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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



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Table of Contents 1



About this Document



5



1.1 1.2 1.3 1.4 1.5 1.6



Purpose of this document Target groups Other applicable documents Symbols and identifications Item numbers Imprint



6 6 6 7 7 7



2



Basic Safety Information



8



2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10



Product safety Staff qualification Safety-conscious working Environmental protection Special tools Diagnosis and Troubleshooting Maintenance and repair Driving mode Storage Warranty



9 9 9 9 9 9 9 10 10 10



3



Design and Function



11



3.1 3.2 3.3



Overview of the modules Retarder identification VERA™ control unit identification



12 14 15 Page 2



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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



3.4 3.5



Function and control scheme Function description



16 17



4



Maintenance and Service



19



4.1 4.2 4.3 4.4



Maintenance intervals Oil change Checking the oil level Coolant



20 21 24 27



5



Diagnosis and Troubleshooting



29



5.1 5.2 5.3 5.4



Overview Checking Checking Checking



30 40



6



Removing and Installing the Retarder



50



7



Repair



53



7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9



Components overview Retarder ventilation Oil separator module Casing ventilation Non-return valve (inlet) Non-return valve (outlet) 2/2-way valve Diaphragm housing cover Diaphragms



54 57 59 60 67 69 71 73 75



of the possible complaints the constant-air pressure control loop the pump pressure pdyn the proportional valve current



44



48



Page 3



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



7.10 7.11 7.12 7.13 7.14 7.15



Heat exchanger Circuit parts Output restrictor Valve block Oil temperature sensor Coolant temperature sensor



81 85 90 91 93 95



8



Overview of the Tools



97



8.1 8.2



Diagnosis Repair



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



98 100



Page 4



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



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



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



1.



Page 5



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



1.1



Purpose of this document



This Aftersales Service Manual provides information and instructions on the maintenance and repair of the Voith Retarder VR 115 HV.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



1.3



1.2



Purpose of this document



Target groups



This Aftersales Service Manual is intended for service personnel for maintenance and diagnostics and may not be reproduced or given to third parties.



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



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 of the "DIANA Lite" test software (153.000776xx)



•



Constant-air pressure control loop



•



Pump pressure pdyn



controller



On request



Operating instructions for the "WinDia®" diagnostic software



Instruction on PC diagnosis for retarders



3623-020900



Conversion instructions for the basic retarder VR 115 HV



Instructions for removing and installing the circuit parts and returning the defective circuit parts



153.001905xx



Page 6



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



1.4



Symbols and identifications



Structure of warnings



LEVEL OF DANGER



WARNING Possible imminent danger that could lead to death



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



DANGER Immediate danger that leads to death or serious



•



one- or two-digit item numbers



•



item numbers with a slash



injury if not prevented.



1.6 Levels of danger



Notes



The warnings are categorized into four levels of danger:



CAUTION Possible imminent danger that could lead to damage to property if not prevented.



NOTE Information on easier and safer work with the retarder. Ö Measures for easier and safer work with the retarder. Distinctions



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Item numbers



Exceptions:



Possible consequences if not heeded. consequences.



1.5



or serious injury if not prevented.



Type and source of danger! Ö Measures for the prevention of danger and its



Symbols and identifications



CAUTION Possible imminent danger that could lead to slight injury if not prevented.



Ö One-step action instruction. 1. First step of an action instruction. Other steps follow and are numbered in sequence.



Imprint



For questions and work procedures not described in these documents, contact the respective organization for your area. Voith Turbo Produktgruppe Retarder Postfach 1555 74555 Crailsheim Deutschland Phone: +49 79 51 / 32-401, 32-422, 32-1860 Fax: +49 79 51 / 32-756 [email protected] www.voith.com



Page 7



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



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



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



2.



Page 8



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



2.1



Product safety



The retarder is constructed according to the state of the art in 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 Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Voith does not assume any liability for personal injury and/or property damage caused by improper and unprofessional work. Ö Observe the following regulations: -



Accident-prevention regulations



-



Other generally acknowledged safety regulations and occupational health



-



Motor Vehicle Regulations



-



Safety regulations for handling chemical substances such as oils and greases



2.4



Environmental protection



Ö Drained fuels and fluids, consumables and old parts must be disposed of properly.



2.5



Special tools



Product safety



Danger of accidents if the retarder tester is used improperly! Diagnosis while the vehicle is traveling results in an uncontrollable operating state of the vehicle. Ö Carry out diagnosis only while the vehicle is standing still.



Damage to property if false special tools are used! The special tools required are described in the respective action instructions. The chapter "Overview of the Tools" contains an overview of the special tools.



2.7



Maintenance and repair



In the case of special tools that may only be used from a specific version on, the version number is contained in the last two digits of the Voith item no. Example: H53.942811.



Ö Work carefully.



Ö Only use special tools from the specified version



Ö Work carefully.



Danger of burning and scalding via squirting oil! The oil in the retarder may be hot.



Danger of burning and scalding via hot coolant! The coolant may be hot.



on. Ö Take the last two digits of the Voith item no. into account in the graphics of the special tools.



Danger of burns via hot parts! Parts of the retarder may be hot. Ö Work carefully.



2.6



Diagnosis and Troubleshooting



Ö Wear protective gloves or use cloths if necessary.



Voith provides a warranty/goodwill service for defective parts only. Ö Do not replace parts on mere speculation.



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



Considerable damage or malfunctions may occur due to soiling.



Ö Tow the vehicle with the retarder rotating for max.



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



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, sensors or the exhaust of the retarder.



100 km at max. 40 km/h. Ö Voith recommendation: Remove the prop shaft.



Warranty



Ö Use only parts approved by Voith to ensure the



Parking Ö Do not use retarder as a parking brake, as it does not act as a brake when the vehicle is standing still.



safety of the vehicle and functioning of the retarder.



Failure or performance reduction while driving



2.8



Driving mode



Ö Ensure that the retarder is fully functional for all



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



vehicle maneuvers, i.e.: -



Retarder properly filled with oil



-



Retarder electronic equipment connected and functional



-



Pneumatic control connected and functional



-



The retarder connected to the vehicle's cooling system



During failure of the retarder, or while temperature adaptation is active: Ö Adjust the speed of the vehicle with the engine/ service brake. Ö Engage the lowest possible gear in order to achieve a high engine speed. Ö During a temperature adaptation continue driving in 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 braking stage 2 or 3.



2.9



Storage



Ö Store or transport the retarder vertically, otherwise oil may escape.



Page 10



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



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



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



3.



Page 11



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



3.1



Overview of the modules



Overview of the modules 1200



Item No.



Name



801a



Screw plug/oil drain plug



801b



Screw plug/coolant drainage screw



900



3100



2700 3200a



Diaphragm housing cover



1200



Valve block VERA™



2700



Retarder ventilation



3100



Oil separator module



3200a



Oil temperature sensor



3200b



Coolant temperature sensor



3800a



Non-return valve (outlet)



900



3800a



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



3200b



801b 801a



36001



Page 12



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



Item No. 100



Overview of the modules



Name Retarder housing



3500



2/2-way valve



3600



Service measuring point



3700



Screw plug/oil filler plug



3800b



Non-return valve (inlet)



3500



3700



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



3600



3800b 100



36002



Page 13



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



3.2



Retarder identification



Retarder identification



NOTE Ö Specify the following data in case you have questions or are ordering spare parts: -



Serial No. (1)



-



Voith Item No. (2)



1 0003394116



2



H67.3861.10 A9304300295



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



16 0 41 .1 5 39 61 29 03 .38 00 00 67 43 H 30 9 A



36004



Page 14



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



3.3



VERA™ control unit identification



VERA™ control unit identification



Position of the retarder control unit in the vehicle: at the MB Actros: to the right in the electronics compartment



•



at the MB Axor: behind the front passenger seat



06



X3



V



o



it



h



T



u



rb



o



NOTE



e1



x



7x



00



.0 TM TT 53 A M- x-1 xx ER J-M x.x Sx V G J x t ni JJ -D / Z l U x / .D.xxxx ro x nt xxxERA xxx o C V xxx X2 er . x rd No ta al- o. . Re eri rt N No S a M P E X1 O



02



20



84



•



-



Serial-No.



-



Part No.



H IT VO



Ö Specify the following data in case you have questions or are ordering spare parts:



-



Voith Item No.



