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Training
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Aftersales Service Manual
VOITH Retarder 120 with Digiprop Control
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Content
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Table of Contents
1. Preface ....................................................................................................1/1
2. General....................................................................................................2/1
2.1 Assembly Overview ..........................................................................2.1/12.2 Function and Operation Scheme .........................................................2.2/12.3 Retarder Data ..................................................................................2.3/1
3. Maintenance............................................................................................3/13.1 Maintenance Work.............................................................................3.1/13.2 Oil Change .......................................................................................3.2/1
With Stainless-Steel Heat Exchanger ....................................................3.2/1With Aluminium Heat Exchanger ..........................................................3.2/53.3 Checking Oil Level.............................................................................3.3/13.4 Cleaning Line Filter (Optional extra) ......................................................3.4/1
4. Diagnosis/Troubleshooting......................................................................4/14.1 Troubleshooting Diagram ....................................................................4.1/1
Elektrical Connections Diagram ...........................................................4.1/24.2 Troubleshooting and Remedies............................................................4.2/14.3 Checking Pump Pressure ...................................................................4.3/14.4 Checking Control System....................................................................4.4/14.5 Operational Check .............................................................................4.5/1
5. Removing, Installing Retarder .................................................................5/15.1 Removing, Installing Retarder (Free Mount Installation)............................5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment)...............................5.2/1
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Table of Contents
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6. Retarder Basic Group Repair (Gearbox Attachment)..............................6/16.1 Assembly Overview ...........................................................................6.1/16.2 Removing, Checking and Installing Casing Ventilation .............................6.2/16.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......6.3/16.4 Removing, Checking and Installing Non-Return Valve
(Stainless-Steel Heat Exchanger) .........................................................6.4/16.5 Removing, Cleaning and Installing Silencer............................................6.5/16.6 Removing and Installing Bottom Cover ..................................................6.6/16.7 Checking, Removing and Installing Closing Cover of Retarder Housing ......6.7/16.8 Removing and Installing Labyrinth Ring (Output Side),
Renewing Radial Shaft Sealing Ring.....................................................6.8/1
6.9 Removing and Installing Centering Cover (Input Side),Renewing Radial Shaft Sealing Ring.....................................................6.9/1
7. Retarder Basic Group Repair (Free Mount Installation) ..........................7/17.1 Assembly Overview ...........................................................................7.1/17.2 Removing, Checking and Installing Casing Ventilation .............................7.2/17.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......7.3/1
7.4 Removing, Checking and Installing Non-Return Valve(Stainless-Steel Heat Exchanger) .........................................................7.4/1
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7.5 Removing, Cleaning and Installing Silencer............................................7.5/17.6 Removing and Installing Bottom Cover ..................................................7.6/17.7 Removing and Installing Prop Shaft Flanges ..........................................7.7/17.8 Checking, Removing and Installing Closing Cover of Retarder Housing ......7.8/17.9 Removing and Installing Labyrinth Ring (Output Side),
Renewing Radial Shaft Sealing Ring.....................................................7.9/17.10 Removing and Installing Centering Cover (Input Side),
Renewing Radial Shaft Sealing Ring...................................................7.10/1
8. Removing, Checking and Installing Heat Exchanger ..............................8/18.1 Stainless-steel Heat Exchanger ...........................................................8.1/1
8.2 Aluminium Heat Exchanger .................................................................8.2/1
9. Control Parts ...........................................................................................9/1
10. Annex ....................................................................................................10/1Data SheetMiscellaneous Conversions
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Preface
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1 Preface
The present service manual serves as training material of the basics course.The information and instructions which is given to you furthermore provide the basis forappropriate and professional maintenance and repair at the VOITH Retarder 120 with Digiprop control.
We ask you firmly to notice the safety and warning notes which you will find in these instructions.
Caution!
is associated for safety instructions and for warning notes at dangerous situations for persons,at reduction of quality of workmanship and the possibility of damage to property.
Notice
is associated for general notices for a better handling during maintenance of the retarder.
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Preface
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1 Preface
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Caution!
The switched-on retarder will not secure the parked vehicle.
At a fa ilure of the retarder, or while the temperature limitation is effective the vehicle speed must besettled with the service brake.
Notice
Only genuine spare parts may be used for repairs. For inquiries and orders, please provide the followinginformation (see also Section 2.3):
Serial-Number Code-Number
Notice
The used three- or four-digit item numbers in these instructions are corresponding to the item numbers
in the spare part lists in the annex. Items or components shown with an oblique-number are notavailable. Items or components with two-digit item numbers are no spare parts and therefore notavailable in the spare part lists.
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Preface
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1 Preface
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Caution!
Pay attention to absolute cleanliness in maintenance work. Dirt on bearing and sealing surfaces and
electrical contacts may cause considerable damage or operational malfunctions.
Notice
To observe environmental protection you should dispose of drained fuels, coolants and lubricantsprofessionally.
Notice
Shield retarder proportional valve from direct jet of high-pressure cleaner (steam jet cleaner)!
Notice
In troubleshooting you must not replace parts on suspicion. Warranty work or goodwill work can only be
offered, if the parts involved are demonstrably defective.
To exclude injuries and to avoid impairment of the operational reliability of the retarder or damage to theretarder as a result of inexpert workmanship, the information and instructions must be read carefully andcomplied with in their entirety.
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Preface
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Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situationswhich might entail the risk of injury for the person carrying out the work. It is therefore imperative thatany person carrying out repair work on VOITH retarders uses his professional knowledge to make surethat his own safety is not endangered and that the retarder suffers no negative effects, in particularsafety-wise, through the chosen working procedure. For these reasons, no liability can be assumed fordamage incurred.
It is therefore expressly pointed out that all working procedures described must be carried out only incompliance with the valid general directions and regulations of the locally responsible authorities, of thehealth protection, accident prevention and environmental protection organisations.
The technical status of the present instructions can be seen from the updating index. There may bediscrepancies between the actual technical status of the retarders and the descriptions owing to
continuous development and improvement of the retarders.VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and withoutprior notification.
Should you have queries about the descriptions, please contact the responsible person in theappropriate organisation of the country involved or:
VOITH TURBO GmbH & Co. KGD-74564 Crailsheim
Department cb; Voithstrae 1Telephone (07951) 32-0Telefax (07951) 32-756Extensions:Customer telephone and Spare Parts Service32-401 / 32-422
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General
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2 General
2.1 Assembly Overview....................................................................................2.1/1With Stainless-Steel Heat Exchanger .................................................................2.1/1With Aluminium Heat Exchanger .......................................................................2.1/3
2.2 Function and Operation Scheme................................................................2.2/1
2.3 Retarder Data.............................................................................................2.3/1
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General
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2.1 Assembly Overview
Illustration VOITH Retarder R 120
with Digiprop control system
basic group with stainless-steel
heat exchanger
100/1 Retarder data100/2 Constant-air pressure
connection py A100/3 Ventilation connection R1000 Heat exchanger1900 Oil filler/check plug (M 30 x 1,5)
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1900100/1
1000
100/2
100/3
16001
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2.1 Assembly Overview
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Illustration VOITH Retarder R 120
with Digiprop control system
basic group with stainless-steel
heat exchanger
(Continue)
1000 Heat exchanger1000/1 Leakage oil drain plug
(M 14 x 1,5)1000/5 Cooling water drain plug
(M 18 x 1,5)1700 Retarder oil drain plug
(M 22 x 1,5)
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1000/1
1700
1000/5
1000
16002
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2.1 Assembly Overview
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Illustration VOITH Retarder R 120
with Digiprop control system
basic group with aluminium heat exchanger
100/1 Retarder data
100/2 Constant-air pressureconnection py A
100/3 Ventilation connection R1000 Heat exchanger
1000/5 Cooling water drain plug(M 12 x 1,5)
1900 Oil filler/check plug (M 30 x 1,5)
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1900
100/1
1000/5
1000
100/2
100/3
16003
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2.1 Assembly Overview
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Illustration VOITH Retarder R 120
with Digiprop control system
basic group with aluminium heat exchanger(Continue)
1000 Heat exchanger1000/1 Leakage oil drain plug
(M 10 x 1)1000/3 Heat exchanger oil drain plug
(M 12 x 1,5)1000/5 Cooling water drain plug
(M 12 x 1,5)1700 Retarder oil drain plug
(M 22 x 1,5)
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16004
1000/1
1700
1000/5
1000
1000/3
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General 2.2 Function and Operation Scheme
Illustration of VOITH Retarder 120 with Digiprop control system
Notice
The reference numbers indicated in Section 2.2 are not identical with the reference numbers of the spare parts lists.
