Retardador 120 (of 1721 )
May 2, 2017 | Author: Roger Sologuren | Category: N/A
Short Description
Descripción: Mercedes-Benz 1721...
Description
Training
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Aftersales Service Manual VOITH Retarder 120 with Digiprop Control
Content
Table of Contents
1.
Preface ....................................................................................................1/1
2.
General....................................................................................................2/1 2.1 Assembly Overview ..........................................................................2.1/1 2.2 Function and Operation Scheme .........................................................2.2/1 2.3 Retarder Data ..................................................................................2.3/1
3.
Maintenance............................................................................................3/1 3.1 Maintenance Work .............................................................................3.1/1 3.2 Oil Change .......................................................................................3.2/1 With Stainless-Steel Heat Exchanger ....................................................3.2/1 With Aluminium Heat Exchanger ..........................................................3.2/5 3.3 Checking Oil Level .............................................................................3.3/1 3.4 Cleaning Line Filter (Optional extra) ......................................................3.4/1
4.
Diagnosis/Troubleshooting......................................................................4/1 4.1 Troubleshooting Diagram ....................................................................4.1/1 Elektrical 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
5.
Removing, Installing Retarder .................................................................5/1 5.1 Removing, Installing Retarder (Free Mount Installation)............................5.1/1 5.2 Removing, Installing Retarder (Gearbox Attachment) ...............................5.2/1
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Content
6.
Table of Contents (Continue)
Retarder Basic Group Repair (Gearbox Attachment)..............................6/1 6.1 Assembly Overview ...........................................................................6.1/1 6.2 Removing, Checking and Installing Casing Ventilation .............................6.2/1 6.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......6.3/1 6.4 Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger) .........................................................6.4/1 6.5 Removing, Cleaning 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 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) ..........................7/1 7.1 Assembly Overview ...........................................................................7.1/1 7.2 Removing, Checking and Installing Casing Ventilation .............................7.2/1 7.3 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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Content
Table of Contents (Continue)
Removing, Cleaning and Installing Silencer ............................................7.5/1 Removing and Installing Bottom Cover ..................................................7.6/1 Removing and Installing Prop Shaft Flanges ..........................................7.7/1 Checking, Removing and Installing Closing Cover of Retarder Housing ......7.8/1 Removing and Installing Labyrinth Ring (Output Side), Renewing Radial Shaft Sealing Ring .....................................................7.9/1 7.10 Removing and Installing Centering Cover (Input Side), Renewing Radial Shaft Sealing Ring ...................................................7.10/1 7.5 7.6 7.7 7.8 7.9
8.
Removing, Checking and Installing Heat Exchanger ..............................8/1 8.1 Stainless-steel Heat Exchanger ...........................................................8.1/1 8.2 Aluminium Heat Exchanger .................................................................8.2/1
9.
Control Parts ...........................................................................................9/1
10.
Annex ....................................................................................................10/1 Data Sheet Miscellaneous Conversions
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Preface
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 for appropriate 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
1
Preface (Continue)
Caution! The switched-on retarder will not secure the parked vehicle. At a failure of the retarder, or while the temperature limitation is effective the vehicle speed must be settled with the service brake. Notice Only genuine spare parts may be used for repairs. For inquiries and orders, please provide the following information (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 not available. Items or components with two-digit item numbers are no spare parts and therefore not available in the spare part lists.
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Preface
1
Preface (Continue)
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 lubricants professionally. 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 the retarder as a result of inexpert workmanship, the information and instructions must be read carefully and complied with in their entirety.
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1
Preface
Preface (Continue)
Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situations which might entail the risk of injury for the person carrying out the work. It is therefore imperative that any person carrying out repair work on VOITH retarders uses his professional knowledge to make sure that his own safety is not endangered and that the retarder suffers no negative effects, in particular safety-wise, through the chosen working procedure. For these reasons, no liability can be assumed for damage incurred. It is therefore expressly pointed out that all working procedures described must be carried out only in compliance with the valid general directions and regulations of the locally responsible authorities, of the health protection, accident prevention and environmental protection organisations. The technical status of the present instructions can be seen from the updating index. There may be discrepancies 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 without prior notification. Should you have queries about the descriptions, please contact the responsible person in the appropriate organisation of the country involved or: VOITH TURBO GmbH & Co. KG D-74564 Crailsheim Department cb; Voithstraße 1 Telephone (07951) 32-0 Telefax (07951) 32-756 Extensions: Customer telephone and Spare Parts Service 32-401 / 32-422
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General
2
General
2.1
Assembly Overview ....................................................................................2.1/1 With Stainless-Steel Heat Exchanger .................................................................2.1/1 With 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
2.1
Assembly Overview
Illustration VOITH Retarder R 120 with Digiprop control system basic group with stainless-steel heat exchanger 100/1 100/2 100/3 1000 1900
100/3
Retarder data Constant-air pressure connection p y „A“ Ventilation connection „R“ Heat exchanger Oil filler/check plug (M 30 x 1,5)
100/2
100/1 1900
1000 16001
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General
2.1
Assembly Overview (Continue)
Illustration VOITH Retarder R 120 with Digiprop control system basic group with stainless-steel heat exchanger (Continue) 1000 1000/1 1000/5 1700
Heat exchanger Leakage oil drain plug (M 14 x 1,5) Cooling water drain plug (M 18 x 1,5) Retarder oil drain plug (M 22 x 1,5)
1700
1000/1
1000/5
1000 16002
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General
2.1
Assembly Overview (Continue)
Illustration VOITH Retarder R 120 with Digiprop control system basic group with aluminium heat exchanger 100/1 100/2 100/3 1000 1000/5 1900
100/3
Retarder data Constant-air pressure connection p y „A“ Ventilation connection „R“ Heat exchanger Cooling water drain plug (M 12 x 1,5) Oil filler/check plug (M 30 x 1,5)
100/2
1900 100/1
1000 1000/5
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General
2.1
Assembly Overview (Continue)
Illustration VOITH Retarder R 120 with Digiprop control system basic group with aluminium heat exchanger (Continue) 1000 1000/1 1000/3 1000/5 1700
Heat exchanger Leakage oil drain plug (M 10 x 1) Heat exchanger oil drain plug (M 12 x 1,5) Cooling water drain plug (M 12 x 1,5) Retarder oil drain plug (M 22 x 1,5)
1700
1000/3
1000/1
1000/5
1000 16004
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2.2
General
Function and Operation Scheme
Illustration of VOITH Retarder 120 with Digiprop control system
25
21 44
12
50
A R
67
46
4
16
P
26
37
5
8
69
7
23
52
20 2
19
45
18
53
43
56
66
4
7
17
15
47
70
1 Oil sump
Coolant (water)
Supply-air pressure p V Constant-air pressure p y
Pump pressure p P
16005e
Notice The reference numbers indicated in Section 2.2 are not identical with the reference numbers of the spare parts lists.
1 2 4 5 7 8 12 15 16 17 18 19 20 21 23 25 26 37
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Heat exchanger Control unit Connection terminal 15 Connection terminal 30 Fuses (5A) Connection ground Pump pressure test connection ABS-Signal Retarder stage switch Retarder pilot light Stop light relay Temperature pick-up cooling water Oil temperature pick-up Proportional valve Casing ventilation Constant-air pressure line p y „A“ Supply-air pressure line p v „P“ Ventilation line „ R“
43 44 45 46 47 50 52 53 56 66 67 69 70
Oil sump Stator Stator pin Rotor Speedometer signal Output restrictor D1 Filling restrictor D2 Filling duct Leakage oil return line Check valve (stainless-steel heat exchanger) Check valve (casing ventilation cover) ISO interface plug Extra operations plug
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General
2.2
Function and Control System (Continue)
Description of the function The VOITH Retarder 120 is a powerful hydrodynamic continous brake of compact design for buses and commercial vehicles of the medium range. The VOITH Retarder 120 is mounted between the gearbox and 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 be used to regulate the vehicle speed. A retarder stage switch (16) with a maximum of 5 switching stages is used to control the VOITH 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 limit of the maximum braking torque. If the retarder is switched off (0 position), or switched to braking stage (position 2 to 5), the memorized constant speed is deleted. If the constant speed function is re-activated, the new present speed is 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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General
2.2
Function and Control System (Continue)
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 holds the vehicle speed downhill constant within the limits of the maximum braking torque. Another push on the push button in any switch position will delete the speed data.
c
a
b
On a downhill run with „constant speed“ operation, the vehicle can be slowed down within the limits of the maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting to braking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle accelerates to the speed previously transferred to memory. The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank for auxiliary 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 the proportional valve (21). The proportional valve (21), depending on the magnitude of the control current, provides a constant-air pressure p y on the oil sump (43).
16006
The hydrodynamic principle a Rotor (46) b Stator (44) c Oil flow
The constant-air pressure p y in 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).
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General
2.2
Function and Control System (Continue)
The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarder housing. The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between the 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, part of the circulating oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and via filling 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 vehicle and dissipated via the vehicle radiator to the ambient air.
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General
2.2
Function and Control System (Continue)
Temperatur pick-ups, water (19), oil (20) The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from the retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and oil temperature to the control unit (2). To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarder braking torque is limited to protect the vehicle cooling system and the retarder. The constant-air pressure p y is limited. The braking torque and consequently the heat generated are reduced until a balance is obtained between the braking energy of the retarder and the amount of heat which can be dissipated by the 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 the temperature 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 to control the vehicle. The control unit (2) also cuts back braking torque if oil temperature rises too rapidly, irrespective of actual oil temperature.
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General
2.2
Function and Control System (Continue)
Casing ventilation (23) During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) and the 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 of the stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent the build-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back on their 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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General
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 queries or ordering spare parts.
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16007
Maintenance
3
Maintenance
3.1
Maintenance Work .....................................................................................3.1/1
3.2
Oil Change .................................................................................................3.2/1 Stainless-steel Heat Exchanger ........................................................................3.2/1 Aluminium 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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Maintenance
3.1
Maintenance Work
Overview of maintenance work Carry out the following maintenance work at each oil 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 appropriate torque (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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Maintenance
3.2
Oil Change
Illustration oil change R 120 with stainless-steel heat exchanger 1000/1 1000/2 1000/5 1000/6 1600 1700 1800 1900
Leakage oil drain plug (M 10 x 1), 13 Nm Sealing ring (A 10 x 13,5), renew Cooling water drain plug (M12 x 1,5), 25 Nm Sealing ring (A12 x 18), renew Sealing ring (A 22 x 29), renew Retarder oil drain plug (M 22 x 1,5), 66 Nm Sealing ring (A 30 x 36), renew Oil filler/check plug (M 30 x 1,5), 150 Nm
1900
1800
1000/6 1000/5
1000/2 1000/1 1600 1700
16008
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Maintenance
3.2
Oil Change (Continue)
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) for operating the retarder in the relevant application.
Heat exchanger
Service filling
Stainless-steel heat exchanger (L+R)
4,5 l
After complete After exchange of taking apart and cle- heat exchanger aning, as well as emptied heat exchanger 5,8 l
6,5 l
The retarder oil temperature must be higher than 60 o C (operating temperature) for the oil to be drained. Caution! While the oil is being changed, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off!
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Maintenance
3.2
Oil Change (Continue)
Job scope 1.
Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch it off after approx. 5 sec. Repeat this procedure twice. Switch off the retarder and ignition and wait 5 minutes (control function). Caution! Risk of injury!
The oil filler/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.
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Screw out the retarder oil drain plug (1700) and remove sealing ring (1600) and drain oil.
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Maintenance
5.
