mercedes voith retarder

Voith Turbo

Aftersales Service Manual Voith Retarder VR 115 E

153.00009710 I 2005-11

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

Table of Contents

1 About this Document 5

1.1 Purpose of this Document 6

1.2 Target Groups 6

1.3 Other Applicable Documents 6

1.4 Symbols and Identifications 7

1.5 Item Numbers 7

1.6 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 Environmental Protection 9

2.5 Troubleshooting 9

2.6 Maintenance and Repair 9

2.7 Driving Mode 9

2.8 Warranty 10

3 Design and Function 11

3.1 Overview of the Modules 12

3.2 Retarder Identification 14

3.3 Controller Identification (VERA

TM

) 15

3.4 Controller Identification (Digiprop) 16

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 2

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

3.5 Function and Control Scheme 17

3.6 Function Description 19

4 Maintenance and Service 20

4.1 Maintenance Intervals 21

4.2 Oil Change 22

4.3 Checking the 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 (p

) 39

dyn

5.4 Proportional Valve Current 42

6 Removing and Installing the Retarder 44

7 Repair 51

7.1 Components Overview 52

7.2 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 Inlet 79

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 3

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

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 Proportional Valve and Damping Plate 89

8 Appendix 91

8.1 Tightening Torques 92

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 4

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

1. About this Document

1.1 Purpose of this Document 6

1.2 Target Groups 6

1.3 Other Applicable Documents 6

1.4 Symbols and Identifications 7

1.5 Item Numbers 7

1.6 Legal/Contact Information 7

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 5

1.1 Purpose of this Document

This Aftersales Service Manual provides information
and instructions on maintenance and repa ir of the
Voith Retarder VR 115 E.

1.2 Target Groups

This Aftersales Service Manual is intended for service
people for service and diagnoses only and may not be
reproduced or given to third parties.

1.3 Other Applicable Documents

Documents Information Item number

Voith retarder oil change intervals/oil specification list Oil change intervals and approved oil types 153.000831xx

Purpose of this DocumentVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document

Operating instructions for Voith Retarder VR 115 E Information on the safe, professional and economical operation of the

H67.2964xx

Voith Retarder VR 115 E
Cooling water quality list Approved coolants H67.2224xx
Operating instructions for retarder tester Measured values for constant-air pressure a nd pu mp p ressure Included in scope of delivery of

the retarder tester(153.001085xx)

Operating instructions for Diana-Lite test software Information on the testing of:

• Constant-Air Pressure Control Loop

Operating instructions for the WinDia diagnostic

• pump pressure (p

Instructions on PC diagnosis for the Digiprop and VERA

dyn

)

TM

controllers 3623-020900

Included in the scope of delivery
of the Diana-Lite test software
(153.000776xx)

software
Gearbox-specific documents on the retarder Information on safe, professional installation and removal of the retarder On request

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 6

Symbols and IdentificationsVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document

1.4 Symbols and Identifications

Structure of warnings

LEVEL OF DANGER

Type and source of danger!

Possible consequences if not observed.
Ö Measures for the prevention of danger and its

consequences.

Levels of danger

The warnings are categorized into four levels of
danger:

CAUTION

Potentially hazardous situation which, if not avoided,
may result in property damage.

CAUTION

Potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.

WARNING

Potentially hazardous situation which, if not avoided,
could result in death or serious injury.

DANGER

Imminently hazardous situation which, if not
avoided, will result in death or serious injury.

Notes

NOTE

Information on easier and safer work with the
retarder.

Ö Measures for easier and safer work with the

retarder.

Distinctions

Ö One-step action instruction.

1. First step of an act i on instruction. Other steps
follow and are numbered in sequence.

1.5 Item Numbers

The item numbers used are usually found in the spare
parts lists.

Exceptions:

• One- or two-digit item numbers

• Item numbers with a slash

1.6 Legal/Contact Information

For questions and work procedures not d escribe d in
these documents, contact the respective organisation
for your area.

