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Page 45

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

h T

I 15

3.00

009

710

I ar

d I 2

-1

200

Retarder can fall!

Your body can be crushed severely.

Secure retarder against falling.

Use a suitabe device for hanging it up.

Improper removal/installation!

Damage to/failure of the retarder.

Warranty is voided.

Request and use gearbox-specific documents

and special tools from VOITH.

Hot parts!

Hands could be burned.

Work carefully.

Wear protective gloves or use cloths if necessary.

DANGER

CAUTION

Summary of Contents for VR 115 E

Page 1: ...Voith Turbo Aftersales Service Manual Voith Retarder VR 115 E 153 00009710 I 2005 11...

Page 2: ...ymbols and Identifications 7 1 5 Item Numbers 7 1 6 Legal Contact Information 7 2 Basic Safety Information 8 2 1 Product Safety 9 2 2 Staff Qualification 9 2 3 Safety Conscious Working 9 2 4 Environme...

Page 3: ...Oil Level 25 4 4 Draining the Coolant 28 5 Diagnosis and Troubleshooting 30 5 1 Troubleshooting Chart 31 5 2 Constant Air Pressure Control Loop 36 5 3 Pump Pressure pdyn 39 5 4 Proportional Valve Curr...

Page 4: ...able of Contents Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 7 10 Non Return Valve Outlet 81 7 11 Oil Temperature Sensor 84 7 12 Coolant Temperature Sensor 86 7 13 Pressure Sensor 88 7 14 Propor...

Page 5: ...5 E I About this Document Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 1 About this Document 1 1 Purpose of this Document 6 1 2 Target Groups 6 1 3 Other Applicable Documents 6 1 4 Symbols and Id...

Page 6: ...xx Operating instructions for Voith Retarder VR 115 E Information on the safe professional and economical operation of the Voith Retarder VR 115 E H67 2964xx Cooling water quality list Approved coolan...

Page 7: ...s contact the respective organisation for your area Voith Turbo Produktgruppe Retarder Postfach 1555 74555 Crailsheim Deutschland Phone 00 49 79 51 32 401 32 422 32 1860 Fax 00 49 79 51 32 756 service...

Page 8: ...Information Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 2 Basic Safety Information 2 1 Product Safety 9 2 2 Staff Qualification 9 2 3 Safety Conscious Working 9 2 4 Environmental Protection 9 2...

Page 9: ...stances such as oils and greases 2 4 Environmental Protection Drained fuels and fluids consumables and old parts must be disposed of properly 2 5 Troubleshooting Voith provides a warranty goodwill ser...

Page 10: ...etarder as a parking brake as it does not act as a brake when the vehicle is standing still Failure while driving During failure of the retarder or while temperature adaptation is active only the serv...

Page 11: ...unction Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 3 Design and Function 3 1 Overview of the Modules 12 3 2 Retarder Identification 14 3 3 Controller Identification VERATM 15 3 4 Controller Ide...

Page 12: ...on Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 3 1 Overview of the Modules Item No Designation 100 Retarder housing 1600 Valve cover non return valve outlet 1900 Non return valve inlet 2810 Vent...

Page 13: ...153 00009710 I arrtd I 2005 11 2005 Item No Designation 103 Screw plug M12x1 5 107 Screw plug M24x1 5 oil drain plug 3500 Screw plug M30x1 5 4200 Screw plug M24x1 5 oil drain plug 5200 2 Coolant tempe...

Page 14: ...10 I arrtd I 2005 11 2005 3 2 Retarder Identification Specify the following data in case you have questions or are ordering spare parts Serial number Serien Nr Voith item number Voith Sach Nr Kd Sach...

Page 15: ...mber Part No Specify the following data of the retarder see page 14 Serial number Serien Nr Voith item number Voith Sach Nr Retarder Control Unit VERA Serial No XXXXXX JJJJ MM TT Part No VERA D H E02...

Page 16: ...4 Controller Identification Digiprop Example Specify the following data in case you have questions or are ordering spare parts Basic number Basis Nr Serial number Serien Nr Specify the following data...

Page 17: ...essed air line brake circuit 1 E Compressed air line parking brake F Air tank for auxiliary equipment G Supply air pressure pv P H Constant air pressure py A I Ventilation line R J Oil tank K Rising d...

