Asm Vr115hv

Voith Turbo
Aftersales Service Manual Voith Retarder VR 115 HV
153.00132310 I 2008-04
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV 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 Imprint 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 Special tools 9
2.6 Diagnosis and Troubleshooting 9
2.7 Maintenance and repair 9
Voith Turbo I 153.00132310 I arrtd I 2008-04
2.8 Driving mode 10

2.9 Storage 10
2.10 Warranty 10
3 Design and Function 11

3.1 Overview of the modules 12
3.2 Retarder identification 14
© 2008
3.3 VERA™ control unit identification 15
Page 2
3.4 Function and control scheme 16

3.5 Function description 17
4 Maintenance and Service 19

4.1 Maintenance intervals 20
4.2 Oil change 21
4.3 Checking the oil level 24
4.4 Coolant 27
5 Diagnosis and Troubleshooting 29

5.1 Overview of the possible complaints 30
5.2 Checking the constant-air pressure control loop 40
5.3 Checking the pump pressure pdyn 44
5.4 Checking the proportional valve current 48
6 Removing and Installing the Retarder 50
7 Repair 53
7.1 Components overview 54
7.2 Retarder ventilation 57

7.3 Oil separator module 59
7.4 Casing ventilation 60
7.5 Non-return valve (inlet) 67
7.6 Non-return valve (outlet) 69
7.7 2/2-way valve 71
7.8 Diaphragm housing cover 73
© 2008
7.9 Diaphragms 75
Page 3
7.10 Heat exchanger 81

7.11 Circuit parts 85
7.12 Output restrictor 90
7.13 Valve block 91
7.14 Oil temperature sensor 93
7.15 Coolant temperature sensor 95
8 Overview of the Tools 97

8.1 Diagnosis 98
8.2 Repair 100
© 2008
Page 4
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV 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 Imprint 7
© 2008
Page 5
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I About this Document Purpose of this document
1.1 Purpose of this document 1.2 Target groups
This Aftersales Service Manual provides information This Aftersales Service Manual is intended for service
and instructions on the maintenance and repair of the personnel for maintenance and diagnostics and may
Voith Retarder VR 115 HV. not be reproduced or given to third parties.
1.3 Other applicable documents
Documents Information Voith Item No.

Voith retarder oil change intervals/oil selection list Oil change intervals and approved oil types 153.000900xx
Cooling water quality list Approved coolants H67.2224xx
TM
ECU specifications Instructions on diagnosis for the VERA controller On request
Operating instructions for retarder tester Measured values for constant-air pressure py and pump pressure pdyn 153.001355xx, included in scope
of delivery of the retarder tester
(153.001085xx)
Operating instructions for "DIANA Lite" test software Information on the testing of: Included in the scope of delivery
• Constant-air pressure control loop of the "DIANA Lite" test software
(153.000776xx)
• Pump pressure pdyn
Operating instructions for the "WinDia®" diagnostic Instruction on PC diagnosis for retarders 3623-020900
software
Conversion instructions for the basic retarder Instructions for removing and installing the circuit parts and returning the 153.001905xx
VR 115 HV defective circuit parts
© 2008
Page 6
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I About this Document Symbols and identifications
1.4 Symbols and identifications 1.5 Item numbers

WARNING
Structure of warnings The item numbers used are usually found in the spare
Possible imminent danger that could lead to death
parts lists.
or serious injury if not prevented.
LEVEL OF DANGER Exceptions:
Type and source of danger!
Possible consequences if not heeded. DANGER • one- or two-digit item numbers
Ö Measures for the prevention of danger and its • item numbers with a slash
Immediate danger that leads to death or serious
consequences. injury if not prevented.
1.6 Imprint
Levels of danger Notes
For questions and work procedures not described in
The warnings are categorized into four levels of
these documents, contact the respective organization
danger: NOTE for your area.
Information on easier and safer work with the
Voith Turbo
CAUTION retarder.
Produktgruppe Retarder
Ö Measures for easier and safer work with the
Possible imminent danger that could lead to
retarder. Postfach 1555
damage to property if not prevented.
74555 Crailsheim
Distinctions Deutschland
CAUTION
Ö One-step action instruction. Phone: +49 79 51 / 32-401, 32-422, 32-1860

Fax: +49 79 51 / 32-756
Possible imminent danger that could lead to slight 1. First step of an action instruction. Other steps service-retarder@voith.com
injury if not prevented. follow and are numbered in sequence. www.voith.com
© 2008
Page 7
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV 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 Special tools 9
2.6 Diagnosis and Troubleshooting 9
2.7 Maintenance and repair 9
2.8 Driving mode 10
2.9 Storage 10
2.10 Warranty 10
© 2008
Page 8
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Basic Safety Information Product safety
2.1 Product safety 2.4 Environmental protection Danger of accidents if the retarder tester is used
improperly!
The retarder is constructed according to the state of Ö Drained fuels and fluids, consumables and old parts
Diagnosis while the vehicle is traveling results in an
the art in technology and acknowledged safety must be disposed of properly. uncontrollable operating state of the vehicle.
regulations.
2.5 Special tools Ö Carry out diagnosis only while the vehicle is
Nevertheless, hazardous situations and property standing still.
damage may occur as a result of improper usage,
Damage to property if false special tools are used!
maintenance and repair.
The special tools required are described in the 2.7 Maintenance and repair
Ö Observe safety and warning information. respective action instructions.
The chapter "Overview of the Tools" contains an Danger of burning and scalding via squirting oil!
2.2 Staff qualification overview of the special tools. The oil in the retarder may be hot.
In the case of special tools that may only be used from Ö Work carefully.
Ö Allow only qualified professionals to carry out repair
a specific version on, the version number is
and maintenance work.
contained in the last two digits of the Voith item no. Danger of burning and scalding via hot coolant!
Example: H53.942811. The coolant may be hot.
2.3 Safety-conscious working
Ö Only use special tools from the specified version Ö Work carefully.
Voith does not assume any liability for personal injury on.
and/or property damage caused by improper and
Danger of burns via hot parts!
unprofessional work. Ö Take the last two digits of the Voith item no. into
account in the graphics of the special tools. Parts of the retarder may be hot.
Ö Observe the following regulations:

Ö Work carefully.
- Accident-prevention regulations
2.6 Diagnosis and Troubleshooting
- Other generally acknowledged safety Ö Wear protective gloves or use cloths if necessary.
regulations and occupational health Voith provides a warranty/goodwill service for
- Motor Vehicle Regulations defective parts only.
- Safety regulations for handling chemical Ö Do not replace parts on mere speculation.
© 2008
substances such as oils and greases
Page 9
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Basic Safety Information Driving mode
Damage to property via soiled parts! Towing 2.10 Warranty

Considerable damage or malfunctions may occur due
Ö Tow the vehicle with the retarder rotating for max. Voith accepts no liability for damage caused by
to soiling.
100 km at max. 40 km/h. changes to the retarder or the use of spare parts,
Ö Ensure cleanliness. accessories, attachments and special features not
Ö Voith recommendation: Remove the prop shaft.
tested and approved by Voith.
Damage to property via improper cleaning!
Parking Ö Use only parts approved by Voith to ensure the
Ö Do not aim the jet of a high-pressure cleaner safety of the vehicle and functioning of the
Ö Do not use retarder as a parking brake, as it does
(steam-jet device) at valves, sensors or the exhaust retarder.
not act as a brake when the vehicle is standing still.
of the retarder.
Failure or performance reduction while driving

2.8 Driving mode
During failure of the retarder, or while temperature
Ö Ensure that the retarder is fully functional for all adaptation is active:
vehicle maneuvers, i.e.: Ö Adjust the speed of the vehicle with the engine/
- Retarder properly filled with oil service brake.
- Retarder electronic equipment connected and
Ö Engage the lowest possible gear in order to achieve
functional
a high engine speed.
- Pneumatic control connected and functional
- The retarder connected to the vehicle's cooling Ö During a temperature adaptation continue driving in
system this way until the retarder is available at full capacity

again.
Driving after oil change/checking the oil level
Ö When starting driving: Activate the retarder briefly in 2.9 Storage

braking stage 2 or 3. Ö Store or transport the retarder vertically, otherwise
oil may escape.
© 2008
Page 10
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Design and Function
3. Design and Function
3.1 Overview of the modules 12

3.2 Retarder identification 14
3.3 VERA™ control unit identification 15
3.4 Function and control scheme 16
3.5 Function description 17
© 2008
Page 11
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Design and Function Overview of the modules
3.1 Overview of the modules

1200 3100
Item No. Name
2700
801a Screw plug/oil drain plug 3200a
801b Screw plug/coolant drainage screw
900 Diaphragm housing cover
1200 Valve block VERA™
2700 Retarder ventilation 900
3100 Oil separator module
3200a Oil temperature sensor
3800a
3200b Coolant temperature sensor
3800a Non-return valve (outlet)
3200b
801b
© 2008
801a 36001
Page 12
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Design and Function Overview of the modules
Item No. Name

100 Retarder housing
3500 2/2-way valve 3500
3600 Service measuring point
3700 Screw plug/oil filler plug
3800b Non-return valve (inlet)
3700
3600
3800b
100
© 2008
36002
Page 13
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Design and Function Retarder identification
3.2 Retarder identification
NOTE
Ö Specify the following data in case you have
questions or are ordering spare parts:
1
- Serial No. (1) 0003394116
2
- Voith Item No. (2)
H67.3861.10
A9304300295
16 0
41 .1 5
39 61 29
03 .38 00
00 67 43
H 30
9
A
© 2008
36004
Page 14
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Design and Function VERA™ control unit identification
3.3 VERA™ control unit identification
Position of the retarder control unit in the vehicle:
• at the MB Actros: to the right in the electronics

compartment
84
20
02
x
e1
7x
06
• at the MB Axor: behind the front passenger seat .0
00
TM TT 53
A M- x-1 xx
V ER J-M x.x Sx
G
X3
t J x
ni JJ -D / Z
l U x / .D.xxxx
ro x
o nt xxxERA xxx
V xxx
C
X2
NOTE
er . x
rd No
ta al- o. .
Re eri rt N No
S a M
o
rb
X1
u
P E
T
h
it
o
O
V
Ö Specify the following data in case you have
H
IT
VO
questions or are ordering spare parts:
- Serial-No.
- Part No.
Ö Specify the following data of the retarder (see
page 14):
- Serial No.
- Voith Item No.
Retarder Control Unit VERATM