Retarder Control Unit VERATM Serial-No. xxxxx / JJJJ-MM-TT Part No. VERA.D.x-Dxx.xx-153.000067xx OEM No. xxxxxxxxxx / ZGSxxx



X1



X2



e1 022084



Serial No.



Voith Turbo



-



VOITH



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Ö Specify the following data of the retarder (see page 14):



X3 36006



Page 15



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



3.4



Function and control scheme



Item No.



Name



A



Rotor



B



Stator



C



Oil tank



D



Oil equalizing tank



E



Ventilation duct "R"



F



Air and vent duct "A1"



G



Air and vent duct "A2"



800



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Function and control scheme



NSG9 R D



3100



3200a



Diaphragm



1200



Valve block



2300



Casing ventilation



2700



Retarder ventilation "R"



3100



Oil separator module



3200a



Oil temperature sensor



3200b



Coolant temperature sensor



Non-return valve (outlet)



3800b



Non-return valve (inlet)



A2NG4 1200 NG3 2 G



5



A1



P



1p 3 p



2300



1000 1000



F



B 3800a



800 3200b



2/2-way valve



3800a



C



3800b



A



12



2700 3500



Heat exchanger



1000



3500



E



Oil sump Constant-air pressure py Coolant



36007



Page 16



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



3.5



Function description



Rotor (A) The rotor (A) must include the oil in its rotation and accelerate it. Stator (B) In the stator (B) the oil is re-directed and is returned to the rotor (A) at the internal diameter of the working chamber.



Diaphragm (1000)



Casing ventilation (2300)



The oil tank of the retarder (C) is located between the diaphragms (1000). The purpose of the diaphragms (1000) is to separate the retarder oil and the constantair pressure py.



At the start of the braking process, the oil displaces the air in the system circuit. The air is displaced via the casing ventilation (2300) and the oil separator (3100).



When the retarder is switched off, the constant-air pressure present at the diaphragms (1000) py is routed through the valve block (1200) and escapes at the retarder ventilation (2700). The constant-air pressure py and the retarder ventilation (2700) are not connected to the retarder oil.



Oil equalizing tank (D) When the retarder is switched off, the oil equalizing tank (D) takes up some of the oil flowing back from the system circuit. The oil is fed back to the oil tank (C) via the open 2/2-way valve (3500). The air separated out of the oil is fed into the atmosphere via the oil equalizing tank (D) and the oil separator (3100).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Heat exchanger (800) The heat exchanger (800) dissipates the generated heat to the vehicle cooling system.



Function description



Once the system circuit is free of air, the casing ventilation (2300) closes. Retarder ventilation "R" (2700) When the retarder is switched off, the constant-air pressure present at the diaphragms (1000) py is routed via the valve block (1200) and escapes into the atmosphere at the retarder exhaust (2700).



Valve block (1200) The valve block (1200) is connected to the compressed air system of the vehicle (auxiliary equipment circuit). The proportional valve integrated in the valve block (1200) receives an electrical input signal from the retarder control unit. A pneumatic constant-air pressure py is then applied to the diaphragms (1000). This is dependent on the intensity of the electrical input signal. This applies pressure to the oil in the oil tank (C). A pressure sensor integrated in the valve block (1200) measures and regulates the pneumatic constant-air pressure py.



Oil separator (3100) The oil separator (3100) separates out the oil from the exhaust air. The minimum exhaust air containing oil comes out of the system circuit via the casing ventilation (2300) and from the oil equalizing tank (D). Temperature sensors for oil (3200a) and coolant (3200b) The temperature sensors forward information about the temperature of oil and coolant to the retarder control unit in the vehicle. 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.



Page 17



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



If one of the temperature limit points is exceeded during a braking operation, the braking torque is adjusted via the constant-air pressure py. The braking moment is adjusted until an equilibrium is achieved between the produced braking energy and the heat dissipated via the vehicle cooling system. If one of the maximum values is exceeded, the braking torque is no longer actuated (corresponds to a reduction to 0). In addition the braking torque is adjusted if the oil temperature rises rapidly (gradient), regardless of the actual oil temperature. The vehicle speed has to be adjusted with the service brake while the adjustment is active.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



2/2-way valve (3500) The 2/2-way valve (3500) closes when the retarder is switched on. This separates the connection of the oil tank (C) to the oil equalizing tank (D) and the oil separator (3100).



Function description



(3500). There is a connection to the atmosphere via the oil separator (3100). The 2/2-way valve (3500) prevents too much of the oil flowing back into the oil tank (C) from entering the oil equalizing tank (D). The oil that has accumulated in the oil equalizing tank (D) flows back into the oil tank (C) via the opened 2/ 2-way valve (3500). Non-return valve (outlet) (3800a) In braking mode, the oil reaches the heat exchanger (800) from the working chamber via the non-return valve (outlet) (3800a), is cooled down and is fed back into the system circuit or the oil tank (C). Non-return valve (inlet) (3800b) When the retarder is switched on, pressure is applied to the oil via the diaphragms (1000). This opens the non-return valve (inlet) (3800b) and allows the oil into the working chamber.



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



Page 18



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



Maintenance and Service



4.1



Maintenance intervals



20



4.2



Oil change



21



4.3



Checking the oil level



24



4.4



Coolant



27



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



4.



Page 19



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



4.1



Maintenance intervals



Maintenance intervals



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



CAUTION Exceeding of the maintenance intervals/incorrect oil sort! Damage to/failure of the retarder. Ö Observe the maintenance intervals. Ö Use only approved oils.



Interval



See



Change oil



ÖSee the specifications of the vehicle manufacturer or the Voith retarder oil change interval/oil selection list.



Page 21



Checking the oil level



–



Page 24



Draining the coolant



ÖObserve the specifications of the vehicle manufacturer.



Page 27



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Activity



Page 20



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



4.2



Oil change



Oil change



Item No.



Name



801



Screw plug M 14 x 1.5; 25 Nm



802



Sealing ring A 14 x 20; replace



3600



Screw plug M 14 x 1.5; 30 Nm



5000



Sealing ring A 14 x 20; replace



3700



Screw plug M 30 x 1.5; 100 Nm



5100



3700



Sealing ring A 30 x 36; replace



5100 5000



NOTE



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



3600



Oil filling level Service filling (checking of the oil level, oil change)



5.6 l



After replacement of the heat exchanger



7.0 l



Refilling of the emptied heat exchanger after complete disassembly and cleaning



7.0 l



802 801 36005



Page 21



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



Maintenance work during each oil change



Requirements



Ö Visual inspection of retarder for leaks before and



•



Vehicle is horizontal



•



Oil is at operating temperature (> 60 °C)



•



Retarder switched off



•



Ignition switched off



after the oil change. Ö Tighten the hex.-head screws (5400) at the heat exchanger (see page 81).



Oil change



3600



Additional maintenance work at every 2nd oil change Ö Replace the oil separator at the oil separator module (see page 59).



Draining the oil



WARNING



Aids Manual tire filler Hot exiting oil! Special tools



801



1. Place oil pan below the retarder.



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



36008



2. Unscrew the screw plug (801) and drain the oil.



WARNING Hot oil comes out under increased pressure! Face and hands could be burned.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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



Page 22



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



50/31



50/39



Oil change



7. Apply short pulses of air onto the hole of the screw plug (3600) of the retarder.



15.Fill in the oil slowly via the hole of the screw plug (3700).



8. Repeat the procedure until only oil mist comes out at the hole of the screw plug (801).



16.Lubricate the new sealing ring (5100) with silicone-free and non-corrosive grease.



9. Lubricate the new sealing ring (802) with siliconefree and non-corrosive grease.



17.Screw in the screw plug (3700) with the sealing ring (5100) and tighten it to 100 Nm.



10.Screw in the screw plug (801) with the new sealing ring (802) and tighten it to 25 Nm. 11.Remove the manual tire filler (50/39) and unscrew the throttle piece (50/31).



NOTE Ö When starting driving: Activate the retarder briefly in braking stage 2 or 3.



36003



4. Screw in the throttle piece (50/31) with the sealing ring (5000) present. 5. Tighten the throttle piece with 10 Nm. 6. Connect the manual tire filler (50/39) to the throttle piece (50/31).



12.Lubricate the new sealing ring (5000) with silicone-free and non-corrosive grease. 13.Screw in the screw plug (3600) with the sealing ring (5000) and tighten it to 30 Nm. Filling in oil



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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!