1 Heat exchanger2 Control unit
4 Connectio n ter minal 155 Connectio n ter minal 307 Fuses (5A)
8 Connection ground12 Pump pressure test connection15 ABS-Signal16 Reta rder stage switch
43 Oil sump44 Stator
45 Stator pin46 Rotor47 Speedometer signal
50 Output restrictor D152 Fil ling restrictor D253 Filling duct56 Leakage o il re turn line
R
P
A
46
44 12 50
25
52
45
23
53
19
37
67
20
26
21
7
416 5 8
2
7015 47177418
69
43 156 66
Oil sump
Supply-air pressure pV
Constant-air pressure p y
Coolant (water)
Pump pressure pP
16005e
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2.2 Function and Control System
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Description of the function
The VOITH Retarder 120 is a powerful hydrodynamic continous brake of compact design for buses andcommercial vehicles of the medium range. The VOITH Retarder 120 is mounted between the gearboxand the rear axle of the vehicle.
The retarder braking torque is sustained even when gear changes are made.The switched-on retarder will not secure a parked vehicle.In the event of a retarder failure or when the temperature limit is effective, the service brake must beused to regulate the vehicle speed.
A retarder stage switch (16) with a maximum of 5 switching stages is used to control theVOITH Retarders 120. A special version combines the retarder stage switch (16) with ABS,a 3-stage pedal-operated brake valve or a service-brake pressure switch.
The following variaties in operation are available:
Operation with function ,,Constant speed"
The retarder is operated by a 5-stage retarder stage switch.
When the retarder stage switch (16) is shifted to position 1, the Constant Speed function is activated.The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limitof the maximum braking torque.
If the retarder is switched off (0 position), or switched to braking stage (position 2 to 5), the memorizedconstant speed is deleted. If the constant speed function is re-activated, the new present speedis memorized.
When the retarder stage switch is shifted to position 2 to 5, braking stage 1 to 4 is energized.
Maximum braking torque is obtained when the retarder stage switch is in the maximum position.
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Description of operation of retarder R 120 with digiprop control system
As a special version, the control system is available with push button operation for constant speed.The retarder is operated in this case by a 4-stage retarder stage switch.When the push button is pushed in any position of the retarder stage switch, the momentary speed is
transferred to memory. In the 0 braking stage, this transfer to memory takes effect and the retarder holdsthe vehicle speed downhill constant within the limits of the maximum braking torque. Another push onthe push button in any switch position will delete the speed data.
On a downhill run with constant speed operation, the vehicle can be slowed down within the limits ofthe maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting tobraking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle acceleratesto the speed previously transferred to memory.
The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank forauxiliary equipment on the vehicle.
When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2).From this input signal, the control unit (2) provides a control current which flows to theproportional valve (21).The proportional valve (21), depending on the magnitude of the control current, provides aconstant-air pressure pyon the oil sump (43).
The constant-air pressure pyin the oil sump (43), depending on the operating conditions(prop shaft speed), forces a certain quantity of oil into the working chamber between rotor (46)and stator (44).
c
a b
16006
The hydrodynamic principlea Rotor (46)b Stator (44)c Oil flow
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The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarderhousing.The rotation of the rotor sets the oil in motion and circulates it in a closed circuit betweenthe rotor (46) and stator (44).The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking of
the rotor (46) and consequently to braking of the vehicle.
During braking, the kinetic energy of a deceleration is transformed into heat. To dissipate this heat, partof the circulat ing oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and viafilling ducts to join the circulating flow again.In the heat exchanger (3300), the heat energy of the oil is transferred to the cooling water of the vehicleand dissipated via the vehicle radiator to the ambient air.
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Temperatur pick-ups, water (19), oil (20)
The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from theretarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water andoil temperature to the control unit (2).To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarderbraking torque is limited to protect the vehicle cooling system and the retarder.The constant-air pressure pyis l imited.
The braking torque and consequently the heat generated are reduced until a balance is obtainedbetween the braking energy of the retarder and the amount of heat which can be dissipated bythe vehicle cooling system.
If the cooling water temperature rises into the temperature limit range, the consequence is a limitation of
the retarder braking torque to protect the vehicle cooling system. If the temperature rises above thetemperature limit range, there is no more braking torque output.
While the temperature limit is effective or if there is a retarder failure, the service brake must be used tocontrol the vehicle.The control unit (2) also cuts back braking torque if oil temperature rises too rapidly, irrespective of actualoil temperature.
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Casing ventilation (23)
During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) andthe ventilation system (22) out of the retarder.Once the working circuit is free of air, a float rises and closes the casing ventilation.
Stator pins (45)
When the working chamber is empty, the rotor (46) sets up in it an air flow, which is retarded by the stator(44). To minimize this loss, automatically operating stator pins have been installed in the outer zone ofthe stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent thebuild-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back ontheir seats against the force of the spring and the full space between the blades is available.
Check valve (66) stainless-steel heat exchanger
The check valve (66) prevents the airflow emptying the heat exchanger insert of oil when idling.
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2.3 Retarder Data
The retarder data (arrow) are punched on the left side on the retarder housing.
The retarder data plate (2) provides the following information:
1. Serial number:
Six-digit number
2. Code number:Eight-digit number
Notice
Please, always quote the retarder serial-No. and code-No. when submitting queriesor ordering spare parts.
16007
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Maintenance
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3 Maintenance
3.1 Maintenance Work .....................................................................................3.1/1
3.2 Oil Change .................................................................................................3.2/1Stainless-steel Heat Exchanger
........................................................................3.2/1Aluminium Heat Exchanger ..............................................................................3.2/5
3.3 Checking Oil Level .....................................................................................3.3/1
3.4 Cleaning Line Filter (Optional Extra) ..........................................................3.4/1
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3.1 Maintenance Work
Overview of maintenance work
Carry out the fo llowing maintenance work at eachoil change:
l Clean the cleaning line filter (optional extra)
l Carry out visual inspection on leaks at the complete retarder
l Check hex.-head screws of prop shaft on correct fitment, or tighten.
Observe guidelines and instructions!
l Tighten all screw plugs of the retarder basic groups and the heat exchanger with the appropriatetorque (see Annex) except all fastening nuts of the heat exchanger (see Annex).
Caution!
Tighten fastening nuts of heat exchanger only in case of leakage. Tightening torque: 23 Nm
The oil change intervals and operating specifications have to be taken from the annex!