Voith Turbo
Serial-No. xxxxx / JJJJ-MM-TT

Part No. VERA.D.x-Dxx.xx-153.000067xx
e1 022084
OEM No. xxxxxxxxxx / ZGSxxx
VOITH
X1 X2 X3
© 2008
36006
Page 15
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Design and Function Function and control scheme
3.4 Function and control scheme

E
Item No. Name
A Rotor
NSG9 R 12
B Stator D 2700
C Oil tank
3500 A1
D Oil equalizing tank A2NG4 1200
2 NG3
E Ventilation duct "R"
G 5 1p 3 P
F Air and vent duct "A1" 3100 C
G Air and vent duct "A2"

800 Heat exchanger 3200a p
2300
1000 Diaphragm 1000 1000 F
3800b
1200 Valve block
2300 Casing ventilation
A B
2700 Retarder ventilation "R"
3100 Oil separator module 3800a
800
3200a Oil temperature sensor
3200b Coolant temperature sensor

3200b
3500 2/2-way valve
3800a Non-return valve (outlet)
3800b Non-return valve (inlet)
Oil sump
Constant-air pressure py
© 2008
Coolant
36007
Page 16
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Design and Function Function description
3.5 Function description Diaphragm (1000) Casing ventilation (2300)

The oil tank of the retarder (C) is located between the At the start of the braking process, the oil displaces
Rotor (A) diaphragms (1000). The purpose of the diaphragms the air in the system circuit. The air is displaced via the
The rotor (A) must include the oil in its rotation and (1000) is to separate the retarder oil and the constant- casing ventilation (2300) and the oil separator (3100).
accelerate it. air pressure py.
Once the system circuit is free of air, the casing
When the retarder is switched off, the constant-air ventilation (2300) closes.
Stator (B)
pressure present at the diaphragms (1000) py is
In the stator (B) the oil is re-directed and is returned to routed through the valve block (1200) and escapes at Retarder ventilation "R" (2700)
the rotor (A) at the internal diameter of the working the retarder ventilation (2700). The constant-air When the retarder is switched off, the constant-air
chamber. pressure py and the retarder ventilation (2700) are pressure present at the diaphragms (1000) py is
not connected to the retarder oil. routed via the valve block (1200) and escapes into the
Oil equalizing tank (D)
atmosphere at the retarder exhaust (2700).
When the retarder is switched off, the oil equalizing Valve block (1200)
tank (D) takes up some of the oil flowing back from the The valve block (1200) is connected to the Oil separator (3100)
system circuit. The oil is fed back to the oil tank (C) via compressed air system of the vehicle (auxiliary The oil separator (3100) separates out the oil from the
the open 2/2-way valve (3500). The air separated out equipment circuit). The proportional valve integrated exhaust air. The minimum exhaust air containing oil
of the oil is fed into the atmosphere via the oil in the valve block (1200) receives an electrical input comes out of the system circuit via the casing
equalizing tank (D) and the oil separator (3100). signal from the retarder control unit. A pneumatic ventilation (2300) and from the oil equalizing tank (D).
constant-air pressure py is then applied to the
Heat exchanger (800) diaphragms (1000). This is dependent on the intensity Temperature sensors for oil (3200a) and coolant
The heat exchanger (800) dissipates the generated of the electrical input signal. This applies pressure to (3200b)
heat to the vehicle cooling system. the oil in the oil tank (C).
The temperature sensors forward information about
A pressure sensor integrated in the valve block (1200) the temperature of oil and coolant to the retarder
measures and regulates the pneumatic constant-air control unit in the vehicle.
pressure py.
Limiting points and maximum values for the coolant
and oil temperature are set in the control unit to
protect the cooling system and the retarder.
© 2008
Page 17
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Design and Function Function description
If one of the temperature limit points is exceeded (3500). There is a connection to the atmosphere via
during a braking operation, the braking torque is the oil separator (3100).
adjusted via the constant-air pressure py. The
The 2/2-way valve (3500) prevents too much of the oil
braking moment is adjusted until an equilibrium is
flowing back into the oil tank (C) from entering the oil
achieved between the produced braking energy and
equalizing tank (D).
the heat dissipated via the vehicle cooling system.
The oil that has accumulated in the oil equalizing tank
If one of the maximum values is exceeded, the
(D) flows back into the oil tank (C) via the opened 2/
braking torque is no longer actuated (corresponds to
2-way valve (3500).
a reduction to 0).
In addition the braking torque is adjusted if the oil Non-return valve (outlet) (3800a)
temperature rises rapidly (gradient), regardless of the In braking mode, the oil reaches the heat exchanger
actual oil temperature. (800) from the working chamber via the non-return
valve (outlet) (3800a), is cooled down and is fed back
The vehicle speed has to be adjusted with the service
into the system circuit or the oil tank (C).
brake while the adjustment is active.
Non-return valve (inlet) (3800b)

2/2-way valve (3500)
When the retarder is switched on, pressure is applied
The 2/2-way valve (3500) closes when the retarder is
to the oil via the diaphragms (1000). This opens the
switched on. This separates the connection of the oil
non-return valve (inlet) (3800b) and allows the oil into
tank (C) to the oil equalizing tank (D) and the oil
the working chamber.
separator (3100).
When the retarder is switched off, the 2/2-way valve

(3500) is opened again with a time delay.
The air in the oil tank (C) and in the oil flowing back
out of the system circuit can escape into the oil
equalizing tank (D) via the opened 2/2-way valve
© 2008
Page 18
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Maintenance and Service
4. Maintenance and Service
4.1 Maintenance intervals 20

4.2 Oil change 21
4.3 Checking the oil level 24
4.4 Coolant 27
© 2008
Page 19
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Maintenance and Service Maintenance intervals
4.1 Maintenance intervals
The maintenance intervals depend on the load placed on the retarder.
CAUTION
Exceeding of the maintenance intervals/incor-
rect oil sort!
Damage to/failure of the retarder.
Ö Observe the maintenance intervals.
Ö Use only approved oils.
Activity Interval See

Change oil ÖSee the specifications of the vehicle manufacturer or the Page 21
Voith retarder oil change interval/oil selection list.
Checking the oil level – Page 24
Draining the coolant ÖObserve the specifications of the vehicle manufacturer. Page 27
© 2008
Page 20
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Maintenance and Service Oil change
4.2 Oil change
Item No. Name

801 Screw plug M 14 x 1.5;
25 Nm
802 Sealing ring A 14 x 20; replace
30 Nm
100 Nm 3700
5100
5000
NOTE
Ö Lubricate sealing rings, O-rings and shaft 3600
sealing rings with silicone-free and non-
corrosive grease before installation.
Oil filling level

Service filling (checking of the oil level, 5.6 l

oil change)
After replacement of the heat exchanger 7.0 l 802
Refilling of the emptied heat exchanger 7.0 l
after complete disassembly and cleaning
801
© 2008
36005
Page 21
Maintenance work during each oil change Requirements
Ö Visual inspection of retarder for leaks before and • Vehicle is horizontal 3600
after the oil change.
• Oil is at operating temperature (> 60 °C)
Ö Tighten the hex.-head screws (5400) at the heat
• Retarder switched off
exchanger (see page 81).
• Ignition switched off
Additional maintenance work at every
2nd oil change
Draining the oil
Ö Replace the oil separator at the oil separator module
(see page 59). 1. Place oil pan below the retarder. 801
36008
Aids WARNING
Manual tire filler 2. Unscrew the screw plug (801) and drain the oil.
Hot exiting oil!
Special tools
Face and hands could be burned. WARNING
Ö Ensure that the retarder and the ignition are
Hot oil comes out under increased pressure!
switched off.
Face and hands could be burned.
Ö Unscrew the screw plug (3600) slowly.
CAUTION
3. Unscrew the screw plug (3600) slowly.

Hot screw plugs!
Hands could be burned.
153.000885xx Ö Work carefully.
Ö Wear protective gloves or use cloths if
Throttle piece necessary.
50/31
© 2008
Page 22
7. Apply short pulses of air onto the hole of the screw 15.Fill in the oil slowly via the hole of the screw plug
plug (3600) of the retarder. (3700).
8. Repeat the procedure until only oil mist comes out 16.Lubricate the new sealing ring (5100) with
50/31
at the hole of the screw plug (801). silicone-free and non-corrosive grease.
9. Lubricate the new sealing ring (802) with silicone- 17.Screw in the screw plug (3700) with the sealing
50/39 free and non-corrosive grease. ring (5100) and tighten it to 100 Nm.
10.Screw in the screw plug (801) with the new NOTE

sealing ring (802) and tighten it to 25 Nm.
Ö When starting driving: Activate the retarder
11.Remove the manual tire filler (50/39) and unscrew briefly in braking stage 2 or 3.
the throttle piece (50/31).
36003
12.Lubricate the new sealing ring (5000) with
4. Screw in the throttle piece (50/31) with the sealing silicone-free and non-corrosive grease.
ring (5000) present.
13.Screw in the screw plug (3600) with the sealing
5. Tighten the throttle piece with 10 Nm. ring (5000) and tighten it to 30 Nm.
6. Connect the manual tire filler (50/39) to the throttle Filling in oil
piece (50/31).
14.Unscrew the screw plug (3700).
NOTE
CAUTION
To completely empty the retarder circuit, pulsed air
is applied to the hole of the screw plug (3600). Wrong oil type!
Damage to/failure of the retarder.
Ö Do not use a constant air pressure.
Ö Fill only with approved oil (see Voith retarder oil
change intervals/oil selection list).
© 2008
Page 23
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Maintenance and Service Checking the oil level
4.3 Checking the oil level
Item No. Name

25 Nm
30 Nm
100 Nm 3700
5100
5000
NOTE
Oil filling level

Service filling (checking of the oil level, 5.6 l

oil change)
802
801
© 2008
36005
Page 24
Draining the oil

Aids
Manual tire filler 1. Place oil pan below the retarder. 3600
Special tools WARNING

Hot exiting oil!
Ö Ensure that the retarder and the ignition are
switched off.
CAUTION 801
153.000885xx 36008
Hot screw plugs!
Hands could be burned. 2. Unscrew the screw plug (801) and drain the oil.
Throttle piece
Ö Work carefully.
50/31 Ö Wear protective gloves or use cloths if WARNING
necessary. Hot oil comes out under increased pressure!
Requirements
Ö Unscrew the screw plug (3600) slowly.
• Vehicle is horizontal
• Oil is at operating temperature (> 60 °C) 3. Unscrew the screw plug (3600) slowly.