3.2
Oil Change (Continue)
Screw out the leakage oil drain plug (1000/1) and remove sealing ring (1000/2) and drain the accumulated oil. 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 the vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two radial 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 side completely (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): Leakage oil drain plug (1000/1):
Tightening torque 66 Nm 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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Maintenance
3.2
Oil Change (Continue)
Illustration oil change R 120 with aluminium heat exchanger 1000/1 1000/2 1000/3 1000/4 1600 1700 1800 1900
Leakage oil drain plug (M 10 x 1), 13 Nm Sealing ring (A 10 x 13,5), renew Heat exchanger oil drain plug (M 12 x 1,5), 25 Nm Sealing ring (A 12 x 15,5), renew Sealing ring (A 22 x 29), renew Retarder oil drain plug (M 22 x 1,5), 66 Nm Sealing ring (A 30 x 36), renew Oil filler/check plug (M 30 x 1,5), 150 Nm
1900
1000/4 1000/3 1800 1000/2 1000/1 1600
1700
16009
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Maintenance
3.2
Oil Change (Continue)
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) for operating the retarder in the relevant application.
Heat exchanger
Service filling
New filling
Aluminium heat exchanger (AKG)
5,5 l
6,0 l
The retarder oil temperature must be higher than 60 o C (operating temperature) for the oil to be drained.
Caution! While the oil is being changed, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off!
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Maintenance
3.2
Oil Change (Continue)
Job scope 1.
Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch it off after approx. 5 sec. Repeat this procedure twice. Switch off the retarder and ignition and wait 5 minutes (control function). Caution! Risk of injury!
The oil filler/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) and remove 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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Maintenance
3.2
Oil Change (Continue)
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 the vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two radial 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, 1000/2 and 1000/4). Retarder oil drain plug (1700): Heat exchanger oil drain plug (1000/3): Leakage oil drain plug (1000/1):
Tightening torque 66 Nm Tightening torque 25 Nm 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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Maintenance
3.3
Checking Oil Level
Illustration checking oil level
1900
Notice The oil change intervals and operating specifications have to be taken from the annex. 1800 1900
1800
Sealing ring (A 30 x 36), renew Oil filler/check plug (M 30 x 1,5), 150 Nm
Notice The illustration shows a retarder 120 with stainless-steel heat exchanger. A version with aluminium heat exchanger is possible.
16010
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Maintenance
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 the mounted heat exchanger. For relevant application approved oils Use only approved oils specified in the operating specifications (see Annex).
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Maintenance
3.3
Checking Oil Level (Continue)
Notice For the oil level check, the temperature of the retarder oil must be higher than 60°C (operating temperature). The oil level check must be carried out with the vehicle in a horizontal position. 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 and switch 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 have been 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.
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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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Maintenance
3.3
Checking Oil Level (Continue)
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 slowly any 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
1900 Max Min
16011
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Maintenance
3.4
Cleaning Line Filter (Optional Extra)
Illustration line filter Complete line filter Pressure spring Intermediate plate Cover Holding plate Pressure spring Filter housing Filter insert O-ring (36,2 x 3), renew, coat with silicone-free and non-corossive grease for installation
12000/1
12000/6 12111
12000/2 12000
12000 12000/1 12000/2 12000/3 12000/4 12000/5 12000/6 12111 12112
12000/5 Lubricants O-ring
12112
Silicone-free and non-corossive grease
12000/3
12000/4
16012
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Maintenance
3.4
Cleaning Line Filter (Continue)
Notice Vehicle specific can be installed a line filter within the constant-air pressure line between air tank for 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 valve also 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 for damages and renew if necessary.
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Maintenance
3.4
Cleaning Line Filter (Continue)
5.
Insert the pressure spring (12000/1), the filter insert (12111), the intermediate plate (12000/2) and the 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 to the cover (12000/3).
7.
Press in the cover (12000/3) into the filter housing (12000/6) and put in the holding plate (12000/4). Notice
If complete filter (12000) has to be removed, observe the correct installing position.
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Diagnosis / Troubleshooting
4
Diagnosis / Troubleshooting
4.1
Troubleshooting Diagram ...........................................................................4.1/1 Electrical 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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4.1
Diagnosis /
Troubleshooting Diagram
Troubleshooting Illustration troubleshooting diagram
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 non-return valve
NOK
Contact VOITH
OK
Check non-return valve in cover of casing ventilation (Chapter 6.3)
Renew casing ventilation
NOK
OK Correct oil level of retarder (*)
see chapter6.4
Check casing ventilation (Chapter6.2)
Check cooling system: Check heat exchanger NO
YES
YES OK
Water in the oil? (emulsion)
NOK
-coolant level -thermostat -coolant pump -radiator fan -radiator grill for dirtiness
NO
Water in the oil? (emulsion)
Check oil level of retarder
Retarder: Check Temp.-Sens. (oil/water)
Driver instruction!
Oil leak by ventilation OK flashes
If the retarder is still leaking, or the chamber of leakage oil is filled again with oil after 1000 km, renew radial shaft seal
Empty chamber of return of leakage oil (at heat exchanger) (Chapter3.3)
Check operation (by braking with retarder nominal engine speed, if possible
Complaint Oil leak input side or output side
NOK
Temperature limit!
Retarder pilot light
R 120 Digiprop
Permanent lighting No respectively too insufficient retarder braking effect
Activate flash code and read out trouble code (Chapter4.2)
Clear faults and delete fault memory (Chapter4.2)
Check oil level of retarder Water in the oil? (emulsion) NO
OK
YES
YES
NO
Check heat exchanger
Check yp(static) (Chapterl 4.4 ) OK
Water in the oil? (emulsion)
NOK
see chapter
Correct oil level of retarder
6.4
NOK
Check p (dynamic) (Kapitel4.3) OK
NOK
Check voltage of proportional valve (Chapter4.4) OK
Contact VOITH
NOK
Contact VOITH Check control unit (Chapter4.4) OK
Contact VOITH
Check compressed-air supply (Chapter 4.4) OK
NOK
Contact VOITH
NOK
Check vehicle compressed-air supply
Mechanical fault of proportional valve
OK
Contact VOITH
* If you get oil leakage after a trail run again: continue at ´´Checking casing ventilation´´
NOK
Contact vehicle manufacturer
FD 1601
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4.1
Diagnosis / Troubleshooting
Troubleshooting Diagram (Continue)
Electrical Diagram Version 1
Connecting plug 4 pins "ISO Interface" 3 1 2 4
Digiprop
X1. 18pins
X2. 9pins
X3. 12pins
3 2 1 6 5 4 9 8 7
CAN-high CAN-Ground CAN-low Position 1 Position 2 Position 3 Position 4 Position 5 T 15 (Ignition lock)
Lead E-Box
T 30 (Battery) Output / high side 1 `HS 1` Output / low side 1 `LS 1` Output / high side `HS 2`
pink blue orange white weiß grey red red blue/white orange/white purple purple brown brown black beige yellow/green black/white
Prop valve `+` Prop valve `-` Changeover valve `+` Changeover valve `-` Water temp.`+` Water temp.`-` Oil temp.`+` Oil temp.`-`
pink grey orange beige yellow/green blue purple white
12 11 10
ISO K ISO L Retarder Stage Switch`+`
15 14 13 18 17 16
T 31 (Ground)
3 2 1 6 5 4 9 8 7
Connecting plug 8 pins "Retarder Stage Switch"
3 2 1 6 5 4 9 8 7 12
ABS Speedometer signal Input / pull-up `DIU 1` Input / pull-up `DIU 2` Input / pull-down `DID 1` Input / pull-down `DID 2` Input / pull-down `DID 3 ` Retarder pilot light Input / (m 0...5V ) `INA-U ` Input / p.-down / PWM-in `DID 4 `
11 10
Stop light relay Input / (0...20mA ) `INA-I ´
7 6 5 3 2 8 4
Position 1 Position 2 Position 3 Position 4 Position 5 Retarder Stage Switch`+`
T 15 (Ignition lock) T 31 (Ground) T 30 (Battery)
+ +
Lead Retarder Pin 1 2 3 4
Prop valve `+` Prop valve `-` Changeover valve `+` Changeover valve `-` Water temp.`+` Water temp.`-` Oil temp.`+` Oil temp.`-`
black/white blue white pink blue/white brown/white orange/white yellow/green grey/black grey grey orange red/white
ABS Speedometer signal
+
Retarder pilot light
Stop light relay
1 9 5 8 4 3 2 7 6 1112101314 Connecting plug 14 ins "Additional Functions"
16014e
Electrical Diagram Version 2
"ISO Interface" 3 1 2 4
Digiprop
X1. 18pins
X2. 9pins
X3. 12pins
3 2 1 6 5 4 9 8 7
CAN-high CAN-Ground CAN-low Position 1 Position 2 Position 3 Position 4 Position 5 T 15 (Ignition lock)
Lead E-Box
T 30 (Battery) Output / high side 1 `HS 1` Output / low side 1 `LS 1` Output / high side `HS 2`
pink blue orange white weiß grey red red blue/white orange/white purple purple brown brown black beige yellow/green black/white
Prop valve `+` Prop valve `-` Changeover valve `+` Changeover valve `-` Water temp.`+` Water temp.`-` Oil temp.`+` Oil temp.`-`
pink grey orange beige yellow/green blue purple white
12 11 10
ISO K ISO L Retarder Stage Switch`+`
15 14 13 18 17 16
T 31 (Ground)
3 2 1 6 5 4 9 8 7
Connecting plug 8 pins "Retarder Stage Switch"
3 2 1 6 5 4 9 8 7 12
ABS Speedometer signal Input / pull-up `DIU 1` Input / pull-up `DIU 2` Input / pull-down `DID 1` Input / pull-down `DID 2` Input / pull-down `DID 3 ` Retarder pilot light Input / (m 0...5V ) `INA-U ` Input / p.-down / PWM-in `DID 4 `
11 10
Stop light relay Input / (0...20mA ) `INA-I ´
7 6 5 3 2 8 4
Position 1 Position 2 Position 3 Position 4 Position 5 Retarder Stage Switch`+`
T 15 (Ignition lock) T 31 (Ground) T 30 (Battery)
+ +
Lead Retarder Pin 1 2 3 4 Pin 1 2 3 4
black/white blue white pink blue/white brown/white orange/white yellow/green grey/black grey grey orange red/white
Prop valve `+` Prop valve `-` Changeover valve `+` Changeover valve `-` Water temp.`+` Water temp.`-` Oil temp.`+` Oil temp.`-`
ABS Speedometer signal
Retarder pilot light
+
Stop light relay
1 9 5 8 4 3 2 7 6 1112101314 Connecting plug 14 pins "Additional Functions"
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16015e
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies
Troubleshooting and remedies Check requirements • • • • l
Battery voltage 18 - 32 V Vehicle 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. Compressed-air pressure 6 - 11 bar 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 and at 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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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Notice
R
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. 16016
Notice If the ignition is switched off and on, the retarder is in operation again and the retarder pilot light goes off. If a serious fault remains present or reoccurs, the retarder switches off again and the retarder pilot light comes on permanently in position 0 to 5 of the retarder stage switch.