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3.2 Oil Change
Illustration oil change R 120
with stainless-steel heat exchanger
1000/1 Leakage oil drain plug(M 10 x 1), 13 Nm
1000/2 Sealing ring (A 10 x 13,5), renew1000/5 Cooling water drain plug
(M12 x 1,5), 25 Nm1000/6 Sealing ring (A12 x 18), renew
1600 Sealing ring (A 22 x 29), renew1700 Retarder oil drain plug
(M 22 x 1,5), 66 Nm1800 Sealing ring (A 30 x 36), renew1900 Oil filler/check plug
(M 30 x 1,5), 150 Nm
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1900
18001000/2
1000/6 1000/5
1000/1
1700
1600
16008
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Notice
For satisfactory retarder operation, it is important to adhere to the specified service filling(see table below) and to use only oils specified in the operating specifications (see Annex) foroperating the retarder in the relevant application.
The retarder oil temperature must be higher than 60 oC(operating temperature) for the oilto be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressureis acting in the retarder.The retarder and the ignition must have been switched off!
Heat exchanger Service fill ing After complete
taking apart and cle-aning, as well as
emptied heatexchanger
After exchange of
heat exchanger
Stainless-steelheat exchanger
(L+R)4,5 l 5,8 l 6,5 l
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Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec.Repeat this procedure twice.Switch off the retarder andignition and wait 5 minutes (control function).
Caution! Risk of injury!
The oil f iller/check plug is heated up (oil temperature)!
2. Push an oil collecting pan under retarder.
3. Screw out the oil check plug (1900) and remove sealing ring (1800).
Caution! Risk of injury!
The retarder oil drain plug is heated up (oil temperature)!
4. Screw out the retarder oil drain plug (1700) and remove sealing ring (1600) and drain oil.
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5. Screw out the leakage oil drain plug (1000/1) and remove sealing ring (1000/2) and drain theaccumulated oil.
Notice
If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening theleakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with thevehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the tworadial shaft sealing rings at the Retarder and renew those, if necessary(see Section 6.8, 6.9, 7.9, 7.10).
If it is necessary to drain the cooling water during the service, remove and empty the retarder on oil sidecompletely (see Section 8.1, 8.2).
This process also must be enforced with strongly spent oil.
6. Screw the oil drain plugs (1700 and 1000/1) tight with new sealing rings (1600 and 1000/2).
Retarder oil drain plug (1700): Tightening torque 66 NmLeakage oil drain plug (1000/1): Tightening torque 13 Nm
7. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified(see page 3.2/2) in accordance with the operating specifications (see Annex).
8. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm
9. Check the oil level (see Section 3.3).
The oil change intervals and operating specifications have to be taken from the annex!
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3.2 Oil Change
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Illustration oil change R 120
with aluminium heat exchanger
1000/1 Leakage oil drain plug(M 10 x 1), 13 Nm
1000/2 Sealing ring (A 10 x 13,5), renew1000/3 Heat exchanger oil drain plug
(M 12 x 1,5), 25 Nm1000/4 Sealing ring (A 12 x 15,5), renew
1600 Sealing ring (A 22 x 29), renew1700 Retarder oil drain plug
(M 22 x 1,5), 66 Nm1800 Sealing ring (A 30 x 36), renew1900 Oil filler/check plug
(M 30 x 1,5), 150 Nm
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1000/3
1000/4
1000/2
1000/1
17001600
1900
1800
16009
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3.2 Oil Change
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Notice
For satisfactory retarder operation, it is important to adhere to the specified service filling(see table below) and to use only oils specified in the operating specifications (see Annex) foroperating the retarder in the relevant application.
The retarder oil temperature must be higher than 60 oC(operating temperature) for the oilto be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressureis acting in the retarder.The retarder and the ignition must have been switched off!
Heat exchanger Service filling New filling
Aluminium heat exchanger (AKG) 5,5 l 6,0 l
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Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec.Repeat this procedure twice.Switch off the retarder andignition and wait 5 minutes (control function).
Caution! Risk of injury!
The oil f iller/check plug is heated up (oil temperature)!
2. Push an oil collecting pan under retarder.
3. Screw out the oil filler/check plug (1900) and remove sealing ring (1800).
Caution! Risk of injury!
The retarder oil drain plug is heated up (oil temperature)!
4. Screw out the retarder oil drain plug (1700) and the heat exchanger oil drain plug (1000/3) andremove the sealing rings (1600 and 1000/4) and drain oil.
5. Screw out the leakage oil drain plug (1000/1) and drain the accumulated oil.
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Notice
If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening the
leakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with thevehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the tworadial shaft sealing rings at the Retarder and renew those, if necessary(see Section 6.8, 6.9, 7.9, 7.10).
6. Screw the oil drain plugs (1700, 1000/3 and 1000/1) tight with new sealing rings (1600, 1000/2and 1000/4).
Retarder oil drain plug (1700): Tightening torque 66 NmHeat exchanger oil drain plug (1000/3): Tightening torque 25 NmLeakage oil drain p lug (1000/1): Tightening torque 13 Nm
7. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified(see page 3.2/2) in accordance with the operating specifications (see Annex).
8. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm
9. Check the oil level (see Section 3.3).
The oil change intervals and operating specifications have to be taken from the annex!
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3.3 Checking Oil Level
Illustration checking oil level
Notice
The oil change intervals and operatingspecifications have to be taken from the annex.
1800 Sealing ring (A 30 x 36), renew1900 Oil filler/check plug (M 30 x 1,5),
150 Nm
Notice
The illustration shows a retarder 120 withstainless-steel heat exchanger. A version withaluminium heat exchanger is possible.
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1900
1800
16010
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3.3 Checking Oil Level
(Continue)
Notice
For satisfactory retarder operation, it is important to use only oils specified in the operating specifications(see Annex) for operating the retarder in the relevant application.
Service filling
The service filling for the complete retarder system depends on the version of themounted heat exchanger.
For relevant application approved oils
Use only approved oils specified in the operating specifications (see Annex).
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3.3 Checking Oil Level
(Continue)
Notice
For the oil level check, the temperature of the retarder oil must be higherthan 60C (operating temperature).
The oil level check must be carried out with the vehicle in a horizontalposition.Difference between min. and max. mark on oil filler/check plug is approx. 0,5 l.
Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary andswitch it off after approx. 5 sec.Repeat this procedure twice.
Caution!
While the oil level is being checked, make sure that retarder and ignition system must havebeen switched off!
Risk of injury exists at nonobservance, by hot leaving oil when screw out oil filler/check plug!
2. Switch off the retarder and wait 5 minutes (control function).
Caution! Risk of injury!
The oil filler/check plug (1900) is heated up (oil temperature)!
3. Screw out the oil filler/check plug (1900) and remove sealing ring (1800).Wipe off oil of the oil filler/check plug.
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3.3 Checking Oil Level
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4. Position oil filler/check plug (1900) plane at the thread.
Do not screw in the oil filler/check plug!
5. Pull out again the oil filler/check plug (1900).Oil level is correct bewteen min. and max. mark of the oil filler/check plug.
6. Top up slowlyany lacking oil through the hole for the oil filler/check plug.
7. Screw the oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm
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Max
Min
1900
16011
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3.4 Cleaning Line Filter
(Optional Extra)
Illustration line filter
12000 Complete line filter12000/1 Pressure spring12000/2 Intermediate plate
12000/3 Cover12000/4 Holding plate12000/5 Pressure spring12000/6 Filter housing
12111 Filter insert12112 O-ring (36,2 x 3), renew,
coat with silicone-free andnon-corossive greasefor installation
Lubricants
O-ring Silicone-free andnon-corossive grease
12000/1
12111
12000/2
12000/5
12112
12000/3
12000/4
12000/6
12
000
16012
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3.4 Cleaning Line Filter
(Continue)
Notice
Vehicle specific can be installed a line filter within the constant-air pressure line between air tankfor auxiliary equipment and the proportional valve of the retarder control system.