© 2008
Page 25
8. Repeat the procedure until only oil mist comes out Filling in the oil
of the hole of the screw plug (801).
3. Unscrew the screw plug (3700).
9. Lubricate the new sealing ring (802) with silicone-
50/31
free and non-corrosive grease. CAUTION
10.Screw in the screw plug (801) with the new Wrong oil type!
50/39 sealing ring (802) and tighten it to 25 Nm. Damage to/failure of the retarder.
Ö Fill only with approved oil (see Voith retarder oil
11.Remove the manual tire filler (50/39) and unscrew
change intervals/oil selection list).
the throttle piece (50/31).
12.Lubricate the new sealing ring (5000) with 4. Fill in the oil slowly via the hole of the screw plug
silicone-free and non-corrosive grease. (3700).
36003
13.Screw in the screw plug (3600) with the sealing 5. Lubricate the new sealing ring (5100) with
ring (5000) and tighten it to 30 Nm. silicone-free and non-corrosive grease.
4. Screw in the throttle piece (50/31) with the sealing
ring (5000) present. 6. Screw in the screw plug (3700) with the sealing
Measuring the volume
ring (5100) and tighten it to 100 Nm.
5. Tighten the throttle piece with 10 Nm.
6. Connect the manual tire filler (50/39) to the throttle NOTE NOTE
piece (50/31). For technical reasons, it is possible for the drained- Ö When starting driving: Activate the retarder
off oil quantity to be up to 0.2 l less than the service briefly in braking stage 2 or 3.
NOTE
filling of 5.6 l.
To completely empty the retarder circuit, pulsed air

1. Measure the volume of the drained oil.
is applied to the hole of the screw plug (3600).
Ö Do not use a constant air pressure. 2. If necessary, correct the oil volume.
7. Apply short pulses of air onto the hole of the screw

plug (3600) of the retarder.
© 2008
Page 26
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Maintenance and Service Coolant
4.4 Coolant
Item No. Name

800 Heat exchanger
801b Screw plug M 14 x 1.5;
hexagon socket head, w.a.f. 6;
25 Nm
Requirements
• Ignition switched off 801b
802
801b
800
© 2008
36055
Page 27
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Maintenance and Service Coolant
1. Place a clean coolant collecting pan under the

retarder.
CAUTION
Hot parts and coolant!
Burns and scalding could occur.
Ö Work carefully.
necessary.
2. Unscrew the screw plug (801b) and drain the

coolant.
CAUTION
Wrong coolant!
Damage to the vehicle and retarder cooling circuit.
Ö Observe the specifications of the vehicle
manufacturer or those of Voith Turbo coolant
quality list.
3. Fill the vehicle and retarder cooling circuit (see

specifications of vehicle manufacturer).
© 2008
Page 28
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting
5. Diagnosis and Troubleshooting
5.1 Overview of the possible complaints 30

5.2 Checking the constant-air pressure control loop 40
5.3 Checking the pump pressure pdyn 44
5.4 Checking the proportional valve current 48
© 2008
Page 29
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting Overview of the possible complaints
5.1 Overview of the possible complaints
No. Complaint See

A Retarder pilot light flashes (standard type): Page 31
On-board diagnosis is possible at some vehicle
manufacturers (display).
ÖObserve the specifications of the vehicle
manufacturer.
B Oil leak via retarder ventilation (2700) or oil separator Page 32
(3101)
C No or insufficient brake efficiency Page 33
D Other external leak: Page 36
ÖEnsure that there are no leaks at the screw plugs or
sealing rings.
E High driving resistance Page 38
Possible effects:
• Coolant temperature too high
–and/or–
• Fuel consumption too high
–and/or–
• Engine power too low
© 2008
Page 30
A Retarder pilot light flashes (standard type)
NOTE
On-board diagnosis is possible at some vehicle
manufacturers (display).
manufacturer.
No. Activity Result Continue with No.

1. ÖCheck the operation (for retarder braking, nominal NOK 2.
speed of the engine, if possible).
OK 3.
2. ÖInstruct the driver. In doing so, observe the operating – –

conditions.
3. ÖCheck the oil temperature sensor (3200) (see NOK 4.
page 93).
OK 5.
ÖCheck the coolant temperature sensor (3200) (see
page 95).
4. ÖReplace the oil temperature sensor (3200) (see – –
page 93).
–and/or–
ÖReplace the coolant temperature sensor (3200) (see
page 95).
5. ÖCheck the cooling system of the vehicle (see – –
specifications of the vehicle manufacturer).
NOK = does not work correctly

© 2008
OK = works correctly
Page 31
B Oil leak via retarder ventilation (2700) or oil separator (3101)

1. ÖCheck whether the retarder leaks oil via the retarder Yes 2.
ventilation (2700).
No 3.
2. ÖCheck the diaphragms (1000) for damage and – –
correct installation position, replace if necessary (see
page 75).
3. ÖCheck whether water is contained in oil (emulsion). Yes 4.
No 5.
4. ÖCheck the heat exchanger (800), replace if necessary – –
(see page 81).
5. ÖCheck the casing ventilation (2300) (see page 60). NOK 6.
OK 7.
6. ÖReplace the casing ventilation (2300) (see page 60). – –
7. ÖOn the 2/2-way valve (3500), replace the O-rings – –

(3502, 3503) and the sealing ring (3501) (see
page 71).
ÖIf the problem occurs again: Replace the 2/2-way

valve (3500) (see page 71).

© 2008
Page 32
C No or insufficient brake efficiency

1. Check whether an external leak is visible at the retarder Yes 2.
(except the retarder ventilation).
No 3.
2. ÖRepair the retarder. – D
3. ÖCheck whether water is contained in oil (emulsion). Yes 4.
No 5.
4. ÖCheck the heat exchanger (800), replace if necessary – –
(see page 81).
5. ÖCheck the retarder oil level (see page 24). NOK 6.
ÖCheck the gearbox oil level (see specifications of
vehicle manufacturer). OK 9.
6. ÖCorrect the retarder oil level (see page 24). – 7.

ÖCorrect the gearbox oil level (see specifications of
vehicle manufacturer).
7. If the gearbox oil level is too low and the retarder oil – –
level is too high:
ÖCheck the gearbox ventilation and repair/clean if
necessary (see specifications of vehicle

manufacturer).
The fault search is completed at this point.
Problem occurs again? Yes 8.

© 2008
Page 33

8. ÖReplace the circuit parts (33) (see page 85). – –
9. ÖCheck the constant-air pressure control loop (see NOK 10.
page 40).
OK 11.
10. ÖReplace the valve block (1200) (see page 91). – –
11. ÖCheck the proportional valve current as well as the NOK 12.
leads and the plug connections (see page 48).
OK 15.
12. ÖCheck the oil temperature sensor (3200) and the NOK 13.
supply line (see page 93).
ÖCheck the coolant temperature sensor (3200) and the OK 14.
13. ÖReplace the oil temperature sensor (3200) or the – –
–and/or–
ÖReplace the coolant temperature sensor (3200) or
the supply line (see page 95).
14. ÖPerform diagnosis with WinDia®. Use Voith ECU – –
specification for this.
–or–
ÖCarry out off-board diagnosis (see specifications of

vehicle manufacturer).
15. ÖCheck the pump pressure pdyn (see page 44). NOK 16.
OK 19.

© 2008
Page 34

16. ÖCheck the casing ventilation (2300) (see page 60). NOK 17.
OK 18.
17. ÖReplace the casing ventilation (2300) (see page 60). – –
18. ÖReplace the circuit parts (33) (see page 85). – –
19. Complaint mentioned above is not possible. – –
ÖClarify the complaint again with the customer or
perform the tests once again.

© 2008
Page 35
D Other external leak
NOTE
Ö Ensure that there are no leaks at the screw
plugs or sealing rings.

1. ÖCheck whether the retarder leaks oil or water near the Yes 2.
heat exchanger (800).
No 7.
2. ÖCheck the heat exchanger (800) and O-rings (3300) NOK 3.
(see page 81).
OK 4.
3. ÖReplace the heat exchanger (800) (see page 81). – –

–and/or–
ÖReplace the O-rings (3300) (see page 81).
4. ÖCheck the hose connection between the water neck NOK 5.
at the heat exchanger (800) and the water pipe in the
OK 6.
vehicle (see specifications of the vehicle
manufacturer).
5. ÖReplace the hose connection (see specifications of – –
the vehicle manufacturer).
6. ÖContact Voith. – –

© 2008
Page 36

7. ÖCheck whether the retarder leaks near the non-return Yes 8.
valve (inlet or outlet) (3800).
No 9.
8. Version with integrated sealing ring: – –
ÖCheck the sealing ring (see page 67 onw.).
ÖIf necessary, replace the non-return valve (inlet or
outlet) (3800) (see page 67 onw.).
Version with copper sealing ring:
ÖReplace the sealing ring (5200) (see page 67 onw.).
ÖIf necessary, replace the non-return valve (inlet or
outlet) (3800) (see page 67 onw.).
9. ÖCheck whether the retarder leaks near the housing Yes 10.
cover of the diaphragms.
No 11.
10. ÖCheck the diaphragms (1000) for damage and – –
correct installation position, replace if necessary (see
page 75).
ÖReplace the O-ring (3900) (see page 75).
11. ÖCheck whether the retarder leaks near the circuit Yes 12.
parts (33).
No 13.
12. ÖRemove, reseal and refit the circuit parts (33) (see – –
page 85).