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Diagnosis / Troubleshooting
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 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
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Not in use Not in use Not in use Retarder stage switch, position 3 -(or) Retarder stage switch, position 2 -(bl) Retarder stage switch, position 1 -(pi) Terminal 15 (rd) Retarder stage switch, position 5 -(gr) Retarder stage switch, position 4 -(wh) Retarder stage switch + (vi) ISO-interface, L-lead (or/wh) ISO-interface, K-lead (bl/wh) Terminal 30 (bl) Not in use Terminal 31 (br) Output / high side 2 „HS2“ (bl/wh) Output / low side 1 „LS1“ (ye/gr) Output / high side 1 „HS1“ (be)
16
13
10
7
4
1
17
14
11
8
5
2
18
15
12
9
6
3
16017
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Plug X2 Control unit 1 2 3 4 5 6 7 8 9
Not operational/usable for applications (or) Proportional valve - (gr) Proportional valve + (pi) Cooling water temperature pick-up - (bl) Cooling water temperature pick-up + (ye/gr) Not operational/ground (be) Not in use Oil temperature pick-up - (wh) Oil temperature pick-up + (vi)
7
4
1
8
5
2
9
6
3
16018
Plug X3 Control unit 1 2 3 4 5 6 7 8 9 10 11 12
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Input / pull up „DIU 1“ (wh) Speedometer signal (bl) ABS-Signal (bl/wh) Input / pull down „DID 2“ (br/wh) Input / pull down „DID 1“ (bl/wh) Input / pull up „DIU 2“ (pi) Input / (0...5V) „INA-U“ (gr/bl) Retarder pilot light (ye/gr) Input / pull down „DID 3“ (or/wh) Input / (0...20 mA) „INA-I“ (rd/wh) Stop light relay (or) Input / pull down / PWM-in „DID4“ (gr) / engine-speed signal
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/4
10
7
4
1
11
8
5
2
12
9
6
3
16019
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Extra operations plug 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Retarder stage switch + (vi) Input / pull down „DID 1“ (bl/wh) Input / pull down „DID 2“ (br/wh) Input / pull down „DID 3“ (or/wh) Input / pull down / PWM -in „DID 4“ (gr) Input / pull up „DIU 1“ (wh) Input / pull up „DIU 2“ (pi) Input / (0...5V) „INA-U“ (gr/bl) Input / (0...20 mA) „INA-I“ (rd/wh) Output / high side 1 „HS1“ (be) Output / high side 2 „HS2“ (bl/wh) Output / low side 1 „LS1“ (ye/gr) Terminal 15 (rd) Terminal 31 (br)
2
4
6
8
10
12
14
1
3
5
7
9
11
13
16020
ISO-Interface plug 1 2 3 4
K-lead (bl/wh) K-lead (or/wh) Terminal 15 (rd) Terminal 31 (br)
4
3
2
1
16021
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Cooling water temperature pick-up plug Oil temperature pick-up plug
16022
Proportional valve plug 1 2 3 4
Proportional valve + (pi) Proportional valve + (gr) Not operational (or) Not operational (be)
4 1
2 3
16023
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Retarder stage switch plug 1 2 3 4 5 6 7 8
Not in use Position 5 - (gr) Position 4 - (wh) Retarder stage switch + (vi) Position 3 - (or) Position 2 - (bl) Position 1 - (pi) Bridge to pin 4
5
6
7
8
1
2
3
4
16024
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
A. With fault code Special tool
53.8224.10
Commercially available tool Multimeter
recommended: Fluke 87
Notice The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-out from the fault memory. Furthermore a diagnosis with the PC „DigiDia“ software is possible. In this case please contact VOITH TURBO or a responsible contracting party.
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Fault memory read-out via retarder pilot light blinking code
R 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. 16016
Fault memory read-out with service cable (Digiprop-Version 0.2) Requirements -
1.
Retarder stage switch in position 0 Vehicle in parking position, Ignition ON 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 -
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long blinking signals (2 sec.) tens unit. short blinking signals (0,5 sec.) single unit.
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Digiprop-Version 1.0 The blinking code can be triggered analogous to V 0.2, the conditions are the same. Additionally the blinking code can be triggered with the help of the retarder stage switch during the service function: 1. 2. 3. 4. 5.
Shift RSS-Position 0 Shift RSS-Position 1 ( ≥ 2 Seconds) Shift RSS-Position 0 Blinking code of first fault is indicated 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 retarder pilot light is switched off.
16025
Display example: Fault code 23
Display example for fault code 23: The number of tens will be indicated first as long ON-time: The number of singles afterwards will be indicated as short ON-time: Breaks between each ON-time:
each 2 seconds each 0,5 seconds each 1 second
E A t
If a relevant fault is indicated, the retarder pilot light is ON before triggering of the blinking code, the retarder 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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Retarder stage switch on Retarder stage switch off Time
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
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 of service cable switch.
3.
Ignition: ON
4.
Disconnect after ≥ 2 seconds the L-lead of ground.
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Notice Meaning of entries in „Measurement/test connection“ column: X 1/15 W X 3/11 Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3 Table 1: Fault
Code 01
Fault text
Fault class
Trigger time
Requirement / Operation
Measurement/ test connection1 )
Result/ Set point
Cause/ Remedy 2)
Stop light relay/
slight
1s
- Ignition: OFF - Pull plug X3 out of control unit
X 3/11 W X 1/15
Relay is installed: 250 - 350 W
Check lead, plugs and relay or consumers
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
0V
Check lead, plugs and relay or consumers
(Check)
Short circuit to ground 02
LS 1 output Short circuit to battery
1) 2)
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X 1/15 = ground control unit Only, if no fault is recognizable after a complete check of the periphery: change control unit.
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 2: Fault text Fault Code 03
Fault class
Trigger time
slight
1s
Measurement/ test connection
Result/ Set point
Cause/ Remedy
- Ignition: OFF - Pull plug X1 out of control unit
X 1/18
W X 1/ 15
With relay installed: 250 - 350 W
Check lead, plugs and relay or consumers
slight
1s
- Ignition: OFF - Pull plug X1 out of control unit
X 1/16 W X 1/15
With relay installed: 250 - 350 W
Check lead, plugs and relay or consumers
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, plugs and fuses
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 electrical installation of vehicle (see manufacturer instructions)
Operation
(Check) HS 1 output Short circuit
04
HS 2 output Short circuit
05
Terminal 15 Undervoltage
06
Terminal 15 Overvoltage
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Requirement /
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 3: Fault text Fault Code 08 09
Fault class
Trigger time
Requirement / Operation
Measurement/ test connection
Result/ Set point
(Check) 1s
Water temperature sensor Discontinuity / Short circuit to battery
serious/ slight *
- Ignition: OFF - Pull plug X2 out of control unit
X 2/5 W X 2/4 20°C ± 10 °C = 1039 - 1117W 60°C ± 10 °C = 1099 - 1271W 80°C ± 10 °C = 1271 - 1347W Notice: The measuring in one temperature range normally is sufficient.
*
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Cause/ Remedy
Fault is in serious class, if temperature sensor for oil and water are defective at the same time.
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Check lead and sensor
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 4: Fault text Fault Code 11 12
Fault class
Trigger time
Requirement / Operation
Measurement/ test connection
Result/ Set point
Cause/ Remedy
X 2/9 W X 2/8
20°C ± 10 °C = 1039 - 1117W
Check lead and sensor
(Check) Oil temperature sensor
1s serious/ slight *
- Ignition: OFF - Pull plug X2 out of control unit
60°C ± 10 °C = 1099 - 1271W
Discontinuity / Short circuit to battery
80°C ± 10 °C = 1271 - 1347W Notice: The measuring in one temperature range normally is sufficient. *
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Fault is in serious class, if temperature sensor for oil and water are defective at the same time.
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Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 5: Fault text Fault Code
(Check)
13
1
13
13
2
3
Retarder stage switch Undefined switch state
Fault class
Trigger time
serious
100 ms
Requirement /
Measurement/ test connection
Result/ Set point
Cause/ Remedy
- Ignition: ON - Retarder stage switch: Position 0
X 1/10 V X 1/15
≥ 17,5 V
Check lead, plug and retarder stage switch
- Ignition: ON - Retarder stage switch: Position 1
X 1/10 V X 1/15 X 1/6 V X 1/15
Operation
- Ignition: ON - Retarder stage switch: Position 2
X 1/6 X 1/5 X 1/4 X 1/9 X 1/8
X 1/5 X 1/4 X 1/9 X 1/8
V V V V
X 1/15 X 1/15 X 1/15 X 1/15 X 1/15
X 1/15 X 1/15 X 1/15 X 1/15
X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 X 1/9 X 1/8
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V V V V V
V X 1/15 V X 1/15 V X 1/15
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0V 0V 0V 0V 0V ≥ 17,5 V ≥ 17,5 V
Check lead, plug and retarder stage switch
0V 0V 0V 0V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V 0V 0V 0V
Check lead, plug and retarder stage switch
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 6: Fault text Fault Code
(Check)
13
4
Fault class
Trigger time
Requirement / Operation
Measurement/ test connection
Result/ Set point
Cause/ Remedy
- Ignition: ON - Retarder stage switch: Position 3
X 1/10 V X 1/6 V X 1/5 V X 1/4 V
≥ ≥ ≥ ≥
Check lead, plug and retarder stage switch
X 1/15 X 1/15 X 1/15 X 1/15
X 1/9 V X 1/15 X 1/8 V X 1/15 13
5
- Ignition: ON - Retarder stage switch: Position 4
X X X X X
1/10 V 1/6 V 1/5 V 1/4 V 1/9 V
X X X X X
1/15 1/15 1/15 1/15 1/15
X 1/8 V X 1/15 13
cbtd 98-01 53.2659.10
6
- Ignition: ON - Retarder stage switch: Position 5
X 1/10 X 1/6 X 1/5 X 1/4 X 1/9 X 1/8
V V V V V V
X X X X X X
1/15 1/15 1/15 1/15 1/15 1/15
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/17
17,5 V 17,5 V 17,5 V 17,5 V
0V 0V ≥ ≥ ≥ ≥ ≥
17,5 V 17,5 V 17,5 V 17,5 V 17,5 V
Check lead, plug and retarder stage switch
0V ≥ ≥ ≥ ≥ ≥ ≥
17,5 V 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V
Check lead, plug and retarder stage switch
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 7: Fault text Fault Code
Fault class
Trigger time
Requirement / Operation
Measurement/ test connection
Result/ Set point
Cause/ Remedy
(Check)
14
Retarder stage switch Short circuit to battery
serious
10 s
- Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Retarder stage switch: Position 0
X 1/10 V X 1/15
0V
Check lead and plug
15
Retarder stage switch Short circuit to battery
serious
1s
- Ignition: OFF - Pull plug X1 out of control unit - Retarder stage switch: Position 5
X 1/10 W X 1/15
Resistor infinite
Single check of stages for short circuit
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/18
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 8: Fault text Fault Code 16
Fault class
Trigger time
serious
Requirement / Operation
Measurement/ test connection
Result/ Set point
Cause/ Remedy
2s
- Ignition: ON
X 3/2 V X 1/15
≤==1 V
Check lead and speedometer
serious
2s
- Ignition: OFF - Pull plug X3 out of control unit - Ignition: ON
X 3/2 V X 1/15
≤==9 V
Check lead and speedometer
serious
60 s
- Ignition: ON
X 3/3 V X 1/15
≥ 3,5 V
Check lead, relay and ABS-control unit
(Check) Speedometer signal Discontinuity
18
Speedometer signal Short circuit to battery
19
cbtd 98-01 53.2659.10
ABS Short circuit to ground
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/19
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 9: Fault text Fault Code
Fault class
Trigger time
Requirement / Operation
Measurement/ test connection
Result/ Set point
Cause/ Remedy
X 3/3 V X 1/15
≥ 16,5 V
Check lead, relay and ABScontrol unit
−
Replace control unit
≤==10 V
Check lead
(Check)
21
ABS-Signal undefined
serious
60 s
- Ignition: ON
22
Internal fault ABS-current path
serious
1s
-
23
Proportional valve Fault No. 1: Short circuit to battery
serious
1s
- Ignition: OFF - Pull plug X2 out of control unit - Ignition: ON
cbtd 98-01 53.2659.10
X 2/3 V X 1/15
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/20
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 10: Fault text Fault Code
(Check)
24
1
24
2
cbtd 98-01 53.2659.10
Proportional valve Fault No. 2: - Short circuit proportional valve magnetic - Short circuit connection lead proportional valve - Discontinuity proportional valve magnetic Valve magnetic - Discontinuity connection lead proportional valve - Short circuit to ground at proportional valve - Prop.- and shift valve interchanged
Fault class
Trigger time
serious
1s
Requirement /
Measurement/ test connection
Result/ Set point
Cause/ Remedy
- Ignition: ON - Pull plug X2 out of control unit
X 2/2 W X 2/3
18-25 W
Check lead and proportional valve (valve block)
- Ignition: OFF - Pull plug X2 out of control unit
X 2/3 W X 1/15
Resistor infinite
Check lead and proportional valve (valve block)
Operation
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/21
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 11: Fault text Fault Code
(Check)
24
3
Fault class
Trigger time
Requirement / Operation
- Ignition: OFF - Pull plug X2 out of control unit
Measurement/ test connection
Result/ Set point
Cause/ Remedy
X 2/2 W X 1/15
Resistor infinite
Check lead and proportional valve (valve block)
25
Proportional valve Fault No. 3: defective control unit
serious
10 s
Replace control unit
27
Proportional valve Fault No. 5: defective control unit
serious
2s
Replace control unit
28
Terminal 30
serious
60 s
Undervoltage
cbtd 98-01 53.2659.10
- Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON
X 1/13 V X 1/15
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/22
≥ 17,5 V
Check lead, plug and fuse
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 12: Fault text Fault Code
Fault class
Trigger time
Requirement / Operation
Measurement/ test connection
Result/ Set point
Cause/ Remedy
(Check)
29
Fault control unit
serious
180 ms
Replace control unit
31
Control unit: Coding fault
serious
100 ms
Provide new parameters for control unit
32
Retarder pilot light: Discontinuity / Short circuit to ground
serious
3s
- Ignition: OFF - Pull plug X3 out of control unit - Ignition: ON
X 3/8 V X 1/15
≥ 17,5 V
Check lead, retarder pilot light and fuse
33
Retarder pilot light: Short circuit to battery
serious
3s
- Ignition: ON - Retarder stage switch: Position 1
X 3/8 V X 1/15
≤==2 V
Check lead and retarder pilot light
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/23
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
Table 13: Fault text Fault Code
Fault class
Trigger time
Requirement / Operation
Measurement/ test connection
Result/ Set point
Cause/ Remedy
(Check)
35
Fault control unit
serious
500 ms / 123 s
Replace control unit
37
Fault pedal operation
slight
100 ms / 1 s
Check installation relating to OEMrespectively VOITHinstructions
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/24
Diagnosis / Troubleshooting
4.2
Troubleshooting and Remedies (Continue)