Voith Turbo
Produktgruppe Retarder

Postfach 1555
74555 Crailsheim
Deutschland

Phone: [phone] / 32-401, 32-422, 32 -186 0
Fax: [phone] / 32-756
[e-mail]
www.voith.com

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 7

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

2. Basic Safety Information

2.1 Product Safety 9

2.2 Staff Qualification 9

2.3 Safety-Conscious Working 9

2.4 Environmental Protection 9

2.5 Troubleshooting 9

2.6 Maintenance and Repair 9

2.7 Driving Mode 9

2.8 Warranty 10

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 8

Product SafetyVoith Turbo I Aftersales Service M anual Voith Retarder VR 115 E I Basic Safety Information

2.1 Product Safety

The retarder is constructed according to state of the
art technology and acknowledged safety regulations.

Nevertheless, hazardous situations and property
damage may occur as a result of improper usage,
maintenance and repair.

Ö Observe safety and warning information.

2.2 Staff Qualification

Ö Allow only qualified professionals to carry out repair

and maintenance work.

2.3 Safety-Conscious Working

Voith does not assume any liability for personal injury
and/or property damage caused by imp roper and
unprofessional work.

Ö Observe the following regulations:

- Accident-prevention regulation s

2.4 Environmental Protection

Ö Drained fuels and fluids, consumables and old parts

must be disposed of properly.

2.5 Troubleshooting

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

Ö Do not replace parts on mere speculation.

2.6 Maintenance and Repair

Danger of burning and scalding via squirting oil!

The oil in the retarder may be hot.
Ö Work carefully.

Danger of burning and scalding via hot coolant!

The coolant may be hot.
Ö Work carefully.

Damage to property via soiled parts!

Considerable damage or malfunctions may occur due
to soiling.

Ö Ensure cleanliness.

Damage to property via improper cleaning!

Ö Do not aim the jet of a high-pressure cleaner

(steam-jet device) at valves, pressure sensors or
ventilators of the retarder.

2.7 Driving Mode

Ö Ensure that the retarder is fully functional for all

vehicle maneuvers, i.e.:

- Retarder properly filled with oil

- Retarder electronics connected and functional

- Pneumatic control connected and functional

- Other generally acknowledged safety
regulations and occupational health

- Motor vehicle regulations

- Safety regulations for handling chemical
substances such as oils and greases

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Danger of burns via hot parts!

Parts of the retarder may be hot.

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

Page 9

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

Driving after repair/oil change
Oil ejection!

De-aeration not performed.
Ö De-aerate retarder.

- Switch off retarder foot control if present and
possible

- Move vehicle at 50 km/h

- Activate retarder at brake stage one five times
for approx. 5 sec. each time

Towing

Ö Tow vehicle with retarder max. 100 km at max.

40 km/h.

Parking

Ö Do not use retarder 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 service brake is
functional.

Ö Adjust the speed of the vehicle with the service

brake.

Ö Engage the lowest possible gear to achieve a high

engine speed.

Ö Continue driving in this way until the retarder is

available at full capacity again.

2.8 Warranty

Voith accepts no liability for damage caused by
changes to the retarder or the use of spar e part s,
accessories, attachments and special features not
tested and approved by Voith.

Ö Use only parts approved by Voith to ensure the

safety of the vehicle.

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 10

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

3. Design and Function

3.1 Overview of the Modules 12

3.2 Retarder Identification 14

3.3 Controller Identification (VERA

3.4 Controller Identification (Digiprop) 16

3.5 Function and Control Scheme 17

3.6 Function Description 19

TM

) 15

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 11

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 and air filter
3700 Proportional valve
4100 Screw plug M30x1.5 (oil filler plug)

Overview of the ModulesVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function

2810

3700

4100

1900

1600

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

100

28003

Page 12

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 temperature sensor M14x1.5
5500/1 Ventilation

Overview of the ModulesVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function

5500/1

6400 Heat exchanger

6400

20000 Water neck

3500

20000

103

5200/2

20000

107

4200

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

28004

Page 13

3.2 Retarder Identification

NOTE

Ö Specify the following data in case you have

questions or are ordering spare parts:

- Serial number (Serien-Nr.)

- Voith item number (Voith-Sach-Nr.)

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

Typ VR115E; Serien-Nr.

KW/Jahri Ret. = 2.03

Voith-Sach-Nr.

r.

N

-

n

ie

r
e
S

r

;

h

E

a
J
/

15

1

W

R

K

V

p

3

y

.0

T

2

=

t

e

.
r

i R

N

-

h

c

a

.