© 2008
Page 37
E High driving resistance
NOTE
Possible effects:
• Coolant temperature too high
–and/or–
• Fuel consumption too high
–and/or–
• Engine power too low

1. ÖCheck whether the retarder ventilation (2700) is Yes 2.
heavily solied (see page 57).
No 3.
2. ÖClean the retarder ventilation (2700) and replace if – –
necessary.
3. ÖCheck whether the coolant temperature is too high. Yes 4.
No 6.
4. ÖCheck the operation (for retarder braking, nominal NOK 5.
speed of the engine, if possible).

OK 6.
5. ÖInstruct the driver. In doing so, observe the operating – –

conditions.

© 2008
Page 38
6. ÖCheck the 2/2-way valve (3500) (see page 71). NOK 7.
OK 8.
7. ÖReplace the 2/2-way valve (3500) (see page 71). – –


© 2008
Page 39
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting Checking the constant-air pressure control loop
5.2 Checking the constant-air

pressure control loop
NOTE
The constant-air pressure control loop check
provides information about
• internal and external leaks of the retarder
99/7
• proper functioning of the retarder
• proper control of the retarder
Item No. Name 50/56b

99/7 Pressure gauge 0–6 bar
50/56a Retarder tester
50/56b Cable 1: to the valve block
50/56d Cable 3: to the temperature sensors
50/56e Cable 4: to the vehicle voltage supply/PC 50/56a
interface 50/56e
50/56d
© 2008
36075
Page 40
Special tools Commercially available tools

NOTE
Multimeter
Due to construction, a small amount of oil may leak
out; this does, however, not affect retarder
Requirements
operation.
• Retarder switched off DANGER

153.001085xx 153.000776xx H53.1403xx • Battery voltage: 18–32 V Diagnosis with the retarder test device while the
vehicle is traveling!
• Supply-air pressure pv in auxiliary circuit 6–11 bar
Retarder tester, Test software Pressure gauge Uncontrollable operating state of the vehicle.
complete in a "DIANA Lite" 0–6 bar • Oil level checked and in order (see page 24) Risk of accident.
case Ö Carry out diagnosis only while the vehicle is
• Electrical system of vehicle checked and in order
50/56 50/56i 99/7 standing still.
(see specifications of vehicle manufacturer)
• Electrical connections of the retarder completely

NOTE disconnected from the vehicle
The test software "DIANA Lite" (50/56i) is included
in the retarder tester scope of delivery (50/56) CAUTION
Hot parts!

NOTE Ö Work carefully.
With the test software "DIANA Lite" (50/56i), Ö Wear protective gloves or use cloths if
measured values can be read out and stored via the necessary.
PC in addition to the tests with the retarder tester.
The stored measured values can be transmitted to
the Voith customer service for evaluation (see
© 2008
operating instructions on CD-ROM).
Page 41
Connecting the pressure gauge Connecting the retarder tester Checking the supply voltage of the pressure
sensor
5. Switch on the vehicle ignition.

VR 115 HV
50/563b310 1200 6. Set the "RETARDERTYP" (retarder type) switch at
8
153.000
1
the retarder tester (50/56a) to "8".
2
3700 50/56a
3
5100 50 7. Switch the toggle switch to the position "EIN mit
15 /56
4
3.0
00 d Regelkreis" (on with control loop).
83
51 3200a
0
3200b 8. Connect the multimeter to the "U_Versorgung"

50/56e (U_Supply) socket (measuring type: V).
153.00083610
9. Read the measured value: Setpoint 4.75 V–5.25 V.

36101 36099
10.If the value deviates: Replace the valve block

1. Unscrew the screw plug (3700). 1. Connect the cable 1 (50/56b) at the valve block (1200) (see page 91).
(1200).
99/7 Checking the signal value of the pressure sensor
2. Connect the cable 3 (50/56d) at the oil
temperature sensor (3200a) and at the coolant 11.Connect the multimeter to the "U_py IST" (U_py
temperature sensor (3200b). actual) socket (measuring type: V).
3. Connect the cable 4 (50/56e) to the vehicle 12.Read the measured value: Setpoint 0.3 V–0.7 V.
voltage supply/PC interface.

13.If the value deviates: Replace the valve block
4. Connect all the cables to the retarder tester (50/ (1200) (see page 91).
56a) (see also the operating instructions of the
retarder tester).
36076
© 2008
2. Connect the pressure gauge (99/7) to the hole of

the screw plug (3700).
Page 42
Checking the valve block 25.Screw in the screw plug (3700) with O-ring (5100)
"STELLDRUCK" Constant-air pressure py [bar]
and tighten it to 100 Nm.
14.Start the "DIANA-Lite" test software. (constant-air Permissible range
pressure) 26.Complete the retarder and the vehicle.
15.Load the template for the retarder tester (see switch
operating instructions of the "DIANA-Lite" test 0% 0
software).
25% 0.55–1.05
16.Set the "STELLDRUCK" (constant air pressure) 50% 1.25–1.75
switch at the retarder tester to "25%".
75% 1.95–2.45
NOTE 100% 2.60–3.10
To assess the operation of the proportional valve 18.Repeat the test in the switch positions "50%",
block (1200), the results of the following test are "75%" and "100%".
only valid during a testing period of 60 seconds
maximum. 19.If one of the values deviates: Check the valve
block (1200), replace if necessary (see page 91).
17.In "DIANA-Lite" read the "Stelldruck Ist" (constant-
20.Set the "STELLDRUCK" (constant air pressure)
air pressure actual) measured value and the
measured value at the pressure gauge (99/7):
Setpoint after approx. 20 seconds: 21.Switch the toggle switch to the "AUS" (off)
position.
22.Switch off the vehicle ignition.
23.Disconnect the retarder tester (50/56a) and

pressure gauge (99/7).
24.Lubricate the new O-ring (5100) with silicone-free

and non-corrosive grease.
© 2008
Page 43
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting Checking the pump pressure pdyn
5.3 Checking the pump pressure pdyn
NOTE
Checking the pump pressure pdyn provides
information about
• the mechanical status of the rotor parts
• internal leaks of the retarder
• proper functioning of the retarder
Item No. Name

3600 Screw plug M 14 x 1.5; 50/56b
30 Nm
50/56a Retarder tester
50/56b Cable 1: to the valve block 50/56c
50/56a
50/56c Cable 2: to the pressure sensor (50/56g)
50/56e
50/56d Cable 3: to the temperature sensors
50/56d
50/56e Cable 4: to the vehicle voltage supply/PC 50/56g

interface 5000
50/56g Pressure sensor pdyn 0–30 bar 3600
© 2008
36072
Page 44
Requirements
Special tools
NOTE
If the prop shaft screws are screwed in from the
• Retarder switched off transmission side:
Ö Ensure that the prop shaft screws are screwed
• Battery voltage: 18–32 V
out at the drive-side flange.
• Supply-air pressure pv in auxiliary circuit 6–11 bar –or–
Ö Secure the prop shaft screws.
• Oil level checked and in order (see page 24)
153.001085xx 153.000776xx
Retarder tester, Test software (see specifications of vehicle manufacturer) CAUTION
complete in a "DIANA Lite" Hot parts and oil!
• Electrical connections of the retarder completely
case
disconnected from the vehicle Hands can be burned and scalded.
50/56 50/56i Ö Work carefully.
• No external leaks detected at retarder
necessary.
NOTE • Vehicle secured
With the test software "DIANA Lite" (50/56i), • Prop shaft removed from flanges and secured (see
measured values can be read out and stored via the specifications of vehicle manufacturer) NOTE
PC in addition to the tests with the retarder tester.
The stored measured values can be transmitted to Due to construction, a small amount of oil may leak
out; this does, however, not affect retarder

the Voith customer service for evaluation (see
operating instructions on CD-ROM). operation.
© 2008
Page 45
3. Connect the cable 1 (50/56b) on the valve block

DANGER (1200).
Diagnosis with the retarder test device while the 4. Connect the cable 2 (50/56c) on the pressure
vehicle is traveling! sensor (50/56g).
Uncontrollable operating state of the vehicle.
5. Connect the cable 3 (50/56d) at the oil
Risk of accident.
temperature sensor (3200a) and at the coolant
Ö Carry out diagnosis only while the vehicle is
temperature sensor (3200b).
standing still.
50/36 6. Connect the cable 4 (50/56e) to the vehicle
Connecting the pressure sensor voltage supply/PC interface.
36074 7. Connect all the cables to the retarder tester (50/

56a) (see also the operating instructions of the
2. Connect the pressure sensor (50/56g). retarder tester).
Connecting the retarder tester Checking the pump pressure pdyn

VR 115 HV
9. Set the "RETARDER-TYP" (retarder type) switch
50/56b0 1200
at the retarder tester to "8".
8331
153.000
1
5000 50/56c
2
10.Switch the toggle switch to the position "EIN mit

3600 50/56a 153.00

08341
0 50/56g
3
36073 50 Regelkreis" (on with control loop).

