vehicle.
It is possible to use a vehicle-specific warning buzzer
and/or a warning lamp, if a too low gear was used for
downshift.
Danger of engine overspeed! Shift to a higher gear!
R 1 3
L
5
2 4 6
M+P-07A-1711
Operating Instructions Gearbox Retarder System 19
Operation: gearbox 6.1
Note
When driving observe the tachometer and the economi-
cal range.
Drive in the highest gear (before downgrades shift in due
time to reverse gear).
Prior to retarder braking shift to the lowest possible gear
to reach engine rated speed (see chapter 6.2.1: Retard-
er operation temperature limit ).
Skip the gears, if possible, and change gears only, if re-
quired.
Operate the clutch pedal to change gears and move the
gearshift lever to a position as illustrated in the scheme
on page 18.
Shift the lever from idle position (L) to the left front to
change to reverse gear.
20 Operating Instructions Gearbox Retarder System
6.2.1 Operation retarder: temperature limit
During braking with the retarder integrated in the gear-
box, deceleration is converted into heat. To dissipate this
heat, part of the oil in the working chamber is pumped
continuously by the rotor through a heat exchanger and
fed back into the retarder circuit.
In the heat exchanger the heat of oil is transferred to the
vehicle cooling water and dissipated through the vehicle
cooling system.
The cooling water and oil temperature are monitored by
one temperature sensor each transmitting this informa-
tion to the retarder control unit. This guarantees that the
maximum permissible temperatures for cooling water
and oil are not exceeded.
The control unit includes vehicle-specific cooling water
oil temperature limit settings.
To prevent that these temperature limits are exceeded
during retarder operation, the retarder braking torque is
adapted optimally for protection and effective utilization
of vehicle cooling system and retarder.
With already significantly reduced braking torque the re-
tarder pilot light starts flashing.
Caution!
Observe the following when the retarder pilot light is
flashing or the temperature limit is effective:
Adjust the vehicle speed using the service brake and
change to the lowest possible gear (increase the engine
speed).
Keep this driving condition until the retarder regained its
full power.
Operating Instructions Gearbox Retarder System 21
Operation retarder: temperature limit 6.2.1
By driving or operating the retarder properly you can in-
crease and/or secure the vehicle cooling capacity and
thus the availability of the retarder.
How?
On retarder braking shift the gearbox down to reach
engine rated speed!
Thus:
High delivery rate of water pump
High fan speed
Result:
It is possible to make optimum use of the vehicle cool-
ing system performance!
Fuel consumption is not affected by the high engine
speed, as the throttle of the fuel injection system is
closed when the engine is in overrun.
M+P-07A-1624
1
2
3
4
5
10
15
u/pm
20
25
30
M+P-07A-1624
22 Operating Instructions Gearbox Retarder System
6.2.2 Operation retarder:
functions and indications of retarder stage switch, retarder pilot light
A Retarder pilot light
(vehicle-specific installation site)
B Retarder stage switch
(vehicle-specific installation site)
0 Retarder OFF
1 Constant speed
2 Brake stage 1
3 Brake stage 2
4 Brake stage 3
5 Brake stage 4
Caution!
Operate the retarder stage switch only step-by-step to
reach the required braking torque (do not force
through )!
In an emergency situation a force through of the retard-
er stage switch is permitted.
To reduce the actual braking torque, several stages can
be left out at once with the retarder stage switch.
M+P-07A-1590
B
A
M+P-07A-1590
0
1
2
3
4
5
Operating Instructions Gearbox Retarder System 23
Operation retarder:
functions and indications of retarder stage switch, retarder pilot light 6.2.2
Note
In case of very low outside temperatures the braking ac-
tion on first retarder braking starts with a response delay
after starting to drive.
For vehicles with zero gas switch the constant speed
function or the active brake stage is cleared on applica-
tion of the gas pedal. After releasing the pedal, the new
momentary constant speed is stored or the previously
applied brake stage is reactivated.
For vehicles with cruise control it is possible to clear
cruise control automatically, dependent on the equip-
ment, by operating the constant speed function .
The retarder pilot light has the additional function of fault
indication to be able, in the event of a fault, to also find
the fault in the electronic system without service unit.
Display of a fault, which may exist, is possible by a flash
code.
Caution!
Only qualified staff is allowed to activate the flash code
and to perform any repair work which might be neces-
sary.
24 Operating Instructions Gearbox Retarder System
6.2.2 Operation retarder:
functions and indications of retarder stage switch, retarder pilot light
OFF (symbol for retarder pilot
light may differ from vehicle to
vehicle)
Ignition ON
Light test:
Retarder pilot light
5 sec. steady light
Steady light:
constant speed
Steady light:
Brake stages 1 to 4
Flash light:
Temperature limit
0
2
3
4
5
1
0
2
3
4
5
1
0
2
3
4
5
1
0
2
3
4
5
1
Steady light position 0 to 5
Minor fault:
Retarder brakings partly pos-
sible with reduced braking
torque.
Consult a specialized work-
shop!
Steady light position 0 to 5
Major fault:
Retarder braking no longer
possible the retarder is
switched off.
Only continue driving with
considerably reduced
speed - consult immediate-
ly a specialized workshop!