The line filter is designed and in the way installed, to ensure an optimum air flow to the proportional valvealso when filter insert is badly soiled. In this case the compressed air will not be cleaned anymore.
Job scope
Caution! Risk of injury!
Observe fall in pressure in the compressed air circuit for auxiliary equipment (e.g. air springs)!
1. Disconnect constant-air pressure line at the line filter for air tank of auxiliary equipment .
2. Press in the cover (12000/3) and pull out the holding plate (12000/4).
3. Pull out of the filter housing (12000/6) the cover (12000/3) with O-ring (12112),
the pressure spring (12000/5), the intermediate plate (12000/2), the filter insert (12111)and the pressure spring (12000/1) .
4. Blow out the filter insert (12111) with compressed air from inside out. Check filter insert fordamages and renew if necessary.
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5. Insert the pressure spring (12000/1), the filter insert (12111), the intermediate plate (12000/2) andthe pressure spring (12000/5) in filter housing (12000/6).
6. Coat new O-ring (12112) with silicone-free and non-corossive grease. Pull the new O-ring on tothe cover (12000/3).
7. Press in the cover (12000/3) into the filter housing (12000/6) and put in theholding plate (12000/4).
Notice
If complete filter (12000) has to be removed, observe the correct installing position.
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Diagnosis /
Troubleshooting
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4 Diagnosis / Troubleshooting
4.1 Troubleshooting Diagram...........................................................................4.1/1Electrical Connections Diagram ........................................................................4.1/2
4.2 Troubleshooting and Remedies .................................................................4.2/1
4.3 Checking Pump Pressure...........................................................................4.3/1
4.4 Checking Control System...........................................................................4.4/1
4.5 Operational Check......................................................................................4.5/1
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Diagnosis /
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4.1 Troubleshooting Diagram
Illustration troubleshooting d iagram
Notice
Before starting troubleshooting the oil level of the retarder must be checked and corrected(see chapter 3.3 Checking oil level).It is important that the specific service filling is kept for a trouble-free operation of the retarder
(see chapter 3.2 Oil change and annex).
Renew casingventilation
Check oil level ofretarder
OK NOK
YESNO
Water in the oil?(emulsion)
Check casingventilation
(Chapter6.2)
NOK OK
YES NO
Water in the oil?(emulsion)
OK NOK
Check oil level ofretarder
YES NO
Water in the oil?
(emulsion)
NO YES
Water in the oil?
(emulsion)
OK NOK
Check py(static)
(Chapterl4.4)
Complaint
R 120Digiprop
Check p (dynamic)
(Kapitel4.3)
Activate flash codeand read outtrouble code
(Chapter4.2)
Temperature limit!
Permanentlighting
flashes
OK NOK
Check operation(by braking with
retarder nominalengine speed,
if possible
Check cooling system:
-coolant level
-thermostat-coolant pump-radiator fan-radiator grill fordirtiness
Retarder:
Check Temp.-Sens.(oil/water)
Driver instruction!
Clear faults anddelete fault memory
(Chapter4.2)
Check heatexchanger
see chapter 6.4
Check heatexchanger
see chapter 6.4
Retarder pilotlight
No respectivelytoo insufficient
retarder brakingeffect
Oil leak byventilation
Oil leak input sideor output side
Empty chamber ofreturn of leakage oil(at heat exchanger)
(Chapter3.3)
If the retarder isstill leaking, or the
chamber ofleakage oil is filled
again with oil after1000 km,
renew radial shaftseal
Correct oil level ofretarder (*)
Correct oil level ofretarder
Check non-returnvalve in cover ofcasing ventilation
(Chapter6.3)
NOK OK
Contact
VOITH
Renew non-return
valve
i i
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4.1 Troubleshooting Diagram
(Continue)
Electrical Diagram Version 1
Electrical Diagram Version 2
Input / (0...20mA ) `INA-I Stop light relay Stop light relay
Speedometer signal Speedometer signal
Prop valve +`
Output / low side 1 `LS 1`Output / high side `HS 2`
Output / high side 1 `HS 1`
Prop valve -`
T 30 (Battery) T 30 (Battery)
T 31 (Ground)T 31 (Ground)
Retarder Stage Switch`+`
ISO LISO K
Position 5Position 4Position 3Position 2Position 1
Position 5Position 4Position 3Position 2Position 1
CAN-lowCAN-GroundCAN-high
T 15 (Ignition lock)
T 15 (Ignition lock)
Changeover valve -`Changeover valve +`
Water temp.`-`Water temp.`+`
Oil temp.`+`Oil temp.`-`
Prop valve +`Prop valve -`
Changeover valve -`Changeover valve +`
Water temp.`-`Water temp.`+`
Oil temp.`+`Oil temp.`-`
ABS ABSblue
white
white
weiwhite
black
pink
pink
blue/white
blue/white
brown/whiteorange/white
orange/white
orange
orangeorange
orange
yellow/green
yellow/green
grey/black
red/white
grey
bluepurple
32
3
1211
10
151413181716
21654987
7
32165498
1654987
12
12pinsX3.
9pinsX2.
18pinsX1.
Digiprop
1110
grey
brownbrown
beige
beige
redred
grey
grey
pinkblue
black/white
black/whiteyellow/green
Input / p.-down / PWM-in `DID 4 `Input / (m 0...5V ) `INA-U `
Input / pull-down `DID 3 `
Input / pull-up `DIU 1`Input / pull-up `DIU 2`Input / pull-down DID 1`Input / pull-down DID 2`
Retarder pilot light Retarder pilot light
purplepurple
9 5 4 3 2 7 6 101112 131481
Connecting plug 14 ins"Additional Functions"
"ISO Interface"Connecting plug 4 pins
7653284
3 21 4
Retarder Stage Switch`+`
"Retarder Stage Switch"Connecting plug 8 pins
+
+
+
Lead Retarder
Lead E-Box
3
4
2
1Pin
16014e
Prop valve `+`
Output / low side 1 `LS 1`Output / high side `HS 2`
Output / high side 1 `HS 1`
Prop valve ` `
T 30 (Battery) T 30 (Battery)
T 31 (Ground)T 31 (Ground)
Retarder Stage Switch`+`ISO LISO K
Position 5Position 4Position 3Position 2Position 1
Position 5Position 4Position 3Position 2Position 1
CAN-lowCAN-GroundCAN-high
T 15 (Ignition lock)
T 15 (Ignition lock)
Prop valve `+`Prop valve ` `
weiwhite
black
pink
blue/whiteorange/white
orangeorange
3
121110
151413181716
2
7
32165498
18pinsX1.
Digiprop
brownbrown
beige
redred
grey
grey
pinkblue
black/whiteyellow/green
purplepurple
"ISO Interface"
7653284
3 21 4
Retarder Stage Switch`+`
"Retarder Stage Switch"Connecting plug 8 pins
+
+
Lead Retarder
Lead E-Box
21Pin
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Troubleshooting and remedies
Check requirements
Batter y voltage 18 - 32 V
Vehicle electrical system checked in accordance with the Owner s Manual for the vehicleand found satisfactory.
Fuse for retarder control unit checked and found satisfactory. Compressed-air pressure 6 - 11 bar
l For check with the multimeter, pin 15 (plug X1) on the control unit (2)must be connected to pin 15 ground (terminal 31),at pin 7 (plug X1) must be connected terminal 15 andat pin 13 (terminal X1) terminal 30.