15 /56
4
3.0
00 d
83
51 3200a 11.Start the "DIANA-Lite" test software.
0
1. Unscrew the screw plug (3600) with the sealing
ring (5000). 3200b
50/56e 12.Load the template for the retarder tester (see
153.00083610
operating instructions of the "DIANA-Lite" test
36098
software).
© 2008
Page 46
13.Start the engine and warm it up to the operating

temperature. NOTE
NOTE If the setpoint of the constant-air pressure py is
reached, but the pump pressure pdyn is undershot,
Ö Shift in direct gear (ratio 1:1). the retarder has an internal defect.
The engine speed then corresponds to the prop Ö Replace the circuit parts (see page 85).
shaft speed.
14.Set the "STELLDRUCK" (constant-air pressure) NOTE

switch at the retarder tester to "25%". Test when the "STELLDRUCK" (constant-air
pressure) switch is set to "100%":
15.Adjust the engine speed:
"Housing pressure Actual" setpoint > 12 bar.
- for iRet = 2.13 to 1000 min-1 Is normally not possible with the retarder tester
- for iRet = 1.68 to 1200 min-1 when the vehicle is standing still.
16.Set the "STELLDRUCK" (constant-air pressure)

19.Set the "STELLDRUCK" (constant-air pressure)
17.Adjust the engine speed again:
20.Disconnect the retarder tester (50/56a) and all
- for iRet = 2.13 to 1000 min-1 cables.
- for iRet = 1.68 to 1200 min-1
21.Disconnect the pressure sensor (50/56g).
18.In the "DIANA Lite", read off the measured value

22.Lubricate the new sealing ring (5000) with
"Housing pressure Actual": Setpoint > 8 bar.
silicone-free and non-corrosive grease.
23.Screw in the screw plug (3600) with the sealing

ring (5000) and tighten it to 30 Nm.
24.Complete the retarder and vehicle.

© 2008
Page 47
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting Checking the proportional valve current
5.4 Checking the proportional valve Requirements Scope of work – testing

current • Ignition switched off

Special tool
98/8
• Battery voltage: 18–32 V

(see specifications of vehicle manufacturer)
VOITH Messadapter 153.00013210

Drucksensor Steuerdruck
• Fuse for retarder control unit checked and in order
Schaltventil
Propventil
Schaltventil
Propventil
• Male and female plug connectors at valve block

99/10
153.000132xx checked for damage or wear (notch scratches) and
in order 36077
Measuring • Electrical lead and plug connections checked 1. Disconnect the plug from the valve block (1200)
adapter (visual inspection) and in order and connect it to the measuring adapter (99/10).
99/10
2. Connect the plug of the measuring adapter (99/
10) to the valve block (1200).
NOTE
3. Connect the multimeter (98/8) (measuring type:
When performing measurements using a mA).
commercially available multimeter (without real

r.m.s. value measurement), exact readout of these 4. Turn the "Prop flow" switch at the measuring
measured values is not possible (display jumps). adapter to Position "I".

Commercially available tools
Multimeter (98/8) with real r.m.s. value

measurement, e.g. Fluke 179
© 2008
Page 48
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting Checking the proportional valve current
6. Shift the retarder to the highest gear.
NOTE
The measured values correspond to the state of the
art at the time of going to print. The manufacturer
reserves the right to make changes.
7. Read off the measured value on the multimeter

(98/8): Setpoint 471–771 mA.
8. If the value deviates: Check the leads, connectors

and retarder control unit and replace them, if
necessary.
© 2008
Page 49
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Removing and Installing the Retarder
6. Removing and Installing the Retarder
DANGER CAUTION
Retarder can fall! Improper removal/installation!
Your body can be crushed severely. Damage to the retarder.
Ö Secure retarder against falling. When using a hydraulic piston for lifting:
Ö Use a suitable lifting device. Ö Do not press directly onto the heat exchanger
with the hydraulic piston.
Ö Use a wooden board or similar for protection.
CAUTION
Hot parts!
Ö Work carefully.
necessary.
© 2008
Page 50
Item No. Name

11 Electrical connection, valve block
26 Supply-air pressure line pv,
Valve block connection
3200/10
95/1 Flanged nut M 14 x 1.5;
170 Nm
26
95/2 Hex.-head screw M 14 x 1.5 x 120;
170 Nm 100
96 Hose clamp
97 Hose supports
100 Retarder
50300 O-ring 198 x 3; replace
3200/10 Oil temperature sensor connection
3200/20 Coolant temperature sensor connection
NOTE 50300

sealing rings with silicone-free and non- 96
corrosive grease before installation. 97

3200/20
96 97
95/2
95/1
© 2008
95/2 95/1 36078
Page 51
Requirements
?
• Supply-air pressure pv drained
• Retarder oil drained (see page 21)
• Coolant drained (see page 27)
• Oil drained from the gearbox (see specifications of

vehicle manufacturer)
© 2008
Page 52
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair
7. Repair
7.1 Components overview 54

7.2 Retarder ventilation 57
7.3 Oil separator module 59
7.4 Casing ventilation 60
7.5 Non-return valve (inlet) 67
7.6 Non-return valve (outlet) 69
7.7 2/2-way valve 71
7.8 Diaphragm housing cover 73
7.9 Diaphragms 75
7.10 Heat exchanger 81
7.11 Circuit parts 85
7.12 Output restrictor 90
7.13 Valve block 91
7.14 Oil temperature sensor 93
7.15 Coolant temperature sensor 95

© 2008
Page 53
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Components overview
7.1 Components overview

Replace component
Item No. Name Check component according to specifications and
300 Gasket plate 5500 3200a 4200 replace if necessary
800 Heat exchanger 5000 Perform visual inspection and replace if necessary
4800 3101
1000 Diaphragm 3500 3000
1200 Valve block 4500
3501
2200 O-ring 125 x 2.5 2300
2300 Casing ventilation 2301
2301 O-ring 55 x 3
2700 Disc silencer 42 x 2
2200
2800 O-ring 38 x 3 1000 4000
3900 300 2700
2900 Circlip 42 x 1.75 3800 1000 2800 1200
3000 O-ring 6 x 3 2900
4100 4300
3800
3101 Oil separator
3400
3300 3300
NOTE
3200b
900
5400
© 2008
36042
Page 54
Item No. Name Replace component

3200a Oil temperature sensor M 14 x 1.5; Check component according to specifications and
hexagon insert bit, w.a.f. 27;
5500 3200a 4200 replace if necessary
28 Nm
3200b Coolant temperature sensor M 14 x 1.5; 5000 Perform visual inspection and replace if necessary
28 Nm 4800 3101
3300 O-ring 37.46 x 5.33 3500 3000
4500
3400 O-ring 60 x 5 3501
2300
3500 2/2-way valve
2301
3501 Sealing ring A 36 x 42
3800 Non-return valve
3900 O-ring 253.6 x 3.53 2200
1000 4000
4000 Intermediate ring 270/220 x 52.5 3900 300 2700
3800 1000 2800 1200
2900
NOTE 3800
4100 4300
3400
Ö Lubricate sealing rings, O-rings and shaft
3300 3300
3200b
5000
800
900
5400
© 2008
36042
Page 55
Item No. Name Replace component

4100 Hex.-head screw M 8 x 20; Check component according to specifications and
5500 3200a 4200 replace if necessary
22 Nm
4200 Hex.-head screw M 8 x 75; 5000 Perform visual inspection and replace if necessary
25 Nm 4800 3101
4300 Hex.-head screw M 10 x 40; 3500 3000
hexagon insert bit, w.a.f. 16; 4500
50 Nm 3501
2300
4500 O-ring 200 x 3
2301
4800 Sealing cover A 20
5000 Sealing ring A 14 x 20
2200
5400 Hex.-head screw M 10 x 40; 1000 4000
hexagon insert bit, w.a.f. 16; 3900 300 2700
50 Nm 3800 1000 2800 1200
2900
5500 Hex.-head screw M 10 x 40; 4100 4300
hexagon insert bit, w.a.f. 16; 3800
30 Nm 3400
3300 3300
NOTE
3200b
5000
900
5400
© 2008
36042
Page 56
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Retarder ventilation
7.2 Retarder ventilation
Item No. Name

2700 Disc silencer 42 x 2;
check, clean and blow out with
compressed air
2900 Circlip 42 x 1.75 2800
2700
2900
Aids
Benzene for disc silencer
DANGER
Heavily soiled or painted-over retarder
ventilation!
Retarder reduces braking power after a delay.
Ö Replace retarder ventilation.
© 2008
36043
Page 57
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Retarder ventilation
CAUTION
Mechanically damaged retarder ventilation!
Malfunction of the retarder.
Ö Replace retarder ventilation.
Requirements

© 2008
Page 58
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Oil separator module
7.3 Oil separator module

5500
Item No. Name
3100 Oil separator module
3101 Oil separator
5500 Hex.-head screw M 10 x 40; 3100 3101
30 Nm
CAUTION
Hot parts!
Ö Work carefully.
necessary.
Requirements


© 2008
36044
Page 59
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Casing ventilation
7.4 Casing ventilation
Item No. Name 2300/1

2300 Casing ventilation
2301
2300
2300/1 Valve insert
2300/2
2300/2 Float, specified weight max. 12 g
2300/3 Float cage 2300/3
NOTE
NOTE
For casing ventilation from Voith item no.
H53.133214 upwards:
Ö Observe the installation position of the float: The
side marked "O" upwards.