0
2
3
4
5
1
0
2
3
4
5
1
Operating Instructions Gearbox Retarder System 25
Operation retarder: constant speed function 6.2.3
1 Adjust the speed.
2 At the desired speed switch on constant speed .
The retarder keeps this vehicle speed constant within
maximum braking torque.
Should the vehicle accelerate in spite of constant
speed , it is necessary to apply the service brake in
addition. Continued shifting to gear stage 5 does not
increase the braking action.
When leaving the constant speed lever position,
the automatic control is cleared immediately.
3 Switch off the retarder or adjust to the traffic situation
using a brake stage.
M+P-07A-1618
1
1
10 km
6
%
2
3
0
2
3
4
5
0
2
3
4
5
1
0
2
3
4
5
1
M+P-07A-1618
26 Operating Instructions Gearbox Retarder System
6.2.4 Pedal Operation
A Retarder
B Retarder and Service Brake
1 Brake Stage 1 *
2 Brake Stage 2 *
3 Brake Stage 3 *
* The operated brake stages via the pedal operation normally
are identical with the brake stages operated via the hand
operation.
M+P-07A-1591
3
B
A
2
1
M+P-07A-1591
Operating Instructions Gearbox Retarder System 27
Pedal Operation 6.2.4
Note
The graphic shows the 3-stage variant, a 4-stage variant
also is possible.
The main switch Pedal Operation ON-OFF is located at
the dashboard.
ON: The retarder is ready to operate
OFF: i.e. at unsafe road conditions
The higher braking torque is valid with combined hand-
or pedal-operation in each case.
In case of low temperatures outdoors, the braking effect
starts late when braking the first time after starting the
vehicle.
The function Constant Speed can not be selected via
the pedal plate.
The retarder is operated via a 3-stage or 4-stage pedal
operation of the service brake. The maximum braking
torque will be reached in the maximum position.
Pedal plate in position 0:
The retarder is switched off
the retarder pilot light is without indication.
Pedal plate in position 1 to 3 or 1 to 4
The brake stages 1 to 3 or 1 to 4 are tuned accordingly
the light of the retarder pilot light comes on continuously.
28 Operating Instructions Gearbox Retarder System
6.2.4 Pedal Operation
Special functions
at combined Hand-, pedal operation
(without pushbutton for function Constant Speed )
Retarder stage switch in position 1
Constant Speed,
Pedal plate in position 1:
The function constant speed will be cancelled, if first
selected in position 1 with the retarder stage switch and
than operated to the retarder via the pedal plate. After re-
leasing the pedal plate the new momentary speed will be
memorized, assumed that the retarder stage switch
stays unchanged in position 1
the light of the retarder pilot light comes on continuously.
The following operation conditions can be indicated
additionally by the retarder pilot light:
Without Indication:
The retarder is switched off, no fault.
Retarder Pilot Light flashing
- when retarder is operated:
The temperature limitation is effective the retarder
reduces its braking torque. Therefore read the notes on
pages 20 to 21!
Retarder Pilot Light on continuously
- at testing the light:
When vehicle ignition is switched on for approx. 5 secs.
- in Position 0 to 3 or 0 to 4 (minor fault):
Retarder brakings partly possible with reduced braking
torque.
Contact specialized work shop!
Operating Instructions Gearbox Retarder System 29
Pedal Operation 6.2.4
- in Position 0 to 3 or 0 to 4 (serious fault):
Retarder brakings are not possible any longer the
retarder is switched off.
Continue driving only with clear reduced speed
contact immediately specialized work shop!
The retarder pilot light has the additional function of error
indication. The retarder pilot light enables a
troubleshooting in the electronic system without using
the service unit. The indication of an error can be
realized by the flash code of the retarder pilot light.
Caution!
The activation of the flash code as well as maintenance
works must be carried out only by qualified and
specialized personnel.
30 Operating Instructions Gearbox Retarder System
7.1 Maintenance: maintenance works / oil change intervals
Maintenance works
The following works are to be performed on each oil
change (gearbox and retarder):
clean oil screen (gearbox)
Clean screen for pressure control valve (retarder)
check fastening screws on retarder heat exchanger
check all screw plugs for leaks and proper seat
visual inspection for any damages and leaks which
might exist
Please enter the following data in the service overview of
these operating instructions:
performed maintenance works
used oil type for oil change
Operating Instructions Gearbox Retarder System 31
Maintenance: maintenance works / oil change intervals 7.1
1) according to fuel specification, page 48-51
2) according to fuel specification, page 52-54
3) according to fuel speciflication, page 54
4) If the specified operating performance is not
achieved within 1 year, it is necessary to change
the oil.
5) If the specified operating performance is not
achieved within 2 years, it is necessary to change
the oil.
6) The oil change intervals of the retarder oils, listed
under 2), may be adjusted to the oil change intervals
of the gearbox mineral oils.
Gearbox Retarder
6)
Mineral oil
1)
Synthetic oil
1)
Mineral oil
2)
Synthetic oil
2)
Synthetic oil
3)
Normal duty
100 000 km
4)
300 000 km
5)
100 000 km
4)
300 000 km
5)
300 000 km
5)
Heavy duty
50 000 km
4)
300 000 km
5)
50 000 km
4)
300 000 km
5)
300 000 km
5)
32 Operating Instructions Gearbox Retarder System
7.1 Maintenance: maintenance works / oil change intervals
1. Normal duty
Example:
long-distance traffic
2. Heavy duty
Duties exceeding the normal limit.