S

r

­N

th

-

i

h

o

c

V

a

S

.-

d

K

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Kd.-Sach-Nr.

28001

Page 14

3.3 Controller Identification (VERATM)

Example:

NOTE

Controller Identification (VERA

TM

) Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Functio n

Ö Specify the following data in case you have

questions or are ordering spare parts:

- Serial number (Serial-No.)

- Part number (Part No.)

Ö Specify the following data of the retarder (see

page 14):

- Serial number (Serien-Nr.)

- Voith item number (Voith-Sach-Nr.)

Retarder Control Unit VERA

TM

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

er

ial-No

Retard

Ser

Part-No. VERA.D

OEM-No

Voith Turbo

Unit VERA

.H-E02.10-H67.2866.20

Control

. XXXXXX / JJJJ-MM-TT

. 0004463315 / EvoBus

X1

VOITH

e1 022084

e1 022084

M

T

X3

X2

X1

X2

X3

VOITH Voith Turbo

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

28138

Page 15

3.4 Controller Identification (Digiprop)

Example:

NOTE

Ö Specify the following data in case you have

questions or are ordering spare parts:

- Basic number (Basis-Nr.:)

- Serial number (Serien-Nr.:)

Controller Identification (Digiprop)Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function

Ö Specify the following data of the retarder (see

page 14):

- Serial number (Serien-Nr.)

- Voith item number (Voith-Sach-Nr.)

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Basis-Nr.: 53.xxxx.12
Cod

e-Nr.:

Serien-Nr.: xxxx/
VOI

TH

Basis-Nr.:
Code-Nr.:
Serien-Nr.:
VOI T H

xxx

28002

Page 16

3.5 Function and Control Scheme

Function and Control SchemeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function

Item No. Designation

A Compressed-air line (pressure

controller)
B Four-circuit protection valve
C Compressed-air line (brake circuit 2)
D Compressed-air line (brake circuit 1)
E Compressed-air line (parking bra ke)
F Air tank for auxiliary equipment

G Supply-air pressure (p

Constant-air pressure (p

H

I Ventilation line "R"

J Oil tank

K Rising duct

107 Oil drain plug
200 Stator
300 Rotor

1900 Non-return valve (inlet)

) "P"

v

) "A"

y

Vehicle
electronics

A

2810

5500

B

5200/1

300

200

2200

2100

C

1900

2300

E

F

D

9000

G

3700

J

H

P

R

A

I

6400

5200/2

2100 Non-return valve (outlet)
2200 Pressure control valve

Oil sump
Supply-air pressure p
Constant-air pressure p

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

107

v

y

4200

Coolant
Pump pressure p

K

dyn

28005

Page 17

Item No. Designation

2300 Casing ventilation
2810 Ventilation filter

Function and Control SchemeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function

C

B

E

F

A

3700 Proportional valve

4200 Oil drain plug
5200/1 Oil temperature sensor
5200/2 Coolant temperature senso r

5500 Ventilation

6400 Heat exchanger

9000 Pressure sensor

Vehicle
electronics

2810

300

5500

5200/1

1900

200

2200

2100

2300

D

107

J

4200

9000

P

G

R

A

3700

H

I

6400

5200/2

K

Oil sump
Supply-air pressure p
Constant-air pressure p

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

v

y

Coolant
Pump pressure p

dyn

28005

Page 18

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

3.6 Function Description

Non-return valve (inlet) (1900)

When the retarder is switched on, the oil sump is
pressurized. This opens the non-return valve (inlet )
(1900) and allows oil into the working space.

Non-return valve (outlet) (2100)

In braking mode, the oil reaches the heat exchan ger
from the working space via the non-return valve
(outlet) (2100), is cooled down and is fed back into the
system circuit.

Pressure control valve (2200)

In no-load operation of the retarder, th e pres sure
control valve (2200) regulates the lubrication.

Casing ventilation (2300)

At the beginning of the braking process, the oil expels
the air located in the system circuit from the retarder
via the casing ventilation (2300) and a de-aera tion
filter (2810).
Once the system circuit is free of air, a float will rise
and seal the casing ventilation.