B. Without fault code Notice Retarder faults without fault code are not recognized electronically.
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/25
Diagnosis / Troubleshooting
4.3
Checking Pump Pressure
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
101 102
Notice The pump-pressure check provides information on the mechanical condition of rotating parts, on internal leaks and on the operation of the retarder. Special tool
53.4788.10 16026
Pressure gauge 0 - 25 bar cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.3/1
Diagnosis / Troubleshooting
4.3
Checking Pump Pressure (Continue) 99/1
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 and read-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).
16027
99/1 Pressure gauge 53.4788.10
Caution! If the measurement of the static pump pressure falls short of the setpoint, either the retarder is leaking or the control system is defective (see troubleshooting diagram).
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.3/2
Diagnosis / Troubleshooting
Setting [Nm]
4.3
Code Number
3)
Checking Pump Pressure (Continue)
Pump pressure static Setpoint [bar]
Pump pressure dynamic 1 ) v p s = 1000 r.p.m. Minimum value [bar]
1) 2) 3)
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
Retarder stage switch in highest position Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure) 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 make further modifications.
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.3/3
Diagnosis / Troubleshooting
4.3
Checking Pump Pressure (Continue)
Job scope dynamic 1.
Drive the vehicle with a prop-shaft speed of v p 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. and read-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 the dynamic check, please contact VOITH TURBO!
Caution! Risk of injury! The screw of the pressure gauge and the retarder are heated up! 4.
cbtd 98-01 53.2659.10
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 Digiprop Page 4.3/4
4.4
Diagnosis /
Checking Control System
Troubleshooting Illustration checking control system
25
Notice The reference numbers indicated in Section 4.4 are not identical with the reference numbers of the spare parts lists.
33
71 32
21
61
A R P
37 1 2 11 19
20 21 25 26 31
32
33 34 35 37 39
40 61 71
cbtd 98-01 53.2659.10
Heat exchanger Control unit Proportional valve current connection Temperatur pick-up cooling water alternative: positions 19 and 20 joining in the central-plug (see electrical diagram Version 2) Temperature pick-up oil Proportional valve Constant-air pressure line p y (Connection A) Supply-air pressure line p v (Connection P) Compressed air line (pressure regulator - four-circuit protection valve) Compressed-air pressure line (four-circuit protection valve air tank for auxiliary equipment with test connection Compressed-air line (brake circuit No. 1) Compressed-air line (brake circuit No. 2) Compressed-air line (parking brake) Ventilation line „R“ Electrical lead (cooling-water temperature pick-up to control unit, 2 wires) Electrical lead (oil temperature pick-up to control unit, 2 wires) Four-circuit protection valve Air tank for auxiliary equipment
31
1 35
26
34
40 2
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.4/1
20
39 19
1
16028
4.4
Diagnosis / Troubleshooting
Checking Control System (Continue)
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 Ignition OFF
Special tools
Wasser
53.4788.10
Öl
53.8207.10
53.8279.10
53.8198.10
Pressure gauge 0 -25 bar The adapter lead 53.8279.10 (98/5) has to be used only to connect the temperature simulator 53.8207.10 (99/2), if the temperature sensor for oil and water are using one central plug. Commercially available tool Multimeter
cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10
recommended: Fluke 87
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.4/2
Diagnosis / Troubleshooting
4.4
Checking Control System (Continue)
Checking supply-air pressure pv 1.
Connect pressure gauge to test connection of compressed-air line (32) (four-circuit protection valve - air tank for auxiliary equipment) and check supply-air pressure pv . Minimum pressure:
6 bar
Maximum pressure:
11 bar
Notice If the pressure is not within the specified range, the service brake must be checked to the manufacturer´s data.
32 16029
Pressure gauge 53.1403.10
Test set-up job scope 1.
57
98/5
Connect temperature simulator (99/2) with the adapter lead (98/5) at the temperature pick-up (57).
99/2
Notice Pay attention to the correct connection of the plugs for cooling water and oil.
16030
99/2 Temperature simulator 53.8207.10
cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.4/3
Diagnosis / Troubleshooting
2.
4.4
Checking Control System (Continue)
Screw out oil filler/check plug (1900) with sealing ring (1800).
1900
1800
16031
3.
Connect pressure gauge (99/7) to retarder housing.
99/7
16032
99/7 Pressure gauge 53.1403.10
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.4/4
Diagnosis / Troubleshooting
4.4
Checking Control System (Continue)
4.
Connect up „Propstrom“ measuring adapter (99/3).
•
Disconnect plug from proportional valve (21) and connect it up to „Propstrom“ measuring adapter (99/3).
21
•
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“.
98/8
99/3 16033
99/3 „Propstrom“ measuring adapter 53.8198.10 99/8 Multimeter
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.4/5
Diagnosis / Troubleshooting
4.4
Checking Control System (Continue)
Job scope test •
57
98/5
Preconditions for checking Ignition ON
1.
Set the rotary switch of the temperature simulator (99/2) to 95°C cooling water temperature and 165°C oil temperature operate the retarder at the highest stage. The constant-air pressure p y and the control current must reach the values given in table on the next page (page 4.4/7).
2.
Set the rotary switch of the temperature simulator (99/2) to 105 oC cooling water temperature. The constant-air pressure p y must drop to at approx. 7% bar below the set maximum pressure. Set rotary switch of the temperature simulator (99/2) to 125 oC cooling water temperature. There must be no more output of constant-air pressure p y . Set rotary switch of temperature simulator (99/2) again to 95o C cooling water temperature.
16030
99/2 Temperature simulator 53.8207.10
o
3.
Set the rotary switch of the temperature simulator (99/2) to 185 C oil temperature. The constant-air pressure must drop to at approx. 4% below the set maximum pressure. Set the rotary switch of the temperature simulator (99/2) to 225 oC oil temperature. There must be no more output of constant-air pressure p y .
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 for cooling water and oil.
cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10
99/2
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.4/6
Diagnosis / Troubleshooting
4.4
Checking Control System (Continue)
Notice If the control current is reached but the constant-air pressure is not, either the retarder is leaking or the proportional valve is defective and must be renewed. If both values are not reached, please see Section 4.2 „Troubleshooting and Remedies“. Setting [Nm]
1) 2)
3)
cbtd 98-01 53.2659.10
Code Number1 )
Control current [mA] 2 )
Constant-air pressure p y [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
The Code Number is to be found on the control unit. If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!). Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.4/7
Diagnosis / Troubleshooting
4.5
Operational Check
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
R
The following operational states are indicated by the retarder pilot light (arrow):
16016
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 or „Constant Speed“ operation has been selected with the retarder stage switch. The retarder pilot light additionally has the function of a fault indicator. -
slight fault The 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 fault The 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.
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.5/1
Diagnosis / Troubleshooting
4.5
Operational Check (Continue)
Notice If the ignition is switched off and on again, the retarder is in operation and the retarder pilot light is going off. If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch. Retarder pilot light flashes -
cbtd 98-01 53.2659.10
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 Digiprop Page 4.5/2
Diagnosis / Troubleshooting
4.5
Operational Check (Continue)
Troubleshooting Test step 1
2
cbtd 98-01 53.2659.10
Scope of check Retarder pilot light
Retarder
Requirement / Operation Ignition: ON
Vehicle on move - Shift retarder stage switch to stage 1 to 5.
Result / Set point
Note, Cause / Remedy
Retarder pilot light comes on and goes off after approx. 5 sec.
Retarder pilot light trouble-free
Retarder pilot light does not come on, or does not go off.
Troubleshooting as on page 4.1/1
Retarder pilot light comes on, retarder brakes in stages 1 to 5.
Retarder operates trouble-free.
Retarder pilot light does not come on, or retarder does not brake properly.
Troubleshooting as on page 4.1/1
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.5/3
Retarder Removing, Installing
5
Removing, Installing Retarder
5.1
Removing, Installing Retarder (Free Mount Installation) ............................5.1/1
5.2
Removing, Installing Retarder (Gearbox Attachment)................................5.2/1
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 5/1
Retarder Removing, Installing
5.1
Removing, Installing Retarder (Free Mount Installation)
Illustration Retarder (Free mount installation)
1300 1300 1400 1400
1200
1200
94
92
95
36
92
25 1100 96
93 97
1000 96
57 1000/6 1200 1000-5 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 cooling water Retarder stage switch in switch position 0 Ignition OFF Notice
When stainless-steel heat exchanger is installed, oil can not be drained from the heat exchanger. 25 36 57 92 93 94 95 96 97 1000
Constant-air pressure line p y „A“ Ventilation line „R“ Plug temperature pick-up Prop-shaft Hex.-head screw Spring washer Hex.-head screw Hose clamp Hose connection Heat exchanger
1000/5 1000/6 1100 1200 1200/1 1300 1400 1500
Drain plug cooling water (M 18 x 1,5), 50 Nm Sealing ring (A 18 x 22), renew Suspension complete Megi-pads, check, renew if necessary Spacer tube Hex.-head screw (M 16 x 90) Washer (B 16) Hex.-head nut (M 16) self-locking, renew, 110 Nm
Note for installation The universal joints for both prop-shafts must be installed aligned with one another. Max. permissible offset 5° . Tightening torques, see manufacturer´s data. Renew spring washer. Caution! Observe VOITH-Installation instructions. These have to be requested from VOITH TURBO. Should these installation instructions be disregarded, the retarder may be completely wrecked!