Page 18: ...ation 2810 Ventilation filter 3700 Proportional valve 4200 Oil drain plug 5200 1 Oil temperature sensor 5200 2 Coolant temperature sensor 5500 Ventilation 6400 Heat exchanger 9000 Pressure sensor A R...

Page 19: ...ant 5200 2 The temperature sensors are screwed into the cooling system of the vehicle return pipe from retarder to heat exchanger and in the oil duct of the retarder The temperature sensors pass on in...

Page 20: ...e Manual Voith Retarder VR 115 E I Maintenance and Service Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 4 Maintenance and Service 4 1 Maintenance Intervals 21 4 2 Oil Change 22 4 3 Checking the O...

Page 21: ...153 00009710 I arrtd I 2005 11 2005 4 1 Maintenance Intervals The maintenance intervals depend on the stress put on the retarder Activity Interval See Change oil See document Oil change intervals oil...

Page 22: ...pper sealing ring 130 Nm with integrated sealing ring 100 Nm 3550 Sealing ring A30x36 replace 4100 Screw plug M30x1 5 hexagon socket head w a f 17 with copper sealing ring 130 Nm with integrated seali...

Page 23: ...he screw plug 4100 3 Unscrew the screw plugs 107 and 4200 4 Drain oil into an oil collecting pan 5 Lubricate the new sealing rings 108 and 4250 with silicone free non corrosive grease 6 Screw in the s...

Page 24: ...the new sealing ring 4150 with silicone free non corrosive grease 3 Screw in the screw plug 4100 with sealing ring 4150 and tighten to 130 Nm De aerating the retarder 1 Switch off the retarder foot c...

Page 25: ...m 108 Sealing ring A24x29 replace 4100 Screw plug M30x1 5 hexagon socket head w a f 17 with copper sealing ring 130 Nm with integrated sealing ring 100 Nm 4150 Sealing ring A30x36 replace 4200 Screw p...

Page 26: ...Measuring the volume 1 Measure the volume of the drained oil 2 If oil is missing top up oil Filling in the oil 1 Fill in oil via the hole of the screw plug 4100 2 Lubricate the new sealing ring 4150 w...

Page 27: ...ervice Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 De aerating the retarder 1 Switch off the retarder foot control if present and possible 2 Move vehicle at 50 km h 3 Activate retarder at brake...

Page 28: ...tched off Item No Designation 20000 Water neck 20300 Screw plug M14x1 5 hexagon insert bit w a f 13 32 Nm 20400 Sealing ring A14x20 replace Lubricate sealing rings O rings and shaft sealing rings with...

Page 29: ...11 2005 1 Unscrew the screw plug 20300 and drain the coolant into a clean collecting vessel 2 Replace the sealing ring 20400 and lubricate it with silicone free non corrosive grease Incorrect coolant...

Page 30: ...rder VR 115 E I Diagnosis and Troubleshooting Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 5 Diagnosis and Troubleshooting 5 1 Troubleshooting Chart 31 5 2 Constant Air Pressure Control Loop 36 5...

Page 31: ...plaint Retarder VR 115 E A B Oil loss via ventilation 5500 or vent and air filter 2810 Retarder pilot light standard type C No or insufficient brake efficiency On board diagnosis is possible if the OE...

Page 32: ...of the engine if possible IO NIO Check temperature sensors oil coolant Replace temperature sensor Check vehicle cooling system in accordance with the information from the vehicle manufacturer IO in or...

Page 33: ...earbox IO NIO Yes No Outlet valve 11 and greater IO C If the gearbox oil level is too low and the retarder oil level is too high Check gearbox ventilation and repair clean if necessary Troubleshooting...

Page 34: ...ontact Voith Replace pressure sensor or proportional valve Contact Voith Replace temperature sensors or leads Check constant air pressure control loop NIO IO Check P dynamic and py static NIO IO Check...

Page 35: ...inlet 1900 IO in order NIO not in order Before troubleshooting ensure that there are no leaks at the screw plugs or sealing rings 1 Check retarder housing for leaks near the heat exchanger contact Vo...

Page 36: ...al valve 9000 Pressure sensor 99 30 Retarder tester 99 31 Cable 1 to the proportional valve 99 32 Cable 2 to the pressure sensor 99 33 Cable 3 to temperature sensors 99 34 Cable 4 to the vehicle volta...