Proportional valve (3700)

Depending on the intensity of the electric input signal,
the proportional valve (3700) issues a pneumatic
constant-air pressure which acts on the oil tank of the
retarder.

Oil temperature sensor (5200/1) and
coolant (5200/2)

The temperature sensors are screwed into the cooling
system of the vehicle (return pipe from retarder to he at
exchanger) and in the oil duct of the retarder. The
temperature sensors pass on information on the
temperature of the coolant and oil to the controller.

Maximum values for the temperature of coolan t and
oil are set in the controller for protection of the cooling
system and the retarder. To prevent the values being
exceeded, the controller adapts the braking torque of
the retarder accordingly via the constant-air
pressure p

.

y

The braking torque and the heat produced regulate
themselves until an equilibrium has been reached
between the braking force and the heat dissipated via
the vehicle cooling system.

If the critical temperature threshold has been
exceeded, the braking torque is no lon ger ac tive.

The controller also adjusts the braking torque if the
temperature of the oil increases rapidly, regardless of
the actual temperature of the oil.

During temperature adaptation or failure of the
retarder, you must use the service brake to slow down
the vehicle.

Pressure sensor (9000)

The pressure sensor (9000) measures the pneumatic
constant-air pressure. A deviation from the allowed
pressure tolerance is recognized as a fault and
displayed by the controller.

If the temperature limit is exceeded during braking,
the braking torque is adapted to protect the cooling
system and retarder.

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 19

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

4. Maintenance and Service

4.1 Maintenance Intervals 21

4.2 Oil Change 22

4.3 Checking the Oil Level 25

4.4 Draining the Coolant 28

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 20

4.1 Maintenance Intervals

The maintenance intervals depend on the stress put
on the retarder.

Activity Interval See

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

Change oil ÖSee document: Oil

change intervals/
oil specification list

153.000831xx

Check oil

–Page25

level
Drain coolant ÖObserve

specifications of
vehicle
manufacturer

Page 22

Page 28

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 21

4.2 Oil Change

Oil ChangeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenanc e and Servic e

Item No. Designation

107 Screw plug M24x1.5,

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

108 Sealing ring A24x29, replace

3500 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
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 plug M24x1,5,

hexagon socket head, w.a.f. 12,

with copper sealing ring: 80 Nm

with integrated sealing ring: 47 Nm

4100

4150

.
r
N

-

h
c

.

a

r

S

N

-

.

-

d

h
c

K

a

-S

h

it
o
V

108

107

4250 Sealing ring A24x29, replace

NOTE

Ö Lubricate sealing rings, O-rings and shaft

sealing rings with silicone-free, non-corrosive
grease before installation.

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

3500

3550

4250

4200

4250

4200

28009

Page 22

NOTE

• Tighten screw plugs of retarder basic module to
the specified tightening torque (see page 91).

Oil ChangeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenanc e and Servic e

CAUTION

Ö Observe the reduced tightening torque with the

integrated sealing ring.

The copper sealing ring variant is described in the
instructions.

CAUTION

Incorrect tightening torque!

Leaky retarder.
Ö Observe the proper tightening torque.

Oil quantity

Service filling (oil check, oil change) 7.0 l
After replacement of the heat exchanger 7.5 l
Refilling after complete disassembly,

cleaning and emptied heat exchanger

Maintenance work during each oil change

• Visual inspection of retarder for leaks before and
after the oil change.

7.8 l

• Tighten fastening screws at retarder heat
exchanger with the specified tightening torque
(see page 91).

Requirements

• Vehicle is horizontal

• Oil is at operating temperature (> 60 °C)

• Retarder switched off

• Ignition switched off

Draining the oil

1. Place oil collecting pan below the retarder.

WARNING

Hot exiting oil!

Face and hands could be burned.
Ö Ensure that the retarder and ignition are switched

off.

Hot screw plugs!

Hands could be burned.

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

2. Unscrew the 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 screw plugs (107) with sealing rings
(108) and tighten to 80 Nm.

7. Screw in the screw plug (4200) with sealing ring
(4250) and tighten to 80 Nm.

• Check prop shaft screws for proper seating and
tighten if necessary (See specifications of vehicle
manufacturer).

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 23

Oil ChangeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenanc e and Servic e

Pressure control valve

NOTE

There are two variants of the pressure control
valve.