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 5.1/1
Retarder Removing, Installing
5.2
Removing, Installing Retarder (Gearbox Attachment)
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-Installation 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!
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 5.2/1
Repair Gearbox Attachment
6
Repair (Gearbox Attachment)
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 .........................................................6.8/1
6.9
Removing and Installing Centering Cover (input side) Renewing Radial Shaft Sealing Ring .........................................................6.9/1
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6/1
6.1
Repair Gearbox
Assembly Overview
Attachment Illustration assembly overview (retarder basic group)
3200 3100
2800 2700
2900
2500 2902 2901 2903
4600 4400 4500
2600 2300/1
3000
2301
4300
101
2300 2300/2
102
2300/3 2400
1900 1800 700
850 800 900
104 103 103 104
1200 1300
1100
1400
1600
1500
1000
1700 16035
101 102 103 104 700 800 850 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2300 2300/1 2300/2 2300/3
cbtd 98-01 53.2659.10
Hex.-head screw (M 12 x 1,5) Sealing ring (A 12 x 15,5) Silencer-ventilation (30 x 4) Circlip (JL 30 x 1,2) Raduial shaft sealing ring (80 x 100 x 10) Labyrinth cover O-ring (125 x 2,5) Hex.-head screw (M 8 x 25) Cover O-ring (82 x 4) Gasket Bottom cover Washer (B 8,4) Cap screw (M 6 x 20) Sealing ring (A 22 x 29) Screw plug (M 22 x 1,5) Sealing ring (A 30 x 36) Oil filler/check plug (M 30 x 1,5) Casing ventilation (D 30 x 38) contents Position 2301 Valve insert Float Float cage
2301 2400 2500 2600 2700 2800 2900 2901 2902 2903 3000 3100 3200 4300 4400 4500 4600
O-ring (55 x 3) Sieve (D 60 x 23) Cover sheet metal Spacer (D 50/42 x 15,5) Washer (B 6,4) Cap screw (M 6 x 12) Top cover with 7 threads for M 6 Valve internal part Spring Connector Gasket for 7 fixing screws M 6 Washer (B 6,4) Cap screw (M 6 x 30) Radial shaft sealing ring (85 x 105 x 13) Centering cover (D 180 x 70) O-ring (130 x 4) Hex.-head screw (M 8 x 20)
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.1/1
Repair Gearbox Attachment
6.2
Removing, Checking and Installing Casing Ventilation
Illustration casing ventilation Preconditions for job • • •
Retarder removed (see Section 5.1). Retarder stage switch in position 0 Ignition OFF
2800 2700
3200
2500
3100
2600 2300 2300/1 2300/2 2300/3 2301
2400 2500 2600 2700 2800 2900 3000 3100 3200
Casing ventilation Valve insert Float checking, renew if necessary Float cage O-ring (55 x 3), renew, coat of silicone-free and noncorrosive grease for installation Mesh strainer clean with benzine Cover plate Spacer Washer (B 6,4) Hex.-head screw (M 6 x 12), 10 Nm Cover Gasket, renew Washer (B 6,4) Cap screw (M 6 x 30), 10 Nm
2900 2300/1 2300
3000
2301 2300/2 2300/3
2400
16036
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.2/1
6.2
Repair Gearbox Attachment
Removing, Checking and Installing Casing Ventilation (Continue)
Lubricants and cleaning agents Mesh strainer
Benzine
O-ring
Silicone-free and non-corrosive grease
Float
Methylated Spirit
Special tools
53.7712.10
53.9428.10
To remove 1.
Screw out hex.-head screws (3200).
2.
Remove washer (3100).
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.2/2
Repair Gearbox Attachment
6.2
Removing, Checking and Installing Casing Ventilation (Continue)
3.
Remove the cover (2900) from the retarder housing.
4.
Remove gasket (3000) and clean the sealing surface.
5.
Screw out hex.-head screws (2800) and remove Washer (2700).
98/7
6.
Remove cover plate (2500).
2300
7.
Remove spacer (2600).
8.
Use the impact tool (99/5) and adapter (98/9) to extract the casing ventilation (2300).
99/5
16037
98/7 Adapter 53.9428.10 99/5 Impact tool 53.7712.10 9.
Extract the valve insert (2300/1) from float cage (2300/3).
10.
Lever O-ring (2301) out of the groove of the valve insert (2300/1).
11.
Remove the mesh strainer (2400), check and wash with benzine, if necessary.
2300/1 2301
2300/3 16038
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.2/3
Repair Gearbox Attachment
6.2
Removing, Checking and Installing Casing Ventilation (Continue)
To check 1.
Check the float (2300/2) for damage to the surface and to the sealing surfaces (arrow).
2.
Weight the float (2300/2). Specified weight 11g ± 1 Gramm. If the weight is more than the specified weight, renew the complete casing ventilation. 2300/2 Notice
Oil has penetrated into the float, the retarder is impaired in its operation. 16039
3.
Check sealing edge of shaft sealing ring (arrow) in valve insert (2300/1). Set the valve insert (2300/1) down on the float (2300/2) and fill up the cavity between float (2300/2) and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not damaged, the fluid level must not change within 1 minute. If necessary, renew the complete casing ventilation.
2300/2
2300/1
16040
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.2/4
Repair Gearbox Attachment
6.2
Removing, Checking and Installing Casing Ventilation (Continue)
To install 1.
Install the mesh strainer (2400).
2.
Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on to the valve insert (2300/1).
3.
Fit the float (2300/2) into float cage (2300/3).
2300/1
2301
Notice If the float only has one polished surface fit float with this surface on top.
16041
4.
Fit the float cage (2300/3) into the valve insert (2300/1).
5.
Fit the casing ventilation (2300) into the retarder housing.
6.
Use the impact tool (99/5) and adapter (98/9) to knock in carefully the casing ventilation (2300).
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.2/5
Repair Gearbox Attachment
6.2
Removing, Checking and Installing Casing Ventilation (Continue)
7.
Place the spacer (2600) on the casing ventilation (2300)
8.
Position cover plate (2500).
9.
Screw new hex.-head screws (2800) with washer (2700) tight. Tightening torque 10 Nm
10.
Position new gasket (3000) and the cover (2900) at the retarder housing.
Caution! Make sure the gasket (3000) is properly located.
11.
cbtd 98-01 53.2659.10
Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.2/6
Repair Gearbox Attachment
6.3
Removing and Installing Non-Return Valve (Casing Ventilation)
Illustration non-return valve (casing ventilation) 2901
2902
2903
2902
Valve internal components, check for damage, renew complete non-return valve, if necessary Spring, check for damage, renew complete non-return valve, if necessary Connector, install with Loctite 270 locking agent, 100 Nm check valve seat, renew complete non-return valve, if necessary
2901
2903
Locking agent Connector
Loctite 270
16042
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.3/1
Repair Gearbox Attachment
6.4
Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger
Illustration non-return valve (stainless-steel heat exchanger) 1400 1200 1200/1 1200/2 1200/3
1200/4
1200/5
1300 1400
Non-return valve (stainless-steel heat exchanger) Valve cover Valve housing O-ring , renew, coat of silicone-free and noncorrosive grease for installation Spring, check for fatigue, renew complete non-return valve (1200), if necessary Valve piston, check valve seat in heat exchanger and vulcanization, renew complete non-return valve (1200), if necessary. Spring washer, renew Cap screw (M 8 x 20), 25 Nm
1300 1200/1 1200/2 1200/3 1200 1200/4
1200/5
Lubricants O-ring
Silicone-free and non-corrosive grease 16043
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.4/1
6.5
Repair Gearbox Attachment
Removing, Checking and Installing Silencer
Illustration Silencer Preconditions for job • •
Retarder stage switch in position 0 Ignition OFF Notice
This step can be performed with the retarder removed or installed. 103
104
Silencer (30 x 4) clean with Benzine and blow out with compresse-air Circlip (JL 30 x 1,2), concave side must face silencer
104
103
Cleaning agents Silencer
Benzine 103 104 16044
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.5/1
Repair Gearbox Attachment
6.6
Removing and Installing Bottom Cover
Illustration bottom cover Preconditions for job • • •
Oil drained from retarder (see Section 3.2) Retarder stage switch in position 0 Ignition OFF 1200 1300 1400 1500
Gasket, renew Bottom cover Washer (B 6,4) Cap screw (M 6 x 20), 10 Nm 1200
1300
1400 1500
16045
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.6/1
Repair Gearbox Attachment
6.7
Checking, Removing and Installing Closing Cover of Retarder Housing
Special tool
1000
53.7712.10
99/5
To check 1.
1100 1000
Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.
99/5 Impact tool 53.7712.10
To remove 1.
Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).
To install 1.
cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10
Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease and install together with closing covers (1000).
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.7/1
16046
Repair Gearbox Attachment
6.8
Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring
Illustration labyrinth cover (output side) Prior jobs • • • •
Prop shaft removed from flange (see vehicle manufacturer instructions) Prop shaft flange removed (see VOITH-installation schemes) Retarder stage switch in position 0 Ignition OFF
700
850 800
Notice
900
This job can be performed with the retarder removed or installed. 700
800
850
900
cbtd 98-01 53.2659.10
Radial shaft sealing ring (80 x 100 x 10), renew, coat with silicone-free and non-corossive grease for installation Labyrinth cover, coat with Hylomar sealant around leakage oil return bore O-ring (125 x 2,5), renew, coat with silicone-free and non-corossive grease for installation Hex.-head screw (M 8 x 25) self-locking, renew, 23 Nm
16047
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.8/1
Repair Gearbox Attachment
6.8
Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring (Cont.)
Sealants and locking agents Housing sealing surfaces O-ring
Hylomar Silicone-free and non-corossive grease
Special tool
53.0742.10
Job scope 1.
Screw out hex.-head screw (900).
2.
Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the rotor housing.
800
16048
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.8/2
Repair Gearbox Attachment
6.8
Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring (Cont.)
3.
Place the labyrinth cover (800) on a piece of pipe.
4.
Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes (arrows) out of the labyrinth cover (800). Notice
Check race of radial shaft sealing ring for scores and uneven surface. If a sealing function is no longer guaranteed, please contact VOITH TURBO. 5.
800
700
Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (700). 16049
6.
Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into the labyrinth cover (800). Position for installation: Sealing lip at top.
94/4
700
800
16050
94/4 Press-in equipment 53.0742.10 cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.8/3
Repair Gearbox Attachment
6.8
Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring (Cont.)
7.
Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in the labyrinth cover.
8.
Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800). Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow) are in alignment.
9.
Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
850 800
16051
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.8/4
Repair Gearbox Attachment
6.9
Removing and Installing Centering Cover (Input Side), Renewing Radial Shaft Sealing Ring
Illustration centering cover (input side) Prior job •
Retarder removed (see Section 5) 4300
4400 4500
4600
Radial shaft sealing ring (85 x 105 x 13), renew, coat with silicone-free and non-corossive grease for installation Centering cover O-ring (130 x 4), renew, coat with silicone-free and non-corossive grease for installation Hex.-head screw (M 8 x 20), self-locking, renew, 23 Nm
4600
Lubricants O-ring
Silicone-free and non-corossive grease
4500
4300
4400 16052
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.9/1
Repair Gearbox Attachment
6.9
Removing and Installing Centering Cover (Input Side), Renewing Radial Shaft Sealing Ring (Cont.)