Notice
Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary(see Section 3.3 Checking Oil Level ).
For trouble-free retarder operation, it is important that the filling quantity specified is adhered to(see table, Section 3.2, page 3.2/2).
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Notice
The retarder pilot light (arrow) has additionally the function of a fault code:
- slight fault
Permanent lighting in position 0 - 5 of retarder stage switch, braking is still possible to limited extent.
- serious fault
Permanent lighting in position 0 - 5 of retarder stage switch, braking no longer possible- retarder is switched off.
Notice
If the ignition is switched off and on, the retarder is in operation again and the retarder pilot lightgoes off. If a serious fault remains present or reoccurs, the retarder switches off again and the retarderpilot light comes on permanently in position 0 to 5 of the retarder stage switch.
R
16016
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16017
147101316
258111417
369121518
4.2 Troubleshooting and Remedies
(Continue)
Connector arrangement and pin assignment
Notice: All plugs illustrated from plug-in side (i.e. leads at back).
Plug X1 Control unit
1 Not in use2 Not in use
3 Not in use4 Retarder stage switch, position 3 -(or)5 Retarder stage switch, position 2 -(bl)6 Retarder stage switch, position 1 -(pi)7 Terminal 15 (rd)8 Retarder stage switch, position 5 -(gr)9 Retarder stage switch, position 4 -(wh)10 Retarder stage switch + (vi)11 ISO-interface, L-lead (or/wh)12 ISO-interface, K-lead (bl/wh)13 Terminal 30 (bl )14 Not in use15 Terminal 31 (br )16 Output / high side 2 HS2 (bl/wh)17 Output / low side 1 LS1 (ye/gr)18 Output / high side 1 HS1 (be)
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Plug X2 Control unit
1 Not operational/usable for applications (or)2 Proport ional valve - (gr)3 Proportional valve + (pi)4 Cooling water temperature pick-up - (bl)
5 Cooling water temperature pick-up + (ye/gr)6 Not operational/ground (be)7 Not in use8 Oil temperature pick-up - (wh)9 Oil temperature pick-up + (vi)
Plug X3 Control unit
1 Input / pull up DIU 1 (wh)2 Speedometer signal (b l)3 ABS-Signal (bl/wh)4 Input / pull down DID 2 (br/wh)5 Input / pull down DID 1 (bl/wh)6 Input / pull up DIU 2 (p i)7 Input / (0.. .5V) INA-U (gr/bl)8 Retarder pilot light (ye/gr)9 Input / pull down DID 3 (or/wh)10 Input / (0...20 mA) INA-I (rd/wh)11 Stop l ight relay (or)12 Input / pull down / PWM-in DID4 (gr) / engine-speed signal
16018
147
258
369
16019
14710
25811
36912
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Extra o perations plug
1 Retarder stage switch + (vi)2 Input / pull down DID 1 (bl/wh)3 Input / pull down DID 2 (br/wh)4 Input / pull down DID 3 (or/wh)
5 Input / pull down / PWM -in DID 4 (gr)6 Input / pull up DIU 1 (wh)7 Input / pull up DIU 2 (p i)8 Input / (0.. .5V) INA-U (gr/bl)9 Input / (0...20 mA) INA-I (rd/wh)10 Output / high side 1 HS1 (be)11 Output / high side 2 HS2 (bl/wh)12 Output / low side 1 LS1 (ye/gr)13 Terminal 15 (rd)
14 Terminal 31 (br)
ISO-Interface plug
1 K-lead (bl/wh)2 K-lead (or/wh)3 Terminal 15 (rd)4 Terminal 31 (br)
2
1
4
3
6
5
8
7
10
9
12
11
14
13
16020
2 1
4 3
16021
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Cooling water temperature pick-up plug
Oil temperature pick-up plug
Proportional valve p lug
1 Proportional valve + (pi )2 Proportional valve + (gr)3 Not operational (or )4 Not operational (be)
16022
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1
2
3
4
16023
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Retarder stage switch plug
1 Not in use2 Position 5 - (gr)3 Position 4 - (wh)4 Retarder stage switch + (vi)
5 Position 3 - (or)6 Position 2 - (bl)7 Position 1 - (pi)8 Bridge to pin 4
16024
1 2 3 4
5 6 7 8
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A. With fault code
Special tool
Commercially available tool
Notice
The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-outfrom the fault memory.
Furthermore a diagnosis with the PC DigiDia software is possible. In this case please contactVOITH TURBO or a responsible contracting party.
Multimeter recommended: Fluke 87
53.8224.10
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Fault memory read-out via retarder pilot light blinking code
Notice
If several faults have been stored in the memory, they are indicated in the sequence of their occurance,but always only one fault per triggering.
Exception:
The fault Coding fault is not held in the memory but is indicated via the blinking code.
The blinking code can be read-out of the control unit with service cable or retarder stage switch.
Fault memory read-out with service cable
(Digiprop-Version 0.2)
Requirements
- Retarder stage switch in position 0
- Vehicle in parking position, Ignition ON1. Service interface L-lead connected to ground for 2 s. For this purpose, press push-button of
service cable switch.
2. First fault as blinking code output.
3. Repeat from step 2 and 3 for more blinking code outputs.
Meaning
- long blinking signals (2 sec.) tens unit.
- short blinking signals (0,5 sec.) single unit.
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R
16016
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Digiprop-Version 1.0
The blinking code can be triggered analogous to V 0.2, the conditions are the same. Additionally theblinking code can be triggered with the help of the retarder stage switch during the service function:
1. Shift RSS-Position 0
2. Shift RSS-Position 1 ( 2 Seconds)3. Shift RSS-Position 04. Blinking code of first fault is indicated5. Repeat from step 2 to 3 for more blinking code outputs
Addition for versions as of V 1.1
There is a break of 3 seconds before and after each blinking code output, during this time the retarderpilot light is switched off.
Display example for fault code 23:
The number of tens will be indicated first as long ON-time: each 2 secondsThe number of singles afterwards will be indicated as short ON-time: each 0,5 secondsBreaks between each ON-time: each 1 second
If a relevant fault is indicated, the retarder pilot light is ON before tr iggering of the blinking code, theretarder pilot light switches to permanent lighting again after the blinking code.If there is only one fault in the memory, the retarder pilot light stays OFF after the output.
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16025
Display example: Fault code 23
E Retarder stage switch on
A Retarder stage switch o ff
t Time
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Delete fault memory
No marginal conditions in accordance with read-out of fault memory.
1. Ignition: OFF
2. Service interface L-lead connected to ground. For this purpose, press push-button ofservice cable switch.
3. Ignition: ON
4. Disconnect a fter 2 seconds the L-lead of ground.
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Notice
Meaning of entries in Measurement/test connection column: X 1/15 W X 3/11Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3
Table 1:
1) X 1/15 = ground control unit2) Only, if no fault is recognizable after a complete check of the periphery: change control unit.