Examples:
Applications in regions with high outside temperatures
(e.g. Saudi Arabia)
High permissible total weight at low rated engine pow-
er (< 8 PS/ton)
Frequent uphill/downhill roads
Extremely short distances with many road down-
grades
It is possible to fall below the specified maximum values,
if this results in an improvement of operating sequences
relative to the overall maintenance of vehicle.
In case of a total service life of retarder of more than 10
%, relative to the vehicle operating performance as well
as other factors, not mentioned in here, also affecting the
aging of retarder oil, it is necessary to shorten the spec-
ified oil-changing intervals individually.
In case of application in extremely cold zones, use oils of
corresponding low viscosity.
In case of doubt, please consult our Service Department.
Operating Instructions Gearbox Retarder System 33
Maintenance: gearbox oil level check 7.2
26/100/122 Oil filler plug
Inbus, w.a.f. 14 ............................. T
A
= 47 N
26/100/128 Sealing ring A24x29 ...................... renew
26/100/128
26/100/122
M+P-07A-1716
34 Operating Instructions Gearbox Retarder System
7.2 Maintenance: gearbox oil level check
Note
Four sound function of gearbox it is important to adhere
the specified oil service filling and that only oils are used
released by the fuel specification, chapter 7.1: Oil
change intervals and chapter 8.1: Fuel specification
gearbox oil specification .
Note
Check the oil with the vehicle in horizontal position.
For oil level check, the gearbox oil must have working
temperature.
Warning!
Oil filler plug (26/100/122) is hot (oil temperature)!
1. Screw out the oil filler plug (26/100/122) and remove
the sealing ring (26/100/128).
The oil level is correct when it reached the bottom
edge of taphole (see illustration page 32).
2. Fill in slowly any lacking oil through the hole of oil fill-
er plug according to fuel specification, chapter 7.1:
Oil change intervals and chapter 8.1: Fuel specifi-
cation gearbox oil specification .
Note
In the event of any lacking oil, check the gearbox for a
possible external leak.
3. Screw in the oil filler plug with a new sealing ring and
tighten it.
Oil filler plug (26/100/122): 47 Nm
Operating Instructions Gearbox Retarder System 35
Maintenance: retarder oil level check 7.3
109 Oil check plug
Inbus, w. a. f. 12 ............. T
A
= 65 Nm (80 Nm)
4100 Oil filler plug
Inbus, w. a. f. 17 ............. T
A
= 100 Nm (150 Nm)
107 Oil drain plug
Inbus, w. a. f. 12............. T
A
= 65 Nm (80 Nm)
4200 Oil drain plugs
Inbus, w. a. f. 12............. T
A
= 65 Nm (80 Nm)
4100
109
M+P-07A-1713
4200
107
M+P-07A-1712
36 Operating Instructions Gearbox Retarder System
7.3 Maintenance: retarder oil level check
Caution!
For sound retarder operation it is important to adhere the
specified oil level of 7.0 liters and to only use oils re-
leased by the fuel specification, chapter 7.1: Oil change
intervals and chapter 8.2: Fuel specification retarder
oil specification .
Note
Check the oil level with the vehicle in horizontal position.
For oil level check, the retarder oil must have operating
temperature.
Caution!
There are two possible variants of the screw plugs (107,
4100, 4200):
A) with integrated FPM-sealing ring;
corresponding standard design on printing
Performing the oil level check, the integrated sealing
rings have to be checked for any damage; replace the
complete screw plug, if necessary.
B) variant with copper sealing ring attached as loose
part.
In these operating instructions exclusively the variant A
(standard design) is described.
For screw plugs with copper sealing rings attached as
loose part (variant B) the tightening torques given in
brackets are valid. The copper sealing rings are to be re-
placed generally.
Operating Instructions Gearbox Retarder System 37
Maintenance: retarder oil level check 7.3
Two variants are available for selection of oil level check:
A. Volumetric measuring method
1. Put a clean oil collecting pan under the retarder.
Warning!
The oil drain plugs (107, 4200) and oil filler plug (4100)
are hot (oil temperature)!
While the oil level is being checked, make sure that no
constant-air pressure is acting in the retarder. The re-
tarder and the ignition must have been switched off!
2. Remove the oil drain plugs (107, 4200) and drain the
oil into the oil collecting pan.
3. Check the integrated sealing rings of the oil drain
plugs (107, 4200) for any damage; replace the oil
drain plugs, if necessary.
4. Screw the oil drain plugs tight.
Oil drain plugs (107, 4200): 65 Nm (80 Nm)
5. Measure the volume of drained oil.
6. Add the lacking oil which you might determine during
volumetric measurement according to the fuel speci-
fication, chapter 7.1: Oil change intervals and chap-
ter 8.2: Fuel specification retarder oil specification .
38 Operating Instructions Gearbox Retarder System
7.3 Maintenance: retarder oil level check
Note
Should you detect a lack of oil fill, check the retarder for
a possible external leak.