Special tool
53.0742.10
Job scope 1.
Screw out hex.-head screws (4600).
2.
Use two hex.-head screws (M 8 x 30) (arrows) to press centering cover (4400) off retarder housing.
3.
Remove O-ring (4500) of centering cover (4400).
4.
Use an appropriate punch to knock the radial shaft sealing ring (4300) out of the centering cover (4400). Notice
4400
4400
Check race of radial shaft sealing ring for scores and uneven surface. If a sealing function is no longer guaranteed, please contact VOITH TURBO.
cbtd 98-01 53.2659.10
4500
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.9/2
16053
Repair Gearbox Attachment
5.
6.9
Removing and Installing Centering Cover (Input Side), Renewing Radial Shaft Sealing Ring (Cont.)
Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (4300). 94/4
6.
Use a press-in equipment (94/4) to press the radial shaft sealing ring (4300) as far as it will go into the centering cover (4400). Position for installation: Sealing lip at top.
4300
4400 16054
94/4 Press-in equipment 53.0742.10
7.
Apply thin coat of silicone-free and non-corossive grease to new O-ring (4500) and fit in the centering cover.
8.
Apply thin coat of Hylomar sealant around leakage-oil return bore in centering cover (4400). Install so that the leakage-oil return bores in the rotor housing and in the centering cover (arrow) are in alignment.
9.
4600
4500
Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm 4400 16055
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 6.9/3
Repair Free Mount Installation
7
Repair (Free Mount Installation)
7.1
Assembly Overview ....................................................................................7.1/1
7.2
Removing, Checking and Installation Casing Ventilation ...........................7.2/1
7.3
Removing, Installing Non-Return Valve (Casing Ventilation) .....................7.3/1
7.4
Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger) ..............................................................7.4/1
7.5
Removing, Checking and Installing Silencer ..............................................7.5/1
7.6
Removing and Installing Bottom Cover ......................................................7.6/1
7.7
Removing and Installing Prop Shaft Flanges ............................................7.7/1
7.8
Checking, Removing and Installing Closing Cover of Retarder Housing ...7.8/1
7.9
Removing and Installing Labyrinth Cover (output side) Renewing Radial Shaft Sealing Ring .........................................................7.9/1
7.10
Removing and Installing Labyrinth Cover (input side) Renewing Radial Shaft Sealing Ring .........................................................7.10/1
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7/1
Repair Free Mount Installation
7.1
Assembly Overview
Illustration assembly overview (retarder basic group) 3200
2800 2700
2900
3100 2500 4700
2902 2901 2903
800 3000
850
700
2600 2300/1 2301
2300
101 102
2300/2 2300/3
5400 5500
2400
1900 1800 5500 5400
700
850 800
104 900
103 103 104
1200 1300 1400 1500
1100 1600
1000
1700 16056
101 102 103 104 700 800 850 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2300 2300/1 2300/2 2300/3
cbtd 98-01 53.2659.10
Hex.-head screw (M 12 x 1,5) Sealing ring (A 12 x 15,5) Silencer-ventilation (30 x 4) Circlip (JL 30 x 1,2) Raduial shaft sealing ring (80 x 100 x 10) Labyrinth cover O-ring (125 x 2,5) Hex.-head screw (M 8 x 25) Cover O-ring (82 x 4) Gasket Bottom cover Washer (B 8,4) Cap screw (M 6 x 20) Sealing ring (A 22 x 29) Screw plug (M 22 x 1,5) Sealing ring (A 30 x 36) Oil filler/check plug (M 30 x 1,5) Casing ventilation (D 30 x 38) contents Position 2301 Valve insert Float Float cage
2301 2400 2500 2600 2700 2800 2900 2901 2902 2903 3000 3100 3200 4300 4700 5400 5500 5600
O-ring (55 x 3) Sieve (D 60 x 23) Cover sheet metal Spacer (D 50/42 x 15,5) Washer (B 6,4) Cap screw (M 6 x 12) Top cover with 7 threads for M 6 Valve internal part Spring Connector Gasket for 7 fixing screws M 6 Washer (B 6,4) Cap screw (M 6 x 30) Radial shaft sealing ring (95 x 115 x 10) Hex.-head screw (M 8 x 30), self-locking Race O-ring (80 x 3) O-ring (125 x 2,5)
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.1/1
Repair Free Mount7.2 Installation
Removing, Checking and Installing Casing Ventilation
Illustration casing ventilation
2800
3200
2700
Preconditions for job The job in this section can be performed with the retarder removed or installed. • Retarder stage switch in position 0 • Ignition OFF 2300 2300/1 2300/2 2300/3 2301
2400 2500 2600 2700 2800 2900 3000 3100 3200
Casing ventilation Valve insert Float checking, renew if necessary Float cage O-ring (55 x 3), renew, coat of silicone-free and noncorrosive grease for installation Mesh strainer clean with benzine Cover plate Spacer Washer (B 6,4) Hex.-head screw (M 6 x 12), 10 Nm Cover Gasket, renew Washer (B 6,4) Hex.-head screw (M 6 x 30), 10 Nm
3100
2500 2600
2900
2300/1 2300
3000
2301 2300/2 2300/3 2400
16057
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.2/1
Repair Free Mount 7.2 Installation
Removing, Checking and Installing Casing Ventilation (Continue)
Lubricants and cleaning agents Mesh strainer
Benzine
O-ring
Silicone-free and non-corrosive grease
Float
Methylated Spirit
Special tools
53.7712.10
53.9428.10
To remove 1.
Screw out hex.-head screws (3200).
2.
Remove washer (3100).
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.2/2
Repair Free Mount 7.2 Installation
Removing, Checking and Installing Casing Ventilation (Continue)
3.
Remove the cover (2900) from the retarder housing.
4.
Remove gasket (3000) and clean the sealing surface.
5.
Screw out hex.-head screws (2800) and remove Washer (2700).
99/5
99/9 6.
Remove cover plate (2500).
7.
Remove spacer (2600).
8.
Use the impact tool (99/5) and adapter (98/9) to extract the casing ventilation (2300).
16058
99/9 Adapter 53.9428.10 99/5 Impact tool 53.7712.10 9.
Extract the valve insert (2300/1) from float cage (2300/3).
10.
Lever O-ring (2301) out of the groove of the valve insert (2300/1).
11.
Remove the mesh strainer (2400), check and wash with benzine, if necessary.
2300/1 2301
2300/3 16038
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.2/3
Repair Free Mount 7.2 Installation
Removing, Checking and Installing Casing Ventilation (Continue)
To check 1.
Check the float (2300/2) for damage to the surface and to the sealing surfaces (arrow).
2.
Weight the float (2300/2). Specified weight 11g ± 1 Gramm. If the weight is more than the specified weight, renew the complete casing ventilation. 2300/2 Notice
Oil has penetrated into the float, the retarder is impaired in its operation. 16039
3.
Check sealing edge of shaft sealing ring (arrow) in valve insert (2300/1). Set the valve insert (2300/1) down on the float (2300/2) and fill up the cavity between float (2300/2) and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not damaged, the fluid level must not change within 1 minute. If necessary, renew the complete casing ventilation.
2300/2
2300/1
16040
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.2/4
Repair Free Mount 7.2 Installation
Removing, Checking and Installing Casing Ventilation (Continue)
To install 1.
Install the mesh strainer (2400).
2.
Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on to the valve insert (2300/1).
3.
Fit the float (2300/2) into float cage (2300/3).
2300/1
2301
Notice If the float only has one polished surface fit float with this surface on top.
16041
4.
Fit the float cage (2300/3) into the valve insert (2300/1).
5.
Fit the casing ventilation (2300) into the retarder housing.
6.
Use the impact tool (99/5) and adapter (98/9) to knock in carefully the casing ventilation (2300).
cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.2/5
Repair Free Mount 7.2 Installation
Removing, Checking and Installing Casing Ventilation (Continue)
7.
Place the spacer (2600) on the casing ventilation (2300)
8.
Position cover plate (2500).
9.
Screw new hex.-head screws (2800) with washer (2700) tight. Tightening torque 10 Nm
10.
Position new gasket (3000) and the cover (2900) at the retarder housing.
Caution! Make sure the gasket (3000) is properly located.
11.
cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10
Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.2/6
Repair Free Mount7.3 Installation
Removing and Installing Non-Return Valve (Casing Ventilation)
Illustration non-return valve (casing ventilation) 2901
2902
2903
2902
Valve internal components, check for damage, renew complete non-return valve if necessary Spring, check for damage, renew complete non-return valve if necessary Connector, install with Loctite 270 locking agent, 100 Nm check valve seat, renew complete non-return valve if necessary
2901
2903
Locking agent Connector
Loctite 270
16059
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.3/1
Repair Free Mount7.4 Installation
Removing, Checking and Installing Non-Return Valve (Stainless-Steel Heat Exchanger
Illustration non-return valve (stainless-steel heat exchanger) 1400 1200 1200/1 1200/2 1200/3
1200/4
1200/5
1300 1400
Non-return valve (stainless-steel heat exchanger) Valve cover Valve housing O-ring , renew, coat of silicone-free and noncorrosive grease for installation Spring, check for fatigue, renew complete non-return valve (1200), if necessary Valve piston, check valve seat in heat exchanger and vulcanization, renew complete non-return valve (1200), if necessary. Spring washer, renew Cap screw (M 8 x 20), 25 Nm
1300 1200/1 1200/2 1200/3 1200 1200/4
1200/5
Lubricants O-ring
Silicone-free and non-corrosive grease 16043
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.4/1
Repair Free Mount 7.5
Removing, Checking and Installing Silencer
Installation Illustration Silencer Preconditions for job • •
Retarder stage switch in position 0 Ignition OFF Notice
This step can be performed with the retarder removed or installed. 103
104
Silencer (30 x 4) clean with Benzine and blow out with compressed-air Circlip (JL 30 x 1,2), concave side must face silencer
104
103
Cleaning agents Silencer
Benzine 103 104 16044
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.5/1
Repair Free Mount 7.6
Removing and Installing Bottom Cover
Installation Illustration bottom cover Preconditions for job • • •
Oil drained from retarder (see Section 3.2) Retarder stage switch in position 0 Ignition OFF 1200 1300 1400 1500
Gasket, renew Bottom cover Washer (B 6,4) Cap screw (M 6 x 20), 10 Nm 1200
1300
1400 1500
16045
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.6/1
Repair Free Mount 7.7
Removing and Installing Prop Shafts Flanges
Installation Illustration prop shafts flanges Prior jobs •
Prop shafts flanges removed (see vehicle manufacturer instructions) Notice
93/1
97/6
97/8
The jobs in this section can be performed with the retarder removed or installed. 93/1 95/2 97/6 97/7 97/8 97/9 98
98
97/9
Hex.-head screw (M 20 x 180) Hex.-head nut (M 20), 375 Nm Prop shaft flange (output side) Prop shaft screw, renew Guard ring (output side) Guard ring (input side) Prop shaft flange (input side)
95/2
97/7
16060
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.7/1
Repair Free Mount 7.7 Installation
Removing and Installing Prop Shafts Flanges (Continue)
Removing and installing 1.
Screw out hex.-head screw (95/2). Note for installation Screw hex.-head nut (95/2) tight. Tightening torque 375 Nm
2.
Pull out hex.-head screw (93/1) on output side.
3.
Pull both prop shaft flanges (97/6, 98) out of the retarder housing.