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test
connection1 )
Result/
Set point
Cause/
Remedy 2)
C ode (Check)
01 Stop light relay/
Short circuit toground
slight 1 s - Ignition: OFF- Pull plug X3 out of
control unit
X 3/11 W X 1/15 Relay isinstalled:250 - 350 W
Check lead, plugsand relayor consumers
02 LS 1 output
Short circuit tobattery
slight 400 ms - Ignition: OFF- Pull plug X1 out of
control unit- Disconnect plug
for extra operation(e.g. lamp or
relay)- Ignition: ON
X 1/17 V X 1/15 0 V Check lead, plugsand relayor consumers
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Table 2:
Fault
Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
C ode (Check)
03 HS 1 output
Short circuit
slight 1 s - Ignition: OFF- Pull plug X1 out of
control unit
X 1/18 W X 1/15
With relayinstalled:250 - 350 W
Check lead, plugsand relayor consumers
04 HS 2 output
Short circuit
slight 1 s - Ignition: OFF- Pull plug X1 out of
control unit
X 1/16 W X 1/15 With relayinstalled:
250 - 350 W
Check lead, plugsand relay
or consumers
05 Terminal 15
Undervoltage
serious 60 s - Ignition: OFF- Pull plug X1 out of
control unit- Ignition: ON
X 1/7 V X 1/15 17,5 V Check lead, plugsand fuses
06 Terminal 15
Overvoltage
serious 10 s - Ignition: OFF- Pull plug X1 out of
control unit- Ignition: ON- Start engine
(idle speed)
X 1/7 V X 1/15 32,5 V Checking electricalinstallation of vehicle
(see manufacturerinstructions)
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Table 3:
* Fault is in serious class, if temperature sensor for oil and water are defective at the same time.
Fault
Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test connec-
tion
Result/
Set point
Cause/
Remedy
Code (Check)
08
09
Water tempera-ture sensor
Discontinuity /Short circuit tobattery
serious/slight *
1 s - Ignition: OFF- Pull plug X2 out of
control unit
X 2/5 W X 2/4 20C 10 C =1039 - 1117W
60C 10 C =1099 - 1271W
80C 10 C =
1271 - 1347W
Notice:
The measuring inone temperaturerangenormally issufficient.
Check lead andsensor
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Table 4:
* Fault is in serious class, if temperature sensor for oil and water are defective at the same time.
Fault
Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test connec-
tion
Result/
Set point
Cause/
Remedy
C ode (Check)
11
12
Oil temperaturesensor
Discontinuity /Short circuit tobattery
serious/slight *
1 s - Ignition: OFF- Pull plug X2 out of
control unit
X 2/9 W X 2/8 20C 10 C =1039 - 1117W
60C 10 C =1099 - 1271W
80C 10 C =
1271 - 1347W
Notice:
The measuring inone temperaturerangenormally issufficient.
Check lead andsensor
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Table 5:
Fault
Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
Code (Check)
13 1 Retarder stageswitchUndefinedswitch state
serious 100 ms - Ignition: ON- Retarder stage switch:
Position 0
X 1/10 V X 1/15
X 1/6 V X 1/15X 1/5 V X 1/15X 1/4 V X 1/15X 1/9 V X 1/15X 1/8 V X 1/15
17,5 V
0 V0 V0 V0 V0 V
Check lead, plug andretarder stage switch
13 2 - Ignition: ON- Retarder stage switch:
Position 1
X 1/10 V X 1/15X 1/6 VX 1/15
X 1/5 V X 1/15X 1/4 V X 1/15X 1/9 V X 1/15X 1/8 V X 1/15
17,5 V
17,5 V
0 V0 V0 V0 V
Check lead, plug andretarder stage switch
13 3 - Ignition: ON- Retarder stage switch:
Position 2
X 1/10 V X 1/15X 1/6 VX 1/15X 1/5 VX 1/15
X 1/4 V X 1/15X 1/9 V X 1/15X 1/8 VX 1/15
17,5 V17,5 V
17,5 V
0 V0 V0 V
Check lead, plug andretarder stage switch
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Table 6:
Fault
Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
C ode (Check)
13 4 - Ignition: ON- Retarder stage switch:
Position 3
X 1/10 VX 1/15X 1/6 VX 1/15
X 1/5 V X 1/15X 1/4 VX 1/15
X 1/9 VX 1/15X 1/8 VX 1/15
17,5 V
17,5 V
17,5 V
17,5 V
0 V0 V
Check lead, plug andretarder stage switch
13 5 - Ignition: ON- Retarder stage switch:
Position 4
X 1/10VX 1/15X 1/6 VX 1/15X 1/5 VX 1/15X 1/4 VX 1/15X 1/9 VX 1/15
X 1/8 VX 1/15
17,5 V17,5 V
17,5 V
17,5 V
17,5 V
0 V
Check lead, plug andretarder stage switch
13 6 - Ignition: ON
- Retarder stage switch:
Position 5
X 1/10 VX 1/15
X 1/6 VX 1/15X 1/5 VX 1/15X 1/4 VX 1/15X 1/9 VX 1/15X 1/8 VX 1/15
17,5 V
17,5 V17,5 V
17,5 V17,5 V17,5 V
Check lead, plug and
retarder stage switch
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.2/17
4 2 Tro bleshooting and Remedies
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Table 7:
Fault
Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test connection
Result/
Set point
Cause/
Remedy
C ode (Check)
14 Retarder stageswitchShort circuit tobattery
serious 10 s - Ignition: OFF- Pull plug X1 out of
control unit- Ignition: ON- Retarder stageswitch:
Position 0
X 1/10 V X 1/15 0 V Check lead and plug
15 Retarder stageswitchShort circuit tobattery
serious 1 s - Ignition: OFF- Pull plug X1 out of
control unit- Retarder stageswitch:
Position 5
X 1/10 W X 1/15 Resistorinfinite
Single check ofstages forshort circuit
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Di i / 4 2 Troubleshooting and Remedies
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Table 8:
Fault
Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test connec-
tion
Result/
Set point
Cause/
Remedy
C ode (Check)
16 Speedometersignal
Discontinuity
serious 2 s - Ignition: ON X 3/2 VX 1/15 1 V Check lead andspeedometer
18 Speedometer si-gnal
Short circuit tobattery
serious 2 s - Ignition: OFF- Pull plug X3 out of
control unit- Ignition: ON
X 3/2 VX 1/15 9 V Check lead andspeedometer
19 ABSShort circuit toground
serious 60 s - Ignition: ON X 3/3 VX 1/15 3,5 V Check lead,relay and ABS-con-trol unit
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Di i / 4 2 Troubleshooting and Remedies
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Table 9:
Fault
Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
test connec-
tion
Result/
Set point
Cause/
Remedy
C ode (Check)
21 ABS-Signal undefined serious 60 s - Ignition: ON X 3/3 V X 1/15 16,5 V Check lead,relay and ABS-control unit
22 Internal faultABS-current path
serious 1 s - - Replace controlunit
23 Proportional valveFault No. 1:Short circuit to battery
serious 1 s - Ignition: OFF- Pull plug X2 out of
control unit- Ignition: ON
X 2/3 V X 1/15 10 V Check lead
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Diagnosis / 4 2 Troubleshooting and Remedies
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Table 10:
Fault
Fault text Fault
class
Trigger t ime Requirement /
Operation
Measurement/
test connec-
tion
Result/
Set point
Cause/
Remedy
C ode (Check)
24 1 Proportional valveFault No. 2:- Short circuit proportional
valve magnetic- Short circuit connection
lead proportional valve- Discontinuity proportio-
nal valve magneticValve magnetic
- Discontinuity connec- tion lead proportional
valve- Short circuit to ground at proportional valve- Prop.- and shift valve
interchanged
serious 1 s - Ignition: ON- Pull plug X2 out of control unit
X 2/2 W X 2/3 18-25 W Check lead andproportionalvalve (valveblock)
24 2 - Ignition: OFF- Pull plug X2 out of control unit
X 2/3W X 1/15 Resistorinfinite
Check lead andproportionalvalve (valveblock)
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Diagnosis / 4.2 Troubleshooting and Remedies
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Table 11:
Fault
Fault text Fault
class
Trigger t ime Requirement /
Operation
Measurement/
test connec-
tion
Result/
Set point
Cause/
Remedy
C ode (Check)
24 3 - Ignition: OFF- Pull plug X2 out of
control unit
X 2/2 W X 1/15 Resistorinfinite
Check lead andproportionalvalve (valveblock)
25 Proportional valveFault No. 3:
defective control unit
serious 10 s Replacecontrol unit
27 Proportional valveFault No. 5:defective control unit
serious 2 s Replacecontrol unit
28 Terminal 30
Undervoltage
serious 60 s - Ignition: OFF- Pull plug X1 out of
control unit- Ignition: ON
X 1/13VX 1/15 17,5 V Check lead,plug and fuse
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.2/22
Diagnosis / 4.2 Troubleshooting and Remedies
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Table 12:
Fault
Fault text Fault
class
Trigger t ime Requirement /
Operation
Measurement/
test connec-
tion
Result/
Set point
Cause/
Remedy
C ode (Check)
29 Fault control unit serious 180 ms Replacecontrol unit
31 Control unit:Coding fault
serious 100 ms Provide newparameters forcontrol unit
32 Retarder pilot light:Discontinuity /Short circuit to ground
serious 3 s - Ignition: OFF- Pull plug X3 out of
control unit- Ignition: ON
X 3/8 V X 1/15 17,5 V Check lead,retarder pilotlight and fuse
33 Retarder pilot light:Short circuit to battery
serious 3 s - Ignition: ON- Retarder stage
switch:Position 1
X 3/8 V X 1/15 2 V Check lead andretarder pilotlight
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Diagnosis / 4.2 Troubleshooting and Remedies
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Table 13:
Fault
Fault text Fault
class
Trigger t ime Requirement /
Operation
Measurement/
test connec-
tion
Result/
Set point
Cause/
Remedy
C ode (Check)
35 Fault control unit serious 500 ms / 123 s Replacecontrol unit
37 Fault pedal operation slight 100 ms / 1 s Check installati-on relating toOEM-respectively
VOITH-instructions
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.2/24
Diagnosis / 4.2 Troubleshooting and Remedies
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B. Without fault code
Notice
Retarder faults without fault code are not recognized electronically.