Page 37: ...portional valve 3700 Connect cable 2 99 32 to pressure sensor 9000 Connect cable 3 99 33 to oil temperature sensors 5200 1 and coolant 5200 2 Connect cable 4 99 34 to the vehicle voltage supply PC int...

Page 38: ...0 7 V If this value is not reached Replace proportional valve 3700 7 Retarder tester switch Stelldruck in position 100 8 After approx 20 seconds the value Act setting pressure displayed in Diana Lite...

Page 39: ...re sensor 50 36 Pressure sensor 0 30 bar 99 30 Retarder tester 99 31 Cable 1 to the proportional valve 99 32 Cable 2 to the pressure sensors 99 33 Cable 3 to temperature sensors 99 34 Cable 4 to the v...

Page 40: ...r tester in case compl 99 29 comprising 99 30 99 35 99 40 50 35 50 36 With the test software Diana Lite 99 40 measured values can be read out and stored via the PC in addition to the tests with the re...

Page 41: ...gnition and start the engine 6 Check pump pressure at engine speed 1000 min 1 see operating instructions of the retarder tester 7 Compare the measured pump pressure to the minimum dynamic pump pressur...

Page 42: ...tions checked visual inspection and in order Test scope 1 Disconnect the plug from the proportional valve 3700 and connect it to the measuring adapter 99 3 2 Connect the plug of the measuring adapter...

Page 43: ...it to the proportional valve 3700 Due to continuous readjustment in the control loop the measured values may not be constant but are within the specified range Controller Item number Code number Meas...

Page 44: ...Page 44 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 6 Removing and Installing the Retarder...

Page 45: ...Your body can be crushed severely Secure retarder against falling Use a suitabe device for hanging it up Improper removal installation Damage to failure of the retarder Warranty is voided Request and...

Page 46: ...Screw plug M30x1 5 hexagon socket head w a f 17 with copper sealing ring 130 Nm with integrated sealing ring 100 Nm 4150 Sealing ring A30x36 replace 25000 Shim 25100 O ring 14x4 replace 25200 Hex hea...

Page 47: ...sensor removed Retarder with gearbox removed from vehicle Removal 1 Unscrew the hex head screws 25200 and 25300 2 Remove retarder from the gearbox with a suitable lifting device Special tools Measurin...

Page 48: ...retarder side of the gearbox housing and the bearing surface of the shim and write down the value 2 Place the bearing outer ring 850 onto the inside part 800 3 Place the measuring device 98 1 onto th...

Page 49: ...easuring disk 8 Measure dimension A from the measuring surface of the measuring disk to the interface of the retarder housing and write down the value Tolerance of dimension A is 131 031 132 171 mm 9...

Page 50: ...712010 Voith item No H53 3305xx 6 Lubricate the new O rings 25100 with silicone free non corrosive grease and insert them into gearbox housing 7 Screw two threaded bolts M10x80 see arrows into the gea...

Page 51: ...Top Oil Tank Cover 59 7 3 Bottom Oil Tank Cover 61 7 4 Casing Ventilation 63 7 5 Retarder Ventilation 69 7 6 Water Neck 70 7 7 Heat Exchanger 71 7 8 Pressure Control Valve 76 7 9 Non Return Valve Inle...

Page 52: ...with integrated sealing ring 280 Nm Lubricate sealing rings O rings and shaft sealing rings with silicone free non corrosive grease before installation Observe the reduced tightening torque with the...

Page 53: ...ce Lubricate sealing rings O rings and shaft sealing rings with silicone free non corrosive grease before installation Observe the reduced tightening torque with the integrated sealing ring The copper...

Page 54: ...ing 130 Nm with integrated sealing ring 100 Nm Lubricate sealing rings O rings and shaft sealing rings with silicone free non corrosive grease before installation Observe the reduced tightening torque...

Page 55: ...g 100 Nm 4150 Sealing ring A30x36 replace Lubricate sealing rings O rings and shaft sealing rings with silicone free non corrosive grease before installation Observe the reduced tightening torque with...

Page 56: ...ed spring 5500 Disc silencer 5600 Circlip JL30x1 2 Lubricate sealing rings O rings and shaft sealing rings with silicone free non corrosive grease before installation Observe the reduced tightening to...

Page 57: ...cate sealing rings O rings and shaft sealing rings with silicone free non corrosive grease before installation Observe the reduced tightening torque with the integrated sealing ring The copper sealing...