4.
Remove guard rings (97/8, 97/9).
97/7
97/8 97/9
Note for installation Renew prop shaft screws (97/7). Align hole patterns of both prop shaft flanges prior to installation. Maximum permissible offset 5°. 5.
Install the prop shafts in accordance to the vehicle manufacturer instructions. 16061
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.7/2
Repair Free Mount 7.8 Installation
Checking, Removing and Installing Closing Cover of Retarder Housing
Special tool
99/5 1000 1100
53.7712.10
1000
To check 1.
16062
Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.
To remove 1.
Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).
To install 1.
cbtd 98-01 cbtd 98-01 53.2659.10 53.2640.10
Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease and install together with closing covers (1000).
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.8/1
Repair Free Mount 7.9 Installation
Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring
Illustration labyrinth cover Prior jobs • • • •
Prop shaft removed from flange (see vehicle manufacturer instructions) Prop shaft flange removed (see VOITH-installation schemes) Retarder stage switch in position 0 Ignition OFF
5500
5400
700
850 800 900
Notice This job can be performed with the retarder removed or installed. 700
800
850
900 5400 5500
cbtd 98-01 53.2659.10
Radial shaft sealing ring (80 x 100 x 10), renew, coat with silicone-free and non-corossive grease for installation Labyrinth cover, coat with Hylomar sealant around leakage oil return bore O-ring (125 x 2,5), renew, coat with silicone-free and non-corossive grease for installation Hex.-head screw (M 8 x 25) self-locking, renew, 23 Nm Race O-ring (80 x 3), renew, coat with silicone-free and non-corossive grease for installation
16063
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.9/1
Repair Free Mount 7.9 Installation
Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring (Cont.)
Sealants and locking agents Housing sealing surfaces O-ring
900
Hylomar Silicone-free and non-corossive grease
Special tool
16064
53.0742.10
Job scope 1.
Screw out hex.-head screw (900).
2.
Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the rotor housing.
800
16065
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.9/2
Repair Free Mount 7.9 Installation
Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring (Cont.)
3.
Place the labyrinth cover (800) on a piece of pipe.
4.
Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes (arrows) out of the labyrinth cover (800).
5.
Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft.
6.
Remove O-ring (5500) of hollow shaft.
7.
Check race for scores and radial shaft sealing ring for uneven surface and renew race if necessary. Notice
800
700
16049
If a sealing function is no longer guaranteed, please contact VOITH TURBO. Recommendation: Always change radial shaft sealing ring and race together. 8.
Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500) and pull-on to the hollow shaft.
9.
Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it will go.
10.
Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).
5400
16066
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.9/3
Repair Free Mount 7.9 Installation 11.
Removing and Installing Labyrinth Cover (Output Side), Renewing Radial Shaft Sealing Ring (Cont.)
Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into the labyrinth cover (800). Position for installation: Sealing lip at top.
94/4
700
800
94/4 Press-in equipment 53.0742.10 12.
Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in the labyrinth cover.
13.
Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800). Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow) are in alignment.
14.
Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
850 800
16051
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.9/4
Repair Free Mount 7.10 Installation
Removing and Installing Labyrinth Cover (Input Side), Renewing Radial Shaft Sealing Ring
Illustration labyrinth cover Prior jobs • •
Prop shaft removed from flange (see vehicle manufacturer instructions) Prop shaft flange removed (see Section 7.7) 5500 Notice
5400
700
850 800
This job can be performed with the retarder removed or installed. 700
800
850
4700 5400 5500
cbtd 98-01 53.2659.10
Radial shaft sealing ring (95 x 115 x 10), renew, coat with silicone-free and non-corossive grease for installation Labyrinth cover, coat with Hylomar sealant around leakage oil return bore O-ring (125 x 2,5), renew, coat with silicone-free and non-corossive grease for installation Hex.-head screw (M 8 x 30) self-locking, renew, 25 Nm Race O-ring (80 x 3), renew, coat with silicone-free and non-corossive grease for installation
4700
16067
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.10/1
Repair Free Mount 7.10 Installation
Removing and Installing Labyrinth Cover (Input Side), Renewing Radial Shaft Sealing Ring (Cont.)
Sealants and locking agents Housing sealing surfaces
Hylomar
O-ring
Silicone-free and non-corossive grease
Special tool
53.0742.10
Job scope 1.
Screw out hex.-head screws (4700).
2.
Use two hex.-head screws (M 8 x 40) (arrows) to press labyrinth cover (4400) off retarder housing.
3.
Place the labyrinth cover (800) on a piece of pipe.
800
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.10/2
16068
Repair Free Mount 7.10 Installation
Removing and Installing Labyrinth Cover (Input Side), Renewing Radial Shaft Sealing Ring (Cont.)
4.
Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes (arrows) out of the labyrinth cover (800).
5.
Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft.
6.
Remove O-ring (5500) of hollow shaft.
7.
Check race for scores and radial shaft sealing ring for uneven surface and renew race if necessary. 800
700
Notice If a sealing function is no longer guaranteed, please contact VOITH TURBO.
16049
Recommendation: Always change radial shaft sealing ring and race together. 8.
Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500) and pull-on to the hollow shaft.
9.
Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it will go.
10.
Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).
16069
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.10/3
Repair Free Mount 7.10 Installation 11.
Removing and Installing Labyrinth Cover (Input Side), Renewing Radial Shaft Sealing Ring (Cont.)
Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into the labyrinth cover (800). Position for installation: Sealing lip at top.
94/4
700
800
16050
94/4 Press-in equipment 53.0742.10 12.
Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in the labyrinth cover.
13.
Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800). Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow) are in alignment.
14.
Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
850 800
16051
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.10/4
Repair Heat Exchanger
8
Removing, Checking and Installing Heat Exchanger
8.1
Removing, Checking and Installing Stainless-steel Heat Exchanger.........8.1/1
8.2
Removing, Checking and Installing Aluminium Heat Exchanger ...............8.2/1
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8/1
8.1
Repair Heat Exchanger
Removing, Checking and Installing Stainless-steel Heat Exchanger
Illustration stainless-steel heat exchanger
1000/6 1000/5
9500 3000 2000
1000/2
8000
1000/1
15000 9000
17000
1800
4000
7000 1700 4000
16000
4000
17000
5000
13000 14000
97
5000 96 1000
17000 16000 12000
14000 16070
Prior jobs • Retarder removed (Section 5.1) This job sequence can also be performed with the retarder installed, if necesary. • Retarder stage switch on stage position 0 • Ignition OFF 96 97 1000 1000/1 1000/2 1000/5 1000/6 1600 1700 2000 3000 4000
Hose clamp Cooling water hose Heat exchanger Leaking oil drain plug (M 14 x 1,5), 32 Nm Sealing ring (A 14 x 18), renew Cooling water drain plug (M 18 x 1,5), 50 Nm Sealing ring (A 18 x 22), renew Sealing ring (A 22 x 29), renew Retarder oil drain plug (M 22 x 1,5), 66 Nm Throttle disc (outlet throttle) O-ring (36 x 4), renew, coat with silicone-free and non-corrosive grease Washer (B 8,4)
5000 7000 8000 9000 9500 12000 13000 14000 15000 16000 17000
Hex.-head nut M 8, self-locking, renew, 23 Nm Hex.-head screw (M 8 x 35), 23 Nm Pin screw (M 10 x 50) O-ring (45 x 4) renew, coat with silicone-free and non-corrosive grease O-ring (8 x 2) renew, coat with silicone-free and non-corrosive grease Connecting piece Connecting piece Sealing ring, renew Hex.-head screw (M 10 x 65), 46 Nm Hex.-head screw (M 10 x 35), 46 Nm Washer (B 10,6)
Data Pressure test (oil section) max.10 bar
Lubricants O-ring
cbtd 98-01 53.2659.10
Silicone-free and non-corrosive grease
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.1/1
Repair
8.1
Heat Exchanger
Removing, Checking and Installing Stainless-steel Heat Exchanger (Continue)
Notice If this job sequence will be performed with the retarder installed, the following prior jobs must be performed prior to removal of the heat exchanger. Caution! Risk of injury! The coolant drain plug is heated up! 1.
Screw out coolant drain plug (1000/5) with sealing ring (1000/6) and drain the cooling water from the heat exchanger. Remove the cooling water hoses (97) from the retarder.
2.
Push an oil collecting pan under retarder. Caution! Risk of injury!
The oil drain plugs are heated up (oil temperature)! 3.
Screw out the oil drain plugs (1700, 1000/1) and remove the sealing rings (1600, 1000/2). Drain the oil.
4.
Screw the coolant drain plug (1000/5) with new sealing ring (1000/6) and the oil drain plugs (1700, 1000/1) with new sealing rings (1600, 1000/2) tight.
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.1/2
Repair
8.1
Heat Exchanger
Removing, Checking and Installing Stainless-steel Heat Exchanger (Continue)
To remove 1.
Screw out the four hex.-head nuts (5000) and remove the washers (4000).
2.
Screw out the two hex.-head screws (7000) remove the washers (4000) and heat exchanger (1000).
3.
Remove the three O-rings (9000, 3000, 9500) and throttle disc (2000) from retarder housing. Notice
Do not remove insert (93/8) with the throttle disc. 4.
Check closing cover (1000) for leaks, renew O-ring (1100), if necessary (see Section 6.7 and 7.8 „Checking, removing and installing closing cover“).
Caution! Do not pressurize heat exchanger with pressure-test plate 53.4786.10. An appropriate variant on the stainless-steel heat exchanger is in preperation. Please, contact VOITH TURBO.
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.1/3
Repair Heat Exchanger
8.1
Removing, Checking and Installing Stainless-steel Heat Exchanger (Continue)
To install
Notice New heat exchangers are wetted with preserving oil in the cooling water section and in the oil section. Prior to installation of a new heat exchanger, drain any preserving oil which has collected and flush out the cooling water section with hot water. 1.
Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (9000, 3000, 9500). Fit them in the feed bores of the retarder housing.
2.
Apply thin coat of silicone-free and non-corrosive grease to the throttle disc (2000) and fit it in the right bore.
3.
Install the heat exchanger (1000) to the retarder housing and use new self-locking hex.-head nuts (5000) and washers (4000), hex.-head screws (7000) and washers (4000) to screw it tight on the retarder housing. Tightening torque 23 Nm
4.
Install retarder, if necessary (see Section 5.1).
5.
Fill in cooling water and bleed coolant circuit according to the vehicle instructor manual. Notice
Heed the statements of the vehicle-manufacturer respecting the cooling water-quality, as well as the VOITH cooling water-list in the appendix.
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.1/4
Repair
8.1
Heat Exchanger 6.
Removing, Checking and Installing Stainless-steel Heat Exchanger (Continue)
If the heat exchanger (1000) had been leaking in the oil section, splush the retarder: While flushing, brake lightly several times to avoid the retarder oil overheating. Caution! Risk of injury!
The oil drain plug is heated up (oil temperature)! Fill retarder with 4,5 litres engine oil or flushing oil. Flush the retarder system by braking several times and drain the oil through the oil drain plug (1700). Repeat the procedure two or three times until no more oil is visible in the water. Screw oil drain plug (1700) tight with new sealing ring. Tightening torque 66 Nm 7.