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.2/25
Diagnosis / 4.3 Checking Pump Pressure
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Troubleshooting
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Illustration checking pump pressure
Preconditions for checking
Ignition OFF Retarder stage switch in position 0
101 Hex.-head screw (M 12 x 1,5),
(Pump pressure measuring point)25 Nm
102 Sealing ring (A 12 x 15,5), renew
Notice
The pump-pressure check provides informationon the mechanical condition of rotating parts,
on internal leaks and on the operationof the retarder.
Special tool
Pressure gauge 0 - 25 bar
53.4788.10
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.3/1
102
101
16026
Diagnosis / 4.3 Checking Pump Pressure
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Caution! Risk of injury!
The screw plug is heated up!
Job scope
1. Screw out screw plug (101) with sealing ring (102) at the retarder housing.
2. Connect up pressure gauge (99/1) to retarder housing.
3. Shift retarder stage switch (16) to the highest braking stage with the vehicle in parking position andread-off after 30 sec. the pump pressure from the pressure gauge (99/1).
4. Compare read-off pump pressure with the setpoint of the static pump pressure(see following table page 4.3/3).
Caution!
If the measurement of the static pump pressure falls short of the setpoint, either the retarder is leaking orthe control system is defective (see troubleshooting diagram).
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.3/2
99/1
16027
99/1 Pressure gauge 53.4788.10
Diagnosis / 4.3 Checking Pump Pressure
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1) Retarder stage switch in highest position2) Decisive is the pressure which has built up i tself after 30 seconds (stabilized, constant pressure)3) The code number is to be found at the control unit
Notice
The data represent the state of the art at the time of going to print.
Control units with different values are still in circulation. The manufacturer reserves the right to makefurther modifications.
Setting [Nm] Code Number 3 ) Pump pressure static
Setpoint [bar]Pump pressure dynamic 1 )
vps= 1000 r.p.m.
Minimum value [bar]
1000 027 1,15 1,45 7
1250 028 1,45 1,75 9
1500 029 1,75 2,05 12
1750 030 2,05 2,35 14
2000 031 2,35 2,65 16
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.3/3
Diagnosis / 4.3 Checking Pump Pressure
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Job scope dynamic
1. Drive the vehicle with a prop-shaft speed of vp s= 1000 r.p.m.
2. Shift the retarder stage switch (16) to position 5 while on the move at vps= 1000 r.p.m. andread-off pump pressure at pressure gauge (99/1).
3. Compare read-off pump pressure with the value of dynamic pump pressure(see table page 4.3/3).
Caution!
If the setpoint is obtained in the check at parking position but the minimum value is not reached in thedynamic check, please contact VOITH TURBO!
Caution! Risk of injury!
The screw of the pressure gauge and the retarder are heated up!
4. Disconnect the pressure gauge (99/1). Screw in screw plug (101) with new sealing ring.Tightening torque 25 Nm
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.3/4
Diagnosis /
Troubleshooting
4.4 Checking Control System
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Illustration checking control system
Notice
The reference numbers indicated in Section 4.4are not identical with the reference numbers ofthe spare parts li sts.
1 Heat exchanger
2 Con tro l un it11 Proportional valve
current connection
19 Temperatur pick-up cooling wateralternative: positions 19 and 20joining in the central-plug (see elec-trical diagram Version 2)
20 Temperature pick-up oil21 Proportional valve25 Constant-air pressure line py
(Connection A)
26 Supply-air pressure line pv(Connection P)
31 Compressed air line
(pressure regulator - four-circuitprotection valve)
32 Compressed-air pressure line(four-circuit protection valve -
air tank for auxiliary equipmentwith test connection
33 Compressed-air line
(brake circuit No. 1)34 Compressed-air line
(brake circuit No. 2)35 Compressed-air line
(parking brake)
37 Ventilation line R39 Electrical lead (cooling-water
temperature pick-up to control unit,
2 wires)40 Electrical lead (oil temperature
pick-up to control unit, 2 wires)
61 Four-circuit protection valve71 Air tank for auxiliary equipment
R
P
A
71
32
33
31
3435
61
39
19
1
40
202
25
1
37
21
26
16028
Diagnosis /
T bl h ti
4.4 Checking Control System
(C ti )
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Check requirements
Battery voltage 18 - 32 V Electrical system checked in accordance with the Owner s Manual for the vehicle
and found satisfactory. Fuse for retarder control unit checked and found satisfactory. Retarder stage switch in Position 0 Igni ti on OFF
Special tools
Pressure gauge 0 -25 bar
The adapter lead 53.8279.10 (98/5) has to be used only to connect the temperature simulator53.8207.10 (99/2), if the temperature sensor for oil and water are using one central plug.
Commercially available tool
Multimeter recommended: Fluke 87
53.4788.10
Wasser l
53.8207.10 53.8279.10 53.8198.10
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.4/2
Diagnosis /
Troubleshooting
4.4 Checking Control System
(C ti )
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Checking supply-air pressure pv
1. Connect pressure gauge to test connection of compressed-air line (32) (four-circuit protectionvalve - air tank for auxiliary equipment) and check supply-air pressure pv.
Notice
If the pressure is not within the specified range, the service brake must be checkedto the manufacturers data.
Test set-up job scope
1. Connect temperature simulator (99/2) with the adapter lead (98/5) at the temperature pick-up (57).
Notice
Pay attention to the correct connection of the plugs for cooling water and oil.