Warning!
The retarder may only be filled through the hole for the
oil filler plug (4100)!
7. Refill oil slowly through the hole for the oil filler plug
(4100) over a duration of more than 3 minutes.
This working step is necessary for correct ventilation
of the retarder system.
8. Check the integrated sealing ring of the oil filler plug
(4100) for any damage; replace the oil filler plug, if
necessary.
9. Screw the oil filler plug tight.
Oil filler plug (4100): 100 Nm (150 Nm)
Caution!
After the oil level check engage the retarder during driv-
ing with min. 50 km/h at least briefly 5 times for approx.
5 secs. each time in stage position 2 (corresponds to
braking stage 1).
Operating Instructions Gearbox Retarder System 39
Maintenance: retarder oil level check 7.3
B. Using the oil check plug
1. Vehicle ignition OFF , then rest to ON .
2. Operate the retarder at standstill in braking stage 2
(corresponds to braking stage 1) and switch it off after
approx. 5 secs.
Repeat this procedure twice.
3. Switch off the retarder and wait for 5 minutes.
Warning!
The oil check plug (109) and oil filler plug (4100) are hot
(oil temperature)!
While the oil level is being checked, make sure that no
constant-air pressure is acting in the retarder. The re-
tarder and the ignition must have been switched off!
4. Unscrew the oil check plug (109).
The oil level is correct when it reached the lower edge
of the oil check hole (see illustration page 35).
Note
In the event of any lacking oil, check the retarder for a
possible external leak.
Caution!
The retarder may only be filled through the hole for the
oil filler plug (4100)!
5. Fill in any lacking oil slowly through the hole for the
oil filler plug (4100) according to fuel specification,
chapter 7.1: Oil change intervals and chapter 8.2:
Fuel specification retarder oil specification .
40 Operating Instructions Gearbox Retarder System
7.3 Maintenance: retarder oil level check
6. Check the integrated sealing ring of the oil level
check plug for any damage; replace the oil level
check plug, if necessary.
7. Screw the oil check plug tight.
Oil check plug (109): 65 Nm (80 Nm)
8. Check the integrated sealing ring of the oil filler plug
for any damage; replace the oil filler plug, if neces-
sary.
9. Screw the oil filler plug tight.
Oil filler plug (4100): 100 Nm (150 Nm)
Operating Instructions Gearbox Retarder System 41
Maintenance: gearbox oil change 7.4
26/100/107 Oil screen.......................................clean
26/100/113 Spring
26/100/116 Screw plug oil screen.....................T
A
= 60 Nm
Inbus, w.a.f. 17
26/100/119 Sealing ring A38x46.......................replace
26/100/122 Oil filler plug ..................................T
A
= 47 Nm
Inbus, w.a.f. 14
26/100/125 Oil drain plugs ...............................T
A
= 47 Nm
Inbus, w.a.f. 14
26/100/128 Sealing ring A24x29.......................replace
26/100/116
26/100/125
26/100/107
26/100/119
26/100/122
26/100/128
26/100/128
26/100/128
26/100/125
M+P-07A-1715a
26/100/113
42 Operating Instructions Gearbox Retarder System
7.4 Maintenance: gearbox oil change
Warning!
Dispose of drained oil in a professional manner!
Observe the statutory provisions!
Caution!
For sound gearbox function it is important to observe the
specified oil fill and to only use oils released by the fuel
specification, chapter 7.1: Oil change intervals and
chapter 8.1: Fuel specification gearbox oil specifica-
tion .
Note
For draining the gearbox oil must have operating tem-
perature.
Oil fill
Service fill (oil change) ................................ 12.5 liters
Initial fill ....................................................... 13.0 liters
1. Put a clean oil collecting pan under the gearbox.
Warning!
Oil drain plugs (26/100/125) are hot (oil temperature)!
2. Unscrew the oil drain plugs (26/100/125), remove the
sealing rings (26/100/128) and drain the oil.
3. Screw the oil drain plugs tight with new sealing rings.
Oil drain plugs (26/100/125): 47 Nm
4. Unscrew the screw plug (26/100/116) and remove
the sealing ring (26/100/119).
Operating Instructions Gearbox Retarder System 43
Maintenance: gearbox oil change 7.4
5. Clean oil screen (26/100/107) using a corresponding
cleaning agent (benzine) and blow out using com-
pressed air. Check the cleaned oil screen for damage
and replace it, if necessary.
6. Screw oil screen (26/100/107) with spring (26/100/
113) in the hole of the screw plug (26/100/116).
7. Screw the screw plug (26/100/116) with new sealing
ring (26/100/119) tight.
Screw plug with oil screen (26/100/116): 60 Nm
8. Unscrew oil filler plug (26/100/122) and remove the
sealing ring (26/100/128).
9. Fill in slowly oil through the hole for the oil filler plug,
according to the fuel specification, chapter 7.1: Oil
change intervals and chapter 8.1: Fuel specification
- gearbox oil specification and oil fill, page 42.
10.Screw the oil filler plug tight with new sealing ring.