Ö Do not use a constant air pressure.



Damage to/failure of the retarder. Ö Fill only with approved oil (see Voith retarder oil change intervals/oil selection list).



Page 23



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



4.3



Checking the oil level



Checking the oil level



Item No.



Name



801



Screw plug M 14 x 1.5; 25 Nm



802



Sealing ring A 14 x 20; replace



3600



Screw plug M 14 x 1.5; 30 Nm



5000



Sealing ring A 14 x 20; replace



3700



Screw plug M 30 x 1.5; 100 Nm



5100



3700



Sealing ring A 30 x 36; replace



5100 5000



NOTE



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



3600



Oil filling level Service filling (checking of the oil level, oil change)



5.6 l



802 801 36005



Page 24



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



Checking the oil level



Draining the oil



Aids Manual tire filler



1. Place oil pan below the retarder.



3600



WARNING



Special tools Hot exiting oil!



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



CAUTION



153.000885xx



801 36008



Hot screw plugs! Throttle piece 50/31



Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if necessary.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Requirements •



Vehicle is horizontal



•



Oil is at operating temperature (> 60 °C)



•



Retarder switched off



•



Ignition switched off



2. Unscrew the screw plug (801) and drain the oil.



WARNING Hot oil comes out under increased pressure! Face and hands could be burned. Ö Unscrew the screw plug (3600) slowly.



3. Unscrew the screw plug (3600) slowly.



Page 25



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



8. Repeat the procedure until only oil mist comes out of the hole of the screw plug (801).



Checking the oil level



Filling in the oil 3. Unscrew the screw plug (3700).



9. Lubricate the new sealing ring (802) with siliconefree and non-corrosive grease.



50/31



10.Screw in the screw plug (801) with the new sealing ring (802) and tighten it to 25 Nm.



50/39



CAUTION Wrong oil type! 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 the throttle piece (50/31).



change intervals/oil selection list).



12.Lubricate the new sealing ring (5000) with silicone-free and non-corrosive grease.



4. Fill in the oil slowly via the hole of the screw plug (3700).



13.Screw in the screw plug (3600) with the sealing ring (5000) and tighten it to 30 Nm.



5. Lubricate the new sealing ring (5100) with silicone-free and non-corrosive grease.



Measuring the volume



6. Screw in the screw plug (3700) with the sealing ring (5100) and tighten it to 100 Nm.



36003



4. Screw in the throttle piece (50/31) with the sealing ring (5000) present. 5. Tighten the throttle piece with 10 Nm.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



6. Connect the manual tire filler (50/39) to the throttle piece (50/31).



NOTE



NOTE For technical reasons, it is possible for the drainedoff oil quantity to be up to 0.2 l less than the service filling of 5.6 l.



To completely empty the retarder circuit, pulsed air is applied to the hole of the screw plug (3600).



1. Measure the volume of the drained oil.



Ö Do not use a constant air pressure.



2. If necessary, correct the oil volume.



NOTE Ö When starting driving: Activate the retarder briefly in braking stage 2 or 3.



7. Apply short pulses of air onto the hole of the screw plug (3600) of the retarder.



Page 26



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



4.4



Coolant



Coolant



Item No. 800



Name Heat exchanger



801b



Screw plug M 14 x 1.5; hexagon socket head, w.a.f. 6; 25 Nm



802



Sealing ring A 14 x 20; replace



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Requirements •



Ignition switched off



•



Retarder switched off



801b



800



802 801b 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. Ö Wear protective gloves or use cloths if 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



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



quality list. 3. Fill the vehicle and retarder cooling circuit (see specifications of vehicle manufacturer).



Page 28



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



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



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



5.



Page 29



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



5.1



Overview of the possible complaints



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 (3101)



Page 32



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– Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



•



Fuel consumption too high



–and/or– •



Engine power too low



Page 30



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



A



Overview of the possible complaints



Retarder pilot light flashes (standard type)



NOTE On-board diagnosis is possible at some vehicle manufacturers (display). Ö Observe the specifications of the vehicle manufacturer.



No.



Activity



1.



ÖCheck the operation (for retarder braking, nominal speed of the engine, if possible).



2.



ÖInstruct the driver. In doing so, observe the operating conditions.



3.



ÖCheck the oil temperature sensor (3200) (see page 93). ÖCheck the coolant temperature sensor (3200) (see page 95).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



4.



ÖReplace the oil temperature sensor (3200) (see page 93).



Result



Continue with No.



NOK



2.



OK



3.



–



–



NOK



4.



OK



5.



–



–



–



–



–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 OK = works correctly Page 31



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



B



Overview of the possible complaints



Oil leak via retarder ventilation (2700) or oil separator (3101)



No.



Activity



1.



ÖCheck whether the retarder leaks oil via the retarder ventilation (2700).



Yes



2.



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.



–



–



NOK



6.



OK



7.



4.



ÖCheck the heat exchanger (800), replace if necessary (see page 81).



5.



ÖCheck the casing ventilation (2300) (see page 60).



Result



Continue with No.



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). NOK = does not work correctly OK = works correctly



Page 32



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



C



No or insufficient brake efficiency



No.



Activity



1.



Check whether an external leak is visible at the retarder (except the retarder ventilation).



2.



ÖRepair the retarder.



3.



ÖCheck whether water is contained in oil (emulsion).



4.



ÖCheck the heat exchanger (800), replace if necessary (see page 81).



5.



ÖCheck the retarder oil level (see page 24). ÖCheck the gearbox oil level (see specifications of vehicle manufacturer).



6.



Overview of the possible complaints



ÖCorrect the retarder oil level (see page 24).



Result



Continue with No.



Yes



2.



No



3.



–



D



Yes



4.



No



5.



–



–



NOK



6.



OK



9.



–



7.



–



–



Yes



8.



ÖCorrect the gearbox oil level (see specifications of vehicle manufacturer).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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?



NOK = does not work correctly OK = works correctly



Page 33



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



No.



Activity



8.



ÖReplace the circuit parts (33) (see page 85).



9.



ÖCheck the constant-air pressure control loop (see page 40).



Result –



Continue with No. –



NOK



10.



OK



11.



10.



ÖReplace the valve block (1200) (see page 91).



11.



ÖCheck the proportional valve current as well as the leads and the plug connections (see page 48).



NOK



12.



OK



15.



ÖCheck the oil temperature sensor (3200) and the supply line (see page 93).



NOK



13.



OK



14.



12.



ÖCheck the coolant temperature sensor (3200) and the supply line (see page 95). 13.



ÖReplace the oil temperature sensor (3200) or the supply line (see page 93).



–



Overview of the possible complaints



–



–



–



–



–



–and/or– ÖReplace the coolant temperature sensor (3200) or the supply line (see page 95).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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.



NOK = does not work correctly OK = works correctly



Page 34



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



No.



Activity



16.



ÖCheck the casing ventilation (2300) (see page 60).



Result



Overview of the possible complaints



Continue with No.



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. NOK = does not work correctly



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



OK = works correctly



Page 35



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



D



Overview of the possible complaints



Other external leak



NOTE Ö Ensure that there are no leaks at the screw plugs or sealing rings.



No.



Activity



1.



ÖCheck whether the retarder leaks oil or water near the heat exchanger (800).



Yes



2.



No



7.



ÖCheck the heat exchanger (800) and O-rings (3300) (see page 81).



NOK



3.



OK



4.



–



–



ÖCheck the hose connection between the water neck at the heat exchanger (800) and the water pipe in the vehicle (see specifications of the vehicle manufacturer).



NOK



5.



OK



6.



5.



ÖReplace the hose connection (see specifications of the vehicle manufacturer).



–



–



6.



ÖContact Voith.



–



–



2.



3.



ÖReplace the heat exchanger (800) (see page 81).



Result



Continue with No.



–and/or– ÖReplace the O-rings (3300) (see page 81).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



4.



NOK = does not work correctly OK = works correctly



Page 36



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



No.



Activity



7.



ÖCheck whether the retarder leaks near the non-return valve (inlet or outlet) (3800).



8.



Version with integrated sealing ring:



Result



Overview of the possible complaints



Continue with No.



Yes



8.



No



9.



–



–



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.



10.



ÖCheck whether the retarder leaks near the housing cover of the diaphragms. ÖCheck the diaphragms (1000) for damage and correct installation position, replace if necessary (see page 75).