Page 58: ...g rings O rings and shaft sealing rings with silicone free non corrosive grease before installation Observe the reduced tightening torque with the integrated sealing ring The copper sealing ring varia...

Page 59: ...head screw M8x30 hexagon insert bit w a f 13 30 Nm 3300 Combined hex head screw M8x80 hexagon insert bit w a f 13 30 Nm 6100 Pipe mind mounting position 6101 O ring 15 3x2 4 replace 8000 Intermediate...

Page 60: ...and 3300 3 Insert new intermediate washer 8000 4 Lubricate the new O rings 6101 with silicone free non corrosive grease and pull them on the pipe 6100 5 Insert pipe 6100 into top oil tank cover 2000 a...

Page 61: ...w M8x30 hexagon insert bit w a f 13 30 Nm 4200 Screw plug M24x1 5 hexagon socket head w a f 12 with copper sealing ring 80 Nm with integrated sealing ring 47 Nm 4250 Sealing ring A24x29 replace Lubric...

Page 62: ...00 Installation 1 Clean sealing surface on retarder housing 100 and bottom cover 2500 2 Insert new cover gasket bottom 2600 3 Screw on cover 2500 with the combined hex head screws 3100 4 Screw tight c...

Page 63: ...12 g 2300 3 Float cage 2800 Cover of casing ventilation 2801 Cover 2810 Vent and air filter 2900 Casing ventilation cover gasket replace 3300 Combined hex head screw M8x80 hexagon insert bit w a f 13...

Page 64: ...alve and damping plate removed see page 89 Removal 1 Unscrew the combined hex head screws 3300 Incorrect adapter Damage to casing ventilation Use only the adapter 98 9 as from item number H53 942811 S...

Page 65: ...g ventilation cover gasket 2900 4 Remove the pipe 6100 5 Knock valve insert 2300 1 with the impact puller 99 5 and the adapter 98 9 upward from the retarder housing 100 6 Remove float 2300 2 and float...

Page 66: ...ert 2300 1 For this purpose place the float 2300 2 on a suitable object e g hex head nut Place the valve insert 2300 1 on the float 2300 2 and weigh it down using the test ring 99 4 Fill empty space b...

Page 67: ...osive grease 7 Press valve insert 2300 1 carefully into the retarder housing with the impact puller 99 5 and the adapter 98 9 8 Lubricate the new O rings 6101 with silicone free non corrosive grease a...

Page 68: ...ce Manual Voith Retarder VR 115 E I Repair Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 13 Screw on cover of casing ventilation 2800 with the combined hex head screws 3300 14 Tighten combined hex...

Page 69: ...No Designation 5400 Corrugated spring 5500 Check clean and blow out disc silencer with compressed air 5600 Circlip Cleaning agent Retarder ventilation Benzine Kd Sa ch N r Voit h S ach Nr 5500 5400 5...

Page 70: ...page 28 Item No Designation 20000 Water neck 20100 Gasket replace 20200 Combined hex head screw M8x80 hexagon insert bit w a f 13 30 Nm Lubricate sealing rings O rings and shaft sealing rings with sil...

Page 71: ...Screw plug M24x1 5 hexagon socket head w a f 12 with copper sealing ring 80 Nm with integrated sealing ring 47 Nm 4250 Sealing ring A24x29 replace 6400 Heat exchanger 6600 Hex head screw M14x45 hexago...

Page 72: ...d tightening torque with the integrated sealing ring The copper sealing ring variant is described in the instructions Special tools Pressure test equipment 50 22 Sealing agent Heat exchanger Elring Se...

Page 73: ...gs and attach the compressed air line to the connection 2 Fill cooling water section of heat exchanger 6400 with hot water approx 70 C 3 Slowly pressurize heat exchanger 6400 with compressed air from...

Page 74: ...6700 5 Tighten hex head screws 6600 crosswise to 150 Nm The water and oil section of new heat exchangers are coated with anti corrosion oil Before installing discharge any anti corrosion oil which as...

Page 75: ...115 E I Repair Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 6 With housing models up to retarder serial number 963 690 the gap at the top between the heat exchanger 6400 and the retarder housing...