Fill in retarder oil in accordance with the operating specifications (see Section 3.2 „Oil change“ and annex). Notice
If retarder oil has entered the cooling-water system, the vehicle-cooling system must be cleaned in accordance with the instructions of the vehicle manufacturer. 8.
cbtd 98-01 53.2659.10
If heat exchanger (1000) had been leaking, deoil vehicle cooling and heating system in accordance with vehicle manufacturer´s data.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.1/5
1700
16071
8.2
Repair Heat Exchanger
Removing, Checking and Installing Aluminium Heat Exchanger
Illustration aluminium heat exchanger
1000/4 9500
1000/3 1000/6
3000
1000/2
1000/5
2000 8000
1000/1 20
4000
93/9
4000
9000 7000 4000
1600 5000
1700
5000 1000 97 96
16072
Prior jobs • Retarder removed (Section 5.1) This job sequence van also be performed with the retarder installed, if necessary. • Retarder stage switch in stage position 0 • Ignition OFF
20 96 97 93/9 1000 1000/1 1000/2 1000/3 1000/4 1000/5 1000/6 1600
Oil temperature pick-up (M 14 x 1,5), 32 Nm Hose clamp Cooling water hose Sealing ring (A 14 x 20), renew Heat exchanger Leaking oil drain plug (M 14 x 1,5), 32 Nm Sealing ring (A14 x 18), renew Oil drain plug heat exchanger (M 12 x 1,5), 25 Nm Sealing ring (A 12 x 15,5), renew Cooling water drain plug (M 18 x 1,5), 50 Nm Sealing ring (A12 x 15,5), renew Sealing ring (A 22 x 29), renew
1700 2000 3000 4000 5000 7000 8000 9000 9500
Heat exchanger oil drain plug (M 22 x 1,5), 66 Nm Throttle disc (outlet throttle) O-ring (36 x 4), renew, coat with silicone-free and non-corrosive grease Washer (B 8,4) Hex.-head nut M 8, self-locking, renew, 23 Nm Hex.-head screw (M 8 x 35), 23 Nm Pin screw (M 10 x 50) O-ring (45 x 4), renew, coat with silicone-free and non-corrosive grease O-ring (8 x 2), renew, coat with silicone-free and non-corrosive grease
Data Pressure test (oil section) max.10 bar Special tool Lubricants O-ring
Silicone-free and non-corrosive grease
53.4786.10
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.2/1
Repair
8.2
Heat Exchanger
Removing, Checking and Installing Aluminium Heat Exchanger (Continue)
Notice If this job sequence will be performed with the retarder installed, the following prior jobs must be performed prior to removal of the heat exchanger. Caution! Risk of injury! The coolant drain plug is heated up!
1.
Screw out coolant drain plug (1000/5) with sealing ring (1000/6) and drain the cooling water from the heat exchanger. Remove the cooling water hoses (97) from the retarder.
2.
Push an oil collecting pan under retarder. Caution! Risk of injury!
The oil drain plugs are heated up (oil temperature)! 3.
Screw out the oil drain plugs (1700, 1000/1, 1000/3) and remove the sealing rings (1600, 1000/2, 1000/4). Drain the oil.
4.
Screw the coolant drain plug (1000/5) with new sealing ring (1000/6) and the oil drain plugs (1700, 1000/1, 1000/3) with new sealing rings (1600, 1000/2, 1000/4) tight.
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.2/2
Repair
8.2
Heat Exchanger
Removing, Checking and Installing Aluminium Heat Exchanger (Continue)
To remove 1.
Screw out the four hex.-head nuts (5000) and remove the washers (4000).
2.
Screw out the two hex.-head screws (7000) remove the washers (4000) and heat exchanger (1000).
3.
Remove the three O-rings (9000, 3000, 9500) and throttle disc (2000) from retarder housing. Notice
Do not remove insert (93/8) with the throttle disc. 4.
Check closing cover (1000) for leaks, renew O-ring (1100), if necessary (see Section 6.7 and 7.8 „Checking, removing and installing closing cover“).
To check 1.
Fit pressure-test plate (99/6) on heat exchanger (1000) and connect compressed-air line and pressure minimizer.
2.
Fill the heat exchanger (1000) in water section with hot water (approx. 70°C).
3.
Pressurize the heat exchanger (1000) slowly from 0 to max. 10 bar overpressure (oil section).
99/6
Notice If air bubbles form in the hot water, the heat exchanger is leaking and must be renewed.
1000 16073
99/6 Pressure-test plate 53.4786.10 cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.2/3
Repair
8.2
Heat Exchanger 4.
Removing, Checking and Installing Aluminium Heat Exchanger (Continue)
Remove the pressure-test plate (99/6).
To install
Notice New heat exchangers are wetted with preserving oil in the cooling water section and in the oil section. Prior to installation of a new heat exchanger, drain any preserving oil which has collected and flush out the cooling water section with hot water.
1.
Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (9000, 3000, 9500). Fit them in the feed bores of the retarder housing.
2.
Apply thin coat of silicone-free and non-corrosive grease to the throttle disc (2000) and fit it in the right bore.
3.
Install the heat exchanger (1000) to the retarder housing and use new self-locking hex.-head nuts (5000) and washers (4000), hex.-head screws (7000) and washers (4000) to screw it tight on the retarder housing. Tightening torque 23 Nm
4.
Install retarder, if necessary (see Section 5.1).
5.
Fill in cooling water and bleed coolant circuit according to the vehicle instructor manual. Notice
Heed the statements of the vehicle-manufacturer respecting the cooling water-quality, as well as the VOITH cooling water-list in the appendix.
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.2/4
Repair
8.2
Heat Exchanger 6.
Removing, Checking and Installing Aluminium Heat Exchanger (Continue)
If the heat exchanger (1000) had been leaking in the oil section, splush the retarder: While flushing, brake lightly several times to avoid the retarder oil overheating. Caution! Risk of injury!
The oil drain plug is heated up (oil temperature)! Fill retarder with 5,5 litres engine oil or flushing oil. Flush the retarder system by braking several times and drain the oil through the oil drain plugs (1700, 1000/3). Repeat the procedure two or three times until no more oil is visible in the water. Screw oil drain plug (1700, 1000/3) tight with new sealing rings. Oil drain plug retarder (1700) 66 Nm Oil drain plug heat exchanger (1000/3) 25 Nm 7.
Screw out oil drain plug leakage oil (1000/1) and drain any leaking oil and water which has collected.
8.
Fill in retarder oil in accordance with the operating specifications (see Section 3.2 „Oil change“ and annex).
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 8.2/5
Control Parts
9.1
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9
Control Parts
Proportional valve.................................................................. in preparation Cooling Water Temperature Pick-up ..................................................................9.1/1 Oil Temperature Pick-up ..................................................................................9.1/2
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 9/1
Control Parts
9.1
Control Parts
Removing and installing cooling water temperature pick-up
Caution! Risk of injury! The temperature pick-up is heated up (cooling water temperature)! Job scope 1.
2.
3.
Disconnect cooloing water temperature pick-up (19). Tightening torque 28 Nm The electrical lead of the temperature pick-up is pured alternatively. Screw out temperature pick-up (19) and lock the opening immediately with one stuffing.
38 19
Mount the temperature pick-up (19) in reverse sequence.
16074
cbtd 98-01 53.2659.10
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 9.1/1
Control Parts
9.1
Control Parts (Continue)
Removing and installing oil temperature pick-up
Caution! Risk of injury! The oil control plug is heated up (oil temperature)! Job scope 1.
Disconnect oil temperature pick-up (20). Tightening torque 28 Nm The electrical lead of the temperature pick-up is pured alternatively.
2.
Screw out temperature pick-up (20) and lock the opening immediately with one stuffing.
3.
Mount the temperature pick-up (20) in reverse sequence.
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Aftersales Service Manual VOITH Retarder 120 Digiprop Page 9.1/2
Annex
10
Annex
Data Sheet Miscellaneous Conversions Operating Specifications Spare Parts Lists Other Information
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Aftersales Service Manual VOITH Retarder R 120 Digiprop Page 10/1
Data Sheet VOITH Retarder 120 Digiprop Max. braking torque at prop shaft M (Br) ma x
2000 Nm *
Max. retarder speed (= max. prop shaft speed v(m ax. )
4870 r.p.m. at vps = 2400 r.p.m.
with stainless-steel heat exchanger
v(m ax. ) = 3000 r.p.m.
with aluminium heat exchanger
v(m ax. ) = 2800 r.p.m.
Working medium
Oil grade given in Operating Specification
Service filling:
With AKG heat exchanger
-
service filling (Oil change, checking oil level)
5,5 Litre
4,5 Litre
-
after complete taking apart and cleaning
-
5,8 Litre **
-
new filling
6,0 Litre
6,5 Litre
Overall weight (with flange and heat exchanger, without oil filling)
*
Overall weight will depend on the retarder version.
**
Emptied heat exchanger
cbtd 98-01 53.2659.10
With heat exchanger L+R
approx. 70 kg *
Service-Handbuch VOITH Retarder R 120 Digiprop Seite 10/2
Miscellaneous Conversions Retarder 120 with Digiprop Control
cbtd 98-01 53.2659.10
D
GB
USA
D
GB
USA
10 oC
50 oF
50 o F
110 Nm
81 lbf-ft
81 lbf-ft
20 o C
68 oF
68 o F
150 Nm
111 lbf-ft
111 lbf-ft
60 o C
140 o F
140 oF
375 Nm
277 lbf-ft
277 lbf-ft
70 o C
158 o F
158 oF
1000 Nm
740 lbf-ft
740 lbf-ft
80 o C
176 o F
176 o F
1250 Nm
925 lbf-ft
925 lbf-ft
95 o C
203 oF
203 oF
1500 Nm
1110 lbf-ft
1110 lbf-ft
105 oC
221 o F
221 oF
1750 Nm
1295 lbf-ft
1295 lbf-ft
125 oC
257 oF
257 oF
2000 Nm
1480 lbf-ft
1480 lbf-ft
185 oC
365 oF
365 oF
1,15 - 1,45 bar
16,7 - 21,0 psi
16,7 - 21,0 psi
225 oC
437 oF
437 oF
1,45 - 1,75 bar
21,0 - 25,4 psi
21,0 - 25,4 psi
10 Nm
7 lbf-ft
7 lbf-ft
1,75 - 2,05 bar
25,4 - 29,7 psi
25,4 - 29,7 psi
13 Nm
10 lbf-ft
10 lbf-ft
2,05 - 2,35 bar
29,7 - 34,1 psi
29,7 - 34,1 psi
23 Nm
17 lbf-ft
17 lbf-ft
2,35 - 2,65 bar
34,1 - 38,4 psi
34,1 - 38,4 psi
25 Nm
18 lbf-ft
18 lbf-ft
7 bar
101,5 psi
101,5 psi
32 Nm
24 lbf-ft
24 lbf-ft
9 bar
130,5 psi
130,5 psi
50 Nm
37 lbf-ft
37 lbf-ft
12 bar
174 psi
174 psi
66 Nm
49 lbf-ft
49 lbf-ft
14 bar
203 psi
203 psi
100 Nm
74 lbf-ft
74 lbf-ft
16 bar
232 psi
232 psi
Service-Handbuch VOITH Retarder R 120 Digiprop Seite 10/3
Miscellaneous Conversions Retarder 120 with Digiprop Control (Continue)
cbtd 98-01 53.2659.10
D
GB
USA
0 - 25 bar
0 - 362,5 psi
0 - 362,5 psi
0 - 10 bar
145 psi
145 psi
0,2 l
0,044 UK gal
0,053 US gal
0,5 l
0,110 UK gal
0,132 US gal
4,5 l
0,99 UK gal
1,188 US gal
5,5 l
1,210 UK gal
1,452 US gal
5,8 l
1,276 UK gal
1,531 US gal
6,0 l
1,320 UK gal
1,584 US gal
6,5 l
1,430 UK gal
1,716 US gal
1000 km
621,4 miles
621,4 miles
Service-Handbuch VOITH Retarder R 120 Digiprop Seite 10/4
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