Yes



10.



No



11.



–



–



ÖReplace the O-ring (3900) (see page 75).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



11.



ÖCheck whether the retarder leaks near the circuit parts (33).



Yes



12.



No



13.



12.



ÖRemove, reseal and refit the circuit parts (33) (see page 85).



–



–



13.



ÖContact Voith.



–



–



NOK = does not work correctly OK = works correctly



Page 37



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



E



Overview of the possible complaints



High driving resistance



NOTE Possible effects: •



Coolant temperature too high



–and/or– •



Fuel consumption too high



–and/or–



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



•



Engine power too low



No.



Activity



1.



ÖCheck whether the retarder ventilation (2700) is heavily solied (see page 57).



Result



Continue with No.



Yes



2.



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.



NOK



5.



OK



6.



–



–



4.



5.



ÖCheck the operation (for retarder braking, nominal speed of the engine, if possible). ÖInstruct the driver. In doing so, observe the operating conditions.



NOK = does not work correctly OK = works correctly



Page 38



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



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).



–



–



8.



ÖContact Voith.



–



–



Overview of the possible complaints



NOK = does not work correctly



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



OK = works correctly



Page 39



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



5.2



Checking the constant-air pressure control loop



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



•



proper functioning of the retarder



•



proper control of the retarder



Item No.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



99/7



99/7



Name



50/56b



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 interface



50/56a 50/56e 50/56d



36075



Page 40



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



Special tools



Due to construction, a small amount of oil may leak out; this does, however, not affect retarder operation.



Requirements



Retarder tester, complete in a case 50/56



153.000776xx Test software "DIANA Lite" 50/56i



H53.1403xx Pressure gauge 0–6 bar 99/7



NOTE



•



Ignition switched off



•



Retarder switched off



•



Battery voltage: 18–32 V



•



Supply-air pressure pv in auxiliary circuit 6–11 bar



•



Oil level checked and in order (see page 24)



•



Electrical system of vehicle checked and in order (see specifications of vehicle manufacturer)



•



Electrical connections of the retarder completely disconnected from the vehicle



The test software "DIANA Lite" (50/56i) is included in the retarder tester scope of delivery (50/56) Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



NOTE



Commercially available tools Multimeter



153.001085xx



Checking the constant-air pressure control loop



DANGER Diagnosis with the retarder test device while the vehicle is traveling! Uncontrollable operating state of the vehicle. Risk of accident. Ö Carry out diagnosis only while the vehicle is standing still.



CAUTION Hot parts!



NOTE With the test software "DIANA Lite" (50/56i), measured values can be read out and stored via the PC in addition to the tests with the retarder tester. The stored measured values can be transmitted to the Voith customer service for evaluation (see operating instructions on CD-ROM).



Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if necessary.



Page 41



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



Connecting the pressure gauge



Checking the constant-air pressure control loop



Connecting the retarder tester



1



50/563b310



Checking the supply voltage of the pressure sensor 5. Switch on the vehicle ignition.



VR 115 HV 1200



6. Set the "RETARDERTYP" (retarder type) switch at the retarder tester (50/56a) to "8".



8



153.000



2



3700



50/56a 3 4



5100



15



7. Switch the toggle switch to the position "EIN mit Regelkreis" (on with control loop).



50



3.0



/56



d



00



83



51



0



50/56e



3200a



8. Connect the multimeter to the "U_Versorgung" (U_Supply) socket (measuring type: V).



3200b



153.00083610



36099



36101



1. Unscrew the screw plug (3700).



1. Connect the cable 1 (50/56b) at the valve block (1200).



99/7



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



2. Connect the cable 3 (50/56d) at the oil temperature sensor (3200a) and at the coolant temperature sensor (3200b). 3. Connect the cable 4 (50/56e) to the vehicle voltage supply/PC interface. 4. Connect all the cables to the retarder tester (50/ 56a) (see also the operating instructions of the retarder tester).



9. Read the measured value: Setpoint 4.75 V–5.25 V. 10.If the value deviates: Replace the valve block (1200) (see page 91). Checking the signal value of the pressure sensor 11.Connect the multimeter to the "U_py IST" (U_py actual) socket (measuring type: V). 12.Read the measured value: Setpoint 0.3 V–0.7 V. 13.If the value deviates: Replace the valve block (1200) (see page 91).



36076



2. Connect the pressure gauge (99/7) to the hole of the screw plug (3700). Page 42



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



Checking the valve block 14.Start the "DIANA-Lite" test software. 15.Load the template for the retarder tester (see operating instructions of the "DIANA-Lite" test software). 16.Set the "STELLDRUCK" (constant air pressure) switch at the retarder tester to "25%".



NOTE To assess the operation of the proportional valve block (1200), the results of the following test are only valid during a testing period of 60 seconds maximum.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



17.In "DIANA-Lite" read the "Stelldruck Ist" (constantair pressure actual) measured value and the measured value at the pressure gauge (99/7): Setpoint after approx. 20 seconds:



"STELLDRUCK" (constant-air pressure) switch



Constant-air pressure py [bar] Permissible range



0%



0



25%



0.55–1.05



50%



1.25–1.75



75%



1.95–2.45



100%



2.60–3.10



Checking the constant-air pressure control loop



25.Screw in the screw plug (3700) with O-ring (5100) and tighten it to 100 Nm. 26.Complete the retarder and the vehicle.



18.Repeat the test in the switch positions "50%", "75%" and "100%". 19.If one of the values deviates: Check the valve block (1200), replace if necessary (see page 91). 20.Set the "STELLDRUCK" (constant air pressure) switch at the retarder tester to "0%". 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.



Page 43



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



5.3



Checking the pump pressure pdyn



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



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Item No.



Name



3600



Screw plug M 14 x 1.5; hexagon socket head, w.a.f. 6; 30 Nm



5000



Sealing ring A 14 x 20; replace



50/56a



Retarder tester



50/56b



Cable 1: to the valve block



50/56c



Cable 2: to the pressure sensor (50/56g)



50/56d



Cable 3: to the temperature sensors



50/56e



Cable 4: to the vehicle voltage supply/PC interface



50/56g



Pressure sensor pdyn 0–30 bar



50/56b



50/56c



50/56a 50/56e 50/56d



50/56g 5000 3600



36072



Page 44



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



Requirements



Special tools



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



153.001085xx



Checking the pump pressure pdyn



153.000776xx



Retarder tester, complete in a case



Test software "DIANA Lite"



50/56



50/56i



NOTE



•



Ignition switched off



•



Retarder switched off



If the prop shaft screws are screwed in from the transmission side:



•



Battery voltage: 18–32 V



Ö Ensure that the prop shaft screws are screwed out at the drive-side flange.



•



Supply-air pressure pv in auxiliary circuit 6–11 bar



–or–



•



Oil level checked and in order (see page 24)



•



Electrical system of vehicle checked and in order (see specifications of vehicle manufacturer)



•



Electrical connections of the retarder completely disconnected from the vehicle



Ö Secure the prop shaft screws.



CAUTION Hot parts and oil! Hands can be burned and scalded. Ö Work carefully.



•



No external leaks detected at retarder



NOTE



•



Vehicle secured



With the test software "DIANA Lite" (50/56i), measured values can be read out and stored via the PC in addition to the tests with the retarder tester. The stored measured values can be transmitted to the Voith customer service for evaluation (see operating instructions on CD-ROM).



•



Prop shaft removed from flanges and secured (see specifications of vehicle manufacturer)



Ö Wear protective gloves or use cloths if necessary.



NOTE Due to construction, a small amount of oil may leak out; this does, however, not affect retarder operation.



Page 45



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



Checking the pump pressure pdyn



3. Connect the cable 1 (50/56b) on the valve block (1200).



DANGER Diagnosis with the retarder test device while the



4. Connect the cable 2 (50/56c) on the pressure sensor (50/56g).



vehicle is traveling! Uncontrollable operating state of the vehicle.



5. Connect the cable 3 (50/56d) at the oil temperature sensor (3200a) and at the coolant temperature sensor (3200b).



Risk of accident. Ö Carry out diagnosis only while the vehicle is standing still.