© 2008
36045
Page 60
Aids
NOTE Item No. Name
Ethyl alcohol for float 10 Plate 140x30x8; S 235JR
If, for space reasons, the impact puller Voith item
11 2 x web 30x8x8, S 235JR; weld onto the
no. H53.7712xx cannot be used to remove the
CAUTION casing ventilation, a puller (98/7) for self-fabrication
plate
is available as an alternative. 12 Hex.-head screw M8x90; DIN 931
Incorrect adapter!
13a Hex.-head nut M8; ISO 4032
Damage to casing ventilation.
Ö Only use adapter (98/9) from Voith item no. Tools for self-fabrication 13b Hex.-head nut M8; ISO 4032; attach to
the screw (12)
H53.942811 upwards.
12
10 13a Tools for self-fabrication
Special tools
11 13b 11
8
16 Ø10
8 8
Ø 40.5 mm
7 mm
12
Ø 60 mm
37.5 37.5 27079_en

H53.7712xx H53.9428xx
Test ring
Impact puller Adapter

99/4
30
99/5 98/9
Material: St 37
140
36105 Weight: 0.085 kg
Puller The test ring (99/4) can be ordered from Voith Turbo
98/7 GmbH & Co. KG: Voith item no. H67.2757xx.
© 2008
Page 61
2. Use the impact puller (99/5) including the adapter 4. Take O-ring (2301) out of the groove in the valve
CAUTION (98/9) to pull the valve insert (2300/1) upwards insert (2300/1).
and out of the retarder housing.
Hot parts!
Removing with puller (98/7)
0
2300/2 98/7
Ö Work carefully.
Ö Wear protective gloves or use cloths if 2300/3 98/9
necessary.
Requirements
• Oil separator module (3100) removed (see page 59)

36067
36106
Removing with impact puller (99/5)
3. If necessary, remove the float (2300/2) and the 1. Screw the puller (98/7) to the adapter (98/9).
99/5 float cage (2300/3) from the retarder housing. )
98/9 13a
98/7
2300/1
36066
2301
© 2008
36107
1. Screw the impact puller (99/5) to the adapter
36068
(98/9).
Page 62
2. Use the puller (98/7) including the adapter (98/9) Checking

to pull the valve insert (2300/1) upwards and out
1. Check the casing ventilation (2300) for soiling and
of the retarder housing. Tighten the hex.-head nut
sludge and clean it.
(13a) to do this.
2300/1
2300/2
0
0
2300/3
2301 2300/2
36068
4. Take the O-ring (2301) out of the groove in the

valve insert (2300/1).
36069
36067
2. Check the float (2300/2) for damaged surfaces

3. If necessary, remove the float (2300/2) and the
and sealing areas (see arrow/diagram).
float cage (2300/3) from the retarder housing.
3. Weight float (2300/2): Specified weight:
max. 12 g.
4. For exceeded specified weight: Replace the entire

casing ventilation (2300).
© 2008
Page 63
Installing with impact puller (99/5) 2. Clean the float with ethyl alcohol.
99/4
NOTE
2300/2 H53.133214 upwards:
0 2300/1
2300/1
3. Insert the float (2300/2) into the float cage
(2300/3).
2301
36070 4. Place valve insert (2300/1) on the float cage
(2300/3).
36068
5. Check the sealing edge of the radial shaft sealing 5. Lubricate the bore of the casing ventilation (2300)
ring in the valve insert (2300/1) (see arrow/ 1. Lubricate the new O-ring (2301) with silicone-free in the retarder housing with silicone-free and non-
diagram): and non-corrosive grease and pull it on the valve corrosive grease.
- Place the float (2300/2) on a suitable object, insert (2300/1).
e.g. hex.-head nut. 6. Insert the casing ventilation (2300) into the
retarder housing.
- Place the valve insert (2300/1) on the float and
weigh it down using the test ring (99/4).
2300/1
- Fill the empty space between the float (2300/2)
and upper edge of the valve insert with ethyl

0
alcohol. 2300/2
NOTE
The sealing edge is damaged, if the fluid level 2300/3
drops within 1 minute.
© 2008
36071
Page 64
Installing with puller (98/7) 2. Clean the float with ethyl alcohol.
99/5
98/9
NOTE
2300/1 H53.133214 upwards:
3. Insert the float (2300/2) into the float cage

(2300/3).
2301
36066 4. Place valve insert (2300/1) on float cage (2300/3).
36068 5. Lubricate the bore of the casing ventilation (2300)

7. Use the impact puller (99/5) including the adapter in the retarder housing with silicone-free and non-
(98/9) to press the casing ventilation (2300) 1. Lubricate the new O-ring (2301) with silicone-free corrosive grease.
carefully into the retarder housing. and non-corrosive grease and pull it on the valve
insert (2300/1). 6. Insert the casing ventilation (2300) into the
8. Complete the retarder. retarder housing.
2300/1
0
2300/2
2300/3
© 2008
36071
Page 65
98/9
98/7
36108
7. Use the puller (98/7) including the adapter (98/9)

to press the casing ventilation (2300) carefully
into the retarder housing.
8. Complete the retarder.

© 2008
Page 66
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Non-return valve (inlet)
7.5 Non-return valve (inlet)
NOTE
2 variants of the non-return valve (inlet) are
possible:
• with integrated sealing ring
• with copper sealing ring (5200)
The variant with an integrated sealing ring is shown
in the diagram.
Both variants are described in the instructions.
Item No. Name

3800 Non-return valve (inlet), complete
3800/1 Guide M 48 x 1.5
with integrated sealing ring: 180 Nm
with copper sealing ring A 48 x 55
(5200): 230 Nm
3800/2 Spring
3800/3 Piston
3800
NOTE
sealing rings with silicone-free and non- 3800/3
3800/2
© 2008
3800/1 36047
Page 67
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Non-return valve (inlet)
Checking Installing
Aids
Thread seal Loctite 243 for the guide thread 3800/1 Ö For guide with integrated sealing ring:
- Apply Loctite 243 to the thread of the guide
CAUTION (3800/1).
- Screw in the non-return valve (inlet) (3800)
Hot parts!
Ö Work carefully. 3800/3 Ö For guide with copper sealing ring :
Ö Wear protective gloves or use cloths if - Apply Loctite 243 to the thread of the guide
necessary. (3800/1).
3800/2 - Lubricate the new sealing ring (5200) with

Requirements silicone-free and non-corrosive grease.
36095
• Retarder switched off - Screw in the non-return valve (inlet) (3800) with
1. Check the rubber coating of the piston (3800/3) for sealing ring (5200).
• Ignition switched off damage. - Tighten the non-return valve (inlet) (3800) to
• Retarder oil drained (see page 21) Replace the complete non-return valve (inlet) 230 Nm.
(3800) if necessary.
2. Check the guide (3800/1) and the spring (3800/2)

Removing for wear.
Replace the complete non-return valve (inlet)
1. Unscrew the guide (3800/1).

(3800), if necessary.
2. Remove the spring (3800/2) and the piston
(3800/3) from the retarder housing.
© 2008
Page 68
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Non-return valve (outlet)
7.6 Non-return valve (outlet)
NOTE
2 variants of the non-return valve (outlet) are
possible:
• with integrated sealing ring
• with copper sealing ring (5200)
The variant with an integrated sealing ring is shown
in the diagram.
Both variants are described in the instructions.
Item No. Name

3800 Non-return valve (outlet), complete
3800/1 Guide M 48 x 1.5
with integrated sealing ring: 180 Nm
with copper sealing ring A 48 x 55
(5200): 230 Nm
3800/2 Spring
3800/3 Piston
3800
NOTE
3800/3
3800/2
© 2008
3800/1 36048
Page 69
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Non-return valve (outlet)
Checking Installing
Aids
Thread seal Loctite 243 for the guide thread 3800/1 Ö For guide with integrated sealing ring:
- Apply Loctite 243 to the thread of the guide
CAUTION (3800/1).
- Screw in the non-return valve (outlet) (3800)
Hot parts!
Ö Work carefully. 3800/3 Ö For guide with copper sealing ring :
Ö Wear protective gloves or use cloths if - Apply Loctite 243 to the thread of the guide
necessary. (3800/1).
3800/2 - Lubricate the new sealing ring (5200) with

Requirements silicone-free and non-corrosive grease.
36095
• Retarder switched off - Screw in the non-return valve (outlet) (3800)
1. Check the rubber coating of the piston (3800/3) for with sealing ring (5200).
• Ignition switched off damage. - Tighten the non-return valve (outlet) (3800) to
• Retarder oil drained (see page 21) Replace the complete non-return valve (outlet) 230 Nm.
2. Check the guide (3800/1) and spring (3800/2) for

Removing wear.
Replace the complete non-return valve (outlet)
1. Unscrew the guide (3800/1).

2. Remove the spring (3800/2) and the piston
(3800/3) from the retarder housing.
© 2008
Page 70
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair 2/2-way valve
7.7 2/2-way valve 4800
Item No. Name

3500 2/2-way valve, M 36 x 1.5;
3500
hexagon insert bit, w.a.f. 19; 130 Nm
3501
3501 Sealing ring A 36 x 42; replace 3502
3502 O-ring 28 x 2; replace 3503
4800 Sealing cover A 20
NOTE
CAUTION
Hot parts!
Ö Work carefully.
necessary.
Requirements

© 2008
• Retarder switched off 36049
Page 71
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair 2/2-way valve
Removing Checking 4. If there are corrosion traces:

- Check and repair the compressed air system
CAUTION (see specifications of vehicle manufacturer).
Improper removal! - Replace the 2/2-way valve (3500).

Damage to the 2/2-way valve (3500).
Ö Do not remove/install the 2/2-way valve (3500)
with an inpact screwdriver.
NOTE
If the screw plug becomes detached from the valve
body during removal:
Ö Remove the sealing ring (3501). 36102
Ö Screw in the screw plug without a sealing ring
(3501) manually until the screw plug is against 1. Check whether the brass piston is in the correct
the retarder housing and the valve body position (see A/diagram).
engages.
Ö Loosen and unscrew the screw plug with the 2. If the piston is stuck (see B/diagram), replace the
engaged valve body manually. complete 2/2-way valve (3500).
–or–
NOTE
Ö Pull the valve body out of the retarder housing

with a bearing outer race puller. If there are corrosion traces on the 2/2-way valve,
Bearing outer race puller: e.g. Kukko, there is water in the vehicle's compressed air
tool no. 21-5, Ø 28–40 mm and pusher no. 22-1 system.
3. Check the 2/2-way valve for corrosion traces.