Oil filler plug (26/100/122): 47 Nm
44 Operating Instructions Gearbox Retarder System
7.5 Maintenance: oil change of retarder
3500 Screw plug with screen
Inbus, w.a.f. 17.................. T
A
= 100 Nm (150 Nm)
4100 Oil filler plug
Inbus, w.a.f. 17.................. T
A
= 100 Nm (150 Nm)
107 Oil drain plug
Inbus, w.a.f. 12..................T
A
= 65 Nm (80 Nm)
4200 Oil drain plugs
Inbus, w.a.f. 12..................T
A
= 65 Nm (80 Nm)
4100
3500
M+P-07A-1714a
4200
107
M+P-07A-1712a
Operating Instructions Gearbox Retarder System 45
Maintenance: retarder oil change 7.5
Warning!
Dispose of drained oil in a professional manner!
Observe the statutory provisions!
Caution!
For sound retarder operation it is necessary to adhere
the specified oil fill, see below. It is only allowed to use
oils released by the fuel specification, chapter 7.1: Oil
change intervals and chapter 8.2: Fuel specification
retarder oil specification !
Note
For draining the retarder oil must have operating temper-
ature!
Oil fill
Service fill (oil change) ................................. 7.0 liters
Initial fill ....................................................... 7.8 liters
Caution!
There are two possible variants of the screw plugs (107,
3500, 4100, 4200):
A) with integrated FPM-sealing ring;
corresponding standard design on printing
Performing the oil level check, the integrated sealing
rings have to be checked for any damage; replace the
complete screw plug, if necessary.
B) variant with copper sealing ring attached as loose
part.
In these operating instructions exclusively the variant A
(standard design) is described.
For screw plugs with copper sealing rings attached as
loose part (variant B) the tightening torques given in
brackets are valid. The copper sealing rings are to be re-
placed generally.
46 Operating Instructions Gearbox Retarder System
7.5 Maintenance: oil change of retarder
1. Put a clean oil collecting pan under the retarder.
Warning!
The oil drain plugs (107, 4200) are hot (oil temperature)!
While the oil is being drained, make sure that no con-
stant-air pressure is acting in the retarder. The retarder
and the ignition must have been switched off!
2. Remove the oil drain plugs (107, 4200) and drain the
oil.
3. Check the integrated sealing rings of the oil drain
plugs for any damage; replace the oil drain plugs, if
necessary.
4. Screw the oil drain plugs tight.
Oil drain plugs (107, 4200): 65 Nm (80 Nm)
5. Unscrew the screw plug with screen (3500) out of the
retarder housing.
6. Clean the screen in the screw plug using a corre-
sponding cleaning agent (benzine) and blow it out us-
ing compressed air.
7. Check the integrated sealing ring of the screw plug
with screen for any damage; replace the screw plug,
if necessary.
8. Screw the screw plug with screen tight.
Screw plug with screen (3500): 100 Nm (150 Nm)
9. Unscrew the oil filler plug (4100).
Operating Instructions Gearbox Retarder System 47
Maintenance: retarder oil change 7.5
Caution!
The retarder may be only filled through the hole of the oil
filler plug (4100)!
10.Fill in oil slowly through the hole for the oil filler plug,
according to fuel specification, chapter 7.1: Oil
change intervals and chapter 8.2: Fuel specification
- retarder oil specification and oil fill, page 45, over a
duration of more than 3 minutes.
This working step is necessary for correct ventilation
of the retarder system.
11.Check the integrated sealing ring of the oil filler plug
(4100) for any damage; replace the oil filler plug, if
necessary.
12.Screw the oil filler plug tight.
Oil filler plug (4100): 100 Nm (150 Nm)
Caution!
After the oil lchange engage the retarder during driving
with min. 50 km/h at least briefly 5 times for approx. 5
secs. each time in stage position 2 (corresponds to brak-
ing stage 1).
48 Operating Instructions Gearbox Retarder System
8.1 Fuel specification: gearbox oil specification
Warning!
Hazard of intoxication!
Fuels are harmful to the health!
Consult a physician immediately after swallowing fuel!
Keep fuels away from children!