6. Connect the cable 4 (50/56e) to the vehicle voltage supply/PC interface.



50/36 Connecting the pressure sensor



2. Connect the pressure sensor (50/56g).



7. Connect all the cables to the retarder tester (50/ 56a) (see also the operating instructions of the retarder tester).



Connecting the retarder tester



Checking the pump pressure pdyn



36074



8. Switch on the vehicle ignition.



4



36073



3



50/56a



9. Set the "RETARDER-TYP" (retarder type) switch at the retarder tester to "8".



8331



50/56c



153.00



08341



15



0



50



3.0



/56



d



00



83



1. Unscrew the screw plug (3600) with the sealing ring (5000).



VR 115 HV 1200



153.000



2



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



1



5000 3600



50/56b0



51



0



50/56e



50/56g



10.Switch the toggle switch to the position "EIN mit Regelkreis" (on with control loop).



3200a



11.Start the "DIANA-Lite" test software.



3200b



153.00083610



36098



12.Load the template for the retarder tester (see operating instructions of the "DIANA-Lite" test software).



Page 46



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



13.Start the engine and warm it up to the operating temperature.



NOTE Ö Shift in direct gear (ratio 1:1). The engine speed then corresponds to the prop shaft speed. 14.Set the "STELLDRUCK" (constant-air pressure) switch at the retarder tester to "25%". 15.Adjust the engine speed: -



for iRet = 2.13 to 1000 min-1



-



for iRet = 1.68 to 1200 min-1



16.Set the "STELLDRUCK" (constant-air pressure) switch at the retarder tester to "50%".



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



17.Adjust the engine speed again: -



for iRet = 2.13 to 1000 min-1



-



for iRet = 1.68 to 1200 min-1



18.In the "DIANA Lite", read off the measured value "Housing pressure Actual": Setpoint > 8 bar.



Checking the pump pressure pdyn



NOTE If the setpoint of the constant-air pressure py is reached, but the pump pressure pdyn is undershot, the retarder has an internal defect. Ö Replace the circuit parts (see page 85).



NOTE Test when the "STELLDRUCK" (constant-air pressure) switch is set to "100%": "Housing pressure Actual" setpoint > 12 bar. Is normally not possible with the retarder tester when the vehicle is standing still. 19.Set the "STELLDRUCK" (constant-air pressure) switch at the retarder tester to "0%". 20.Disconnect the retarder tester (50/56a) and all cables. 21.Disconnect the pressure sensor (50/56g). 22.Lubricate the new sealing ring (5000) with 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.



Page 47



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



5.4



Checking the proportional valve current



Special tool



Requirements Ignition switched off



•



Retarder switched off



•



Battery voltage: 18–32 V



•



Electrical system of vehicle checked and in order (see specifications of vehicle manufacturer)



•



Fuse for retarder control unit checked and in order



•



Male and female plug connectors at valve block checked for damage or wear (notch scratches) and in order



Scope of work – testing



98/8



Electrical lead and plug connections checked (visual inspection) and in order



Propventil



•



Schaltventil



Measuring adapter



Drucksensor Steuerdruck



153.000132xx



VOITH Messadapter 153.00013210



Propventil



Schaltventil



Drucksensor Steuerdruck



VOITH Messadapter 153.00013210



•



Checking the proportional valve current



99/10 36077



1. Disconnect the plug from the valve block (1200) and connect it to the measuring adapter (99/10).



99/10



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



NOTE When performing measurements using a commercially available multimeter (without real r.m.s. value measurement), exact readout of these measured values is not possible (display jumps).



2. Connect the plug of the measuring adapter (99/ 10) to the valve block (1200). 3. Connect the multimeter (98/8) (measuring type: mA). 4. Turn the "Prop flow" switch at the measuring adapter to Position "I". 5. Switch on the vehicle ignition.



Commercially available tools Multimeter (98/8) with real r.m.s. value measurement, e.g. Fluke 179



Page 48



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Diagnosis and Troubleshooting



6.



Checking the proportional valve current



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



8. If the value deviates: Check the leads, connectors and retarder control unit and replace them, if necessary.



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.



CAUTION



Ö Use a wooden board or similar for protection.



Hot parts! Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



necessary.



Page 50



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



Item No.



Name



11



Electrical connection, valve block



26



Supply-air pressure line pv, Valve block connection



95/1



Flanged nut M 14 x 1.5; 170 Nm



95/2



Hex.-head screw M 14 x 1.5 x 120; 170 Nm



96



Hose clamp



97



Hose supports



100 50300



3200/10 26 100



Retarder O-ring 198 x 3; replace



3200/10



Oil temperature sensor connection



3200/20



Coolant temperature sensor connection



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



NOTE



50300



Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



11



96



97



3200/20 96



97



95/2 95/1 95/2



95/1



36078



Page 51



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



Requirements Retarder switched off



•



Ignition switched off



•



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)



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



•



?



Page 52



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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



Page 53



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.1



Components overview



Components overview



Item No.



Replace component



Name



300



Gasket plate



800



Heat exchanger



900



Diaphragm housing cover



1000



Diaphragm



1200



Valve block



2200



O-ring 125 x 2.5



2300



Casing ventilation



2301



O-ring 55 x 3



2700



Disc silencer 42 x 2



2800



O-ring 38 x 3



2900



Circlip 42 x 1.75



3000



O-ring 6 x 3



3101



Oil separator



5500



3200a



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



4200



Perform visual inspection and replace if necessary



5000 4800



3101



3500



3000 4500



3501



2300 2301



2200 1000 3800



4000 3900



300 1000



2700 2800 1200 2900



3800



4100



4300



3400 3300



3300



NOTE Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



Check component according to specifications and replace if necessary



3200b 5000 800



900 5400 36042



Page 54



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Item No. 3200a



3200b



Components overview



Name



Replace component



Oil temperature sensor M 14 x 1.5; hexagon insert bit, w.a.f. 27; 28 Nm



Check component according to specifications and replace if necessary



5500



3200a



Coolant temperature sensor M 14 x 1.5; hexagon insert bit, w.a.f. 27; 28 Nm



4800



3101



3300



O-ring 37.46 x 5.33



3500



3400



O-ring 60 x 5



3501



3000 4500



3500



2/2-way valve



3501



Sealing ring A 36 x 42



3800



Non-return valve



3900



O-ring 253.6 x 3.53



4000



Intermediate ring 270/220 x 52.5



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



Perform visual inspection and replace if necessary



5000



2300 2301



2200 1000 3800



NOTE



4200



4000 3900



300 1000



2700 2800 1200 2900



3800



4100



4300



3400 3300



3300



3200b 5000 800



900 5400 36042



Page 55



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Item No. 4100



4200



4300



Name



Replace component



Hex.-head screw M 8 x 20; hexagon insert bit, w.a.f. 13; 22 Nm



Check component according to specifications and replace if necessary



5500



Hex.-head screw M 8 x 75; hexagon insert bit, w.a.f. 13; 25 Nm



O-ring 200 x 3



4800



Sealing cover A 20



5000



Sealing ring A 14 x 20



5400



Hex.-head screw M 10 x 40; hexagon insert bit, w.a.f. 16; 50 Nm Hex.-head screw M 10 x 40; hexagon insert bit, w.a.f. 16; 30 Nm



3200a



4800



3101



3500



3000 4500



3501



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Perform visual inspection and replace if necessary



2300 2301



2200 1000 3800



4000 3900



300 1000



2700 2800 1200 2900



3800



4100



4300



3400 3300



3300



NOTE Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



4200



5000



Hex.-head screw M 10 x 40; hexagon insert bit, w.a.f. 16; 50 Nm



4500



5500



Components overview



3200b 5000 800



900 5400 36042



Page 56



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.2



Retarder ventilation



Retarder ventilation



Item No.



Name



2700



Disc silencer 42 x 2; check, clean and blow out with compressed air



2800



O-ring 38 x 3; replace



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Ö Replace retarder ventilation.



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 Retarder switched off



•



Ignition switched off



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



•



Page 58



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.3



Oil separator module



Oil separator module 5500



Item No.



Name



3100



Oil separator module



3101



Oil separator



5500



Hex.-head screw M 10 x 40; hexagon insert bit, w.a.f. 16; 30 Nm



3100



3101



CAUTION Hot parts! Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if necessary.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Requirements •



Retarder switched off



•



Ignition switched off



36044



Page 59



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.4



Casing ventilation



Casing ventilation



Item No. 2300



2300/1



Name Casing ventilation



2300/1



Valve insert



2300/2



Float, specified weight max. 12 g



2300/3



Float cage



2301



2300



2301 2300/2 2300/3



O-ring 55 x 3; replace



NOTE Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



NOTE



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



For casing ventilation from Voith item no. H53.133214 upwards: Ö Observe the installation position of the float: The side marked "O" upwards.