- Pressure control valve variant 1 witho ut siev e.

Sieve is at the screw plug (3500)

- Variant 2; sieve is located directly in the

pressure control valve

1. Unscrew the screw plug (3500).

2. Drain any oil that has accumulated in the oil

collecting pan.

3. Lubr icate the new sealing ring (3550) with
silicone-free, non-corrosive grease.

4. Screw in the screw plug (3500) with sealing ring
(3550) and tighten to 130 Nm.

2. Lubricate 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

CAUTION

Oil ejection!

De-aeration not performed.
Ö De-aerate retarder.

1. Switch off the retarder foot control if present and
possible.

2. M ove vehicle at 50 k m/h.

3. Activate retarder at brake stage one five times for

approx. 5 sec. each time.

Filling in the oil

CAUTION

Wrong oil type!

Damage to/failure of the retarder.
Ö Use only approved oil (see oil specification list).

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

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 24

4.3 Checking the Oil Level

Checking the Oil LevelVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service

Item No. Designation

107 Screw plug M24x1.5,

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

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 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

NOTE

Ö Lubricate sealing rings, O-rings and shaft

sealing rings with silicone-free, non-corrosive
grease before installation.

4100

4150

.
r
N

­h
c

.

a

r

S

N

-

.

-

d

h
c

K

a

-S

h

it
o
V

108

107

4250

4200

4250

4200

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

28154

Page 25

Checking the Oil LevelVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service

NOTE

Ö Observe the reduced tightening torque with the

integrated sealing ring.

The copper sealing ring variant is described in the
instructions.

Oil quantity

Service filling (oil check,
oil change)

Requirements

• Vehicle is horizontal

• Oil is at operating temperature (> 60 °C)

• Retarder switched off

• Ignition switched off

Draining the oil

1. Place oil collecting pan below the retarder.

7.0 l

WARNING

Hot exiting oil!

Face and hands could be burned.
Ö Ensure that the retarder and ignition are switched

off.

CAUTION

Hot screw plugs!

Hands could be burned.

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

2. Unscrew the screw plug (4100).

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

4. Drain oil into an oil collecting pan.

5. Lubr icate the new sealing rin gs (108 and 4250)

with silicone-free, non-corrosive grease.

6. Screw in the screw plugs (107) with sealing rings
(108) and tighten to 80 Nm.

7. Screw in the screw plugs (4200) with sealing ring
(4250) and tighten to 80 Nm.

Measuring the volume

1. Measure the volume of the drained oil.

NOTE

Ö If oil is missing, check the retarder for leaks.

CAUTION

Wrong oil type!

Damage to/failure of the retarder.
Ö Use only approved oil (see oil specifi cation lis t ) .

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) with

silicone-free, non-corrosive grease.

3. Screw in the oil filler plug (4100) with sealing ring
(4150) and tighten to 130 Nm.

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 26

De-aerating the retarder

CAUTION

Oil ejection!

De-aeration not performed.
Ö De-aerate retarder.

1. Switch off the retarder foot control if present and
possible.

2. Move vehicle at 50 km/h.

3. Activate retarder at brake stage one five times for

approx. 5 sec. each time.

Checking the Oil LevelVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 27

4.4 Draining the Coolant

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

NOTE

Ö Lubricate sealing rings, O-rings and shaft

sealing rings with silicone-free, non-corrosive
grease before installation.

Requirements

Draining the CoolantVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service

• Retarder switched off

• Ignition switched off

CAUTION

Hot parts and coolant!

Burns and scalding could occur.

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

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

r.

-N
h

c

.

a

Nr

.-S

-

d

h

c

K

a

-S

ith
o
V

20000

20400
20300

28155

Page 28

CAUTION

Incorrect coolant!

Damage to vehicle and retarder cooling circuits.
Ö Observe the specifications of the vehicle

manufacturer or those of Voith Turbo cooling
water quality list.

1. Unscrew the screw plug (20300) and drain the
coolant into a clean collecting vessel.

2. Replace the sealing ring (20400) and lu bricat e it
with silicone-free, non-corrosive grease.

Draining the CoolantVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service

Voith Turbo I 153.00009710 I arrtd I 2005-11

© 2005

Page 29