Minimum pressure: 6 bar
Maximum pressure: 11 bar
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.4/3
Pressure gauge 53.1403.10
16029
32
5798/5
99/2
16030
99/2 Temperature simulator 53.8207.10
Diagnosis /
Troubleshooting
4.4 Checking Control System
(Continue)
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2. Screw out oil filler/check plug (1900) with sealing ring (1800).
3. Connect pressure gauge (99/7) to retarder housing.
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.4/4
1900
1800
16031
99/7
16032
99/7 Pressure gauge 53.1403.10
Diagnosis /
Troubleshooting
4.4 Checking Control System
(Continue)
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4. Connect up Propstrom measuring adapter (99/3).
Disconnect plug from proportional valve (21) and connect it upto Propstrom measuring adapter (99/3).
Connect plug of Propstrom measuring adapter (99/3) to proportional valve (21).
Connect up multimeter (98/8) to measure mA.
Set switch Propvalve on Propstrom measuring adapter (99/3) to position I.
99/3 Propstrom measuring adapter 53.8198.1099/8 Multimeter
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.4/5
16033
98/8
99/3
21
Diagnosis /
Troubleshooting
4.4 Checking Control System
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Job scope test
Preconditions for checking
Ignition ON
1. Set the rotary switch of the temperature simulator (99/2) to 95C cooling water temperature and
165C oil temperature operate the retarder at the highest stage.The constant-air pressure pyand the control current must reach the values given in table on thenext page (page 4.4/7).
2. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. Theconstant-air pressure pymust drop to at approx. 7% bar below the set maximum pressure. Setrotary switch of the temperature simulator (99/2) to 125oC cooling water temperature. There mustbe no more output of constant-air pressure p y.Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature.
3. Set the rotary switch of the temperature simulator (99/2) to 185oC oil temperature.The constant-air pressure must drop to at approx. 4% below the set maximum pressure. Set therotary switch of the temperature simulator (99/2) to 225oC oil temperature. There must be no moreoutput of constant-air pressure py.
4. Carry out measurements for current and constant-air pressure regarding the following table(see page 4.4/7).
5. Screw oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm
6. Reconnect electrical lead (57) for cooling water and oil to temperature pick-ups forcooling water and oil.
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.4/6
5798/5
99/2
16030
99/2 Temperature simulator 53.8207.10
Diagnosis /
Troubleshooting
4.4 Checking Control System
(Continue)
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Notice
If the control current is reached but the constant-air pressure is not, either the retarder is leaking or theproportional valve is defective and must be renewed.
If both values are not reached, please see Section 4.2 Troubleshooting and Remedies.
1) The Code Number is to be found on the control unit.2) If a commercially available multimeter is used for measurements (without real effective measuring)
exact readings cannot be made (indication jumps!).3) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
Setting [Nm] Code Number1 ) Control current
[mA] 2 )Constant-air pressure py
[bar] 3 )
1000 027 429 441 1,15 1,45
1250 028 449 461 1,45 1,75
1500 029 470 482 1,75 2,05
1750 030 490 502 2,05 2,35
2000 031 510 522 2,35 2,65
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.4/7
Diagnosis /
Troubleshooting
4.5 Operational Check
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Requirements for check
Battery voltage 18 - 32 V Electrical system checked in accordance with the Owner s Manual for the vehicle
and found satisfactory. Constant-air pressure 6 -11 bar Retarder oil level satisfactory
The following operational states are indicated by the retarder pilot light (arrow):
Retarder pilot light without indication
The retarder is switched off. There is no fault in the memory.
Retarder pilot light permanently on
The retarder is switched on, i.e., one of the four possible retarder braking stages orConstant Speed operation has been selected with the retarder stage switch.
The retarder pilot light additionally has the function of a fault indicator.
- slight faultThe retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch, braking
operations are possible (the retarder operates with limited braking torque).
- serious faultThe retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch.There are no more braking operations possible - the retarder is switched off.
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.5/1
R
16016
Diagnosis /
Troubleshooting
4.5 Operational Check
(Continue)
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Notice
If the ignition is switched off and on again, the retarder is in operation and the retarder pilot lightis going off.If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on inposition 0 to 5 of the retarder stage switch.
Retarder pilot light f lashes
- while the retarder is braking
The temperature limitation is functioning, the retarder cuts back its braking torque.This flashing function only is realized at defined control variants!
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.5/2
Diagnosis /
Troubleshooting
4.5 Operational Check
(Continue)
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Troubleshooting
Test step Scope of check Requirement /
Operation
Result / Set point Note, Cause / Remedy
1 Retarder pilot l ight Ignition: ON Retarder pilot light comes on and
goes off after approx. 5 sec.
Retarder pilot light does not comeon, or does not go off.
Retarder pilot light trouble-free
Troubleshooting as on page 4.1/1
2 Retarder Vehicle on move- Shift retarder stage
switchto stage 1 to 5.
Retarder pilot light comes on,retarder brakes in stages 1 to 5.
Retarder pilot light does not come
on, or retarder does not brakeproperly.
Retarder operates trouble-free.
Troubleshooting as on page 4.1/1
Aftersales Service Manual VOITH Retarder 120 DigipropPage 4.5/3
Retarder Remo-
ving, Installing
5 Removing, Installing Retarder
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5.1 Removing, Installing Retarder (Free Mount Installation) ............................5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment)................................5.2/1
Aftersales Service Manual VOITH Retarder 120 DigipropPage 5/1
Retarder Remo-
ving, Installing
5.1 Removing, Installing Retarder
(Free Mount Installation)
Illustration Retarder (Free mount installation)
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1000-5
1000/6
1300
93
96
97
96
92
1000
9294
95
36
25
1100
1400
1200
1300
1400
1200
1200
57
1200/1
1500
16034
Preconditions for job
Drain oil from retarder (see Section 3.2) Drain oil from heat exchanger (see Section 8.1 and 8.2) Drain cool ing water Retarder stage switch in switch position 0
Igni ti on OFF
Notice
When stainless-steel heat exchanger is installed, oil can notbe drained from the heat exchanger.
25 Constant-air pressure line py A36 Ventilation line R
57 Plug temperature pick-up92 Prop-shaf t93 Hex head screw
1000/5 Drain plug cooling water (M 18 x 1,5), 50 Nm1000/6 Sealing ring (A 18 x 22), renew
1100 Suspension complete1200 Megi-pads, check, renew if necessary
1200/1 Spacer tube
Retarder Remo-
ving, Installing
5.2 Removing, Installing Retarder
(Gearbox Attachment)
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To install the retarder 120 according to regulations to the gearbox or to remove from the gearbox,specific working steps requiring special tools have to be carried out.
Caution!
Observe VOITH-Installat ion instructions and gear-box specific installation instructions.These have to be requested from VOITH TURBO.Should these installation instructions be disregarded, the retarder may be completely wrecked!
Aftersales Service Manual VOITH Retarder 120 DigipropPage 5.2/1
Repair Gearbox
Attachment
6 Repair (Gearbox Attachment)
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cbtd 98-0153.2659.10
6.1 Assembly Overview....................................................................................6.1/1
6.2 Removing, Checking and Installing Casing Ventilation ..............................6.2/1
6.3 Removing, Installing Non-Return Valve (Casing Ventilation) .....................6.3/1
6.4 Removing, Checking and Installing Non-Return Valve(Stainless-Steel Heat Exchanger) ..............................................................6.4/1
6.5 Removing, Checking and Installing Silencer ..............................................6.5/1
6.6 Removing and Installing Bottom Cover ......................................................6.6/1
6.7 Checking, Removing and Installing Closing Cover of Retarder Housing ...6.7.1
6.8 Removing and Installing Labyrinth Cover (output side)
Renewing Radial Shaft Sealing Ring ......................