© 2008
Page 72
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Diaphragm housing cover
7.8 Diaphragm housing cover
Item No. Name 4300
300 Gasket plate; replace

4300 Hex.-head screw M 10 x 40;
900
50 Nm
Aids
300
2 stud bolts M 10
CAUTION
Hot parts!
Ö Work carefully.
necessary.
© 2008
36050
Page 73
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Diaphragm housing cover
1. Screw two stud bolts M 10 into the retarder 4. Screw in the hex.-head screw (1) hand-tight.
CAUTION housing (see arrows/diagram).
5. Tighten the hex.-head screw (2) to 17 Nm.
Improper removal! 2. Place the new gasket plate (300) onto the retarder
Malfunction/damage to the retarder. 6. Tighten the hex.-head screw (1) to 17 Nm.
housing.
Ö To remove/install the diaphragm housing cover: 7. Tighten the hex.-head screw (3) to 50 Nm.
3. Place the new diaphragm housing cover (900)
Lay the retarder on its side.
onto the retarder housing. 8. Unscrew the stud bolts M 10.
Requirements
CAUTION 9. Tighten the hex.-head screws in the prescribed
• Ignition switched off sequence (4–8) to 50 Nm.
Incorrect sequence when tightening the hex.-
• Retarder removed (see page 50) head screws! 10.Tighten the hex.-head screw (9) to 50 Nm.
Damage to diaphragms.
• Valve block removed (see page 91) 11.Tighten the hex.-head screw (2) to 50 Nm.
Ö Tighten the hex.-head screws in the prescribed
sequence. 12.Tighten the hex.-head screws in the prescribed
Removing
sequence (10–13) to 50 Nm.
1. Unscrew the hex.-head screws (4300).
13.Tighten the hex.-head screw (1) to 50 Nm.
2. Remove the diaphragm housing cover (900). 4 5 6
3. Remove the gasket plate (300).

12 13 1 7
Installing
11
8
NOTE
Ö Ensure that the diaphragm housing cover (900)
is dry and free of dirt.
10
3
2 9
© 2008
36083
Page 74
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Diaphragms
7.9 Diaphragms
1000b
Item No. Name
1000a Diaphragm
1000b Diaphragm 3900
3900 O-ring 253.6 x 3.53; replace

4000 Intermediate ring
4000
NOTE
sealing rings with silicone-free and non- 1000a
Special tools
153.001540xx
Puller hook
50/38
© 2008
36051
Page 75
Removing
CAUTION
Hot parts! CAUTION
Hands could be burned. Incorrect sequence during removal!
Ö Work carefully. Damage to the 2/2-way valve (3500)
Ö Wear protective gloves or use cloths if Ö Ensure that the 2/2-way valve (3500) has been
necessary. removed.
4000
NOTE 1. Remove the first diaphragm (1000b).
50/38
If the intermediate ring (4000) is replaced:
CAUTION 100
36081
Ö In the case of retarder housing up to Voith item
no. ".15", use only the intermediate ring with Improper removal!
Voith item no. ".11". Damage to the retarder. 2. Use the puller hook (50/38) to pull the
Ö In the case of retarder housing from Voith item Ö Remove the intermediate ring (4000) only with a intermediate ring (4000) carefully and smoothly
no. ".20", use only the intermediate ring with out of the retarder housing (100).
puller hook (50/38).
Voith item no. ".20" or higher.
3. Remove the O-ring (3900).
Requirements
4. Remove the second diaphragm (1000a).
• Retarder removed (see page 50)
• 2/2-way valve removed (see page 71)
• Diaphragm housing cover removed (see page 73)

© 2008
Page 76
Installing (intermediate ring up to Voith item

no. ".11") 1000b
3900
NOTE 100
Ö Ensure that the following parts are dry and free

of dirt:
100
- Diaphragms (1000a and 1000b)
- Retarder housing (100) 4000
- Diaphragm housing cover (900)
1000a
36082 36093
100 2. Insert the first diaphragm (1000a) centered. In 3. Lubricate the diaphragm (1000a) in the contact
doing so, observe the installation position of the area of the intermediate ring (4000) with silicone-
diaphragm bead. free and non-corrosive grease (see gray
area/diagram).
36092
1. Lubricate the retarder housing (100) in the contact

area of the diaphragm (1000a) bead with silicone-
free and non-corrosive grease (see gray
© 2008
area/diagram).
Page 77
8. Lubricate the diaphragm (1000b) in the contact

1000b area of the diaphragm housing cover (900) with
3900 silicone-free and non-corrosive grease.
CAUTION
Improper installation!
100 Damage to diaphragms.
Malfunction.
4000
Ö Complete the installation of the intermediate
ring (4000) and the diaphragms (1000a and
1000b) together with the diaphragm housing
1000a
cover.
36082
9. Install the gasket plate (300) and the diaphragm

4. Lubricate the new O-ring (3900) with silicone-free
housing cover (900) (see page 73).
and non-corrosive grease and pull it onto the
intermediate ring (4000). 10.Complete the retarder.
5. Insert the intermediate ring (4000) in the retarder

housing (100) and press it in hand-tight.
6. Lubricate the intermediate ring (4000) in the

contact area of the diaphragm (1000b) with

7. Place the second diaphragm (1000b) centered on

the intermediate ring. In doing so, observe the
installation position of the diaphragm bead.
© 2008
Page 78
Installing (intermediate ring from Voith item

no. ".20")
1000b
NOTE 4000 100
Ö Ensure that the following parts are dry and free

of dirt:
- Diaphragms (1000a and 1000b)
- Retarder housing (100) 3900
100
- Diaphragm housing cover (900)
1000a
36103 36093
100 2. Insert the first diaphragm (1000a) centered. In 3. Lubricate the diaphragm (1000a) in the contact
doing so, observe the installation position of the area of the intermediate ring (4000) with silicone-
diaphragm bead. free and non-corrosive grease (see gray
area/diagram).
36092
1. Lubricate the retarder housing (100) in the contact

area of the diaphragm (1000a) bead with silicone-
free and non-corrosive grease (see grey
© 2008
area/diagram).
Page 79
8. Lubricate the diaphragm (1000b) in the contact

area of the diaphragm housing cover (900) with
1000b
4000
3900
CAUTION
100
Improper installation!
1000a Damage to diaphragms.
Malfunction.
36103 Ö Complete the installation of the intermediate
ring (4000) and the diaphragms (1000a and
4. Lubricate the new O-ring (3900) with silicone-free 1000b) together with the diaphragm housing
and non-corrosive grease and pull it onto the cover.
intermediate ring (4000).
10.Install the gasket plate (300) and the diaphragm
5. Insert the intermediate ring (4000) in the retarder
housing cover (900) (see page 73).
housing (100) and press it in hand-tight.
11.Complete the retarder.
6. Lubricate the intermediate ring (4000) in the
contact area of the diaphragm (1000b) with


© 2008
Page 80
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Heat exchanger
7.10 Heat exchanger
Item No. Name

800 Heat exchanger
3200 Coolant temperature sensor M 14 x 1.5;
28 Nm
3300 O-ring 37.46 x 5.33; replace
50 Nm
5000
NOTE 3300 3200
800
5400
© 2008
36052
Page 81
Removing
NOTE DANGER
Ö Please procure any connecting pieces that are Heat exchanger can fall! NOTE
not listed here by yourself. Your body can be crushed severely. If the heat exchanger is replaced:
Ö Secure the heat exchanger against falling. Ö Unscrew the coolant temperature sensor (3200)
Special tools Ö Use a suitable lifting device. with sealing ring (5000).
1. Unscrew the hex.-head screws (5400) and

Aids
remove the heat exchanger (800).
Elring sealing compound for sealing surface heat
Dirko-S Profi press HT: exchanger/ 2. Remove the O-rings (3300 and 3400).
retarder housing
• Color black
• Temperature-resistant
–50 °C ... + 250 °C
153.001375xx • Voith item no.
190.001697xx
Pressure-test
equipment Requirements
50/58 • Retarder switched off

CAUTION
• Retarder oil drained (see page 21)

Hot parts!
Ö Work carefully. • Electrical connecting lead at the coolant
Ö Wear protective gloves or use cloths if temperature sensor disconnected
necessary.
• Coolant connecting hose disconnected at the heat
© 2008
exchanger
Page 82
Checking 6. Slowly pressurize the heat exchanger (800) with a

max. of 4 bars overpressure.
1. Lubricate the O-rings (3300 and 3400) with
silicone-free and non-corrosive grease and insert CAUTION
them into the grooves of the pressure-test
equipment (50/58). Heat exchanger leaks!
Malfunction of the retarder.
Ö If air bubbles occur in the water or if an external
800/1 leak is found: Replace the heat exchanger.
A 7. If air bubbles occur in the water at the water neck

(800/1): Replace the heat exchanger.
50/58
8. Drain the overpressure.
C B
800
36100
2. Attach the pressure-test equipment (50/58) using

the hex.-head screws to the heat exchanger (800).
3. Close the connections "B" and "C".
4. Fill the water section of the heat exchanger (800)

with hot water (approx. 70 °C).
5. Connect the compressed-air line with pressure

reducer to connection "A".
© 2008
Page 83
Installing 3. Place on the heat exchanger (800) and fasten it

using the hex.-head screws (5400). CAUTION
NOTE 4. Tighten the hex.-head screws (5400) crosswise to In case of water in the retarder!
The water and oil section of new heat exchangers 50 Nm. Oil loss via oil separator.
are coated with anti-corrosion oil. Malfunction of the retarder.
Ö Before installation drain any anti-corrosion oil Ö Fill the retarder with 5.6 l engine oil or flush oil.
and rinse the water section with hot water.
CAUTION Ö Flush the retarder system by braking several
times lightly.
Wrong coolant type! Ö Drain the oil.
Damage to the vehicle and retarder cooling circuit.
Ö Repeat the process 2 or 3 times.
Ö De-oil the cooling and heating system (see
manufacturer or those of Voith Turbo coolant specifications of vehicle manufacturer).
quality list.
7. Fill in the oil (see "Filling in the oil" on page 26).
6. Fill the vehicle and retarder cooling circuit (see
100
specifications of vehicle manufacturer).
3300
3300
3400 36104
1. Lubricate the new O-rings (3300 and 3400) with

silicone-free and non-corrosive grease and insert
them into the grooves of the retarder
housing (100).
2. Apply Dirko-S Profi press HT to the sealing

surfaces of the retarder housing (100) (see
© 2008
dashed line/figure 36104).
Page 84
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Circuit parts
7.11 Circuit parts
NOTE
The circuit parts (33) on retarders with Voith item
no. 67.3861.03, 67.3861.04 or 67.3862.04 cannot
be replaced (see retarder identification).
Ö If necessary, contact Voith.
Item No. Name