36045



Page 60



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Casing ventilation



Aids Ethyl alcohol



NOTE



for float



CAUTION Incorrect adapter!



Item No.



If, for space reasons, the impact puller Voith item no. H53.7712xx cannot be used to remove the casing ventilation, a puller (98/7) for self-fabrication is available as an alternative.



Damage to casing ventilation. Ö Only use adapter (98/9) from Voith item no.



Tools for self-fabrication



H53.942811 upwards.



Name



10



Plate 140x30x8; S 235JR



11



2 x web 30x8x8, S 235JR; weld onto the plate



12



Hex.-head screw M8x90; DIN 931



13a



Hex.-head nut M8; ISO 4032



13b



Hex.-head nut M8; ISO 4032; attach to the screw (12)



12 13a



10



Special tools



13b



11



8



Ø10 8



8 12



Ø 40.5 mm Ø 60 mm



H53.7712xx



H53.9428xx



Impact puller



Adapter



99/5



98/9



37.5



37.5



7 mm



16



11



Tools for self-fabrication



27079_en



99/4



30



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Test ring



Material: St 37 140



Puller 98/7



36105



Weight: 0.085 kg The test ring (99/4) can be ordered from Voith Turbo GmbH & Co. KG: Voith item no. H67.2757xx.



Page 61



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Casing ventilation



2. Use the impact puller (99/5) including the adapter (98/9) to pull the valve insert (2300/1) upwards and out of the retarder housing.



CAUTION Hot parts!



4. Take O-ring (2301) out of the groove in the valve insert (2300/1). Removing with puller (98/7)



Hands could be burned. 0



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



2300/2



98/7



2300/3



98/9



necessary. Requirements •



Retarder switched off



•



Ignition switched off



•



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 float cage (2300/3) from the retarder housing.



99/5 98/9



1. Screw the puller (98/7) to the adapter (98/9). )



13a



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



98/7 2300/1



36066



1. Screw the impact puller (99/5) to the adapter (98/9).



2301 36107 36068



Page 62



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



2. Use the puller (98/7) including the adapter (98/9) to pull the valve insert (2300/1) upwards and out of the retarder housing. Tighten the hex.-head nut (13a) to do this. 0



Casing ventilation



Checking 1. Check the casing ventilation (2300) for soiling and sludge and clean it.



2300/1



2300/2



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



3. If necessary, remove the float (2300/2) and the float cage (2300/3) from the retarder housing.



2. Check the float (2300/2) for damaged surfaces and sealing areas (see arrow/diagram).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



3. Weight float (2300/2): Specified weight: max. 12 g. 4. For exceeded specified weight: Replace the entire casing ventilation (2300).



Page 63



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Casing ventilation



Installing with impact puller (99/5)



2. Clean the float with ethyl alcohol.



NOTE



99/4



0



2300/2



2300/1



For casing ventilation from Voith item no. H53.133214 upwards: Ö Observe the installation position of the float: The side marked "O" upwards.



2300/1



2301 36070 36068



5. Check the sealing edge of the radial shaft sealing ring in the valve insert (2300/1) (see arrow/ diagram):



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



-



Place the float (2300/2) on a suitable object, e.g. hex.-head nut.



-



Place the valve insert (2300/1) on the float and weigh it down using the test ring (99/4).



-



Fill the empty space between the float (2300/2) and upper edge of the valve insert with ethyl alcohol.



1. Lubricate the new O-ring (2301) with silicone-free and non-corrosive grease and pull it on the valve insert (2300/1).



3. Insert the float (2300/2) into the float cage (2300/3). 4. Place valve insert (2300/1) on the float cage (2300/3). 5. Lubricate the bore of the casing ventilation (2300) in the retarder housing with silicone-free and noncorrosive grease. 6. Insert the casing ventilation (2300) into the retarder housing.



2300/1 0



2300/2



NOTE The sealing edge is damaged, if the fluid level drops within 1 minute.



2300/3 36071



Page 64



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Casing ventilation



Installing with puller (98/7)



2. Clean the float with ethyl alcohol.



99/5



NOTE



98/9 2300/1



2301 36068



8. Complete the retarder.



Ö Observe the installation position of the float: The side marked "O" upwards. 3. Insert the float (2300/2) into the float cage (2300/3). 4. Place valve insert (2300/1) on float cage (2300/3).



36066



7. Use the impact puller (99/5) including the adapter (98/9) to press the casing ventilation (2300) carefully into the retarder housing.



For casing ventilation from Voith item no. H53.133214 upwards:



1. Lubricate the new O-ring (2301) with silicone-free and non-corrosive grease and pull it on the valve insert (2300/1).



5. Lubricate the bore of the casing ventilation (2300) in the retarder housing with silicone-free and noncorrosive grease. 6. Insert the casing ventilation (2300) into the retarder housing.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



2300/1 0



2300/2



2300/3 36071



Page 65



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Casing ventilation



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



8. Complete the retarder.



Page 66



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.5



Non-return valve (inlet)



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



3800



Name Non-return valve (inlet), complete



3800/1



Guide M 48 x 1.5 hexagon insert bit, w.a.f. 55; 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 Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



3800/3 3800/2 3800/1



36047



Page 67



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Non-return valve (inlet)



Checking



Aids Thread seal Loctite 243



for the guide thread



Installing



3800/1



Ö For guide with integrated sealing ring: -



Apply Loctite 243 to the thread of the guide (3800/1).



-



Screw in the non-return valve (inlet) (3800) and tighten it to 180 Nm.



CAUTION Hot parts! Hands could be burned. Ö Work carefully.



Ö For guide with copper sealing ring :



3800/3



Ö Wear protective gloves or use cloths if



-



Apply Loctite 243 to the thread of the guide (3800/1).



-



Lubricate the new sealing ring (5200) with silicone-free and non-corrosive grease.



-



Screw in the non-return valve (inlet) (3800) with sealing ring (5200).



-



Tighten the non-return valve (inlet) (3800) to 230 Nm.



necessary. Requirements •



Retarder switched off



•



Ignition switched off



•



Retarder oil drained (see page 21)



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Removing 1. Unscrew the guide (3800/1).



3800/2 36095



1. Check the rubber coating of the piston (3800/3) for damage. Replace the complete non-return valve (inlet) (3800) if necessary. 2. Check the guide (3800/1) and the spring (3800/2) for wear. Replace the complete non-return valve (inlet) (3800), if necessary.



2. Remove the spring (3800/2) and the piston (3800/3) from the retarder housing.



Page 68



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.6



Non-return valve (outlet)



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



3800



Name Non-return valve (outlet), complete



3800/1



Guide M 48 x 1.5 hexagon insert bit, w.a.f. 55; 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 Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



3800/3 3800/2 3800/1



36048



Page 69



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Non-return valve (outlet)



Checking



Aids Thread seal Loctite 243



for the guide thread



Installing



3800/1



Ö For guide with integrated sealing ring: -



Apply Loctite 243 to the thread of the guide (3800/1).



-



Screw in the non-return valve (outlet) (3800) and tighten it to 180 Nm.



CAUTION Hot parts! Hands could be burned. Ö Work carefully.



Ö For guide with copper sealing ring :



3800/3



Ö Wear protective gloves or use cloths if



-



Apply Loctite 243 to the thread of the guide (3800/1).



-



Lubricate the new sealing ring (5200) with silicone-free and non-corrosive grease.



-



Screw in the non-return valve (outlet) (3800) with sealing ring (5200).



-



Tighten the non-return valve (outlet) (3800) to 230 Nm.



necessary. Requirements •



Retarder switched off



•



Ignition switched off



•



Retarder oil drained (see page 21)



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Removing 1. Unscrew the guide (3800/1).



3800/2 36095



1. Check the rubber coating of the piston (3800/3) for damage. Replace the complete non-return valve (outlet) (3800), if necessary. 2. Check the guide (3800/1) and spring (3800/2) for wear. Replace the complete non-return valve (outlet) (3800), if necessary.



2. Remove the spring (3800/2) and the piston (3800/3) from the retarder housing.



Page 70



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.7



2/2-way valve



Item No.