Mineral oil for gearbox application
SAE 80, 80W, 80W/85W
Oil type Supplier
Addinol Gearbox Oil GS Addinol Mineral Oil, Krumpa
Agip Rotra Hy DB Agip Petroli, Rom/Italy
Antar EP Elf Lubrifiants, Paris/France
Aral Gearbox Oil EP Aral Lubricants, Bochum
Armorine BM
Armorine,
Lanester Cedex/ France
Aseol Gepress 11-508 Shell Aseal, Bern/Switzerland
Autol Gearbox Oil D8 Agip Schmiertechnik, Wrzburg
Avia Gear Oil MZ Avia Minerall, Munich
Aviaricon Gold MZ Emil Finke Minerallwerk, Bremen
BayWa Multipurpose
Gearbox Oil
BayWa, Munich
BP Energear EP BP Oil International, London/GB
BP Energear FE GL4 BP Oil International, London/GB
BP Gear Oil EP BP Oil International, London/GB
Operating Instructions Gearbox Retarder System 49
Fuel specification: gearbox oil specification 8.1
Mineral oil for gearbox application
SAE 80, 80W, 80W/85W
Oil type Supplier
Calpam Multipurpose Gear Oil
Calpam Minerall-Gesellschaft,
Aschaffenburg
Caltez Universal Gear Oil HD Caltez (UK) Limited, London/GB
Carrier Hykomol
MOL Hungarian Oil and Gas Co.,
Kornrom/Hungary
Castrol EP Castrol, Swindon/GB
Condat Gear A Condat, Chasse-sur Rhne/France
CS 80 M-EP Repso Distribucin, Madrid/Spain
Deagear EP-A DEA Minerall, Hamburg
Dearon EP-A DEA Minerall, Hamburg
Deutz Oil GO-MP Klckner Energiehandel, Cologne
Divinal Multipurpose
Gearbox Oil
Zeller+Gmelin, Eislingen
Dragon Gear TM
Ssang Yong Oil Refining,
Seoul/Rep. of Korea
Ellmo-Multipurpose
Gearbox Oil
Eller-Montan-Comp., Duisburg
Engen Gearlube HP
Engen Petroleum,
Cape Town/South Africa
Oil type Supplier
Ertoil Transmissiones F Ertoil, Madrid/Spain
Esso Gear Oil GP-D Esso, Hamburg
Fina Pontonic N Fina Europe, Brussels/Belgium
Frontol Gearbox Oil MZ M BP Schmierstoff, Hamburg
Fuchs Titan Gear MP Fuchs Minerallwerke, Mannheim
Galp Transoil
Petroleos de Portugal, Petrogal,
Lisbon/Portugal
Geartex EP-A
Texaco Services (Europe),
Brussels/Belgium
Gulf Gear Lubricant (EP) SAEL, Madrid/Spain
Gulf Ultragear 4000 (GB) Gulf Oil (GB), Cheltenham/GB
H.o.B. Gearbox Oil ML H. o.. Burrenkopf, Cologne
Hafa MPB Hafa, Paris/France
Homberg Gearbox Oil MZ J. & A. Homberg, Wuppertal
Hyperol Multipurpose Gearbox
Oil
Hyperol Minerall-Vertrieb, Stuttgart
Igol Trans EPA Igol France, Paris/France
50 Operating Instructions Gearbox Retarder System
8.1 Fuel specification: gearbox oil specification
Mineral oil for gearbox application
SAE 80, 80W, 80W/85W
Oil type Supplier
Ina Transmol DB
INA Rafinerija Zagreb,
Zagreb/Croatia
IP Pontiax DB Italiana Petroli, Genova/Italy
Kompressol Multipurpose
Gearbox Oil
Kompressol-l, Cologne
Leprinzol SP Leprince & Siveke, Herford
Mac MP Gearbox Oil Deutsche Shell, Hamburg
megol Multipurpose
Gearbox Oil GL4
Meguin, Saarlouis
MHG Manual Gearbox Oil EP MHG, Sulzbach-Rosenberg
Mobilube GX-A Mobil Schmierstoff, Hamburg
Motorex Gear Oil EP Bucher, Langenthal/Switzerland
Neste Gear EP
Neste Oy Lubrication,
Espoo/Finland
Oest Multipurpose Gearbox Oil Oest Minerallwerke, Freudenstadt
OMV Gear Oil MP OMV, Vienna/Austria
Optimol Multipurpose
Gearbox Oil
Optimol lwerke Industrie GmbH,
Munich
Oil type Supplier
Orly XP Luna
Orly International,
Vieux-Thann/France
P. O. Keban EP MB
Petrol Ofisi,
Bakanlikar-Ankara/Turkey
Panolin EP Gear GL4 Panolin, Madetswill/Switzerland
Parnas Parnalube GP Parnas/Saksan, Athens/Greece
Pennasol Multipurpose
Gearbox Oil GL4
Minerall-Raffinerie Dollbergen
Petrol Transol GL4 Petrol d. d., Ljubljana/Slovenia
Petramin Gear Oil MB
Petramin Lubricating Oil,
Jeddah/Saudi Arabia
Q8 T 35
Kuwait Petroleum,
Hoogvliet RT/Netherlands
Raloy Transmission EP
Raloy Lubricantes,
Santiago Tianguistenco/Mexico
Rexol MBG Ryazan Oil Refinery, Ryazan/Russia
Rored EPA Pertamina, Jakarta/Indonesia
Operating Instructions Gearbox Retarder System 51
Fuel specification: gearbox oil specification 8.1
Mineral oil for gearbox application
SAE 80, 80W, 80W/85W
Synthetic oil for gearbox application
Oil type Supplier
Selectol Multipurpose
Gearbox Oil
Kppler, Stuttgart
Shell Spirax MA Shell International, London/GB
Sonolgear DBM Sonol Israel, Haifa/Israel
Spirol XEP
Bharat Petroleum Corpn.,
Bombay/India
Tor Multi Purpose Gearbox Oil
De Oliebron,
Zwijndrecht/Netherlands
Total EP Total Deutschland, Dsseldorf
Tranself EP Elf Lubrifiants, Paris/France
Triathlon Gear Wrth, Knzelsau
Unil EP Unil Deutschland, Bremen
Unil Opal Gear EP Unil-Opal, Rueil-Malmaison/France
Valvoline X-18
Valvoline International Europe,
Dardrecht/Netherlands
Veba Movara EP-Gearbox Oil Veba l, Gelsenkirchen
Veedol Multigear Veedol International, Swindon/GB
Westfalen Grado Gearbox Oil Westfalen AG, Mnster
Oil type Supplier
Wintershall Wiolin
Multipurpose Gearbox Oil
Schmierstoffraffinerie Salzbergen
Wisura GL Wisura Minerallwerk, Bremen
WLZ-Raiffeisen Multipurpose
Gearbox Oil
WLZ-Raiffeisen, Stuttgart
York 791
Ginouves Georges
La Farlde/France
Zenex Gear Oil ZP Zenex Oil, Rivonia/South Africa
Oil type Supplier
MB 235.11 Manual
Gearbox Oil
A 001 989 2803
Daimler-Chrysler AG, Stuttgart
Veedol Synmesh-AT Burrmah Oil Technology
Castrol Syntrans-AT Burrmah Oil Technology
Deagear Synth DEA Minerall GmbH
52 Operating Instructions Gearbox Retarder System
8.2 Fuel specification: retarder oil specification
For the retarder application authorized oil types must meet the following specification:
1)
Respecting the oil type selection, the statements of the vehicle manufacturer are valid.