33 Circuit parts
3000
2200 O-ring 125 x 2.5; replace 2200
4500
33
4200 Hex.-head screw M 8 x 75; 50300 4200
25 Nm
NOTE

3400
© 2008
36053
Page 85
Item No. Name

50 Nm
50300 O-ring, 198 x 3; replace
NOTE
2200
4500
33
NOTE
Instructions are enclosed with the circuit parts 50300 4200
(spare part). These describe the
installation/removal and return of the defective
circuit parts (conversion instructions for basic
retarder VR 115 HV).
3400
© 2008
36053
Page 86
If the stator gets stuck in the retarder housing: Requirements

Aids
Elring sealing compound for sealing surface, circuit • Retarder removed (see page 50)
Dirko-S Profi press HT: parts/retarder housing Commercially available tools
• Color black Two-arm universal puller • Heat exchanger removed (see page 81)
• Temperature-resistant
Removing
–50 °C ... + 250 °C
• Voith item no.
CAUTION 1. Unscrew the hex.-head screw (4200).
190.001697xx Hot parts!
Special tools Ö Work carefully.
Ö Wear protective gloves or use cloths if 50/59 33
necessary.
NOTE
If the retarder circuit parts are mechanically
4200
defective:
153.001547xx
Ö Disassemble the complete retarder (except for
36096
the circuit parts) and clean all components (they
Puller must be free of dirt, metallic residues and water)
2. Pull off the circuit parts (33) with the puller
50/59 Ö Replace the heat exchanger (see page 81).

(50/59).
Ö Replace the diaphragms (see page 75)
NOTE
If the retarder circuit parts are replaced:
Ö Replace the output restrictor (see page 90).
© 2008
Page 87
Installing
1. Clean and dry the retarder housing in the

mounting area of the retarder circuit parts (33).
2. Lubricate the new O-ring (2200) with silicone-free

and non-corrosive grease and pull it on in the
retarder housing.
3. Lubricate the new O-rings (3000 and 4500) with

silicone-free and non-corrosive grease and insert
them in the retarder circuit parts (33).
36097
3. If necessary, use the two-arm universal puller to

pull the stator out of the retarder housing.
4. Remove the O-rings (3400, 2200, 3000 and

4500).
© 2008
Page 88
NOTE
Ö Do not apply Dirko-S Profi press HT in the lower
section of the retarder circuit parts (33) (see
dimensioning/diagram).
4. Apply the sealing agent Dirko-S Profi press HT in

the form of an inchworm with a max. of 0.5 mm
high and max. of 1.5 mm wide to the circuit
parts (33) at the contact surface to the retarder
housing (see dashed line/diagram).
5. Install the retarder circuit parts (33).
6. Screw in the hex.-head screw (4200) and tighten it

to 25 Nm.
7. Lubricate the O-ring (3400) with silicone-free and

non-corrosive grease and insert it.

10 ±3
30 ±3
© 2008
36054
Page 89
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Output restrictor
7.12 Output restrictor
Item No. Name

4400 Cap screw M 8 x 20;
17 Nm
4700 Output restrictor
CAUTION
Hot parts!
Ö Work carefully.
4700
necessary.
4400
Requirements
• Retarder removed (see page 50)
• Circuit parts removed (see page 85)

© 2008
36084
Page 90
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Valve block
7.13 Valve block

4100
Item No. Name

1200 Valve block
1201 Seal assembly valve block
1201/1 O-ring; replace
1201/2 Mould sealing, replace 1201

1200
22 Nm 1201/1
1201/2
CAUTION
Hot parts!
Ö Work carefully.
necessary.
NOTE
Ö Only use the VOSS 232 plug-in system at the
valve block (1200).
The VOSS 230 plug-in system may not be used.
© 2008
36056
Page 91
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Valve block
Requirements
• Supply-air pressure drained
• Compressed air line on the valve block

disconnected
• Electrical connection on the valve block

disconnected. Male and female connector checked
for damage or wear (notch scratches) and
replaced if necessary.
© 2008
Page 92
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Oil temperature sensor
7.14 Oil temperature sensor
Item No. Name

3200 Oil temperature sensor M 14 x 1.5;
28 Nm
5000 Sealing ring A 14 x 20; replace 3200
5000
CAUTION
Hot parts!
Ö Work carefully.
necessary.
Requirements

• Electrical connection at the oil temperature sensor

disconnected. Male and female connector checked
for damage or wear (notch scratches) and
replaced if necessary
© 2008
36057
Page 93
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Oil temperature sensor
Checking the internal resistance
NOTE
Measuring in one temperature range is usually
sufficient.
Polarity: any.
Temperature Resistance
20 °C ± 10 °C 1039–1117 Ω
60 °C ± 10 °C 1194–1271 Ω
80 °C ± 10 °C 1271–1347 Ω
© 2008
Page 94
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Coolant temperature sensor
7.15 Coolant temperature sensor
Item No. Name

3200 Coolant temperature sensor M 14 x 1.5;
28 Nm
CAUTION
Hot parts!
Ö Work carefully.
necessary.
Requirements

• Electrical connecting lead at the coolant

temperature sensor disconnected. Male and
female connector checked for damage or wear 5000
(notch scratches) and replaced if necessary
3200
© 2008
36058
Page 95
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair Coolant temperature sensor
Checking the internal resistance
NOTE
Measuring in one temperature range is usually
sufficient.
Polarity: any.
Temperature Resistance
20 °C ± 10 °C 1039–1117 Ω
60 °C ± 10 °C 1194–1271 Ω
80 °C ± 10 °C 1271–1347 Ω
© 2008
Page 96
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools
8. Overview of the Tools
8.1 Diagnosis 98
8.2 Repair 100
© 2008
Page 97
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools Diagnosis
8.1 Diagnosis
Task Special tools Tools for self-fabrication

Checking the –
constant-air pressure
control-loop
153.001085xx 153.000776xx H53.1403xx
Retarder tester, Test software Pressure gauge

complete in a "DIANA Lite" 0–6 bar
case
50/56 50/56i 99/7
Checking the pump –
pressure pdyn
153.001085xx 153.000776xx
Retarder tester, Test software

complete in a "DIANA Lite"
case
50/56 50/56i
© 2008
Page 98
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools Diagnosis

Checking the –
proportional valve
current
Schaltventil
Propventil
153.000132xx
Measuring
adapter
99/10
© 2008
Page 99
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools Repair
8.2 Repair

Casing ventilation
Ø 40.5 mm
7 mm
Ø 60 mm
H53.7712xx H53.9428xx
27079_en
Impact puller Adapter Test ring

99/5 98/9 99/4
© 2008
Page 100

Casing ventilation
12
10 13a
11 13b 11
8
16
Ø10
8 8
12
37,5 37,5
30
140
36105
Puller
98/7
© 2008
Page 101

Diaphragms –
153.001540xx
Puller hook
50/38
Heat exchanger –
153.001375xx
Pressure-test
equipment
50/58
© 2008
Page 102

Circuit parts –
153.001547xx
Puller
50/59
© 2008
Page 103
Voith Turbo
Produktgruppe Retarder
Postfach 1555
74555 Crailsheim
Deutschland
Phone: +49 79 51 / 32-0

Fax: +49 79 51 / 32-756
service-retarder@voith.com
www.voith.com
Engineered reliability.

Asm Vr115hv

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Asm Vr115hv

Загружено:

Авторское право:

Доступные форматы

Voith Turbo

Aftersales Service Manual Voith Retarder VR 115 HV

1 About this Document 5

2 Basic Safety Information 8

2.8 Driving mode 10

3 Design and Function 11

3.3 VERA™ control unit identification 15

3.4 Function and control scheme 16

4 Maintenance and Service 19

5 Diagnosis and Troubleshooting 29

6 Removing and Installing the Retarder 50

7.2 Retarder ventilation 57

7.10 Heat exchanger 81

8 Overview of the Tools 97

1. About this Document

1.1 Purpose of this document 6

1.1 Purpose of this document 1.2 Target groups

1.3 Other applicable documents

Documents Information Voith Item No.

1.4 Symbols and identifications 1.5 Item numbers

Ö One-step action instruction. Phone: +49 79 51 / 32-401, 32-422, 32-1860

2. Basic Safety Information

2.1 Product safety 9

Ö Observe the following regulations:

substances such as oils and greases

Damage to property via soiled parts! Towing 2.10 Warranty

Failure or performance reduction while driving

system this way until the retarder is available at full capacity

Ö When starting driving: Activate the retarder briefly in 2.9 Storage

3. Design and Function

3.1 Overview of the modules 12

3.1 Overview of the modules

Item No. Name

3.2 Retarder identification

3.3 VERA™ control unit identification

Position of the retarder control unit in the vehicle:

• at the MB Actros: to the right in the electronics

Retarder Control Unit VERATM

Serial-No. xxxxx / JJJJ-MM-TT

3.4 Function and control scheme

G Air and vent duct "A2"

3200b Coolant temperature sensor

3.5 Function description Diaphragm (1000) Casing ventilation (2300)

Non-return valve (inlet) (3800b)

When the retarder is switched off, the 2/2-way valve

4. Maintenance and Service

4.1 Maintenance intervals 20

4.1 Maintenance intervals

The maintenance intervals depend on the load placed on the retarder.

Activity Interval See

4.2 Oil change

Item No. Name

Oil filling level

Service filling (checking of the oil level, 5.6 l

Maintenance work during each oil change Requirements

3. Unscrew the screw plug (3600) slowly.

10.Screw in the screw plug (801) with the new NOTE

4.3 Checking the oil level

Item No. Name

Oil filling level

Service filling (checking of the oil level, 5.6 l

Draining the oil

Special tools WARNING

• Retarder switched off