2/2-way valve



4800



Name



3500



2/2-way valve, M 36 x 1.5; hexagon insert bit, w.a.f. 19; 130 Nm



3501



Sealing ring A 36 x 42; replace



3502



O-ring 28 x 2; replace



3503



O-ring 24 x 2; replace



4800



Sealing cover A 20



3500 3501 3502 3503



NOTE Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



CAUTION Hot parts! Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if necessary. Requirements •



Ignition switched off



•



Retarder switched off



36049



Page 71



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Removing



2/2-way valve



Checking



4. If there are corrosion traces:



CAUTION Improper removal!



-



Check and repair the compressed air system (see specifications of vehicle manufacturer).



-



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). Ö Screw in the screw plug without a sealing ring (3501) manually until the screw plug is against the retarder housing and the valve body engages.



1. Check whether the brass piston is in the correct position (see A/diagram).



Ö Loosen and unscrew the screw plug with the engaged valve body manually.



2. If the piston is stuck (see B/diagram), replace the complete 2/2-way valve (3500).



–or– Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



36102



Ö Pull the valve body out of the retarder housing with a bearing outer race puller. Bearing outer race puller: e.g. Kukko, tool no. 21-5, Ø 28–40 mm and pusher no. 22-1



NOTE If there are corrosion traces on the 2/2-way valve, there is water in the vehicle's compressed air system. 3. Check the 2/2-way valve for corrosion traces.



Page 72



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.8



Diaphragm housing cover



Diaphragm housing cover



Item No.



4300



Name



300



Gasket plate; replace



900



Diaphragm housing cover



4300



Hex.-head screw M 10 x 40; hexagon insert bit, w.a.f. 16; 50 Nm



Aids



900



300



2 stud bolts M 10



CAUTION Hot parts! Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



necessary.



36050



Page 73



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



CAUTION Improper removal! Malfunction/damage to the retarder.



Diaphragm housing cover



1. Screw two stud bolts M 10 into the retarder housing (see arrows/diagram).



4. Screw in the hex.-head screw (1) hand-tight. 5. Tighten the hex.-head screw (2) to 17 Nm.



2. Place the new gasket plate (300) onto the retarder housing.



Ö To remove/install the diaphragm housing cover: Lay the retarder on its side.



3. Place the new diaphragm housing cover (900) onto the retarder housing.



CAUTION



Requirements •



Ignition switched off



Incorrect sequence when tightening the hex.-



•



Retarder removed (see page 50)



head screws!



•



Valve block removed (see page 91)



6. Tighten the hex.-head screw (1) to 17 Nm. 7. Tighten the hex.-head screw (3) to 50 Nm. 8. Unscrew the stud bolts M 10. 9. Tighten the hex.-head screws in the prescribed sequence (4–8) to 50 Nm. 10.Tighten the hex.-head screw (9) to 50 Nm.



Damage to diaphragms. Ö Tighten the hex.-head screws in the prescribed sequence.



11.Tighten the hex.-head screw (2) to 50 Nm. 12.Tighten the hex.-head screws in the prescribed sequence (10–13) to 50 Nm.



Removing 1. Unscrew the hex.-head screws (4300).



13.Tighten the hex.-head screw (1) to 50 Nm.



2. Remove the diaphragm housing cover (900).



6



5



4



3. Remove the gasket plate (300). Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



12



Installing



13



1



7



11



8



NOTE Ö Ensure that the diaphragm housing cover (900) is dry and free of dirt.



10



3 2



9



36083



Page 74



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.9



Diaphragms



Diaphragms 1000b



Item No.



Name



1000a



Diaphragm



1000b



Diaphragm



3900



O-ring 253.6 x 3.53; replace



4000



Intermediate ring



3900



4000



NOTE Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



1000a



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Special tools



153.001540xx Puller hook 50/38 36051



Page 75



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



CAUTION



Diaphragms



Removing



CAUTION



Hot parts! 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.



NOTE If the intermediate ring (4000) is replaced: Ö In the case of retarder housing up to Voith item no. ".15", use only the intermediate ring with Voith item no. ".11". Ö In the case of retarder housing from Voith item no. ".20", use only the intermediate ring with Voith item no. ".20" or higher.



4000 50/38



1. Remove the first diaphragm (1000b).



CAUTION



100 36081



Improper removal! Damage to the retarder. Ö Remove the intermediate ring (4000) only with a puller hook (50/38).



2. Use the puller hook (50/38) to pull the intermediate ring (4000) carefully and smoothly out of the retarder housing (100). 3. Remove the O-ring (3900).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Requirements •



Ignition switched off



•



Retarder removed (see page 50)



•



2/2-way valve removed (see page 71)



•



Diaphragm housing cover removed (see page 73)



4. Remove the second diaphragm (1000a).



Page 76



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Diaphragms



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: -



Diaphragms (1000a and 1000b)



-



Retarder housing (100)



-



Diaphragm housing cover (900)



100 4000



1000a 36082



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



100



2. Insert the first diaphragm (1000a) centered. In doing so, observe the installation position of the diaphragm bead.



36093



3. Lubricate the diaphragm (1000a) in the contact area of the intermediate ring (4000) with siliconefree 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 siliconefree and non-corrosive grease (see gray area/diagram). Page 77



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Diaphragms



8. Lubricate the diaphragm (1000b) in the contact area of the diaphragm housing cover (900) with silicone-free and non-corrosive grease.



1000b 3900



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 36082



4. Lubricate the new O-ring (3900) with silicone-free and non-corrosive grease and pull it onto the intermediate ring (4000).



cover. 9. Install the gasket plate (300) and the diaphragm housing cover (900) (see page 73). 10.Complete the retarder.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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 silicone-free and non-corrosive grease. 7. Place the second diaphragm (1000b) centered on the intermediate ring. In doing so, observe the installation position of the diaphragm bead.



Page 78



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Diaphragms



Installing (intermediate ring from Voith item no. ".20")



1000b



NOTE



100



4000



Ö Ensure that the following parts are dry and free of dirt: -



Diaphragms (1000a and 1000b)



-



Retarder housing (100)



-



Diaphragm housing cover (900)



3900



100



1000a 36103



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



100



2. Insert the first diaphragm (1000a) centered. In doing so, observe the installation position of the diaphragm bead.



36093



3. Lubricate the diaphragm (1000a) in the contact area of the intermediate ring (4000) with siliconefree 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 siliconefree and non-corrosive grease (see grey area/diagram). Page 79



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



8. Lubricate the diaphragm (1000b) in the contact area of the diaphragm housing cover (900) with silicone-free and non-corrosive grease.



1000b 4000



3900



Diaphragms



9. Place the second diaphragm (1000b) centered on the intermediate ring. In doing so, observe the installation position of the diaphragm bead.



100



CAUTION Improper installation! Damage to diaphragms.



1000a



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 and non-corrosive grease and pull it onto the intermediate ring (4000).



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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 silicone-free and non-corrosive grease.



1000b) together with the diaphragm housing cover. 10.Install the gasket plate (300) and the diaphragm housing cover (900) (see page 73). 11.Complete the retarder.



7. Place the second diaphragm (1000b) centered on the intermediate ring. In doing so, observe the installation position of the diaphragm bead.



Page 80



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.10



Heat exchanger



Heat exchanger



Item No. 800



Name Heat exchanger



3200



Coolant temperature sensor M 14 x 1.5; hexagon insert bit, w.a.f. 27; 28 Nm



3300



O-ring 37.46 x 5.33; replace



3400



O-ring 60 x 5; replace



5000



Sealing ring A 14 x 20; replace



5400



Hex.-head screw M 10 x 40; hexagon insert bit, w.a.f. 16; 50 Nm



NOTE



3300



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



5000 3200 3400 3300



800



5400



36052



Page 81



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



NOTE



Heat exchanger



DANGER



Ö Please procure any connecting pieces that are not listed here by yourself.



Heat exchanger can fall!



If the heat exchanger is replaced:



Ö Secure the heat exchanger against falling.



Ö Unscrew the coolant temperature sensor (3200) with sealing ring (5000).



Aids Elring sealing compound Dirko-S Profi press HT: •



Color black



•



Temperature-resistant –50 °C ... + 250 °C



153.001375xx



•



Voith item no. 190.001697xx



Pressure-test equipment



Requirements



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



50/58



CAUTION Hot parts! Hands could be burned. Ö Work carefully. necessary.



for sealing surface heat exchanger/ retarder housing



•



Retarder switched off



•



Ignition switched off



•



Retarder oil drained (see page 21)



•



Coolant drained (see page 27)



•



Electrical connecting lead at the coolant temperature sensor disconnected



•



Coolant connecting hose disconnected at the heat exchanger



Ö Wear protective gloves or use cloths if



NOTE



Your body can be crushed severely. Ö Use a suitable lifting device.