If no statements are available, the oil types documentated on the following pages are to be used.
2)
Only the synthetic oil documentated on page 54 may be used.
Classification Code
as per DIN 51502
Viscosity class
as per DIN 51511
Performance
class
Single-grade
mineral oil
1)
HD SAE 10W
SAE 20W 20
SAE 30
API - CC/SF
and higher
Synthetic oil /
part-synthetic oil
1)
HD SAE 0W40
SAE 5W30
SAE 5W40
SAE 5W50
SAE 10W30
SAE 10W40
API - CC/SF
and higher
Synthetic oil
2) HC SAE 75W-80W see page 54
Operating Instructions Gearbox Retarder System 53
Fuel specification: retarder oil specification 8.2
Warning!
Hazard of intoxication!
Fuels are harmful to the health!
Consult a physician immediately after swallowing fuel!
Keep fuels away from children!
Mineral oil for retarder application
SAE 10W, 20W20, 30
Oil type Supplier
Agip Diesel Sigma S Agip
Agip Motoroil HD Agip
Aral Basic Turboral Aral
Avia Special HDC Avia
Avia Motor Oil HD Avia
BP Vanellus C3 BP
Castrol CRD-DB Burmah Oil
DEA Cronus Super DEA
DEA Rigis DEA
Elf Performance XC Elf
Elf Performance XR Elf
Elf Performance 3D Elf
Elf Performance Super D Elf
Essolube X 301 Esso
Essolube X 201 Esso
54 Operating Instructions Gearbox Retarder System
8.2 Fuel specification: retarder oil specification
Mineral oil for retarder application
SAE 10W, 20W20, 30
Synthetic oil for retarder application
SAE 75W-80W
Oil type Supplier
Fina Kappa Super Fina
Fina Kappa TC Fina
SAE 30 Series III Krafft
Mobil Delvac 1300-Series Mobil Oil
Extra Motorex
Cobra Motorex
Multimiles R/5 mono Multimiles
Rapsol Series 3 SAE 10W Rapsol
Rapsol Series 3 SAE 30 Rapsol
CS Mizar Series 3 SAE 10W Rapsol
CS Mizar Series 3 SAE30 Rapsol
CS Mizar HD SAE 20W Rapsol
Shell Rimula X Monograde Shell
Shell Rotella MX Shell
Glap Diesel Sofomil
Glap Orion Sofomil
Oil type Supplier
Wintershall Rekord 10W SRS
Wintershall Rekord 20W-20 SRS
Wintershall Rekord 30 SRS
Havoline Motor Oil Texaco
Ursa Super LA Texaco
Total rubia S Total
Unocal Firebird HD Motor Oil Unocal
Oil type Supplier
Emgard MTF Henkel
Operating Instructions Gearbox Retarder System 55
Fuel specification: cooling water quality 8.3
Warning!
Hazard of intoxication!
Fuels are harmful to the health!
Consult a physician immediately after swallowing fuel!
Keep fuels away from children!
Prevent that the coolant is lead into the sewerage sys-
tem. Reuse or dispose it.
The statutory or waste water disposal regulations may
vary from country to country and need to be observed on
disposal of used coolants.
Prior to using the coolant observe the safety data sheets
and product information of the relevant suppliers.
The coolant is a mixture of water and corrosion preven-
tive/antifreeze. For reasons of protection against corro-
sion and to increase the boiling point it is necessary to
keep the coolant the whole year in the cooling system.
Change the coolant every three years, as the corrosion
protection is deteriorating.
Water
Water alone is not permitted as coolant, even when an-
tifreeze qualities are not required. However, the water of
coolant should meet specific requirements, which fre-
quently, but not always, are fulfilled by drinking water. If
the water quality is not sufficient, the water needs treat-
ment.
Please contact us if you should need any information.
56 Operating Instructions Gearbox Retarder System
8.3 Fuel specification: cooling water quality
Corrosion preventive/antifreeze
To avoid any damage in the retarder cooling system:
Use only a corrosion preventive/antifreeze, specifically
released by the supplier for aluminium. It is not allowed
to use pure glycols.