Page 76: ...500 Screw plug M30x1 5 hexagon socket head w a f 17 with copper sealing ring 130 Nm with integrated sealing ring 100 Nm 3550 Sealing ring A30x36 replace Lubricate sealing rings O rings and shaft seali...

Page 77: ...r housing Special tool Impact puller 99 5 Tools for self fabrication Screw plug 50 43 H53 7712xx 20x1 5 M M 8 Hot parts Hands could be burned Work carefully Wear protective gloves or use cloths if nec...

Page 78: ...icone free non corrosive grease and pull it onto the pressure control valve 2200 2 Carefully press pressure control valve 2200 with the impact puller 99 5 and the screw plug 50 43 into the retarder ho...

Page 79: ...ignation 1900 Non return valve inlet complete 1900 1 Guide M48x1 5 hexagon insert bit w a f 55 with copper sealing ring 280 Nm with integrated sealing ring 280 Nm 1900 2 Spring 1900 3 Piston 1950 Seal...

Page 80: ...d spring 1900 2 for wear Replace the complete non return valve inlet 1900 if necessary Installation 1 Apply sealing agent to the thread of the guide 1900 1 2 Lubricate the new sealing ring 1950 with s...

Page 81: ...er mind mounting position 1700 O ring 60x3 replace 2100 Non return valve outlet complete Mind mounting position 2105 O ring 34x3 replace 2106 O ring 54x3 replace 3100 Combined hex head screw M8x30 hex...

Page 82: ...let 2100 out of the retarder housing 5 Remove the O rings 1700 2105 and 2106 Checking 1 Check rubber coating of the valve plate 1 for damage Replace the complete non return valve outlet 2100 if necess...

Page 83: ...and 2106 and pull them onto the non return valve outlet 2100 2 Press the non return valve outlet 2100 into the retarder housing 100 in the correct installation position arrow with a suitable tool 3 A...

Page 84: ...Ignition switched off Item No Designation 5200 1 Oil temperature sensor M14x1 5 hexagon insert bit w a f 21 with copper sealing ring 32 Nm 5300 Sealing ring A14x20 replace Lubricate sealing rings O r...

Page 85: ...Retarder VR 115 E I Repair Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 Checking the internal resistance Measuring in one temperature range is usually sufficient Polarity is irrelevant Temperatur...

Page 86: ...itched off Coolant drained see page 28 Item No Designation 5200 2 Coolant temperature sensor M14x1 5 hexagon insert bit w a f 21 with copper sealing ring 32 Nm 5300 Sealing ring A14x20 replace Lubrica...

Page 87: ...h Retarder VR 115 E I Repair Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 Checking the internal resistance Measuring in one temperature range is usually sufficient Polarity is irrelevant Temperat...

Page 88: ...er switched off Ignition switched off Item No Designation 9000 Pressure sensor M16x1 5 hexagon insert bit w a f 27 with integrated sealing ring 32 Nm Lubricate sealing rings O rings and shaft sealing...

Page 89: ...upply air pressure pv L Electrical connecting lead 3700 Proportional valve 3800 Damping plate replace if damaged 3850 O ring 16x3 replace 3900 Combined hex head screw M8x20 hexagon insert bit w a f 13...

Page 90: ...2005 11 2005 Requirements Retarder switched off Ignition switched off Supply air pressure discharged Compressed air line disconnected Electrical connection lead disconnected from proportional valve M...

Page 91: ...Page 91 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix Voith Turbo I 153 00009710 I arrtd I 2005 11 2005 8 Appendix 8 1 Tightening Torques 92...

Page 92: ...head w a f 12 With copper sealing ring 80 Nm With integrated sealing ring 47 Nm 1400 Dodecagonal nut M38x1 5 SW55 426 Nm 1900 1 Guide of non return valve inlet M48x1 5 hexagon insert bit w a f 55 With...

Page 93: ...ensor M14x1 5 hexagon insert bit w a f 21 32 Nm 5200 2 Coolant temperature sensor M14x1 5 hexagon insert bit w a f 21 32 Nm 5700 Combined hex head screw M8x25 hexagon insert bit w a f 13 30 Nm 6600 Co...

Page 94: ...Voith Turbo Produktgruppe Retarder Postfach 1555 74555 Crailsheim Deutschland Phone 00 49 79 51 32 0 Fax 00 49 79 51 32 756 service retarder voith com www voith com Engineered reliability...

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