Special tools



Removing



1. Unscrew the hex.-head screws (5400) and remove the heat exchanger (800). 2. Remove the O-rings (3300 and 3400).



Page 82



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Checking 1. Lubricate the O-rings (3300 and 3400) with silicone-free and non-corrosive grease and insert them into the grooves of the pressure-test equipment (50/58).



Heat exchanger



6. Slowly pressurize the heat exchanger (800) with a max. of 4 bars overpressure.



CAUTION 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 50/58



7. If air bubbles occur in the water at the water neck (800/1): Replace the heat exchanger. 8. Drain the overpressure.



C



B 800 36100



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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".



Page 83



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Installing



Heat exchanger



3. Place on the heat exchanger (800) and fasten it using the hex.-head screws (5400).



NOTE The water and oil section of new heat exchangers are coated with anti-corrosion oil. Ö Before installation drain any anti-corrosion oil and rinse the water section with hot water.



4. Tighten the hex.-head screws (5400) crosswise to 50 Nm.



CAUTION In case of water in the retarder! Oil loss via oil separator. Malfunction of the retarder.



5. Complete the retarder.



CAUTION



Ö Fill the retarder with 5.6 l engine oil or flush oil. 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 Observe the specifications of the vehicle manufacturer or those of Voith Turbo coolant



Ö De-oil the cooling and heating system (see 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 specifications of vehicle manufacturer).



100 3300



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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 dashed line/figure 36104). Page 84



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.11



Circuit parts



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



33



Name Circuit parts



2200



O-ring 125 x 2.5; replace



3000



O-ring 6 x 3; replace



3400



O-ring 60 x 5; replace



4200



Hex.-head screw M 8 x 75; hexagon insert bit, w.a.f. 13; 25 Nm



3000 4500



33



2200



50300 4200



NOTE Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



3400



36053



Page 85



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Item No.



Name



4500



O-ring 200 x 3; replace



5400



Hex.-head screw M 10 x 40; hexagon insert bit, w.a.f. 16; 50 Nm



50300



Circuit parts



O-ring, 198 x 3; replace



NOTE Ö Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free and noncorrosive grease before installation.



3000 4500



33



2200



NOTE



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Instructions are enclosed with the circuit parts (spare part). These describe the installation/removal and return of the defective circuit parts (conversion instructions for basic retarder VR 115 HV).



50300 4200



3400



36053



Page 86



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Circuit parts



If the stator gets stuck in the retarder housing:



Aids Elring sealing compound Dirko-S Profi press HT: •



Color black



•



Temperature-resistant –50 °C ... + 250 °C



•



Voith item no. 190.001697xx



for sealing surface, circuit parts/retarder housing



Commercially available tools Two-arm universal puller



CAUTION



Requirements •



Retarder removed (see page 50)



•



Heat exchanger removed (see page 81)



Removing 1. Unscrew the hex.-head screw (4200).



Hot parts! Hands could be burned.



Special tools



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



50/59



33



necessary.



NOTE



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



153.001547xx



If the retarder circuit parts are mechanically defective:



Puller



Ö Disassemble the complete retarder (except for the circuit parts) and clean all components (they must be free of dirt, metallic residues and water)



50/59



Ö Replace the heat exchanger (see page 81). Ö Replace the diaphragms (see page 75)



4200 36096



2. Pull off the circuit parts (33) with the puller (50/59).



NOTE If the retarder circuit parts are replaced: Ö Replace the output restrictor (see page 90).



Page 87



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Circuit parts



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



4. Remove the O-rings (3400, 2200, 3000 and 4500).



Page 88



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Circuit parts



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



8. Complete the retarder.



10 ±3 30 ±3



36054



Page 89



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.12



Output restrictor



Output restrictor



Item No.



Name



4400



Cap screw M 8 x 20; hexagon socket head, w.a.f. 5; 17 Nm



4700



Output restrictor



CAUTION Hot parts! Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if necessary.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Requirements •



Retarder removed (see page 50)



•



Circuit parts removed (see page 85)



4700 4400



36084



Page 90



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.13



Valve block



Valve block 4100



Item No.



Name



1200



Valve block



1201



Seal assembly valve block



1201/1



O-ring; replace



1201/2



Mould sealing, replace



4100



Hex.-head screw M 8 x 20; hexagon insert bit, w.a.f. 13; 22 Nm



CAUTION



1201 1200 1201/1 1201/2



Hot parts! Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



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.



36056



Page 91



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



Valve block



Requirements Retarder switched off



•



Ignition switched off



•



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.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



•



Page 92



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.14



Oil temperature sensor



Oil temperature sensor



Item No.



Name



3200



Oil temperature sensor M 14 x 1.5; hexagon insert bit, w.a.f. 27; 28 Nm



5000



Sealing ring A 14 x 20; replace



CAUTION



3200 5000



Hot parts! Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if necessary.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Requirements •



Retarder switched off



•



Ignition switched off



•



Electrical connection at the oil temperature sensor disconnected. Male and female connector checked for damage or wear (notch scratches) and replaced if necessary



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.



Resistance



20 °C ± 10 °C



1039–1117 Ω



60 °C ± 10 °C



1194–1271 Ω



80 °C ± 10 °C



1271–1347 Ω



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Temperature



Page 94



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Repair



7.15



Coolant temperature sensor



Coolant temperature sensor



Item No.



Name



3200



Coolant temperature sensor M 14 x 1.5; hexagon insert bit, w.a.f. 27; 28 Nm



5000



Sealing ring A 14 x 20; replace



CAUTION Hot parts! Hands could be burned. Ö Work carefully. Ö Wear protective gloves or use cloths if necessary.



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Requirements •



Retarder switched off



•



Ignition switched off



•



Coolant drained (see page 27)



•



Electrical connecting lead at the coolant temperature sensor disconnected. Male and female connector checked for damage or wear (notch scratches) and replaced if necessary



5000 3200 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.



Resistance



20 °C ± 10 °C



1039–1117 Ω



60 °C ± 10 °C



1194–1271 Ω



80 °C ± 10 °C



1271–1347 Ω



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Temperature



Page 96



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools



Overview of the Tools



8.1



Diagnosis



8.2



Repair



98 100



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



8.



Page 97



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools



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, complete in a case



Test software "DIANA Lite"



Pressure gauge 0–6 bar



50/56



50/56i



99/7 –



Checking the pump pressure pdyn



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Diagnosis



153.001085xx



153.000776xx



Retarder tester, complete in a case



Test software "DIANA Lite"



50/56



50/56i



Page 98



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools



Task



Special tools



Checking the proportional valve current



Diagnosis



Tools for self-fabrication –



Propventil



Schaltventil



Drucksensor Steuerdruck



VOITH Messadapter 153.00013210



153.000132xx Measuring adapter



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



99/10



Page 99



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools



8.2



Repair



Repair



Task



Special tools



Tools for self-fabrication



Ø 40.5 mm Ø 60 mm H53.7712xx



H53.9428xx



Impact puller



Adapter



Test ring



99/5



98/9



99/4



7 mm



Casing ventilation



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



27079_en



Page 100



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools



Task



Special tools



Repair



Tools for self-fabrication



Casing ventilation



12 13a



10



13b



11



8



16



11 Ø10 8



12



8



37,5



30



37,5



140



36105



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



Puller 98/7



Page 101



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools



Task



Special tools



Diaphragms



Repair



Tools for self-fabrication –



153.001540xx Puller hook 50/38 Heat exchanger



–



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



153.001375xx Pressure-test equipment 50/58



Page 102



Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 HV I Overview of the Tools



Task



Special tools



Circuit parts



Repair



Tools for self-fabrication –



153.001547xx Puller



Voith Turbo I 153.00132310 I arrtd I 2008-04 © 2008



50/59



Page 103



Voith Turbo Produktgruppe Retarder Postfach 1555 74555 Crailsheim Deutschland Phone: +49 79 51 / 32-0 Fax: +49 79 51 / 32-756 [email protected] www.voith.com



Engineered reliability.