On refill (after loss of coolant) a corrosion preventive/
antifreeze of 50 vol.-% (antifreeze up to -37 C) must be
guaranteed.
Do not use more than 55 vol.-% (= max. antifreeze)
corrosion preventive/antifreeze. This reduces the anti-
freeze quality and results in a poor heat dissipation.
Mixture ratio of coolant
In exceptional cases, when a corrosion preventive/anti-
freeze is not available and an antifreeze is not required
(for example in tropical climate), it is necessary to use
1 vol.-% = 10 cm
3
/liters treatment agent. In this case it is
necessary to change the coolant every year.
Regarding any further information please refer to the
Voith cooling water list, which you can obtain from Voith
Turbo under Voith Art. No. 67.2224.10.
Antifreeze
up to C
Water
vol.-%
Corrosion preven-
tive / antifreeze
vol.-%
-37 50 50
approx. -45 45 max. 55
Operating Instructions Gearbox Retarder System 57
Service Overview 9
kilometer reading..............................
Oil change
Gearbox (oil type): Mineral oil Synthetic oil
Retarder (oil type): Mineral oil Synthetic oil
Oil screen(gearbox) cleaned
Screen pressure control valve (retarder) checked
Fastening screws on retarder heat exchanger checked
Screw plugs checked
Visual inspection performed
Company stamp / Signature
Date: ........................................
kilometer reading..............................
Oil change
Gearbox (oil type): Mineral oil Synthetic oil
Retarder (oil type): Mineral oil Synthetic oil
Oil screen(gearbox) cleaned
Screen pressure control valve (retarder) checked
Fastening screws on retarder heat exchanger checked
Screw plugs checked
Visual inspection performed
Company stamp / Signature
Date: ........................................
kilometer reading..............................
Oil change
Gearbox (oil type): Mineral oil Synthetic oil
Retarder (oil type): Mineral oil Synthetic oil
Oil screen(gearbox) cleaned
Screen pressure control valve (retarder) checked
Fastening screws on retarder heat exchanger checked
Screw plugs checked
Visual inspection performed
Company stamp / Signature
Date: ........................................
kilometer reading..............................
Oil change
Gearbox (oil type): Mineral oil Synthetic oil
Retarder (oil type): Mineral oil Synthetic oil
Oil screen(gearbox) cleaned
Screen pressure control valve (retarder) checked
Fastening screws on retarder heat exchanger checked
Screw plugs checked
Visual inspection performed
Company stamp / Signature
Date: ........................................
58 Operating Instructions Gearbox Retarder System
9 Service Overview
kilometer reading..............................
Oil change
Gearbox (oil type): Mineral oil Synthetic oil
Retarder (oil type): Mineral oil Synthetic oil
Oil screen(gearbox) cleaned
Screen pressure control valve (retarder) checked
Fastening screws on retarder heat exchanger checked
Screw plugs checked
Visual inspection performed
Company stamp / Signature
Date: ........................................
kilometer reading..............................
Oil change
Gearbox (oil type): Mineral oil Synthetic oil
Retarder (oil type): Mineral oil Synthetic oil
Oil screen(gearbox) cleaned
Screen pressure control valve (retarder) checked
Fastening screws on retarder heat exchanger checked
Screw plugs checked
Visual inspection performed
Company stamp / Signature
Date: ........................................
kilometer reading..............................
Oil change
Gearbox (oil type): Mineral oil Synthetic oil
Retarder (oil type): Mineral oil Synthetic oil
Oil screen(gearbox) cleaned
Screen pressure control valve (retarder) checked
Fastening screws on retarder heat exchanger checked
Screw plugs checked
Visual inspection performed
Company stamp / Signature
Date: ........................................
kilometer reading..............................
Oil change
Gearbox (oil type): Mineral oil Synthetic oil
Retarder (oil type): Mineral oil Synthetic oil
Oil screen(gearbox) cleaned
Screen pressure control valve (retarder) checked
Fastening screws on retarder heat exchanger checked
Screw plugs checked
Visual inspection performed
Company stamp / Signature
Date: ........................................
Operating Instructions Gearbox Retarder System 59
Technical Data 10
GO170-6 R 115 E GO190-6 R 115 E GO210-6 R 115 E
Gearbox input
up to [kW]
320
Max. input torque [Nm]
(determining factor dependent on
application)

Range of gearbox ratio
1. speed
2. speed
3. speed
4. speed
5. speed
6. speed
Reverse speed
8,170
4,650
2,790
1,810
1,250
1,000
7,683

6,528
3,711
2,231
1,443
1,000
0,799
6,136
Braking torque to [Nm] /
Brake power [kW]
3750 / 700
Permissible vehicle weight [t]
1750 1900 2100
20 t 24 t
60 Operating Instructions Gearbox Retarder System
10 Technical Data
Gear ratio GO170-6 R 115 E GO190-6 R 115 E GO210-6 R 115 E
1. gear 8,170 8,170 6,528
2. gear 4,650 4,650 3,711
3. gear 2,790 2,790 2,231
4. gear 1,810 1,810 1,443
5. gear 1,250 1,250 1,000
6. gear 1,000 1,000 0,799
Reverse gear 7,683 7,683 6,136

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